Operating Instructions

Diesel engine
16 V 1163 Mx4
20 V 1163 Mx4

MS150102/04E
 Engine model kW/cyl. Application group
16V1163M74 300 kW/cyl. 1B; Continuous operation, variable, high load
20V1163M74 300 kW/cyl. 1B; Continuous operation, variable, high load
16V1163M84 325 kW/cyl. 1D; Continuous operation, variable, medium load
20V1163M84 325 kW/cyl. 1D; Continuous operation, variable, medium load
16V1163M94 370 kW/cyl. 1DS; Continuous operation, variable, low load
20V1163M94 370 kW/cyl. 1DS; Continuous operation, variable, low load

Table 1: Applicability

© 2015 Copyright MTU Friedrichshafen GmbH

This publication is protected by copyright and may not be used in any way, whether in whole or in part, without the prior writ-
ten consent of MTU Friedrichshafen GmbH. This particularly applies to its reproduction, distribution, editing, translation, micro-
filming and storage 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. MTU Friedrichshafen GmbH
reserves the right to change, delete or supplement the information provided as and when required.
 Table of Contents
1 Safety 4.11 Pump control EPC – Function check 64
4.12 Plant – Cleaning 65
1.1 Important provisions for all products 5
1.2 Correct use for all products 6
5 Engine Control System
1.3 Personnel and organizational requirements 7
1.4 Safety regulations for startup and operation 8 5.1 Local control mode – Engaging/disengaging
1.5 Safety precautions when working on the gearbox 66
engine 10 5.2 Local control mode – Changing engine
1.6 Fire prevention and environmental speed 68
protection, fluids and lubricants, auxiliary
materials 13 6 Maintenance
1.7 Standards for safety notices in the text 15
1.8 Transport locking devices – Crankshaft 16 6.1 50-hours service 69
1.9 Transport 19 6.2 Maintenance task reference table [QL1] 70
6.3 Maintenance schedule ‒ Additional
2 General Information information 72

2.1 General information on fiber-reinforced 7 Troubleshooting

composites 20
2.2 Engine side and cylinder designations 22 7.1 Troubleshooting 73
2.3 Product description 23 7.2 Oil priming pump, fuel booster pump –
2.4 Engine layout 27 Troubleshooting 80
2.5 Sensors and actuators – Overview 28 7.3 Fault messages – Engine Control Unit 83

3 Technical Data 8 Task Description

3.1 16 V 1163 M74 – Engine data 32 8.1 SOLAS 129

3.2 16 V 1163 M84 – Engine data 35 8.1.1 SOLAS shielding as per MTN 5233 –
Installation 129
3.3 16 V 1163 M94 – Engine data 38
8.1.2 Adhesive tape for SOLAS shielding –
3.4 20 V 1163 M74 – Engine data 41
Application 131
3.5 20 V 1163 M84 – Engine data 44 8.1.3 Installation locations for SOLAS shielding 132
3.6 20 V 1163 M94 – Engine data 47
3.7 Firing order 50 8.2 Engine 162
3.8 Engine – Main dimensions 51 8.2.1 Disabling engine start 162
8.2.2 Engine – Barring manually 163
8.2.3 Enabling engine start 165
4 Operation 8.2.4 Coupling condition – Check 166
4.1 Local Operating Panel LOP 14 – Controls 8.3 Cylinder Liner 167
and displays 52 8.3.1 Combustion chambers – Draining condensate 167
4.2 Pump control EPC – Controls and displays 55 8.3.2 Cylinder liner – Endoscopic examination 168
4.3 Putting the engine into operation after 8.3.3 Instructions and comments on endoscopic and
extended out-of-service periods (>3 months) 56 visual examination of cylinder liners 170
DCL-ID: 0000026046 - 007

4.4 Prelubricating engine after extended out-of- 8.4 Valve Drive 172
service periods 57 8.4.1 Valve clearance – Check and adjustment 172
4.5 Putting the engine into operation after 8.4.2 Cylinder head cover – Removal and
scheduled out-of-service-period 58 installation 174
4.6 Starting engine at LOP 59 8.4.3 Roller tappets – Check 175
4.7 Engine stop at LOP 60 8.4.4 Roller tappets, tappet guide – Tolerances 176
4.8 Operational checks 61 8.5 Injector 178
4.9 Emergency engine shutdown at LOP 62 8.5.1 Checking injector 178
4.10 After stopping the engine 63 8.5.2 Injector – Replacement 179

MS150102/04E 2015-11 | Table of Contents | 3

 8.5.3 Injector – Removal and installation 180 8.14.3 Piston cooling-oil filter – Replacement 230
8.5.4 Limiting valve – Replacement 184 8.14.4 Centrifugal oil filter – Cleaning and filter
sleeve replacement 232
8.6 Fuel System 186 8.14.5 Centrifugal oil filter bracket – Removal and
8.6.1 Fuel system – Venting 186
installation 235
8.6.2 Leak fuel tank – Draining 187
8.15 Coolant Circuit, General, High-Temperature
8.7 Fuel Filter 188
Circuit 236
8.7.1 Fuel prefilter ‒ Draining 188
8.15.1 Drain and venting points 236
8.7.2 Fuel prefilter – Filter element replacement 190
8.15.2 Water drain valve – Check 240
8.7.3 Fuel prefilter – Differential pressure check
8.15.3 Vent line – Obstruction check 241
and adjustment of gauge 192
8.15.4 Heat exchanger – Venting 242
8.7.4 Fuel prefilter – Flushing 193
8.15.5 Engine coolant level – Check 243
8.7.5 Fuel filter – Replacement 195
8.15.6 Engine coolant – Change 244
8.8 Preheater 197 8.15.7 Draining engine coolant 245
8.8.1 Preheating unit 197 8.15.8 Engine coolant – Filling 246
8.8.2 Preheater – Function and leak-tightness check 199 8.15.9 Engine coolant pump – Relief bore check 248
8.8.3 Heating element(s) – Electrical check 200 8.15.10 Engine coolant – Sample extraction and
analysis 249
8.9 Charge-Air Cooling 201 8.15.11 Coolant system – Strainer removal 250
8.9.1 Intercooler drain lines – Check 201
8.9.2 Charge-air cooler – Checking condensate drain 8.16 Raw Water Pump with Connections 251
line for coolant discharge and obstruction 202 8.16.1 Raw water pump – Check 251
8.16.2 Raw water pump – Tolerances 253
8.10 Air Filter 203 8.16.3 Raw water pump – Relief bore check 255
8.10.1 Service indicator – Signal ring position check 203
8.16.4 Automatic seawater inductor – Function check 256
8.10.2 Air filter – Replacement 204
8.10.3 Air filter – Removal and installation 205 8.17 Engine Mounting / Support 257
8.10.4 Air filter element – Cleaning 206 8.17.1 Engine mounts – Checking securing screws for
firm seating 257
8.11 Starting Equipment 207 8.17.2 Engine mounting – Cleaning 258
8.11.1 3-way solenoid valve – Manual operation 207
8.11.2 Pressure reducing station – Putting into 8.18 Wiring (General) for Engine/Gearbox/Unit 259
operation 208 8.18.1 Еngine cabling ‒ Check 259
8.11.3 Pressure reducing station – Venting and
8.19 Accessories for (Electronic) Engine
shutdown 210
8.11.4 Pressure reducing station – Filter cleaning 211 Governor / Control System 260
8.11.5 Compressed-air tank – Draining condensate 212 8.19.1 Connectors and housing – Cleaning 260
8.11.6 Starter – Condition check 213 8.19.2 Plug-in connections – Check 261
8.11.7 Start pilot – Fluid level check 214 8.19.3 Indicator lamp – LED replacement 262
8.11.8 Start pilot filter – Cleaning 215 8.20 Control and Display Elements, General 264
8.11.9 Compressor – Greasing 216 8.20.1 Limit switch – Check 264
8.12 Exhaust Flap with Actuator 217 8.20.2 Fluid level monitor – Check 265
8.12.1 Exhaust turbocharger control linkage – 8.21 Emergency Instrumentation (Local
Lubrication 217 Operating Panel) 266
8.12.2 Air and exhaust flaps – Functional test 218 8.21.1 Engine control system – Operational tests 266
8.13 Lube Oil System, Lube Oil Circuit 220
8.13.1 Engine oil level – Check 220
DCL-ID: 0000026046 - 007

9 Appendix A
8.13.2 Engine oil – Change 222
8.13.3 Engine oil – Sample extraction and analysis 223 9.1 Abbreviations 267
8.13.4 Engine oil sludge – Check for metallic residue 224
9.2 MTU Contact/Service Partners 269
8.13.5 Engine oil bypass filter – Replacement 225
8.13.6 Oil priming pump – Checking direction of
rotation 227 10 Appendix B

8.14 Oil Filtration / Cooling 228 10.1 Special Tools 270

8.14.1 Engine oil filter – Replacement 228 10.2 Index 278
8.14.2 Engine oil filter – Cleaning edge-type filter
element 229

4 | Table of Contents | MS150102/04E 2015-11

 1 Safety
1.1 Important provisions for all products
Nameplate
The product is identified by nameplate, model designation or serial number and must match with the infor-
mation on the title page of this manual.
Nameplate, model designation or serial number can be found on the product.
All EU-certified engines delivered by MTU come with a second nameplate. When operating the machine in the
EU: The second nameplate must be affixed in a prominent position as described in the accompanying specifi-
cations.

General information
This product may pose a risk of injury or damage in the following cases:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Modifications or conversions
• Noncompliance with the safety instructions and warning notices

Emission regulations and emission labels

Responsibility for compliance with emission regulations
Modification or removal of any mechanical/electronic components or the installation of additional compo-
nents including the execution of calibration processes that might affect the emission characteristics of the
product are prohibited by emission regulations. Emission control units/systems may only be maintained, ex-
changed or repaired if the components used for this purpose are approved by the manufacturer.
Noncompliance with these regulations will invalidate the design type approval issued by the emissions regu-
lation authorities. The manufacturer does not accept any liability for violations of the emission regulations.
The maintenance schedules of the manufacturer must be observed over the entire life cycle of the product.

Replacing components with emission labels

On all MTU engines fitted with emission labels, these labels must remain on the engine throughout its opera-
tional life.
Engines used exclusively in land-based, military applications other than by US government agencies are ex-
cepted from this proviso.
Please note the following when replacing components with emission labels:
• The relevant emission labels must be affixed to the spare part.
• Do not transfer the emission labels from the replaced part to the spare part.
• Remove the emission labels from the replaced part and destroy them.
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MS150102/04E 2015-11 | Safety | 5

 1.2 Correct use for all products
Correct 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/MTU con-
tact/Service partner)
• In the original as-delivered configuration or in a configuration approved by the manufacturer in writing (in-
cluding engine control/parameters)
• In compliance with all safety regulations and in adherence with all warning notices in this manual
• In compliance with the maintenance work and intervals specified in the (→ Maintenance Schedule)
throughout the useful life of the product
• 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
• By contracting only workshops authorized by the manufacturer to carry out repair and overhaul
The product shall not be operated in explosive atmospheres unless the necessary approval has been grant-
ed.
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 on the websites:
• For drive systems: http://www.mtu-online.com
• For power generation: http://www.mtuonsiteenergy.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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6 | Safety | MS150102/04E 2015-11

 1.3 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 maintenance based on this manual with a spe-
cial emphasis on safety requirements and warnings.
This is important in the case of personnel who only occasionally perform work on or around the product.
These personnel must be instructed repeatedly.

Personnel requirements
All work on the product shall be carried out by trained and qualified personnel only:
• Training at the Training Center of the manufacturer
• Technical personnel from the areas mechanical engineering, plant construction, and electrical engineering
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 descrip-
tions of the individual activities.
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MS150102/04E 2015-11 | Safety | 7

 1.4 Safety regulations for startup and operation
Safety regulations for startup
Install the product correctly and carry out acceptance in accordance with the manufacturer's specifications
before putting the product into service. All necessary approvals must be granted by the relevant authorities
and all requirements for initial startup must be fulfilled.
Whenever the product is subsequently taken 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 safety equipment is in place.
• No persons wearing pacemakers or any other technical body aids are present.
• The service room is adequately ventilated.
• 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 that the gases are vented to atmosphere.
• Protect battery terminals, generator terminals or cables against accidental contact.
• Check that all connections have been correctly allocated (e.g. +/- polarity, direction).
Immediately after putting the product into operation, make sure that all control and display instruments as
well as the signaling and alarm systems work properly.
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 permanently observed with regard to
present operating status, violation of limit values and warning or alarm messages.

Malfunctions and emergency stop

Practice emergency procedures, especially emergency stopping, at regular intervals.
The following steps must be taken if a malfunction of the system is detected or reported by the system:
• Inform supervisor(s) in charge.
• Analyze the message.
• Respond by taking any necessary emergency action, e.g. emergency stop.

Operation
Do not remain in the operating room when the product is running for any longer than absolutely necessary.
Keep a safe distance away from the product if possible. Do not touch the product unless expressly instructed
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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 ear protection.
• Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binder agent.

Operation of electrical equipment

Parts of the electrical equipment are live, i.e. under voltage/high tension, during operation.

8 | Safety | MS150102/04E 2015-11

 Follow the applicable warning instructions pertaining to such devices.
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MS150102/04E 2015-11 | Safety | 9

 1.5 Safety precautions when working on the engine
Safety regulations prior to maintenance and repair work
Have maintenance or repair work carried out by qualified and authorized personnel only.
Allow the product to cool down to less than 50 °C (risk of explosion for 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 collecting vessels of adequate capacity to catch fluids and lubricants.
When changing the oil or working on the fuel system, ensure that the service room is adequately ventilated.
Never carry out maintenance and repair work with the product in operation, unless:
• It is expressly permitted to do so following a written procedure.
• The product is running in the low load range and only for as long as absolutely necessary.
Lock-out the product to preclude undesired starting, e.g.
• Start interlock
• Key switch
• With hydraulic starting system: shut off supply line.
Attach “Do not operate” sign in the operating area or to control equipment.
Disconnect the battery cables or actuate the battery isolating switch, if fitted. Lock out circuit breakers.
Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic start-
ers are fitted.
Disconnect the control equipment from the product.
Use the recommended special tools or suitable equivalents when instructed to do so.
Elastomer components (e.g. engine mounts, damping elements, couplings and V-belts) must not be painted.
They may only be installed after painting the engine or must be covered before painting work is carried out.
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 during maintenance and repair work

Take special care when removing ventilation or plug screws from the product.
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.
Use only proper and calibrated tools. Observe the specified tightening torques during assembly or disassem-
bly.
Carry out work only on assemblies or plants which are properly secured.
Make sure components or assemblies are placed on stable surfaces. Adopt suitable measures to avoid that
components/tools fall down. Use the specified lifting equipment for all components.
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Never use the product as a climbing aid.

When working high on the equipment, always use suitable ladders and work platforms. Never work on en-
gines or components that are held in place by lifting equipment.
Keep fuel injection lines and connections clean.
Carry out appropriate cleaning procedures to clean and inspect components requiring special cleanness (e.g.
components carrying oil, fuel, or air).
Always seal connections with caps or covers if a line is removed or opened.
Fit new seals when re-installing lines.

10 | Safety | MS150102/04E 2015-11

 Never bend lines and avoid damaging lines, particularly the fuel lines.
Ensure that all retainers and dampers are installed correctly.
Ensure that O-rings are not installed in a slanted/twisted condition.
Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent contact
with other components. Do not place fuel or oil lines near hot components.
Do not touch elastomeric seals (e.g. Viton sealing rings) with your bare hands if they have a carbonized or
resinous appearance.
Note cooling time for components which are heated for installation or removal (risk of burning).
Pay particular attention to cleanliness at all times.
Remove any condensate from components which were chilled before assembly. If necessary, coat the com-
ponents with a suitable corrosion inhibitor.

Safety regulations following maintenance and repair work

Before barring the engine, make sure that nobody is standing in the danger zone of the product.
Check that all access ports/apertures which have been opened to facilitate working are closed again.
Check that all safety equipment has been installed and that all tools and loose parts have been removed
(especially the barring gear).
Ensure that no unattached parts have been left in/on the product (e.g. including rags and cable straps).
Ensure that the grounding system is properly connected.

Welding work
Welding operations on the product or mounted units are not permitted. Cover the product when welding in
its vicinity.
Before starting welding work:
• Switch off the power supply master switch.
• Disconnect the battery cables or actuate the battery isolating switch.
• Separate the electrical ground of electronic equipment from the ground of the unit.
No other maintenance or repair work must be carried out in the vicinity of the product while welding is going
on. Risk of explosion or fire due to oil vapors and highly flammable process materials.
Do not use product as ground terminal.
Never position the welding power supply cable adjacent to, or crossing cabling harnesses of the product. The
welding current may otherwise induce an interference voltage in the cabling harnesses which could conceiv-
ably damage the electrical system.
Remove components (e.g. exhaust pipe) from the product before performing necessary welding work.

Hydraulic installation and removal

Check satisfactory function and safe operating condition of tools, jigs and fixtures to be used. Use only the
specified jigs and fixtures for hydraulic removal/installation procedures.
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Observe the max. permissible force-on pressure specified for the jig/fixture.
Do not attempt to bend or exert force on H.P. lines.
Before starting work, pay attention to the following:
• Vent the installation/removal device, the pumps and the pipework at the relevant designated points.
• During the installation procedure, screw on device with pushed-in plunger.
• During the removal procedure, screw on device with retracted plunger.
For a hydraulic installation/removal device with central expansion pressure supply, screw spindle into shaft
end until correct sealing is established.

MS150102/04E 2015-11 | Safety | 11

 During hydraulic installation/removal of components, ensure that no persons are in the direct vicinity of the
component being pressed.

Working with batteries

Observe the safety instructions of the battery manufacturer when working with batteries.
Gases released from the battery are explosive. Avoid sparks and naked flames.
Do not allow battery acids 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. Battery pole reversal may lead to in-
jury through the sudden discharge of acid or bursting of the battery body.

Working on electrical and electronic assemblies

Always obtain the permission of the person in charge before commencing maintenance and repair work or
switching off any part of the electronic system required to do so.
De-energize the appropriate areas prior to working on assemblies.
Do not damage cabling during removal work. When 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 straps to secure cables.
Always use connector pliers to tighten union nuts on connectors.
Subject the device as well as the product to a functional testing on completion of all repair work. Check cor-
rect execution of the emergency stop function in particular.
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 if necessary.

Work with laser devices

Work with laser devices 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 devices must be equipped, in accordance with their class and usage, with protective devices for ensur-
ing safe operation.
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Measuring component dimensions

Workpieces, components and measuring equipment lie in the specified tolerance range at a reference tem-
perature of 20 °C.

12 | Safety | MS150102/04E 2015-11

 1.6 Fire prevention and environmental protection, fluids and
lubricants, auxiliary materials
Fire prevention
Flames, naked light and smoking are prohibited.
When working with combustible indirect materials, e.g. cleaning agent, ensure area is well ventilated. The
resultant steam/air mixture must be sufficiently diluted to prevent a potentially explosive atmosphere.
Rectify any fuel or oil leaks immediately. Oil or fuel on hot components can cause fires – therefore always
keep the product in a clean condition. Do not leave rags saturated with fluids and lubricants on the product.
Do not store combustible materials near the product.
Do not carry out welding work on pipes and components carrying oil or fuel. Before welding, clean with a
nonflammable fluid.
When starting the engine with an external power source, connect the ground lead last and remove it first. To
avoid sparks in the vicinity of the battery, connect the ground lead from the external power source to the
ground lead of the engine or to the ground terminal of the starter.
Always have a suitable extinguishing agent (fire extinguisher) on hand and familiarize yourself fully with its
handling.

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

Environmental protection and disposal

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

Auxiliary materials
Process materials may also be hazardous or toxic. When using consumables and auxiliary materials as well
as other chemical substances, observe the information contained in the safety data sheet for the product.
The safety data sheet may be obtained from the relevant manufacturer or from MTU.
Take special care when using hot, chilled or caustic materials.

Used oil
Used oil contains combustion residues that are harmful to health.
Wear protective gloves!
Wash relevant areas after contact with used oil.
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Lead
• Adopt suitable measures to avoid the formation of lead dust.
• Switch on extraction system.
• When working with lead or lead-containing compounds, avoid direct contact to the skin and do not inhale
lead vapors.
• Wash relevant areas after contact with lead or lead-containing substances.

MS150102/04E 2015-11 | Safety | 13

 Compressed air
Observe special safety precautions when working with compressed air:
• Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class 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 or replacing pneumatic equipment in the supply line. To de-
pressurize compressed-air lines, shut off the lines first, then release the residual pressure.
• Carry out leak test in accordance with the specifications.

Painting
• Observe the relevant safety data sheet for all materials.
• When carrying out painting work outside the spray stands provided with fume extraction systems, ensure
that the area is well ventilated. Make sure that neighboring work areas are not adversely affected.
• There must be 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.
• Avoid body contact (eyes, hands).
• Wear protective clothing, protective gloves, closed shoes and safety goggles.
• Make sure that working area is well ventilated.
• Avoid knocking or jolting the containers, valves and fittings or workpieces in any way.

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

• 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 urea solution is swallowed, rinse out mouth and drink plenty of water.
• Remove any wet clothing immediately.
• After contact skin, wash body areas with plenty of water.
• Rinse eyes immediately with eyedrops or clean tap water. Seek medical attention as soon as possible.
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14 | Safety | MS150102/04E 2015-11

 1.7 Standards for safety notices in the text
DANGER
In the event of immediate danger.
Consequences: Death, serious or permanent injury!
• Remedial action.

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

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

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

Warning notices
1. This manual with all safety instructions and safety notices must be issued to all personnel involved in opera-
tion, maintenance, repair, assembly, installation, or transportation.
2. The higher level warning notice is used if several hazards apply at the same time. Warnings related to person-
al injury shall be considered to include a warning of potential damage.
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MS150102/04E 2015-11 | Safety | 15

 1.8 Transport locking devices – Crankshaft
Transport locking device
This locking device protects the crankshaft bearings from shocks and vibration damage during engine trans-
port.
The following must be taken into account when removing/installing the transport locking device:
• The transport locking device should remain installed as long as possible during engine installation in order
to avoid damage.
• Starting or barring the engine is allowed only with the transport locking device removed. If the generator
is already mounted on the engine, ensure that the transport locking device of the generator is also re-
moved.
• Prior to every engine transport (without generator), this transport locking device must be reinstalled ac-
cording to the instructions.
• If the engine is to be moved together with the generator, the transport locking device for the generator
must also be installed.
• Install transport locking device first on the driving end and then on the free end!

1 Plate 4 Nut M16 7 Screw

2 Pull rod 5 Crossbeam 8 Crinkled spring washer
3 Washer A17 6 Thrust pad
TIM-ID: 0000042578 - 001

Removing the transport locking device from driving end (KS)

• Remove parts (1) to (8) from engine.
• Lines that were removed for installation of the transport locking device are packed and enclosed with the
engine.
• Remove all cap closures from the connections.
• Clean and install lines.
• When the engine is put into operation, check the connections for leaks.
The removed parts of the transport locking device must be kept for potential reuse!

16 | Safety | MS150102/04E 2015-11

 Fitting the transport locking device on driving end (KS)
• Open decompression valves (→ Page 167).
• Turn crankshaft using barring device to following position:
Counterclockwise-running engine: 10° after TDC B1
Clockwise-running engine: 70° after TDC B1
• Close decompression valves (→ Page 167).
• Do not turn the crankshaft further during subsequent work!
• If lines have to be removed to install the transport locking device, all line connections and openings must
be sealed hermetically!
• Pack removed parts and enclose with engine.
• Screw pull rods (2) into crankcase and plate (1) to the end of the thread. Lubricant: Engine oil.
• Insert thrust pads (6) on crankshaft.
• Insert crossbeam (5) on pull rods (2).
• Arrange thrust pads (6) centrally (not on a screw head).
• Fasten crossbeam (5) with nuts (4) and washers (3).
• Screw nuts (4) manually and evenly onto crossbeam (5) and then tighten alternately in three stages to
specified torque. Tightening torque: 100 +10 Nm, lubricant: Engine oil.
• Mark the engine as "Fitted with transportation locking device".

Removing transport locking device from free end (KGS)

TIM-ID: 0000042578 - 001

• Remove parts 1 to 8.
• Install flange (13) with screws (14) and locking plates (15) on pulse generating ring. Tightening tor-
que: 190 +15 Nm; lubricant: Engine oil.
• Secure screws (14) with locking plates (15).
• Fasten cover (12) with screws (16) and crinkled spring washers (17) on housing.
• Secure cover (9) with spring washers (11) and screws (10) to cover (12).
Store the removed parts of the transport locking device carefully for possible reuse!

MS150102/04E 2015-11 | Safety | 17

 Installing transport locking device on free end (KGS)
• Important! The crankshaft must not be pulled or pushed axially out of its resting position. The axial ten-
sioning of the crankshaft already takes place on the driving end.
• Remove cover (9).
• Remove cover (12) and flange (13).
• Pack parts together and enclose with engine.
• Fasten crossbeam (5) with screws (7) and washers (6) on pulse generating ring. Tighten screws manually;
lubricant: Engine oil.
• Install holder (8) on crossbeam (5) and on pulse generating ring housing with screws (2, 3) and wash-
ers (1, 4). Hand-tighten screws. Lubricant: Engine oil.
• Tighten screws (7). Tightening torque: 180 +20 Nm.
• Tighten screws (3), ensuring clearance-free contact of holder (8) on crossbeam (5). Tightening tor-
que: 21 +2 Nm.
• Tighten screws (2). Tightening torque: 100 +10 Nm.
• Mark the engine as "Fitted with transportation locking device".

TIM-ID: 0000042578 - 001

18 | Safety | MS150102/04E 2015-11

 1.9 Transport
Transport
Always use the lifting eyes on the engine and generator/gearbox when transporting gensets.
Always use the lifting eyes on the engine when transporting an engine separately.
Only use transport and lifting devices approved by MTU.
The engine/genset must only be transported in installation position: maximum permissible diagonal pull 6°.
Remove any loose parts on the genset.
Raise the engine/genset slowly. The lifting ropes or chains must not make contact with the engine or its
components. Readjust lifting device if necessary.
Pay attention to the center of gravity of the engine/genset.
For special packaging with aluminum foil: Suspend the engine/genset by the lifting eyes on the bearing ped-
estal or transport by means of handling equipment (forklift truck) capable of bearing the load.
Prior to transport, install the crankshaft transportation lock on the engine and fit the engine mount locking
devices.
Secure the engine/genset such as to preclude tipping during transport. Secure such as to preclude slipping
and tipping when driving up or down inclines and ramps.

Placement after transport

Place the engine/genset on a firm, flat surface only.
Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate.
Never set an engine down on the oil pan unless expressively authorized to do so by MTU on a case-to-case
basis.
TIM-ID: 0000042956 - 002

MS150102/04E 2015-11 | Safety | 19

 2 General Information
2.1 General information on fiber-reinforced composites
Safety regulations for operation and assembly
WARNING
Incorrect assembly of a coupling with components made of fiber-reinforced composites containing e.g.
carbon or glass fibers.
Overload.
Risk of destruction of the coupling and of flying parts!
Risks due to exposure to fibers and dusts!
• Ensure tension-free assembly.
• Do not use damaged couplings.
• Ensure correct installation position of components.
• Carry out assembly work in accordance with the instructions, do not use tools such as assembly lev-
er or hammer.

WARNING
Discharged fibers or dusts from a damaged coupling with components made of fiber-reinforced compo-
sites containing e.g. carbon or glass fibers.
Risk of injury to respiratory tract or irritation of skin!
• Wear protective clothing, protective gloves, and safety glasses / facial protection.
• Wear breathing mask of protective class FFP2 or higher.
• Avoid contact with skin.

The abrasion of fiber-reinforced components produces very fine particles which can be respirable depending
on the type of fiber. The following instructions must be followed in such cases:
• Ensure proper room ventilation;
• Wear breathing mask of protective class FFP2 or higher;
• Wear protective clothing, protective gloves, and safety glasses / facial protection;
• Avoid contact with skin.

General information on fiber-reinforced composites

A fiber-reinforced composite basically consists two main components (an embedding matrix and reinforcing
fibers) which together form a multi-layer or mixed material.
The interaction of the constituent materials provides better material properties than each of the individual
materials.
The superior material properties of the fiber-reinforced composite are achieved by the combination of the
two components.
Thus, the two components form three effective phases in the material: Fibers of high tensile strength, a com-
paratively smooth embedding matrix and a boundary layer which connects the two components.
TIM-ID: 0000060670 - 001

20 | General Information | MS150102/04E 2015-11

 Constituents
Constituent Task
Matrix The matrix gives the fiber-reinforced composite its
appearance. There are no limits in variation both
with regard to color and to surface structure. The
matrix has the mechanical function to keep the rein-
forcing fibers in position and to transfer and to dis-
tribute stresses between them. In terms of durabili-
ty, the matrix must protect the fibers from external
mechanical and chemical impact.
Fibers The fibers give the fiber-reinforced composite its
strength. This may refer, apart from tensile strength,
also to bending strength, if the material shall be ex-
posed to pressure loads.
Boundary layer The boundary layer transfers the tension between
the two components. It transfers exclusively thrust
and may occur in very abstract shapes, e.g. if thrust
is exerted solely by friction. In other cases, e.g. in
the event of thrust acting through adhesion, the lay-
er is intended as a part of the production technology
and exists physically. In the latter case, the fibers
are coated with a coupling agent before they get into
first contact with the matrix. This substance is able
to react with both components and to provide con-
tinuous transfer to the greatest possible extent.
TIM-ID: 0000060670 - 001

MS150102/04E 2015-11 | General Information | 21

 2.2 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 - 013

22 | General Information | MS150102/04E 2015-11

 2.3 Product description
Description of the engine
Engine
The engine is a liquid-cooled four-stroke diesel engine with c.c.w. or c.w. direction of rotation, direct injec-
tion, sequential turbocharging and charge-air cooling.
An electronic management system provides engine control and monitoring.

Fuel system with common rail injection

Controlled by the engine electronics, the common rail injection system determines injection pressure, injec-
tion timing and injection quantity independently of the engine speed.
Injection pressures up to 1600 bar ensure optimum fuel injection and combustion conditions.

Charging system
The charging system comprises charge-air system, exhaust system and sequential turbocharging.
The exhaust system is equipped with triple-walled, water-cooled exhaust lines.
The triple-walled design permits
• low surface temperature,
• reduced thermal load,
• absolute gas-tightness.

Lube oil system

Wet-sump forced-feed lubrication system
Components supplied with oil:
• Bearings
• Piston cooling
• Control and actuating elements of the sequential turbocharging system

Cooling system
• Two separate cooling circuits:
– Engine coolant
– Raw water
• Coolant cooling by raw water-cooled plate-core heat exchanger
• Thermostat-controlled coolant system
• Coolant-cooled / preheated charge air
• Coolant-cooled fuel return

Electronic system
The electronic engine management system consists of the Engine Control Unit ECU (governor), the Engine
TIM-ID: 0000042953 - 002

Monitoring Unit EMU, the Engine Interface Module EIM and the barring device.

Electronic Engine Control Unit (ECU)

Closed-loop control:
• Speed control
• Injection control with mapped commencement of injection
• Setpoint speed regulation
• HP fuel governor
• Torque control

MS150102/04E 2015-11 | General Information | 23

 Speed injection control
• Closed-loop engine speed control functions integrated in the ECU:
– Maintaining the desired engine speed under changing load conditions.
– Adjusting the engine speed when the setting is changed by the operator.
Open-loop control:
• Engine start
• Engine stop
• Override, to bypass the safety system
• Injection quantity as a function of engine loading and speed
• Torque regulation
Engine stop:
• An engine stop is tripped by closing the 24V supply at the binary input of the ECU or by the engine protec-
tion system. Fuel is no longer injected as injector activation is disrupted.
Any starting procedure which has been initiated is interrupted.
• Power failure results in engine stop

EMU Engine Monitoring Unit

Sensing and evaluation of operating states of the engine in the same way as performed by the ECU but via
autonomous measuring points:
• Engine speed
• Lube oil pressure
• High-pressure fuel
• Coolant temperature
Acquisition of additional measured values for monitoring, e.g.:
• Raw water pressure
• Main bearing temperature
• Splash oil
• Single exhaust gas temperature
Apart from the measured value acquisition, the following actuators are also activated via the EMU:
• Air flaps for the primary turbocharger
• Charge-air heating
• Valve-seat lubrication

Engine Interface Module EIM

Engine interface functions:
• Starter control
• Emergency-stop function with wire break monitoring
• Interface to ECU and EMU
• Interface for MCS-5 dialog
Plant interface functions:
• Combined plant signals from the ECU:
– Speed setting
– Engine speed
– Engine load
TIM-ID: 0000042953 - 002

– ECU stop
– Complete engine
– Speed Up
– Speed Down
– Speed Demand Switch
– ECU emergency stop
• CAN interface (3-fold)
• Priming pump control
• Emergency stop interface
• Key switch logic

24 | General Information | MS150102/04E 2015-11

 Central processing unit - Local Operating Panel LOP
The Local Operating Panel LOP serves as the central processing unit for the Monitoring and Control System
MCS and the Remote Control System RCS. The LOP forms the interface to the Engine Control System ECS
and serves as a local display and operating unit in the engine room.

SOLAS – Fire protection specifications

Special connections

In case of leakage, the above-mentioned connection types are spray-protected even without a cover and
have been confirmed compliant with SOLAS by GL and DNV.

Plug-in pipe connection

The sleeve (2) covers the joint to prevent lateral spray.
Only leak-off along the line is possible, the pressure is decreased significantly if an O-ring (1) defect occurs.
The connection is confirmed as compliant with SOLAS by DNV and GL.

Plugs and sensors

Screw-in plugs (3) are sealed toward the outside either with a copper sealing ring (4), according to DIN, or an
TIM-ID: 0000042953 - 002

O-ring (ISO).
In case of a loose single-ended union or a defective sealing ring (4), the liquid first has to pass the thread.
The pressure is so greatly reduced by this and the faulty sealing ring (4) that any leakage is not under pres-
sure.

MS150102/04E 2015-11 | General Information | 25

 HP line between distributor and HP accumulator

1 Jacket pipe 5 Thrust ring 9 O-ring

2 O-ring 6 O-ring 10 Thrust ring
3 O-ring 7 HP line
4 Thrust screw 8 Pressure pipe

Leak fuel caused by leakages from the sealing cones or the HP lines is returned to the HP pump, from where
it is routed at atmospheric pressure into a level-monitored leak fuel tank.

TIM-ID: 0000042953 - 002

26 | General Information | MS150102/04E 2015-11

 2.4 Engine layout
V 1163-04

1 ETC carrier housing 8 HP accumulator 15 Engine oil pump

2 Exhaust turbocharger 9 Crankcase breather 16 Crank drive
3 Mount for engine manage- 10 Exhaust flap (under carrier 17 Start pilot (cold start sys-
ment system housing) tem)
4 HP intercooler 11 Cylinder head 18 Coolant thermostat
5 Charge-air preheater 12 Valve gear 19 Engine oil heat exchanger
6 LP intercooler 13 HP pump 20 Centrifugal oil filter
7 Vibration damper (cam- 14 Fuel filter 21 Engine oil filter
shaft)

Engine model designation

Explanation based on engine model designation 20 V 1163 M94 (analogously valid for 16 V)
• 20 = Number of cylinders
• V = Cylinder configuration
• 1163 = Series
• M = Mechanical charging
TIM-ID: 0000042567 - 004

• 9 = Marine engine (vessels with low utilization; 1DS) or

– 8 = Marine engine (vessels with medium utilization; 1D)
– 7 = Marine engine (vessels with high utilization; 1B)
• 4 = Design index

MS150102/04E 2015-11 | General Information | 27

 2.5 Sensors and actuators – Overview

Item Designation Meaning

1 B4A1 - B4A10 / B4B1 - B4B10 Single exhaust temperature measurement
2 B4.25 Exhaust temperature
3 Y26 / Y30 / Y31 / Y45 Solenoid valves
4 A19 / B1 / Y45 Engine ident label / Camshaft speed / pres-
sure regulating valve
5 B48.1 / B48.3 High-pressure fuel A / high-pressure redun-
dant A
6 B50 Crankcase pressure
7 B9.5 Charge air temperature A
8 M8.1 / M8.3 / M8.5 / M8.7 Fuel pump A
9 B33.5 Rail fuel temperature rail A
10 B34.4 Rail fuel temperature B
TIM-ID: 0000042599 - 001

11 B38 Fuel temperature

12 B35 Leakage reservoir
13 B21.2 Seawater pressure before pump
14 B5.7 Lube oil pressure piston cooling
15 Y39A1 - Y39A10 Injectors 1-10 A
16 Y45.1 Pressure regulating valve 3.3A

28 | General Information | MS150102/04E 2015-11

 Item Designation Meaning
1 B10.2 Charge air pressure B
2 Y39B1 - Y39B10 Injectors 1-10 B
3 B81.1 Intake air pressure after filter
4 B3 Intake air temperature
5 B8 Seawater temperature
6 B1 Camshaft speed
7 B48.2 High-pressure fuel B
7 B48.4 High-pressure fuel redundant B
8 B33.6 Rail fuel temperature B
9 M8.2 / M8.4 / M8.6 / M8.8 Fuel pump B
10 B9.6 Charge air temperature B
11 B77B1 - B77B10 Splash oil B1 - B10
12 B57.1 - B57.11 Main bearing temperature 1-10
13 Y45.2 Pressure regulating valve 3.3B
TIM-ID: 0000042599 - 001

MS150102/04E 2015-11 | General Information | 29

 Item Designation Meaning
1 B5.4 / B5.5 / B5.6 / B16 / B17 / B21 Lube oil pressure last bearing
1 B5.5 Lube oil pressure before high pressure pump
A
1 B5.6 Lube oil pressure before high pressure pump
B
1 B16 Coolant pressure HT
1 B17 Control air pressure
1 B21 Seawater pressure
2 B54 Oil replenishment pump pressure
3 Start interlock, drive end
4 B13.1 Crankshaft speed
4 B13.2 Crankshaft speed, EMU
4 Y60 Control valve for charge-air preheater
5 B34.1 Fuel pressure after filter
TIM-ID: 0000042599 - 001

5 B34.2 Fuel pressure before filter

6 B5.1 Lube oil pressure after filter
6 B5.2 Lube oil pressure after filter redundant
6 B5.3 Lube oil pressure before filter
7 B7 Lube oil temperature
8 F46 Leak fuel level
9 Control air pressure
10 Cold-start system

30 | General Information | MS150102/04E 2015-11

 Item Designation Meaning
1 B5.9 Lube oil pressure ETC B
2 B5.8 Lube oil pressure ETC A
3 B44.1 Speed ETC A
3 B44.2 Speed ETC B
3 B44.3 Speed ETC C
3 B44.4 Speed ETC D
3 B44.5 Speed ETC E
4 B6.1 Coolant temperature HT
4 B6.2 Coolant temperature HT redundant
TIM-ID: 0000042599 - 001

MS150102/04E 2015-11 | General Information | 31

 3 Technical Data
3.1 16 V 1163 M74 – Engine data
Explanation:
DL Ref. value: Continuous power
BL Ref. value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power setting)
N Not yet defined value
- Not applicable
X Applicable

REFERENCE CONDITIONS
Engine model 16 V
1163 M74
Application group 1B
Intake air temperature °C 25
Charge-air coolant temperature °C 25
Raw water inlet temperature °C 25
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 16
Rated engine speed A rpm 1250
Fuel stop power ISO 3046 A kW 4800

GENERAL CONDITIONS (for maximum power)

Number of cylinders 16
Intake depression (new filter) A mbar 15
Intake depression, max. L mbar 30

MODEL RELATED DATA (basic design)

Number of cylinders 16
TIM-ID: 0000046240 - 002

Cylinder arrangement: V angle Degrees 60

Bore mm 230
Stroke mm 280
Cylinder displacement Liters 11.63
Total displacement Liters 186.1
Number of inlet valves per cylinder 2
Number of exhaust valves per cylinder 2

32 | Technical Data | MS150102/04E 2015-11

 RAW WATER CIRCUIT (open circuit)
Number of cylinders 16
Raw water pump: Inlet pressure, min. L bar -0.2
Raw water pump: inlet pressure, max. L bar 2.7
Pressure loss in off-engine raw water system, max. L bar 1.8

LUBE OIL SYSTEM

Number of cylinders 16
Lube oil operating temperature before engine, from R °C 60
Lube oil operating temperature before engine, to R °C 70
Lube oil operating pressure (low idle) (meas. point: before engine) R bar 3.0

FUEL SYSTEM
Number of cylinders 16
Fuel pressure at engine inlet connection, min. (when engine is starting) L bar -0.2
Fuel pressure at engine inlet connection, max. (when engine is starting) L bar 0.5
When the engine is started with booster pump bar 3.0 to 5.0
Fuel supply flow, max. R Liters/mi 82
n
Fuel pressure at return connection on engine, max. L bar 0.5

INCLINATIONS, STANDARD OIL SYSTEM (reference: waterline)

Number of cylinders 16
Longitudinal inclination, continuous max. L Degrees 12
Longitudinal inclination, temporary max. L Degrees 15
Transverse inclination, continuous max. L Degrees 22.5
Transverse inclination, temporary max. L Degrees 30

CAPACITIES
Number of cylinders 16
Engine coolant capacity, engine side (without cooling equipment) R Liters 560
Raw water, engine side R Liters 320
Fuel, engine side R Liters 31
Max. oil change volume (standard oil system) R Liters 640

WEIGHTS / MAIN DIMENSIONS

TIM-ID: 0000046240 - 002

Number of cylinders 16
Engine dry weight (with standard accessories installed, without coupling) R kg N

MS150102/04E 2015-11 | Technical Data | 33

 ACOUSTICS
Number of cylinders 16
Exhaust noise, unsilenced, BL, (free-field sound-pressure level Lp, 1m dis- R dB(A) 110
tance, ISO 6798) (+3 dB tol-
erance)
Engine surface noise with attenuated intake noise (intake silencer) - BL (free- R dB(A) 109
field sound-pressure level Lp, 1m distance, ISO 6798) (+2 dB tol-
erance)

TIM-ID: 0000046240 - 002

34 | Technical Data | MS150102/04E 2015-11

 3.2 16 V 1163 M84 – Engine data
Explanation:
DL Ref. value: Continuous power
BL Ref. value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power setting)
N Not yet defined value
- Not applicable
X Applicable

REFERENCE CONDITIONS
Engine model 16 V
1163 M84
Application group 1D
Intake air temperature °C 25
Charge-air coolant temperature °C 25
Raw water inlet temperature °C 25
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 16
Rated engine speed A rpm 1280
Fuel stop power ISO 3046 A kW 5200

GENERAL CONDITIONS (for maximum power)

Number of cylinders 16
Intake depression (new filter) A mbar 15
Intake depression, max. L mbar 30

MODEL RELATED DATA (basic design)

Number of cylinders 16
Cylinder arrangement: V angle degrees 60
Bore mm 230
Stroke mm 280
TIM-ID: 0000042573 - 004

Cylinder displacement Liters 11.63

Total displacement Liters 186.1
Number of inlet valves per cylinder 2
Number of exhaust valves per cylinder 2

MS150102/04E 2015-11 | Technical Data | 35

 RAW WATER CIRCUIT (open circuit)
Number of cylinders 16
Raw water pump: Inlet pressure, min. L bar -0.2
Raw water pump: inlet pressure, max. L bar 2.7
Pressure loss in off-engine raw water system, max. L bar 2.0

LUBE OIL SYSTEM

Number of cylinders 16
Lube oil operating temperature before engine, from R °C 60
Lube oil operating temperature before engine, to R °C 70
Lube oil operating pressure (low idle) (meas. point: before engine) R bar 3.0

FUEL SYSTEM
Number of cylinders 16
Fuel pressure at engine inlet connection, min. (when engine is starting) L bar -0.2
Fuel pressure at engine inlet connection, max. (when engine is starting) L bar 0.5
When the engine is started with booster pump bar 3.0 to 5.0
Fuel supply flow, max. R liters/min 84
Fuel pressure at return connection on engine, max. L bar 0.5

INCLINATIONS, STANDARD OIL SYSTEM (reference: waterline)

Number of cylinders 16
Longitudinal inclination, continuous max. L degrees 12
Longitudinal inclination, temporary max. L degrees 15
Transverse inclination, continuous max. L degrees 22.5
Transverse inclination, temporary max. L degrees 30

CAPACITIES
Number of cylinders 16
Engine coolant capacity, engine side (without cooling equipment) R Liters 560
Raw water, engine side R Liters 320
Fuel, engine side R Liters 31
Max. oil change volume (standard oil system) R Liters 640

WEIGHTS / MAIN DIMENSIONS

TIM-ID: 0000042573 - 004

Number of cylinders 16
Engine dry weight (with standard accessories installed, without coupling) R kg 20560

36 | Technical Data | MS150102/04E 2015-11

 ACOUSTICS
Number of cylinders 16
Exhaust noise, unsilenced, BL, (free-field sound-pressure level Lp, 1m dis- R dB(A) 111
tance, ISO 6798) (+3 dB tol-
erance)
Engine surface noise with attenuated intake noise (intake silencer) - BL (free- R dB(A) 110
field sound-pressure level Lp, 1m distance, ISO 6798) (+2 dB tol-
erance)
TIM-ID: 0000042573 - 004

MS150102/04E 2015-11 | Technical Data | 37

 3.3 16 V 1163 M94 – Engine data
Explanation:
DL Ref. value: Continuous power
BL Ref. value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power setting)
N Not yet defined value
- Not applicable
X Applicable

REFERENCE CONDITIONS
Engine model 16 V
1163 M94
Application group 1DS
Intake air temperature °C 25
Charge-air coolant temperature °C 25
Raw water inlet temperature °C 25
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 16
Rated engine speed A rpm 1325
Fuel stop power ISO 3046 A kW 5920

GENERAL CONDITIONS (for maximum power)

Number of cylinders 16
Intake depression (new filter) A mbar 15
Intake depression, max. L mbar 30

MODEL RELATED DATA (basic design)

Number of cylinders 16
Cylinder arrangement: V angle Degrees 60
Bore mm 230
Stroke mm 280
TIM-ID: 0000046241 - 002

Cylinder displacement Liters 11.63

Total displacement Liters 186.1
Number of inlet valves per cylinder 2
Number of exhaust valves per cylinder 2

38 | Technical Data | MS150102/04E 2015-11

 RAW WATER CIRCUIT (open circuit)
Number of cylinders 16
Raw water pump: Inlet pressure, min. L bar -0.3
Raw water pump: inlet pressure, max. L bar 2.7
Pressure loss in off-engine raw water system, max. L bar 1.8

LUBE OIL SYSTEM

Number of cylinders 16
Lube oil operating temperature before engine, from R °C 60
Lube oil operating temperature before engine, to R °C 70
Lube oil operating pressure (low idle) (meas. point: before engine) R bar 3.0

FUEL SYSTEM
Number of cylinders 16
Fuel pressure at engine inlet connection, min. (when engine is starting) L bar -0.2
Fuel pressure at engine inlet connection, max. (when engine is starting) L bar 0.5
When the engine is started with booster pump bar 3.0 to 5.0
Fuel supply flow, max. R Liters/mi 87
n
Fuel pressure at return connection on engine, max. L bar 0.5

INCLINATIONS, STANDARD OIL SYSTEM (reference: waterline)

Number of cylinders 16
Longitudinal inclination, continuous max. L Degrees 12
Longitudinal inclination, temporary max. L Degrees 15
Transverse inclination, continuous max. L Degrees 22.5
Transverse inclination, temporary max. L Degrees 30

CAPACITIES
Number of cylinders 16
Engine coolant capacity, engine side (without cooling equipment) R Liters 560
Raw water, engine side R Liters 320
Fuel, engine side R Liters 31
Max. oil change volume (standard oil system) R Liters 640

WEIGHTS / MAIN DIMENSIONS

TIM-ID: 0000046241 - 002

Number of cylinders 16
Engine dry weight (with standard accessories installed, without coupling) R kg N

MS150102/04E 2015-11 | Technical Data | 39

 ACOUSTICS
Number of cylinders 16
Exhaust noise, unsilenced, BL, (free-field sound-pressure level Lp, 1m dis- R dB(A) 112
tance, ISO 6798) (+3 dB tol-
erance)
Engine surface noise with attenuated intake noise (intake silencer) - BL (free- R dB(A) 111
field sound-pressure level Lp, 1m distance, ISO 6798) (+2 dB tol-
erance)

TIM-ID: 0000046241 - 002

40 | Technical Data | MS150102/04E 2015-11

 3.4 20 V 1163 M74 – Engine data
Explanation:
DL Ref. value: Continuous power
BL Ref. value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power setting)
N Not yet defined value
- Not applicable
X Applicable

REFERENCE CONDITIONS
Engine model 20V
1163 M74
Application group 1B
Intake air temperature °C 25
Charge-air coolant temperature °C 25
Raw water inlet temperature °C 25
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 20
Rated engine speed A rpm 1250
Fuel stop power ISO 3046 A kW 6000

GENERAL CONDITIONS (for maximum power)

Number of cylinders 20
Intake depression (new filter) A mbar 15
Intake depression, max. L mbar 30

MODEL RELATED DATA (basic design)

Number of cylinders 20
Cylinder arrangement: V angle Degrees 60
Bore mm 230
Stroke mm 280
TIM-ID: 0000046242 - 002

Cylinder displacement Liters 11.63

Total displacement Liters 232.6
Number of inlet valves per cylinder 2
Number of exhaust valves per cylinder 2

MS150102/04E 2015-11 | Technical Data | 41

 RAW WATER CIRCUIT (open circuit)
Number of cylinders 20
Raw water pump: Inlet pressure, min. L bar -0.2
Raw water pump: inlet pressure, max. L bar 3.1
Pressure loss in off-engine raw water system, max. L bar 1.8

LUBE OIL SYSTEM

Number of cylinders 20
Lube oil operating temperature before engine, from R °C 60
Lube oil operating temperature before engine, to R °C 75
Lube oil operating pressure (low idle) (meas. point: before engine) R bar 3.0

FUEL SYSTEM
Number of cylinders 20
Fuel pressure at engine inlet connection, min. (when engine is starting) L bar -0.2
Fuel pressure at engine inlet connection, max. (when engine is starting) L bar 0.5
When the engine is started with booster pump bar 3.0 to 5.0
Fuel supply flow, max. R Liters/mi 82
n
Fuel pressure at return connection on engine, max. L bar 0.5

INCLINATIONS, STANDARD OIL SYSTEM (reference: waterline)

Number of cylinders 20
Longitudinal inclination, continuous max. L Degrees 12
Longitudinal inclination, temporary max. L Degrees 15
Transverse inclination, continuous max. L Degrees 22.5
Transverse inclination, temporary max. L Degrees 30

CAPACITIES
Number of cylinders 20
Engine coolant capacity, engine side (without cooling equipment) R Liters 700
Raw water, engine side R Liters 400
Fuel, engine side R Liters 36
Max. oil change volume (standard oil system) R Liters 760

WEIGHTS / MAIN DIMENSIONS

TIM-ID: 0000046242 - 002

Number of cylinders 20
Engine dry weight (with standard accessories installed, without coupling) R kg N

42 | Technical Data | MS150102/04E 2015-11

 ACOUSTICS
Number of cylinders 20
Exhaust noise, unsilenced, BL, (free-field sound-pressure level Lp, 1m dis- R dB(A) 110
tance, ISO 6798) (+3 dB tol-
erance)
Engine surface noise with attenuated intake noise (intake silencer) - BL (free- R dB(A) 107
field sound-pressure level Lp, 1m distance, ISO 6798) (+2 dB tol-
erance)
TIM-ID: 0000046242 - 002

MS150102/04E 2015-11 | Technical Data | 43

 3.5 20 V 1163 M84 – Engine data
Explanation:
DL Ref. value: Continuous power
BL Ref. value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power setting)
N Not yet defined value
- Not applicable
X Applicable

REFERENCE CONDITIONS
Engine model 20V
1163 M84
Application group 1D
Intake air temperature °C 25
Charge-air coolant temperature °C 25
Raw water inlet temperature °C 25
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 20
Rated engine speed A rpm 1280
Fuel stop power ISO 3046 A kW 6500

GENERAL CONDITIONS (for maximum power)

Number of cylinders 20
Intake depression (new filter) A mbar 15
Intake depression, max. L mbar 30

MODEL RELATED DATA (basic design)

Number of cylinders 20
Cylinder arrangement: V angle Degrees 60
Bore mm 230
Stroke mm 280
TIM-ID: 0000046244 - 001

Cylinder displacement Liters 11.63

Total displacement Liters 232.6
Number of inlet valves per cylinder 2
Number of exhaust valves per cylinder 2

44 | Technical Data | MS150102/04E 2015-11

 RAW WATER CIRCUIT (open circuit)
Number of cylinders 20
Raw water pump: Inlet pressure, min. L bar -0.2
Raw water pump: inlet pressure, max. L bar 2.8
Pressure loss in off-engine raw water system, max. L bar 2.0

LUBE OIL SYSTEM

Number of cylinders 20
Lube oil operating temperature before engine, from R °C 60
Lube oil operating temperature before engine, to R °C 75
Lube oil operating pressure (low idle) (meas. point: before engine) R bar 3.0

FUEL SYSTEM
Number of cylinders 20
Fuel pressure at engine inlet connection, min. (when engine is starting) L bar -0.2
Fuel pressure at engine inlet connection, max. (when engine is starting) L bar 0.5
When the engine is started with booster pump bar 3.0 to 5.0
Fuel supply flow, max. R Liters/mi 84
n
Fuel pressure at return connection on engine, max. L bar 0.5

INCLINATIONS, STANDARD OIL SYSTEM (reference: waterline)

Number of cylinders 20
Longitudinal inclination, continuous max. L Degrees 12
Longitudinal inclination, temporary max. L Degrees 15
Transverse inclination, continuous max. L Degrees 22.5
Transverse inclination, temporary max. L Degrees 30

CAPACITIES
Number of cylinders 20
Engine coolant capacity, engine side (without cooling equipment) R Liters 700
Raw water, engine side R Liters 400
Fuel, engine side R Liters 36
Max. oil change volume (standard oil system) R Liters 760

WEIGHTS / MAIN DIMENSIONS

TIM-ID: 0000046244 - 001

Number of cylinders 20
Engine dry weight (with attached standard accessories, without coupling) R kg N

MS150102/04E 2015-11 | Technical Data | 45

 ACOUSTICS
Number of cylinders 20
Exhaust noise, unsilenced, BL, (free-field sound-pressure level Lp, 1m dis- R dB(A) 112
tance, ISO 6798) (+3 dB tol-
erance)
Engine surface noise with attenuated intake noise (intake silencer) - BL (free- R dB(A) 108
field sound pressure level Lp, 1m distance, ISO 6798) (+2 dB tol-
erance)

TIM-ID: 0000046244 - 001

46 | Technical Data | MS150102/04E 2015-11

 3.6 20 V 1163 M94 – Engine data
Explanation:
DL Ref. value: Continuous power
BL Ref. value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power setting)
N Not yet defined value
- Not applicable
X Applicable

Technical data
Engine model 20 V
1163 M94
Application group 1DS
Intake air temperature °C 25
Charge-air coolant temperature °C 25
Raw water inlet temperature °C 25
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 20
Rated engine speed A rpm 1325
Fuel stop power ISO 3046 A kW 7400

GENERAL CONDITIONS (for maximum power)

Number of cylinders 20
Intake depression (new filter) A mbar 15
Intake depression, max. L mbar 30

MODEL RELATED DATA (basic design)

Number of cylinders 20
Cylinder arrangement: V angle Degrees 60
(°)
Bore mm 230
TIM-ID: 0000042574 - 004

Stroke mm 280
Cylinder displacement Liters 11.63
Total displacement Liters 232.6
Number of inlet valves per cylinder 2
Number of exhaust valves per cylinder 2

MS150102/04E 2015-11 | Technical Data | 47

 RAW WATER CIRCUIT (open circuit)
Number of cylinders 20
Raw water pump, inlet pressure, min. L bar -0.2
Raw water pump, inlet pressure, max. L bar 3.1
Pressure loss in off-engine raw water system, max. permissible. L bar 1.9

LUBE OIL SYSTEM

Number of cylinders 20
Lube oil operating temperature before engine, from R °C 60
Lube oil operating temperature before engine, to R °C 75
Lube oil operating pressure (low idle) (meas. point: before engine) R bar 3.0

FUEL SYSTEM
Number of cylinders 20
Fuel pressure at engine inlet connection, min. (when engine is starting) L bar -0.2
Fuel pressure at engine inlet connection, max. (when engine is starting) L bar 0.5
When the engine is started with booster pump bar 3.0 to 5.0
Fuel supply flow, max. R liters/min 95
Fuel pressure at return connection on engine, max. L bar 0.5

INCLINATIONS, STANDARD OIL SYSTEM (reference:

Number of cylinders 20
Longitudinal inclination, continuous max. L Degrees 12
(°)
Longitudinal inclination, temporary max. L Degrees 15
(°)
Transverse inclination, continuous max. L Degrees 22.5
(°)
Transverse inclination, temporary max. L Degrees 30
(°)

CAPACITIES
Number of cylinders 20
Engine coolant capacity, engine side (without cooling equipment) R Liters 700
Raw water, engine side R Liters 400
Fuel, engine side R Liters 36
TIM-ID: 0000042574 - 004

Max. oil change volume (standard oil system) R Liters 760

WEIGHTS / MAIN DIMENSIONS

Number of cylinders 20
Engine dry weight (with standard accessories installed, without coupling) R kg N

48 | Technical Data | MS150102/04E 2015-11

 ACOUSTICS
Number of cylinders 20
Exhaust noise, unsilenced - BL (free-field sound-pressure level Lp, 1m dis- R dB(A) 114
tance, ISO 6798, +3dB(A) tolerance)
Engine surface noise with attenuated intake noise (intake silencer) - BL (free- R dB(A) 109
field sound-pressure level Lp, 1 m distance, ISO 6798, +2dB(A) tolerance)
TIM-ID: 0000042574 - 004

MS150102/04E 2015-11 | Technical Data | 49

 3.7 Firing order
Firing order, c.c.w. direction of rotation (not reversible)
16 V A1-B3-A3-B7-A7-B4-A5-B8-A8-B6-A6-B2-A2-B5-A4-B1

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

Firing order, c.w. direction of rotation (not reversible)

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

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

TIM-ID: 0000042572 - 002

50 | Technical Data | MS150102/04E 2015-11

 3.8 Engine – Main dimensions
Engine – Main dimensions

Engine model Length (A) Width (B) Height (C) Height (D)
16 V 1163 M94 approx. 5066 mm approx. 1834 mm approx. 2912 mm approx. 904 mm
20 V 1163 M94 approx. 5756 mm approx. 1834 mm approx. 2912 mm approx. 1035 mm
TIM-ID: 0000042568 - 005

MS150102/04E 2015-11 | Technical Data | 51

 4 Operation
4.1 Local Operating Panel LOP 14 – Controls and displays

Pushbuttons to control the plant

Item Color Inscription Meaning/function
Speed pushbuttons
1 White INCREASE EN- • Holding the pushbutton down increases engine speed.
GINE SPEED • Lit as long as the pushbutton is held down.
2 White DECREASE EN- • Holding the pushbutton down decreases engine speed.
GINE SPEED • Lit as long as the pushbutton is held down.
3 White – (Not assigned)
Gearbox pushbuttons for marine reversing gear
4 Green CLUTCH AHEAD • Pressing the pushbutton engages the gearbox in the ahead direc-
tion.
TIM-ID: 0000045550 - 001

• Flashes if AHEAD is specified; however, no gearbox feedback for

ahead.
• Lit when the gearbox is engaged ahead.
5 Green CLUTCH NEU- • Pressing the pushbutton disengages the gearbox.
TRAL • Flashes if NEUTRAL is specified; however, no gearbox feedback
for neutral.
• Lit when the gearbox is disengaged.

52 | Operation | MS150102/04E 2015-11

 Item Color Inscription Meaning/function
6 Green CLUTCH AS- • Pressing the pushbutton engages the gearbox in the astern direc-
TERN tion.
• Flashes if ASTERN is specified; however, no gearbox feedback for
astern.
• Lit when the gearbox is engaged astern.
Other pushbuttons
7 White START • Pressing the pushbutton initiates engine start.
• Lit during the starting sequence.
8 White STOP • Pressing the pushbutton initiates engine shutdown.
• Lit during the stopping sequence.
9 White TURN ENGINE • Pressing the pushbutton initiates engine cranking.
• Lit during the cranking sequence.
10 Green OVERSPEED • Pressing the pushbutton initiates an overspeed test.
TEST • Lit during the overspeed test.
11 Green LOCAL CON- • Pressing the pushbutton activates Local mode.
TROL • Lit when Local mode is activated.
12 Green READY FOR OP- • Pressing the pushbutton switches the power train concerned
ERATION ready for operation.
The operator thus cancels the manual start interlock.
• Lit when the power train is switched ready for operation.
13 Red EMERGENCY • Pressing the pushbutton initiates an immediate emergency en-
STOP gine stop.
• Lit when an emergency engine stop has been tripped.
• Lit until the “Emergency engine stop” alarm is acknowledged.
14 White – (Not assigned)
15 White – (Not assigned)

Table 2: Meaning of buttons on LOP 14

Function keys to operate the LCD display

Item Color Inscription Meaning/function
20 White F1 • Function key
19 F2 – to control and operate the graphic screen pages on the LCD
display
18 F3 – to adjust brightness of the LCD display and key illumination on
17 F4 the LOP
16 F5 • Key functions vary and are displayed graphically in the LCD win-
dow.
• The keys are lit when held down.

Table 3: Function keys to operate the LCD display

TIM-ID: 0000045550 - 001

MS150102/04E 2015-11 | Operation | 53

 Additional displays and indicators
Item Color Designation Meaning/function
21 Green Function LED Indicates display operating state:
• LED dark: Operating voltage missing.
• LED lit: Normal operation, configuration data loaded, no error de-
tected.
• LED flashes slowly: Communication to display via field bus (CAN)
disrupted or failed.
• LED flashes rapidly: Watchdog tripped. System in hardware reset
state.
22 – LCD display • Displays detailed information about the propulsion plant.
• The display can be controlled with the function keys below the
window.

Table 4: Additional displays and indicators – LOP 14

TIM-ID: 0000045550 - 001

54 | Operation | MS150102/04E 2015-11

 4.2 Pump control EPC – Controls and displays
Controls and displays for oil priming pump, fuel booster pump

1 Indicator lamp 'Oil priming 3 Switch for fuel booster 5 Door lock
pump on' pump (settings for Automat-
2 Indicator lamp 'Fuel booster ic – Off – Manual)
pump on' 4 Switch for oil priming pump
(settings for Automatic – Off
– Manual)
TIM-ID: 0000042594 - 001

MS150102/04E 2015-11 | Operation | 55

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

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

Item Action
Engine Depreserve (→ MTU Preservation and Represervation Specifications
A001070/..).
Start interlock Verify that cover is installed and limit switch is activated (→ Page 264).
Combustion chamber Blow out combustion chambers (→ Page 167)
Fuel prefilter Fill with fuel (→ Page 193).
Fuel prefilter, pressure gage Align adjustable pointer with position of pressure indicator (→ Page 192).
Fuel system Open shut-off valve(s) before and after fuel heat exchanger.
Fuel system Vent (→ Page 186).
Fuel heat exchanger Vent (→ Page 242).
Lube oil system Check engine oil level (→ Page 220).
Lube oil system Open shut-off valve before bypass oil filter.
Lube oil system Verify that diverter valves of oil filters are in operating position (→ Page 228),
(→ Page 215).
Lubrication points Lubricate control linkage and air flaps of turbochargers (→ Page 217).
Coolant circuit Open shut-off valve(s) after coolant expansion tank.
Coolant circuit Check vent lines for obstructions (→ Page 241).
Raw water circuit Check vent lines for obstructions (→ Page 241).
Preheating unit Put into operation (→ Page 197).
Oil priming pump Check direction of rotation (→ Page 227).
Oil priming pump Run oil priming pump for at least 10 minutes (→ Page 57).
Cold start system Top up start pilot tank (→ Page 214).
Compressed-air system Put into operation (→ Page 208).
Crankshaft Verify that transport locking device has been removed.
Engine mounting Verify that transport locking device has been removed.
Engine Control System Switch on master switch
Press illuminated pushbutton READY FOR OPERATION (→ Page 52).
Engine Control System Carry out operational testsv (→ Page 266).
TIM-ID: 0000042569 - 005

56 | Operation | MS150102/04E 2015-11

 4.4 Prelubricating engine after extended out-of-service periods
Preconditions
☑ Engine is stopped and starting disabled.

Prelubricating engine
1. Turn EPC selector switch of oil priming pump
to position MAN (3).
Result: • Indicator lamp lights up.
• Oil priming pump is running.
2. Keep oil priming pump switched on for at
least 10 minutes.
3. If the engine is to be started: Turn EPC selec-
tor switch of oil priming pump to position AU-
TO (1).
4. If the engine is not to be started: Turn EPC
selector switch of oil priming pump to posi-
tion 0 (2).
TIM-ID: 0000056872 - 001

MS150102/04E 2015-11 | Operation | 57

 4.5 Putting the engine into operation after scheduled out-of-
service-period
Preconditions
☑ Engine is stopped and starting disabled.

Putting into operation

Item Measure
Lube oil system Check engine oil level (→ Page 220);
, preheat engine oil, if required.
Coolant circuit Check coolant level (→ Page 243).
Coolant circuit Preheat coolant with preheating unit.
Raw water supply Open supply.
Fuel prefilter Drain water and contaminants (→ Page 188);
Check if suction-side pressure indicated at the fuel prefilter is within the limit
(→ Page 192).
Cold start system Exchange ethanol cartridge of start pilot (→ Page 214).
Compressed air system Open main valve.
Compressed air system Check operating pressure.
Compressed air system Drain condensate from compressed-air tank.
Mechanical accessories Verify that all protective devices have been installed.
Engine Control System Switch on main switch.
Engine Control System Carry out operational tests (→ Page 266).

TIM-ID: 0000002688 - 006

58 | Operation | MS150102/04E 2015-11

 4.6 Starting engine at LOP
Preconditions
☑ Gearbox is in neutral position.
☑ External start interlock is not activated.

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.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

After out-of-service period > 10 hours: Bar engine with open decompression
valves
Item Action
Engine Open decompression valves (→ Page 167).
Bar engine manually (→ Page 163).

Starting engine at LOP

Item Action
Engine Start in unloaded condition.
Plant Switch on.
LOP:
• Illuminated switch LOCAL OPERATION lights up brightly (local control
mode is active) (→ Page 52);
• Illuminated pushbutton GEARBOX NEUTRAL lights up brightly (gearbox is
disengaged) (→ Page 52).
LOP Press iIluminated switch READY FOR OPERATION briefly (→ Page 52).
• Illuminated switch READY FOR OPERATION lights up brightly.
LOP Press illuminated pushbutton START briefly (→ Page 52).
• Illuminated pushbutton START of the relevant engine lights up brightly;
• Automatic starting sequence is performed;
• Engine speed display instrument indicates increasing speed;
• After completion of the starting sequence, the engine runs at idle speed,
and the illuminated pushbutton START changes to basic brightness.
TIM-ID: 0000042952 - 005

MS150102/04E 2015-11 | Operation | 59

 4.7 Engine stop at LOP
Preconditions
☑ Engine is running in Local mode

NOTICE
Stopping the engine when it is running at full load causes extreme stress to the engine.
Risk of overheating, damage to components!
• Before shutting down, disengage gear and run the engine at idle speed for at least 10 minutes until
engine temperatures have dropped and constant values are displayed.

Stopping engine at LOP

Item Action
LOP Disengage gearbox (→ Page 52).
LOP Operate engine at idle speed (→ Page 52).
Temperature indications Wait until engine temperature does not drop any further.
LOP Press the STOP illuminated pushbutton (→ Page 52).
• Spot LED of the STOP button lights up
• Engine is stopped
• Ready for operation is signaled
• Engine start is enabled
• Change-over to Remote mode is enabled
• Clutch engagement AHEAD is enabled (for solenoid valve test only)
• Clutch engagement ASTERN is enabled (for solenoid valve test only)
• Governor test is enabled
• Turning test is enabled.

TIM-ID: 0000042958 - 003

60 | Operation | MS150102/04E 2015-11

 4.8 Operational checks
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

WARNING
Exhaust gases are harmful to health.
Risk of poisoning!
• Ensure that the engine room is well ventilated.
• Repair leaking exhaust pipework immediately.

Operational checks
Item Measure
Engine under load Visually inspect engine for leaks and general condition
Engine at nominal speed Check for abnormal running noise and vibration
Check exhaust color (→ Page 73).
Fuel prefilter Check that the pointer of vacuum gauge indicator position of fuel prefilter is
within the permissible limit (→ Page 192).
Drain water and contaminants (→ Page 188).
Intercooler Check drain line for water discharge and obstruction (→ Page 202).
Air filter Check signal ring position of service indicator (→ Page 203).
Replace air filter (→ Page 204) if the signal ring is completely visible in the
service indicator control window.
HT coolant pump Check relief bore for oil and coolant discharge and contamination
(→ Page 248).
Raw water pump Check relief bore for oil and coolant discharge and contamination
(→ Page 255).
Fuel treatment system Visually inspect fuel treatment system for leaks and general condition.
Visually inspect mounts of fuel treatment system for damage.
TIM-ID: 0000042570 - 003

MS150102/04E 2015-11 | Operation | 61

 4.9 Emergency engine shutdown at LOP
NOTICE
An emergency stop causes extreme stress to the engine plant.
Risk of overheating, damage to components!
• Initiate emergency stop only in emergency situations.

Emergency engine shutdown at LOP

Item Action
LOP Press illuminated pushbutton EMERGENCY STOP (→ Page 52).
• Horn sounds.
• Alarms are shown on the LOP display.
• Engine is stopped by interrupting fuel injection.
• Switching over to remote control mode is possible.

Following emergency engine shutdown at LOP

Item Action
LOP Alarm acknowledgment at LOP display via function keys (→ Page 52).
• Audible and visual alarm signaling stops.
• Alarm is acknowledged.
LOP At the LOP display, select the function "STORED ALARM RESET" using the
function keys (→ Page 52).
• The alarms stored in the alarm memory are deleted.
Engine Make engine ready for operation again.

TIM-ID: 0000042954 - 003

62 | Operation | MS150102/04E 2015-11

 4.10 After stopping the engine
Preconditions
☑ MTU Preservation and Represervation Specifications (A001070/..) are available.

After stopping the engine

Item Measure
Coolant system Drain coolant if:
• freezing temperatures are to be expected and the engine is to remain out
of service for an extended period and if no antifreeze has been added to
the coolant;
• the engine room is not heated;
• the coolant is not kept at a suitable temperature;
• the antifreeze concentration is insufficient for the engine-room tempera-
ture;
• antifreeze concentration is 50% and engine-room temperature is below
-40 °C.
Drain line Check charge-air cooler drain lines (→ Page 201).
Raw water Close supply.
Raw water Drain
• if freezing temperatures are to be expected and the engine is to remain
out of service for an extended period.
Engine Control System Switch off.
Engine oil Check level (→ Page 220).
Engine oil filter Actuate ratchet lever (→ Page 229).
Air intake and exhaust sys- Out-of-service-period > 1 week:
tem • Seal engine on air and exhaust sides.
Out-of-service-period > 1 month:
• Preserve engine (→ MTU Preservation and Represervation Specifications
A001070/..).
Compressed-air system Close main valve.
TIM-ID: 0000042571 - 003

MS150102/04E 2015-11 | Operation | 63

 4.11 Pump control EPC – Function check
Preconditions
☑ Engine stopped and starting disabled.

Checking oil priming pump EPC

operation
1. Turn selector switch of EPC for oil priming
pump to position MAN (3).
Result: • Indicator lamp lights up.
• Oil priming pump is running.
2. Turn selector switch of EPC for oil priming
pump to position AUTO (1).

Checking fuel booster pump EPC operation

1. Turn selector switch of EPC for fuel booster pump to position MAN (3).
Result: • Indicator lamp lights up.
• Fuel booster pump in operation.
2. Turn selector switch of EPC for fuel booster pump to position AUTO (1).

TIM-ID: 0000042595 - 001

64 | Operation | MS150102/04E 2015-11

 4.12 Plant – Cleaning
Preconditions
☑ Engine is stopped and starting disabled.
☑ Operating voltage is not applied.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Steam jet cleaner - 1
Cleaner (Hakupur 312) 30390 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 ear defenders.

WARNING
Steam jet cleaner ejects jet of pressurized water.
Risk of injury to eyes and scalding!
• Never direct water jet at people.
• Wear protective clothing, protective gloves and safety goggles/face 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.

Plant – Cleaning
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 water/steam jet unit
carefully and observe the safety precautions.
3. For external cleaning of the plant with water or steam-jet cleaners:
• 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.
TIM-ID: 0000010171 - 029

• The temperature of the cleaning medium must not exceed 80°C.

4. For external cleaning with high-pressure jet, use a flat-mouth nozzle only.
Note: Never aim 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.
c) Spray on cleaner sparingly and leave it for 1 to 5 minutes.
d) Use the high-pressure jet to remove the loosened dirt.
e) Dry engine with compressed air.

MS150102/04E 2015-11 | Operation | 65

 5 Engine Control System
5.1 Local control mode – Engaging/disengaging gearbox
Preconditions
☑ Overall system of the power train is switched on.
☑ Power train is switched ready for operation: Illuminated pushbutton READY FOR OPERATION on Local Op-
erating Panel LOP 14 lit green.
☑ Local control mode is switched on: Illuminated pushbutton LOCAL CONTROL on Local Operating Panel
LOP 14 lit green.
☑ Gearbox is disengaged: Illuminated pushbutton CLUTCH NEUTRAL on Local Operating Panel LOP 14 is lit
green (for “engagement” sequence only).
☑ Gearbox engaged: Illuminated pushbutton CLUTCH NEUTRAL on Local Operating Panel LOP 14 is dark (for
“disengagement” sequence only).
☑ Engine speed in engagement/disengagement window.

DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.

DANGER
Vessel is sailing blind.
In Local Operation mode, the propulsion plant is controlled from the engine room.
Risk of accidents!
• Only execute vessel movements on the instructions of a person who has visual contact with the area
outside the vessel.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

NOTICE
Control stations (RCS Remote Control System) deactivated.
Loss of maneuverability, risk of serious property damage!
• Inform authorized control station before switching to local operation.

Engaging gearbox at Local Operating Panel LOP 14

TIM-ID: 0000039799 - 004

1. Establish contact with the control stand.

2. Press one of the following pushbuttons to engage as required:
• To engage ahead: illuminated pushbutton CLUTCH AHEAD
• To engage astern: illuminated pushbutton CLUTCH ASTERN
Result: • Gearbox is engaged as specified.
• The selected illuminated pushbutton lights up green.
• Gearbox state is indicated on the display.

66 | Engine Control System | MS150102/04E 2015-11

 Disengaging gearbox at Local Operating Panel LOP 14
1. Reduce engine speed to idling (→ Page 68).
2. Press illuminated pushbutton CLUTCH NEUTRAL.
Result: • Illuminated pushbutton CLUTCH NEUTRAL lit green.
• The gearbox is disengaged.
• Gearbox state is indicated on the display.
TIM-ID: 0000039799 - 004

MS150102/04E 2015-11 | Engine Control System | 67

 5.2 Local control mode – Changing engine speed
Preconditions
☑ Overall system of the power train is switched on.
☑ Power train is switched ready for operation: Illuminated pushbutton READY FOR OPERATION on Local Op-
erating Panel LOP 14 lit green.
☑ Local control mode is switched on: Illuminated pushbutton LOCAL CONTROL on Local Operating Panel
LOP 14 lit green.

DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.

DANGER
Vessel is sailing blind.
In Local Operation mode, the propulsion plant is controlled from the engine room.
Risk of accidents!
• Only execute vessel movements on the instructions of a person who has visual contact with the area
outside the vessel.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

NOTICE
Control stations (RCS Remote Control System) deactivated.
Loss of maneuverability, risk of serious property damage!
• Inform authorized control station before switching to local operation.

Changing engine speed at Local Operating Panel LOP 14

1. Press and hold down one of the following illuminated pushbuttons as required:
• To increase engine speed: Illuminated pushbutton INCREASE ENGINE SPEED
• To decrease engine speed: Illuminated pushbutton DECREASE ENGINE SPEED
Result: • The selected illuminated pushbutton lights up white when pressed.
• Engine speed increases or decreases.
• Current engine speed is indicated on the display.
2. Release the illuminated pushbutton as soon as the desired engine speed has been reached.
Result: Engine speed remains constant.
TIM-ID: 0000039800 - 004

68 | Engine Control System | MS150102/04E 2015-11

 6 Maintenance
6.1 50-hours service
50-hours service
One-time operations after the first 50 operating hours - with a new engine, after component maintenance or
extended component maintenance.
Qualifi- Interval Item Measures Task
cation [h] [a]
QL1 – – Add-on components Check securing screws for secure seating. –
QL1 – – Valve gear Check valve clearance. (→ Page 172). –
QL1 – – Fuel prefilter Replace filter elements of fuel prefilter. (→ Page 190). –
QL1 – – Fuel filter Replace fuel filter or fuel filter element (→ Page 195). –
QL1 – – Engine oil Take engine oil sample and analyze (→ Page 223). –
QL1 – – Edge-type engine oil filter Operate ratchet lever of oil filters several times (→ Page 229). –
QL1 – – Engine coolant circuit Remove strainer element before thermostat (→ Page 250). -
TIM-ID: 0000002499 - 004

MS150102/04E 2015-11 | Maintenance | 69

 6.2 Maintenance task reference table [QL1]
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 Option Measures

W0500 Check engine oil level. (→ Page 220)
W0501 Visually inspect engine for leaks and general condition. (→ Page 61)
W0502 Check charge-air cooler drain. (→ Page 61)
W0503 Check maintenance indicator of air filter. (→ Page 61)
W0505 Check relief bores of water pump(s). (→ Page 61)
W0506 Check engine for abnormal running noises, exhaust color and (→ Page 61)
vibrations.
W0508 Check contamination indicator position of fuel prefilter. (→ Page 61)
W1001 Replace fuel filter or fuel filter element. (→ Page 195)
W1005 X Replace air filter. (→ Page 204)
W1006 Replace fuel injectors. (→ Page 179)
W1009 Check layer thickness of the oil residue, clean out and re- (→ Page 232)
place filter sleeve during every oil change at the latest.
W1011 Perform endoscopic examination of combustion chambers. (→ Page 168)
W1026 Check buffer clearance of resilient mounts, check securing (→ Page 257)
screws for secure seating.
W1053 Lubricate lubrication points. (→ Page 217)
W1080 Operate ratchet lever several times together with engine oil (→ Page 229)
change.
W1096 Drain oil sludge and examine for metallic residue, replace fil- (→ Page 224)
ter elements during engine oil change or, at the latest, after
the limit number of years.
W1100 X Replace filter elements and sealing rings and clean housing (→ Page 225)
when changing engine oil.
W1142 Check components, replace rotary seal(s), seals and gaskets. (→ Page 251)
W1143 Check components, replace rotary seal, seals and gaskets. (→ Page 251)
W1396 One-time tasks after the first 50 operating hours – with a new (→ Page 69)
engine after maintenance tasks QL3 or a major overhaul QL4.
W1752 Check rocker arms, roller tappets, pushrods and button caps (→ Page 175)
for wear, only one unit A-B side.
TIM-ID: 0000041780 - 001

W1760 Check and adjust valve clearance. IMPORTANT! First adjust- (→ Page 172)
ment after 50 operating hours!
W1763 Replace limiting valves. (→ Page 184)
X5000 X Check for operation and leaks. (→ Page 208)
X5001 Check starting valve. (→ Page 208)
X5004 X Actuate drain valve. (→ Page 212)
X5020 X Check for leaks. (→ Page 208)
X5351 Check condition (visual inspection). (→ Page 166)

70 | Maintenance | MS150102/04E 2015-11

 Task Option Measures
X5403 X Check function. (→ Page 256)
X5501 Check function. (→ Page 265)
X5512 Check function. (→ Page 265)
X5602 X Check for operation and leaks. (→ Page 197)
X5750 X Oil compressor (note: use approved oil of the manufacturer). (→ Page 216)
X5751 X Clean filter. (→ Page 215)
X5900 Replace filter element. (→ Page 195)
X7650 X Clean air filter. (→ Page 206)
X7803 X Actuate water drainage three times during operation and (→ Page 240)
check function.
X7804 X Visually inspect for leaks and general condition. (→ Page 61)

Table 5: Maintenance task reference table [QL1]

TIM-ID: 0000041780 - 001

MS150102/04E 2015-11 | Maintenance | 71

 6.3 Maintenance schedule ‒ Additional information
Remarks on low-load operation
Low-load operation leads to contamination and build-up of carbon deposits in the exhaust system and in the
combustion chambers, which might cause malfunction after extended operation in the lower power range.

Guidelines for burning out carbon deposits

To avoid malfunction, the carbon deposits must be burnt out after extended engine operation at low load.

The interval for burning out the carbon deposits depends on engine load and operating time and is specified
in the following table:

Engine speed in rpm Power in % Operating time in h Action

≤600 ≤10 >0.5 <24 Burn out carbon deposits

To burn out the carbon deposits after a low-load period, the engine must be operated at 1200 rpm minimum
(all turbochargers cut in) for at least 15 minutes.
This burn-out procedure is expected to improve wear characteristics as follows:
• Reduction of oil and oil carbon deposits on valve gear and valve guides.
• Prevention of major oil accumulations on turbine and compressor sides of the cut-out turbocharger, thus
preventing oil combustion in the ship-side exhaust system. Reduction of possible temperature increases in
the combustion chamber due to oil combustion. Reduction of possible hydraulic locks in the combustion
chamber due to oil accumulation.
• Combustion residues are removed from valves, injection nozzles and piston crowns. This will reduce the
wear of pistons, piston rings and cylinder liners.

TIM-ID: 0000053358 - 002

72 | Maintenance | MS150102/04E 2015-11

 7 Troubleshooting
7.1 Troubleshooting

Engine does not turn when starter is actuated

Component Cause Task
Battery Discharged or faulty Charge or replace (see manufacturer's
documentation).
Cable connections faulty Check that cable connections are prop-
erly secured (see manufacturer's docu-
mentation).
Compressed air sup- Inadequate compressed air reserves 1. Check compressed air supply
ply 2. Contact Service.
Starter Starter faulty Contact Service.
Engine wiring Faulty Check (→ Page 259).
LOP Seating of assemblies or connectors Inspect visually.
loose
Engine Blocked (engine cannot be barred man- Contact Service.
ually)
Start interlock limit Limit switch not installed 1. Check that limit switch is installed
switch Limit switch faulty (→ Page 264)
2. Replace limit switch.
Wiring faulty Check wiring (→ Page 259).

Engine turns on starting, but does not fire

Component Cause Task
Starter Poor rotation: 1. Check compressed air supply
2. Contact Service.
Engine wiring Faulty Check (→ Page 259).
Fuel system Air in fuel system Vent fuel system (→ Page 186).
Fuel prefilter clogged Replace fuel prefilter (→ Page 190).
Fuel filter clogged Replace fuel filter (→ Page 195).
Check valve faulty Contact Service.
Fuel line leaking Inspect visually.
Fuel inlet closed Open fuel inlet.
ECS Faulty Contact Service.
TIM-ID: 0000042955 - 002

Governor actuator Faulty Contact Service.

Engine fires unevenly

Component Cause Task
Fuel injection equip- Injector defective Replace (→ Page 179).
ment HP pump defective Contact Service.
Engine wiring Faulty Check (→ Page 259).

MS150102/04E 2015-11 | Troubleshooting | 73

 Component Cause Task
Fuel system Air in fuel system Vent fuel system (→ Page 186).
Fuel inlet closed Open fuel inlet.
Fuel line leaking Inspect visually.
Fuel prefilter clogged Replace fuel prefilter (→ Page 190).
Fuel filter clogged Replace fuel filter (→ Page 195).

Engine does not reach full load speed

Component Cause Task
Fuel supply Fuel inlet closed Fully open shutoff valve upstream of fuel
prefilter.
Fuel prefilter clogged Replace (→ Page 190).
Fuel filter clogged Replace (→ Page 195).
Check valve faulty Contact Service.
Air in fuel system Vent fuel system (→ Page 186).
Fuel line leaking Inspect visually.
Air supply Air filter clogged Check signal ring position of service in-
dicator (→ Page 203).
Turbocharger sequencing system Check function of actuating cylinders
(→ Page 218).
Exhaust turbocharger dirty or damaged Inspect visually.
Air supply line leaking Inspect visually.
Charge-air tempera- Charge-air cooler clogged 1. Inspect visually
ture 2. Clean drain line (→ Page 202)
3. Contact Service.
Raw water pressure available Inspect visually.
Raw water valve open Inspect visually.
Fuel injection equip- Injector defective Replace (→ Page 179).
ment HP pump defective Contact Service.
Engine management Engine governor in ECS Contact Service.
Governor actuator Contact Service.
Compression pressure Valve clearance Check and adjust valve clearance
(→ Page 172).
Cylinder-head gasket faulty Contact Service.
Vessel Overloaded Contact Service.
Vessel too heavy Check load.
Reduce load.
TIM-ID: 0000042955 - 002

Trim Trim vessel.

Hull, shaft, propeller, rudder fouled Clean.
Rudder Rudder position. Align rudder.
Propeller Too large following propeller change Change.

74 | Troubleshooting | MS150102/04E 2015-11

 Engine speed not steady
Component Cause Task
Fuel injection equip- Injector defective Replace (→ Page 179).
ment HP pump defective Contact Service.
Fuel system Air in fuel system Vent fuel system (→ Page 186).
ECU Faulty Contact Service.

Charge-air temperature too high

Component Cause Task
Engine coolant Incorrect coolant concentration Check (→ Page 249).
Charge-air cooler Contaminated Contact Service.
Engine room Air-intake temperature too high Check fan
Check air inlet/outlet ducts.

Charge-air pressure too low

Component Cause Task
Air supply Air filter clogged Clean filter element (→ Page 206).
Turbocharger sequencing system Check function of actuating cylinders
(→ Page 218).
Charge-air cooler Contaminated Contact Service.
Exhaust turbocharger Faulty Contact Service.

Coolant leaks at charge-air cooler

Component Cause Task
Charge-air cooler Leaking, significant coolant loss Contact Service.

Black exhaust gas

Component Cause Task
Air supply Air filter clogged Clean filter element (→ Page 206).
Turbocharger sequencing system Check function of actuating cylinders
(→ Page 218).
Fuel injection equip- Injector defective Check (→ Page 178).
ment HP pump defective Contact Service.
Exhaust gas system Exhaust gas overpressure Contact Service.
Exhaust pipes, exhaust silencers dirty Contact Service.
Exhaust flap actuation defective Contact Service.
TIM-ID: 0000042955 - 002

Compression pressure Valve clearance Adjust valve clearance (→ Page 172).

Valve Worn: Contact Service.
Compression ring Worn: Contact Service.
Vessel Overloaded Contact Service.

MS150102/04E 2015-11 | Troubleshooting | 75

 Blue exhaust gas
Component Cause Task
Engine oil Too much engine oil in the engine Check engine oil level (→ Page 220).
Exhaust turbocharger Faulty Contact Service.
Cylinder head
Piston rings
Cylinder liner, crank-
case breather, valve
stem seal, oil control
ring, valve guide

White exhaust gas

Component Cause Task
Engine Not at operating temperature Run engine to reach operating tempera-
ture.
Fuel system Water in fuel Drain fuel prefilter (→ Page 188).
Combustion chamber Water ingress in cylinder head. Cylinder Contact Service.
liner leak-tightness
Fuel injection equip- Injector defective Replace (→ Page 179).
ment
Charge air preheating Solenoid and control valve Contact Service.
unit
Charge-air cooler Leaking Contact Service.

Exhaust gas temperature too high

Component Cause Task
Air supply Air filter clogged Clean filter element (→ Page 206).
Turbocharger sequencing system Check function of actuating cylinders
(→ Page 218).
Charge-air tempera- Too high, charge-air cooler dirty Contact Service.
ture
Exhaust system down- Exhaust gas overpressure Contact Service.
stream of exhaust tur- Exhaust pipe, exhaust silencer dirty. Ex- Contact Service.
bocharger haust flap actuation defective
Fuel injection equip- Injector defective Replace (→ Page 179).
ment HP pump defective Contact Service.

Exhaust gas temperature too low

TIM-ID: 0000042955 - 002

Component Cause Task

Combustion: Fuel not Injector Replace (→ Page 179).
fully combusted in cyl- HP pump defective Contact Service.
inder

76 | Troubleshooting | MS150102/04E 2015-11

 Starting-air pressure too low
Component Cause Task
Starting system Shutoff valves closed Open shutoff valves.
Starting system leaking Check leak-tightness of following com-
ponents:
• Compressed air tank
• Compressed air lines

Coolant temperature too high

Component Cause Task
Coolant system Engine coolant level Check level (→ Page 243).
Coolant thermostat faulty Contact Service.
Coolant circuit contaminated Contact Service.
Vent line clogged Check for obstructions (→ Page 241).
Coolant temperature Temperature transmitter Contact Service.
monitoring

Coolant temperature too low

Component Cause Task
Coolant system Coolant thermostat faulty Contact Service.
Preheating temperature too low Adjust temperature at coolant preheat-
ing unit.
Coolant temperature Temperature transmitter Contact Service.
monitoring

Engine oil pressure rises

Component Cause Task
Engine oil pressure re- Opening pressure of engine oil pressure Contact Service.
lief valve relief valve incorrect.
Engine oil monitoring Remote pressure transmitter Contact Service.

Engine oil pressure too low

Component Cause Task
Engine oil Engine oil level too low Check engine oil level (→ Page 220).
External lines leaking Visual inspection
Engine oil pressure re- Opening pressure of engine oil pressure Contact Service.
lief valve relief valve incorrect
TIM-ID: 0000042955 - 002

Engine oil filter Engine oil filter element clogged Replace filter (→ Page 228).
Engine oil monitoring Pressure transmitter Contact Service.
Engine oil pump Pump drive faulty Contact Service.

MS150102/04E 2015-11 | Troubleshooting | 77

 Engine oil temperature too high
Component Cause Task
Engine oil heat ex- Engine oil heat exchanger dirty Contact Service.
changer
Engine oil temperature Temperature transmitter, remote-read- Contact Service.
monitoring ing thermometer faulty

Piston cooling oil pressure too low

Component Cause Task
Engine oil Engine oil level too low Check engine oil level (→ Page 220).
External lines leaking Visual inspection
Fuel in engine oil Take engine oil sample and analyze
(→ Page 223).
Engine oil filter Piston cooling oil filter clogged Replace filter (→ Page 215).
Engine oil temperature Temperature transmitter, remote-read- Contact Service.
monitoring ing thermometer faulty
Fuel delivery pump Fuel delivery pump and pump drive faul- Contact Service.
ty
Fuel pressure monitor- Pressure transmitter faulty Contact Service.
ing

Priming oil pressure not reached

Component Cause Task
Engine oil Engine oil level too low Check engine oil level (→ Page 220).
External lines leaking Visual inspection
Priming system Not cut in Open shutoff cock.
Oil priming pump Oil priming pump not running. 1. Check power supply;
2. Perform functional test (→ Page 64).
Engine oil temperature Temperature transmitter, remote-read- Contact Service.
monitoring ing thermometer faulty
Fuel delivery pump Fuel delivery pump and pump drive faul- Contact Service.
ty
Fuel pressure monitor- Pressure transmitter faulty Contact Service.
ing

Fuel in leak fuel tank

Component Cause Task
Fuel line Fuel in leak fuel tank, fuel lines leaking Empty leak fuel tank (→ Page 187).
TIM-ID: 0000042955 - 002

Leak fuel monitoring Leak fuel indicator faulty Contact Service.

78 | Troubleshooting | MS150102/04E 2015-11

 Fuel pressure too low
Component Cause Task
Fuel system Fuel lines leaking 1. Visual inspection
2. Contact Service.
Check valve response value Contact Service.
Fuel prefilter clogged Replace (→ Page 190).
Fuel filter clogged Replace (→ Page 195).
Fuel delivery pump Fuel delivery pump and pump drive faul- Contact Service.
ty
Fuel pressure monitor- Pressure transmitter faulty Contact Service.
ing
TIM-ID: 0000042955 - 002

MS150102/04E 2015-11 | Troubleshooting | 79

 7.2 Oil priming pump, fuel booster pump – Troubleshooting
Oil priming pump does not run in automatic mode.
Green indicator lamp lights up.
Cause Corrective action
Contactor K001 defective. u Contact Service.

Oil priming pump does not run in automatic mode.

Green indicator lamp lights up.
Cause Corrective action
Excessive temperature of pump u Contact Service.
motor.
Wrong setting of motor protection u Contact Service.
relay. • Adjust motor protection relay Q001.
Motor protection relay defective. u Contact Service.
• Replace motor protection relay Q001.
Overcurrent breaker Q002 has u Contact Service.
tripped. • Check oil priming pump.
Wiring faulty. u Contact Service.
• Check wiring.(→ Page 259)
Selector switch is not in AUTO u Turn selector switch to AUTO.(→ Page 55)
position.
Switch S001 defective. u Contact Service.
• Replace switch S001.
No control signal from LOP. 1. Check wiring.(→ Page 259)
2. Contact Service.
Fuse F001 tripped. u Check fuse.

Oil priming pump does not run in manual mode.

Green indicator lamp lights up.
Cause Corrective action
Fault in load circuit: No external u Contact Service.
mains voltage supply.
Wiring faulty. u Check wiring.(→ Page 259)
Contacts or coil of contactor u Contact Service.
K001 defective.
Oil priming pump defective. u Contact Service.
TIM-ID: 0000042596 - 001

80 | Troubleshooting | MS150102/04E 2015-11

 Oil priming pump does not run in manual mode.
Green indicator lamp lights up.
Cause Corrective action
Fault in control circuit: No 24 VDC u Contact Service.
at terminal X001–1.
Switch S001 defective. u Contact Service.
Motor protection relay Q001 has 1. Check wiring. (→ Page 259)
tripped. 2. Contact Service:
• Check oil priming pump.
Fuse E001 tripped u Check fuse.

Oil priming pump runs normally

Green indicator lamp not lit or only glowing dimly.
Cause Corrective action
LED of indicator lamp defective. u Replace LED. (→ Page 262)

Fuel booster pump does not run in automatic mode.

Green indicator lamp lights up.
Cause Corrective action
Contactor K003 defective. u Contact Service.

Fuel booster pump does not run in automatic mode.

Green indicator lamp lights up.
Cause Corrective action
Selector switch is not in AUTO u Turn selector switch to AUTO position (→ Page 55).
position.
Excessive temperature of pump u Contact Service.
motor.
Wrong setting of motor protection u Contact Service.
relay. • Adjust motor protection relay Q004.
Motor protection relay defective. u Contact Service.
• Replace motor protection relay Q004.
Overcurrent breaker Q003 has u Contact Service.
tripped. • Check oil refill pump.
Fault in control or load circuit: u Contact Service.
Switch S002 defective, no control
TIM-ID: 0000042596 - 001

signal from LOP.

Fuse F001 tripped. u Check fuse.

MS150102/04E 2015-11 | Troubleshooting | 81

 Fuel booster pump does not run in manual mode.
Green indicator lamp lights up.
Cause Corrective action
Fault in load circuit: No external 1. Check wiring.(→ Page 259)
mains voltage supply. 2. Contact Service.
Fault in control circuit: Contacts u Contact Service.
or coil of contactor K003
defective
Fuel booster pump faulty. u Contact Service:
• Check fuel booster pump.

Fuel booster pump does not run in manual mode.

Green indicator lamp lights up.
Cause Corrective action
Selector switch is not in AUTO u Turn selector switch to AUTO position.(→ Page 55)
position.
Fault in control circuit: No 24 VDC u Contact Service.
at terminal X001–1. Switch S002
defective, no control signal from
LOP.
Motor protection relay has 1. Check wiring.(→ Page 259)
tripped. 2. Contact Service:
• Check fuel booster pump.
Fuse F001 tripped. u Check fuse.

Fuel booster pump running normally.

Green indicator lamp not lit or only glowing dimly.
Cause Corrective action
LED of indicator lamp defective. u Replace LED. (→ Page 262)

TIM-ID: 0000042596 - 001

82 | Troubleshooting | MS150102/04E 2015-11

 7.3 Fault messages – Engine Control Unit
3 – HI T-Fuel
ZKP-Number: 2.0122.931
Yellow alarm
Cause Corrective action
Fuel temperature too high (limit u Check tank temperature. Contact Service if no malfunction can be
value 1). detected.

4 – SS T-Fuel
ZKP-Number: 2.0122.932
Red alarm
Cause Corrective action
Fuel temperature too high (limit u Check tank temperature. Contact Service if no malfunction can be
value 2). detected.

5 – HI T-Charge Air
ZKP-Number: 2.0121.931
Yellow alarm
Cause Corrective action
Charge-air temperature too high u Check charge-air cooler.
(limit value 1).

6 – SS T-Charge Air
ZKP-Number: 2.0121.932
Red alarm
Cause Corrective action
Charge-air temperature too high u Check charge-air cooler.
(limit value 2).

15 – LO P-Lube Oil
ZKP-Number: 2.0100.921
Yellow alarm
TIM-ID: 0000040293 - 002

Cause Corrective action

Lube oil pressure too low (limit u Contact Service.
value 1).

MS150102/04E 2015-11 | Troubleshooting | 83

 16 – SS P-Lube Oil
ZKP-Number: 2.0100.922
Red alarm
Cause Corrective action
Lube oil pressure too low (limit u Contact Service.
value 2).

21 – HI T-Exhaust B
ZKP-Number: 2.0127.931
Yellow alarm
Cause Corrective action
Exhaust temperature (B side) too u Contact Service.
high (limit value 1).

22 – SS T-Exhaust B
ZKP-Number: 2.0127.932
Red alarm
Cause Corrective action
Exhaust temperature (B side) too u Contact Service.
high (limit value 2).

23 – LO Coolant Level
ZKP-Number: 2.0152.921
Yellow alarm
Cause Corrective action
Coolant level too low (limit value u Check coolant level in expansion tank.
1).

25 – HI P-Diff. Lube Oil

ZKP-Number: 2.0154.931
Yellow alarm
Cause Corrective action
Differential oil pressure at oil filter u Contact Service.
TIM-ID: 0000040293 - 002

too high (limit value 1).

26 – SS P-Diff. Lube Oil

ZKP-Number: 2.0154.932
Red alarm
Cause Corrective action
Differential oil pressure at oil filter u Contact Service.
too high (limit value 2).

84 | Troubleshooting | MS150102/04E 2015-11

 27 – HI Leak Fuel Level
ZKP-Number: 2.0151.931
Yellow alarm
Cause Corrective action
Leak-off fuel level too high (limit u Contact Service.
value 1).

29 – HI ETC Idle Speed Too High

ZKP-Number: 1.8004.206
Yellow alarm
Cause Corrective action
Idling speed of one of the u Contact Service.
secondary turbochargers is too
high.

30 – SS Engine Speed
ZKP-Number: 2.2510.932
Red alarm
Cause Corrective action
Engine overspeed (limit value 2). u Contact Service.

31 – HI ETC1 Speed
ZKP-Number: 2.3011.931
Yellow alarm
Cause Corrective action
Speed of primary turbocharger u Contact Service.
too high (limit value 1).

32 – SS ETC1 Speed
ZKP-Number: 2.3012.932
Red alarm
Cause Corrective action
Speed of primary turbocharger u Contact Service.
TIM-ID: 0000040293 - 002

too high (limit value 2).

33 – HI P-Diff. Fuel
ZKP-Number: 2.0114.931
Yellow alarm
Cause Corrective action
Differential pressure at fuel filter u Contact Service.
too high (limit value 1).

MS150102/04E 2015-11 | Troubleshooting | 85

 34 – SS P-Diff. Fuel
ZKP-Number: 2.0114.932
Red alarm
Cause Corrective action
Differential pressure at fuel filter u Contact Service.
too high (limit value 2).

36 – HI ETC2 Speed
ZKP-Number: 2.3013.931
Yellow alarm
Cause Corrective action
Speed of 1st secondary u Contact Service.
turbocharger too high (limit value
1).

37 – SS ETC2 Speed
ZKP-Number: 2.3013.912
Red alarm
Cause Corrective action
Speed of 1st secondary u Contact Service.
turbocharger too high (limit value
2).

38 – AL ETC Synchro Fault

ZKP-Number: 1.8004.205
Yellow alarm
Cause Corrective action
Synchronization fault between u Contact Service.
primary turbocharger and one of
the secondary turbochargers.

39 – AL ETC2 Cutin Failure

ZKP-Number: 1.8004.204
Yellow alarm
TIM-ID: 0000040293 - 002

Cause Corrective action

ETC2 failed to cut in. u Contact Service.

86 | Troubleshooting | MS150102/04E 2015-11

 44 – LO Coolant Level Charge-Air Cooler
ZKP-Number: 2.0153.921
Yellow alarm
Cause Corrective action
Coolant level of charge-air cooler u Contact Service.
too low (limit value 1).

51 – HI T-Lube Oil
ZKP-Number: 2.0125.931
Yellow alarm
Cause Corrective action
Lube oil temperature too high u Contact Service.
(limit value 1).

52 – SS T-Lube Oil
ZKP-Number: 2.0125.932
Red alarm
Cause Corrective action
Lube oil temperature too high u Contact Service.
(limit value 2).

53 – HI T-Intake Air
ZKP-Number: 2.0123.931
Yellow alarm
Cause Corrective action
Intake air temperature too high u Contact Service.
(limit value 1).

54 – HIHI T-Intake Air

ZKP-Number: 2.0123.932
Red alarm
Cause Corrective action
Intake air temperature too high u Contact Service.
TIM-ID: 0000040293 - 002

(limit value 2).

57 – LO P-Coolant
ZKP-Number: 2.0101.921
Yellow alarm
Cause Corrective action
Coolant pressure too low (limit u Check coolant circuit. Contact Service if no malfunction can be
value 1). detected.

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 58 – SS P-Coolant
ZKP-Number: 2.0101.922
Red alarm
Cause Corrective action
Coolant pressure too low (limit u Check coolant circuit. Contact Service if no malfunction can be
value 2) ==> Engine stop or detected.
injection quantity reduction.

59 – SS T-Coolant L3
ZKP-Number: 2.0120.933
Red alarm
Cause Corrective action
Coolant temperature too high/low u Contact Service.
(limit value 3).

60 – SS T-Coolant L4
ZKP-Number: 2.0120.934
Red alarm
Cause Corrective action
Coolant temperature too high/low u Contact Service.
(limit value 4).

63 – HI P-Crank Case
ZKP-Number: 2.0106.931
Yellow alarm
Cause Corrective action
Crankcase pressure too high (limit u Contact Service.
value 1).

64 – SS P-Crank Case
ZKP-Number: 2.0106.932
Red alarm
Cause Corrective action
TIM-ID: 0000040293 - 002

Crankcase pressure too high (limit u Contact Service.

value 2).

88 | Troubleshooting | MS150102/04E 2015-11

 65 – LO P-Fuel
ZKP-Number: 2.0102.921
Yellow alarm
Cause Corrective action
Fuel supply pressure too low (limit u Check filter (low-pressure fuel side).
value 1).

66 – SS P-Fuel
ZKP-Number: 2.0102.922
Red alarm
Cause Corrective action
Fuel supply pressure too low (limit u Check filter (low-pressure side).
value 2).

67 – HI T-Coolant
ZKP-Number: 2.0120.931
Yellow alarm
Cause Corrective action
Coolant temperature too high u Check coolant circuit.
(limit value 1).

68 – SS T-Coolant
ZKP-Number: 2.0120.932
Red alarm
Cause Corrective action
Coolant temperature too high u Check coolant circuit.
(limit value 2).

81 – AL Rail Leakage
ZKP-Number: 1.8004.046
Yellow alarm
Cause Corrective action
Pressure gradient in the rail too 1. On stopping: Seal system. Contact Service.
TIM-ID: 0000040293 - 002

low on starting or too high on 2. On starting: Check engine for leakage, if none found, attempt
stopping (high-pressure system restarting as per operating instructions.
leaking, air in the system).

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 82 – HI P-Fuel (Common Rail)
ZKP-Number: 2.0104.931
Yellow alarm
Cause Corrective action
Rail pressure > Set value => DBR u Check wiring of HP fuel control block. Contact Service if no fault
reduction, later BOI (==> HP fuel can be detected.
control block faulty or HP fuel
control block wiring).

83 – LO P-Fuel (Common Rail)

ZKP-Number: 2.0104.921
Yellow alarm
Cause Corrective action
Rail pressure < Set value => DBR 1. Check wiring of HP fuel control block.
reduction (==> HP fuel control 2. Check high-pressure system for leakage.
block faulty or leak in HP system). 3. Contact Service if no fault can be detected.

89 – SS Engine Speed too Low

ZKP-Number: 2.2500.030
Red alarm
Cause Corrective action
Engine stalls. In normal operation u Note further alarms.
the engine speed is below the
limit set in parameter 2.2500.027
Engine stalling speed limit and no
engine stop is applied. If this
happens, the engine is stopped
for safety reasons.

90 – SS No Idling Speed
ZKP-Number: 2.1090.925
Red alarm
Cause Corrective action
Idling speed not reached ==> u Check for additional messages.
Start aborted.
TIM-ID: 0000040293 - 002

102 – AL Fuel Cons. Counter Defect

ZKP-Number: 1.8004.624
Yellow alarm
Cause Corrective action
Consumption meter faulty. u Replace Engine Control Unit at next opportunity.

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 104 – AL Runtime Meter Fault
ZKP-Number: 1.8004.623
Yellow alarm
Cause Corrective action
Hour meter faulty. u Replace Engine Control Unit at next opportunity.

118 – LO ECU Supply Voltage

ZKP-Number: 2.0140.921
Yellow alarm
Cause Corrective action
Supply voltage too low (limit value u Check battery / generator.
1).

119 – LOLO ECU Supply Voltage

ZKP-Number: 2.0140.922
Red alarm
Cause Corrective action
Supply voltage too low (limit value u Check battery / generator.
2).

120 – HI ECU Supply Voltage

ZKP-Number: 2.0140.931
Yellow alarm
Cause Corrective action
Supply voltage too high (limit u Check battery / generator.
value 1).

121 – HIHI ECU Supply Voltage

ZKP-Number: 2.0140.932
Red alarm
Cause Corrective action
Supply voltage too high (limit u Check battery / generator.
value 2).
TIM-ID: 0000040293 - 002

122 – HI T-ECU
ZKP-Number: 2.0132.921
Yellow alarm
Cause Corrective action
Electronics temperature too high u Check engine room ventilation.
(limit value 1).

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 141 – AL Power too high
ZKP-Number: 1.1088.007
Yellow alarm
Cause Corrective action
This alarm is activated when the u Contact Service.
average power of the last 24
hours exceeds the maximum
value set in PR1.1088.001.

142 – AL MCR exceeded 1 hour

ZKP-Number: 1.1088.006
Yellow alarm
Cause Corrective action
The alarm is triggered if the MCR u Contact Service.
has been exceeded for more than
1 hour within the last 12 hours.

180 – AL CAN1 Node Lost

ZKP-Number: 2.0500.680
Yellow alarm
Cause Corrective action
Connection to a node on CAN bus u Check devices connected to CAN.
1 failed.

181 – AL CAN2 Node Lost

ZKP-Number: 2.0500.681
Yellow alarm
Cause Corrective action
Connection to a node on CAN bus u Check devices connected to CAN.
2 failed.

182 – AL CAN Wrong Parameters

ZKP-Number: 2.0500.682
Yellow alarm
TIM-ID: 0000040293 - 002

Cause Corrective action

Incorrect parameter values u Check devices connected to CAN.
entered in data record.

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 183 – AL CAN No PU Data
ZKP-Number: 2.0500.683
Yellow alarm
Cause Corrective action
The selected CAN mode initializes u Check devices connected to CAN.
communication by means of the
PU data module. However, the
necessary PU data module is not
present or is invalid.

184 – AL CAN PU Data Flash Error

ZKP-Number: 2.0500.684
Yellow alarm
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

ZKP-Number: 2.0500.686
Yellow alarm
Cause Corrective action
CAN controller 1 is in "Bus-Off" u Contact Service.
status. => Automatic switchover
to CAN 2. ==> Reasons are e.g.
short circuit, major malfunctions
or baud rate incompatibilities.

187 – AL CAN1 Error Passive

ZKP-Number: 2.0500.687
Yellow alarm
Cause Corrective action
CAN controller 1 has signaled a u Contact Service.
warning. ==> Reasons are e.g. no
corresponding node, minor
TIM-ID: 0000040293 - 002

malfunctions or temporary bus

overload.

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 188 – AL CAN2 Bus Off
ZKP-Number: 2.0500.688
Yellow alarm
Cause Corrective action
CAN controller 2 is in "Bus-Off" u Contact Service.
status. => Automatic switchover
to CAN 1. ==> Reasons are e.g.
short circuit, major malfunctions
or baud rate incompatibilities.

189 – AL CAN2 Error Passive

ZKP-Number: 2.0500.689
Yellow alarm
Cause Corrective action
CAN controller 2 has signaled a u Contact Service.
warning. ==> Reasons are e.g. no
corresponding node, minor
malfunctions or temporary bus
overload.

190 – AL EMU Parameter Not Supported

ZKP-Number: 2.0500.690
Yellow alarm
Cause Corrective action
EMU parameters are not u Contact Service.
supported. ==> Incompatibility.

201 – SD T-Coolant
ZKP-Number: 1.8004.570
Yellow alarm
Cause Corrective action
Coolant temperature sensor u Check sensor and wiring (B6.1), replace as necessary.
faulty. ==> Short circuit or wire
break.

202 – SD T-Fuel
TIM-ID: 0000040293 - 002

ZKP-Number: 1.8004.572
Yellow alarm
Cause Corrective action
Fuel temperature sensor faulty. u Check sensor and wiring (B33.5), replace as necessary.
==> Short circuit or wire break.

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 203 – SD T-Charge Air
ZKP-Number: 1.8004.571
Yellow alarm
Cause Corrective action
Charge air temperature sensor u Check sensor and wiring (B9.5), replace as necessary.
faulty. ==> Short circuit or wire
break.

204 – SD Level Lube Oil

ZKP-Number: 1.8004.602
Yellow alarm
Cause Corrective action
Lube oil level sensor faulty. ==> u Check sensor and wiring, replace as necessary.
Short circuit or wire break.

207 – SD T-Exhaust B
ZKP-Number: 1.8004.577
Yellow alarm
Cause Corrective action
Exhaust temperature sensor on B- u Check sensor and wiring (B4.25), replace as necessary.
side faulty. ==> Short circuit or
wire break.

208 – SD P-Charge Air

ZKP-Number: 1.8004.566
Yellow alarm
Cause Corrective action
Charge air pressure sensor faulty. u Check sensor and wiring (B10.1), replace as necessary.
==> Short circuit or wire break.

211 – SD P-Lube Oil

ZKP-Number: 1.8004.563
Yellow alarm
TIM-ID: 0000040293 - 002

Cause Corrective action

Lube oil pressure sensor faulty. u Check sensor and wiring (B5.1), replace as necessary.
==> Short circuit or wire break.

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 212 – SD P-Coolant
ZKP-Number: 1.8004.564
Yellow alarm
Cause Corrective action
Coolant pressure sensor faulty. u Check sensor and wiring (B16), replace as necessary.
==> Short circuit or wire break.

214 – SD P-Crankcase
ZKP-Number: 1.8004.568
Yellow alarm
Cause Corrective action
Crankcase pressure sensor faulty. u Check sensor and wiring (B50), replace as necessary.
==> Short circuit or wire break.

215 – SD P-HP
ZKP-Number: 1.8004.567
Yellow alarm
Cause Corrective action
Rail pressure sensor faulty. ==> u Check sensor and wiring (B48.1), replace as necessary.
HP governor emergency mode
==> Short circuit or wire break.

216 – SD T-Lube Oil

ZKP-Number: 1.8004.575
Yellow alarm
Cause Corrective action
Lube oil temperature sensor u Check sensor and wiring (B7), replace as necessary.
faulty. ==> Short circuit or wire
break.

219 – SD T-Intake Air

ZKP-Number: 1.8004.573
Yellow alarm
TIM-ID: 0000040293 - 002

Cause Corrective action

Intake air temperature sensor u Check sensor and wiring (B3), replace as necessary.
faulty. ==> Short circuit or wire
break.

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 220 – SD Coolant Level
ZKP-Number: 1.8004.584
Yellow alarm
Cause Corrective action
Coolant level sensor faulty. ==> u Check sensor and wiring (XF33), replace as necessary.
Short circuit or wire break.

221 – SD P-Diff Lube Oil

ZKP-Number: 1.8004.585
Yellow alarm
Cause Corrective action
Lube oil differential pressure u Check sensor and wiring (F25), replace as necessary.
sensor faulty. ==> Short circuit or
wire break.

222 – SD Level Leakage Fuel

ZKP-Number: 1.8004.582
Yellow alarm
Cause Corrective action
Leak-off fuel level sensor faulty. u Check sensor and wiring (F46), replace as necessary.
==> Short circuit or wire break.

227 – SD P-Oil bef. Filter

ZKP-Number: 1.8004.620
Yellow alarm
Cause Corrective action
Sensor for lube-oil pressure u Check sensor and wiring (B5.3), replace as necessary.
before filter faulty. ==> Short
circuit or wire break.

228 – SD P-Fuel before Filter

ZKP-Number: 1.8004.595
Yellow alarm
TIM-ID: 0000040293 - 002

Cause Corrective action

Fuel pressure sensor faulty. ==> u Check sensor and wiring (B34.2), replace as necessary.
Short circuit or wire break.

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 229 – AL Stop Camshaft Sensor Defect
ZKP-Number: 1.8004.562
Yellow alarm
Cause Corrective action
Engine stop due to camshaft 1. Check sensor and wiring (B1), replace as necessary.
sensor fault (and a prior 2. Fault is rectified when engine is restarted.
crankshaft sensor fault in the
same operating cycle).

230 – SD Crankshaft Speed

ZKP-Number: 1.8004.498
Yellow alarm
Cause Corrective action
Crankshaft sensor faulty. ==> 1. Check sensor and wiring (B13.1), replace as necessary.
Short circuit or wire break. 2. Fault is rectified when engine is restarted.

231 – SD Camshaft Speed

ZKP-Number: 1.8004.499
Yellow alarm
Cause Corrective action
Camshaft sensor faulty. ==> Short 1. Check sensor and wiring (B1), replace as necessary.
circuit or wire break ==> Check 2. Fault is rectified when engine is restarted.
sensor and wiring (B1), replace as
necessary.

232 – SD ETC Speed 1

ZKP-Number: 1.3011.128
Yellow alarm
Cause Corrective action
Speed sensor of primary u Check sensor and wiring (B44.1), replace as necessary.
turbocharger faulty. ==> Short
circuit or wire break.

233 – SD ETC Speed 2

ZKP-Number: 1.3011.129
TIM-ID: 0000040293 - 002

Yellow alarm
Cause Corrective action
Speed sensor of secondary u Check sensor and wiring (B44.1), replace as necessary.
turbocharger faulty. ==> Short
circuit or wire break.

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 239 – SD P-Diff Fuel
ZKP-Number: 1.8004.598
Yellow alarm
Cause Corrective action
Fuel differential pressure sensor u Check sensor and wiring (B34.1 and B.2), replace as necessary.
faulty. ==> Occurs only in
combination with the alarm SD P-
Fuel before Filter or SD P-Fuel
after Filter.

240 – SD P-Fuel
ZKP-Number: 1.8004.565
Yellow alarm
Cause Corrective action
Fuel pressure sensor faulty. ==> u Check sensor and wiring (B34.1), replace as necessary.
Short circuit or wire break.

245 – SD ECU Supply Voltage

ZKP-Number: 2.8006.589
Yellow alarm
Cause Corrective action
Internal ECU fault. ==> Electronics u Replace Engine Control Unit.
faulty.

266 – SD Speed Demand

ZKP-Number: 2.8006.586
Yellow alarm
Cause Corrective action
Analog nominal speed setting u Check nominal speed transmitter and wiring, replace as necessary.
faulty. ==> Short circuit or wire
break.

321 – AL Wiring Cylinder A1

ZKP-Number: 1.8004.520
TIM-ID: 0000040293 - 002

Yellow alarm
Cause Corrective action
Short circuit fault in injector u Rectify injector solenoid valve short circuit (positive to negative)
wiring cylinder A1. Result: (e.g. by exchanging injectors). Fault rectification: When engine is
Misfiring. started.

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 322 – AL Wiring Cylinder A2
ZKP-Number: 1.8004.521
Yellow alarm
Cause Corrective action
Short circuit fault in injector u Rectify injector solenoid valve short circuit (positive to negative)
wiring cylinder A2. Result: (e.g. by exchanging injectors). Fault rectification: When engine is
Misfiring. started.

323 – AL Wiring Cylinder A3

ZKP-Number: 1.8004.522
Yellow alarm
Cause Corrective action
Short circuit fault in injector u Rectify injector solenoid valve short circuit (positive to negative)
wiring cylinder A3. Result: (e.g. by exchanging injectors). Fault rectification: When engine is
Misfiring. started.

324 – AL Wiring Cylinder A4

ZKP-Number: 1.8004.523
Yellow alarm
Cause Corrective action
Short circuit fault in injector u Rectify injector solenoid valve short circuit (positive to negative)
wiring cylinder A4. Result: (e.g. by exchanging injectors). Fault rectification: When engine is
Misfiring. started.

325 – AL Wiring Cylinder A5

ZKP-Number: 1.8004.524
Yellow alarm
Cause Corrective action
Short circuit fault in injector u Rectify injector solenoid valve short circuit (positive to negative)
wiring cylinder A5. Result: (e.g. by exchanging injectors). Fault rectification: When engine is
Misfiring. started.

326 – AL Wiring Cylinder A6

ZKP-Number: 1.8004.525
TIM-ID: 0000040293 - 002

Yellow alarm
Cause Corrective action
Short circuit fault in injector u Rectify injector solenoid valve short circuit (positive to negative)
wiring cylinder A6. Result: (e.g. by exchanging injectors). Fault rectification: When engine is
Misfiring. started.

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 327 – AL Wiring Cylinder A7
ZKP-Number: 1.8004.526
Yellow alarm
Cause Corrective action
Short circuit fault in injector u Rectify injector solenoid valve short circuit (positive to negative)
wiring cylinder A7. Result: (e.g. by exchanging injectors). Fault rectification: When engine is
Misfiring. started.

328 – AL Wiring Cylinder A8

ZKP-Number: 1.8004.527
Yellow alarm
Cause Corrective action
Short circuit fault in injector u Rectify injector solenoid valve short circuit (positive to negative)
wiring cylinder A8. Result: (e.g. by exchanging injectors). Fault rectification: When engine is
Misfiring. started.

329 – AL Wiring Cylinder A9

ZKP-Number: 1.8004.528
Yellow alarm
Cause Corrective action
Short circuit fault in injector u Rectify injector solenoid valve short circuit (positive to negative)
wiring cylinder A9. Result: (e.g. by exchanging injectors). Fault rectification: When engine is
Misfiring. started.

330 – AL Wiring Cylinder A10

ZKP-Number: 1.8004.529
Yellow alarm
Cause Corrective action
Short circuit fault in injector u Rectify injector solenoid valve short circuit (positive to negative)
wiring cylinder A10. Result: (e.g. by exchanging injectors). Fault rectification: When engine is
Misfiring. started.

331 – AL Wiring Cylinder B1

ZKP-Number: 1.8004.530
TIM-ID: 0000040293 - 002

Yellow alarm
Cause Corrective action
Short circuit fault in injector u Rectify injector solenoid valve short circuit (positive to negative)
wiring cylinder B1. Result: (e.g. by exchanging injectors). Fault rectification: When engine is
Misfiring. started.

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 332 – AL Wiring Cylinder B2
ZKP-Number: 1.8004.531
Yellow alarm
Cause Corrective action
Short circuit fault in injector u Rectify injector solenoid valve short circuit (positive to negative)
wiring cylinder B2. Result: (e.g. by exchanging injectors). Fault rectification: When engine is
Misfiring. started.

333 – AL Wiring Cylinder B3

ZKP-Number: 1.8004.532
Yellow alarm
Cause Corrective action
Short circuit fault in injector u Rectify injector solenoid valve short circuit (positive to negative)
wiring cylinder B3. Result: (e.g. by exchanging injectors). Fault rectification: When engine is
Misfiring. started.

334 – AL Wiring Cylinder B4

ZKP-Number: 1.8004.533
Yellow alarm
Cause Corrective action
Short circuit fault in injector u Rectify injector solenoid valve short circuit (positive to negative)
wiring cylinder B4. Result: (e.g. by exchanging injectors). Fault rectification: When engine is
Misfiring. started.

335 – AL Wiring Cylinder B5

ZKP-Number: 1.8004.534
Yellow alarm
Cause Corrective action
Short circuit fault in injector u Rectify injector solenoid valve short circuit (positive to negative)
wiring cylinder B5. Result: (e.g. by exchanging injectors). Fault rectification: When engine is
Misfiring. started.

336 – AL Wiring Cylinder B6

ZKP-Number: 1.8004.535
TIM-ID: 0000040293 - 002

Yellow alarm
Cause Corrective action
Short circuit fault in injector u Rectify injector solenoid valve short circuit (positive to negative)
wiring cylinder B6. Result: (e.g. by exchanging injectors). Fault rectification: When engine is
Misfiring. started.

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 337 – AL Wiring Cylinder B7
ZKP-Number: 1.8004.536
Yellow alarm
Cause Corrective action
Short circuit fault in injector u Rectify injector solenoid valve short circuit (positive to negative)
wiring cylinder B7. Result: (e.g. by exchanging injectors). Fault rectification: When engine is
Misfiring. started.

338 – AL Wiring Cylinder B8

ZKP-Number: 1.8004.537
Yellow alarm
Cause Corrective action
Short circuit fault in injector u Rectify injector solenoid valve short circuit (positive to negative)
wiring cylinder B8. Result: (e.g. by exchanging injectors). Fault rectification: When engine is
Misfiring. started.

339 – AL Wiring Cylinder B9

ZKP-Number: 1.8004.538
Yellow alarm
Cause Corrective action
Short circuit fault in injector u Rectify injector solenoid valve short circuit (positive to negative)
wiring cylinder B9. Result: (e.g. by exchanging injectors). Fault rectification: When engine is
Misfiring. started.

340 – AL Wiring Cylinder B10

ZKP-Number: 1.8004.539
Yellow alarm
Cause Corrective action
Short circuit fault in injector u Rectify injector solenoid valve short circuit (positive to negative)
wiring cylinder B10. Result: (e.g. by exchanging injectors). Fault rectification: When engine is
Misfiring. = started.

341 – AL Open Load Cylinder A1

ZKP-Number: 1.8004.540
TIM-ID: 0000040293 - 002

Yellow alarm
Cause Corrective action
Disruption fault in injector wiring u Check injector wiring for disruption or rule out disruption in
cylinder A1. Result: Misfiring. solenoid valve (e.g. by exchanging injectors). Fault rectification:
After each working cycle.

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 342 – AL Open Load Cylinder A2
ZKP-Number: 1.8004.541
Yellow alarm
Cause Corrective action
Disruption fault in injector wiring u Check injector wiring for disruption or rule out disruption in
cylinder A2. Result: Misfiring. solenoid valve (e.g. by exchanging injectors). Fault rectification:
After each working cycle.

343 – AL Open Load Cylinder A3

ZKP-Number: 1.8004.542
Yellow alarm
Cause Corrective action
Disruption fault in injector wiring u Check injector wiring for disruption or rule out disruption in
cylinder A3. Result: Misfiring. solenoid valve (e.g. by exchanging injectors). Fault rectification:
After each working cycle.

344 – AL Open Load Cylinder A4

ZKP-Number: 1.8004.543
Yellow alarm
Cause Corrective action
Disruption fault in injector wiring u Check injector wiring for disruption or rule out disruption in
cylinder A4. Result: Misfiring. solenoid valve (e.g. by exchanging injectors). Fault rectification:
After each working cycle.

345 – AL Open Load Cylinder A5

ZKP-Number: 1.8004.544
Yellow alarm
Cause Corrective action
Disruption fault in injector wiring u Check injector wiring for disruption or rule out disruption in
cylinder A5. Result: Misfiring. solenoid valve (e.g. by exchanging injectors). Fault rectification:
After each working cycle.

346 – AL Open Load Cylinder A6

ZKP-Number: 1.8004.545
TIM-ID: 0000040293 - 002

Yellow alarm
Cause Corrective action
Disruption fault in injector wiring u Check injector wiring for disruption or rule out disruption in
cylinder A6. Result: Misfiring. solenoid valve (e.g. by exchanging injectors). Fault rectification:
After each working cycle.

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 347 – AL Open Load Cylinder A7
ZKP-Number: 1.8004.546
Yellow alarm
Cause Corrective action
Disruption fault in injector wiring u Check injector wiring for disruption or rule out disruption in
cylinder A7. Result: Misfiring. solenoid valve (e.g. by exchanging injectors). Fault rectification:
After each working cycle.

348 – AL Open Load Cylinder A8

ZKP-Number: 1.8004.547
Yellow alarm
Cause Corrective action
Disruption fault in injector wiring u Check injector wiring for disruption or rule out disruption in
cylinder A8. Result: Misfiring. solenoid valve (e.g. by exchanging injectors). Fault rectification:
After each working cycle.

349 – AL Open Load Cylinder A9

ZKP-Number: 1.8004.548
Yellow alarm
Cause Corrective action
Disruption fault in injector wiring u Check injector wiring for disruption or rule out disruption in
cylinder A9. Result: Misfiring. solenoid valve (e.g. by exchanging injectors). Fault rectification:
After each working cycle.

350 – AL Open Load Cylinder A10

ZKP-Number: 1.8004.549
Yellow alarm
Cause Corrective action
Disruption fault in injector wiring u Check injector wiring for disruption or rule out disruption in
to cylinder A10. Result: Misfiring. solenoid valve (e.g. by exchanging injectors). Fault rectification:
After each working cycle.

351 – AL Open Load Cylinder B1

ZKP-Number: 1.8004.550
TIM-ID: 0000040293 - 002

Yellow alarm
Cause Corrective action
Disruption fault in injector wiring u Check injector wiring for disruption or rule out disruption in
cylinder B1. Result: Misfiring. solenoid valve (e.g. by exchanging injectors). Fault rectification:
After each working cycle.

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 352 – AL Open Load Cylinder B2
ZKP-Number: 1.8004.551
Yellow alarm
Cause Corrective action
Disruption fault in injector wiring u Check injector wiring for disruption or rule out disruption in
cylinder B2. Result: Misfiring. solenoid valve (e.g. by exchanging injectors). Fault rectification:
After each working cycle.

353 – AL Open Load Cylinder B3

ZKP-Number: 1.8004.552
Yellow alarm
Cause Corrective action
Disruption fault in injector wiring u Check injector wiring for disruption or rule out disruption in
cylinder B3. Result: Misfiring. solenoid valve (e.g. by exchanging injectors). Fault rectification:
After each working cycle.

354 – AL Open Load Cylinder B4

ZKP-Number: 1.8004.553
Yellow alarm
Cause Corrective action
Disruption fault in injector wiring u Check injector wiring for disruption or rule out disruption in
cylinder B4. Result: Misfiring. solenoid valve (e.g. by exchanging injectors). Fault rectification:
After each working cycle.

355 – AL Open Load Cylinder B5

ZKP-Number: 1.8004.554
Yellow alarm
Cause Corrective action
Disruption fault in injector wiring u Check injector wiring for disruption or rule out disruption in
cylinder B5. Result: Misfiring. solenoid valve (e.g. by exchanging injectors). Fault rectification:
After each working cycle.

356 – AL Open Load Cylinder B6

ZKP-Number: 1.8004.555
TIM-ID: 0000040293 - 002

Yellow alarm
Cause Corrective action
Disruption fault in injector wiring u Check injector wiring for disruption or rule out disruption in
cylinder B6. Result: Misfiring. solenoid valve (e.g. by exchanging injectors). Fault rectification:
After each working cycle.

106 | Troubleshooting | MS150102/04E 2015-11

 357 – AL Open Load Cylinder B7
ZKP-Number: 1.8004.556
Yellow alarm
Cause Corrective action
Disruption fault in injector wiring u Check injector wiring for disruption or rule out disruption in
cylinder B7. Result: Misfiring. solenoid valve (e.g. by exchanging injectors). Fault rectification:
After each working cycle.

358 – AL Open Load Cylinder B8

ZKP-Number: 1.8004.557
Yellow alarm
Cause Corrective action
Disruption fault in injector wiring u Check injector wiring for disruption or rule out disruption in
cylinder B8. Result: Misfiring. solenoid valve (e.g. by exchanging injectors). Fault rectification:
After each working cycle.

359 – AL Open Load Cylinder B9

ZKP-Number: 1.8004.558
Yellow alarm
Cause Corrective action
Disruption fault in injector wiring u Check injector wiring for disruption or rule out disruption in
cylinder B9. Result: Misfiring. solenoid valve (e.g. by exchanging injectors). Fault rectification:
After each working cycle.

360 – AL Open Load Cylinder B10

ZKP-Number: 1.8004.559
Yellow alarm
Cause Corrective action
Disruption fault in injector wiring u Check injector wiring for disruption or rule out disruption in
cylinder B10. Result: Misfiring. solenoid valve (e.g. by exchanging injectors). Fault rectification:
After each working cycle.

361 – AL Power Stage Low

ZKP-Number: 1.8004.496
TIM-ID: 0000040293 - 002

Yellow alarm
Cause Corrective action
Internal electronic fault u Start ITS. Check additional messages if ITS indicates diagnosis
(electronics possibly faulty). "Electronics OK" (e.g. wiring faulty).

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 362 – AL Power Stage High
ZKP-Number: 1.8004.497
Yellow alarm
Cause Corrective action
Internal electronic fault u Start ITS. Check additional messages if ITS indicates diagnosis
(electronics possibly faulty). "Electronics OK" (e.g. wiring faulty).

363 – AL Stop Power Stage

ZKP-Number: 1.8004.560
Yellow alarm
Cause Corrective action
Internal electronic fault u Start ITS. Check additional messages if ITS indicates diagnosis
(electronics possibly faulty). "Electronics OK" (e.g. wiring faulty).

365 – AL Stop MV-Wiring Ground

ZKP-Number: 1.8004.561
Yellow alarm
Cause Corrective action
Injector wiring fault. Engine stop u Check wiring, replace wiring harness as necessary.
possible via Protection Module.
Possible causes:
1. Short circuit of injector
positive connection to ground
of one or more injectors.
2. Short circuit of the negative
injector connection or of one
or more injectors to ground.

381 – AL Wiring TOP 1

ZKP-Number: 2.8006.638
Yellow alarm
Cause Corrective action
Short circuit or wire break on u Contact Service.
transistor output, plant-side 1
(TOP 1).
TIM-ID: 0000040293 - 002

382 – AL Wiring TOP 2

ZKP-Number: 2.8006.639
Yellow alarm
Cause Corrective action
Short circuit or wire break on u Contact Service.
transistor output, plant-side 2
(TOP 2).

108 | Troubleshooting | MS150102/04E 2015-11

 383 – AL Wiring TOP 3
ZKP-Number: 2.8006.640
Yellow alarm
Cause Corrective action
Short circuit or wire break on u Contact Service.
transistor output, plant-side 3
(TOP 3).

384 – AL Wiring TOP 4

ZKP-Number: 2.8006.641
Yellow alarm
Cause Corrective action
Short circuit or wire break on u Contact Service.
transistor output, plant-side 4
(TOP 4).

390 – AL MCR Exceeded

ZKP-Number: 1.1085.009
Yellow alarm
Cause Corrective action
DBR/MCR function: MCR u None.
(maximum continuous rate) was
exceeded.

400 – AL Open Load Digital Input 1

ZKP-Number: 2.8006.625
Yellow alarm
Cause Corrective action
Line disruption at digital input 1. u Check wiring. Check resistance via switch. Contact Service if no
==> Wiring faulty or no resistance fault can be detected.
via switch.

401 – AL Open Load Digital Input 2

ZKP-Number: 2.8006.626
TIM-ID: 0000040293 - 002

Yellow alarm
Cause Corrective action
Line disruption at digital input 2. u Check wiring. Check resistance via switch. Contact Service if no
==> Wiring faulty or no resistance fault can be detected.
via switch.

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 402 – AL Open Load Digital Input 3
ZKP-Number: 2.8006.627
Yellow alarm
Cause Corrective action
Line disruption at digital input 3. u Check wiring. Check resistance via switch. Contact Service if no
==> Wiring faulty or no resistance fault can be detected.
via switch.

403 – AL Open Load Digital Input 4

ZKP-Number: 2.8006.628
Yellow alarm
Cause Corrective action
Line disruption at digital input 4. u Check wiring. Check resistance via switch. Contact Service if no
==> Wiring faulty or no resistance fault can be detected.
via switch.

404 – AL Open Load Digital Input 5

ZKP-Number: 2.8006.629
Yellow alarm
Cause Corrective action
Line disruption at digital input 5. u Check wiring. Check resistance via switch. Contact Service if no
==> Wiring faulty or no resistance fault can be detected.
via switch.

405 – AL Open Load Digital Input 6

ZKP-Number: 2.8006.630
Yellow alarm
Cause Corrective action
Line disruption at digital input 6. u Check wiring. Check resistance via switch. Contact Service if no
==> Wiring faulty or no resistance fault can be detected.
via switch.

406 – AL Open Load Digital Input 7

ZKP-Number: 2.8006.631
TIM-ID: 0000040293 - 002

Yellow alarm
Cause Corrective action
Line disruption at digital input 7. u Check wiring. Check resistance via switch. Contact Service if no
==> Wiring faulty or no resistance fault can be detected.
via switch.

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 407 – AL Open Load Digital Input 8
ZKP-Number: 2.8006.632
Yellow alarm
Cause Corrective action
Line disruption at digital input 8. u Check wiring. Check resistance via switch. Contact Service if no
==> Wiring faulty or no resistance fault can be detected.
via switch.

408 – AL Open Load Emerg. Stop Input ESI

ZKP-Number: 2.8006.633
Yellow alarm
Cause Corrective action
Open circuit at input for u Check wiring. Check resistance via switch. Contact Service if no
emergency stop. ==> Wiring faulty fault can be detected.
or no resistance via switch.

410 – LO U-PDU
ZKP-Number: 2.0141.921
Yellow alarm
Cause Corrective action
Injector voltage too low (limit u Execute Engine Control Unit self-test, replace ECU in case of fault.
value 1).

411 – LOLO U-PDU

ZKP-Number: 2.0141.922
Red alarm
Cause Corrective action
Injector voltage too low (limit u Execute Engine Control Unit self-test, replace ECU in case of fault.
value 2).

412 – HI U-PDU
ZKP-Number: 2.0141.931
Yellow alarm
TIM-ID: 0000040293 - 002

Cause Corrective action

Injector voltage too high (limit u Execute Engine Control Unit self-test, replace ECU in case of fault.
value 1).

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 413 – HIHI U-PDU
ZKP-Number: 2.0141.932
Red alarm
Cause Corrective action
Injector voltage too high (limit u Execute Engine Control Unit self-test, replace ECU in case of fault.
value 2).

422 – SD T-Charge Air B

ZKP-Number: 1.8004.605
Yellow alarm
Cause Corrective action
Charge-air temperature B-side u Check sensor and wiring (B9.6), replace as necessary.
faulty. ==> Short circuit or wire
break.

438 – LO P-Fuel 2 (Common Rail)

ZKP-Number: 2.0116.921
Yellow alarm
Cause Corrective action
Rail pressure < Set value => DBR 1. Check wiring of HP fuel control block.
reduction (==> HP fuel control 2. Check high-pressure system for leakage.
block faulty or leak in HP system). 3. Contact Service if no fault can be detected.

439 – HI P-Fuel 2 (Common Rail)

ZKP-Number: 2.0116.931
Yellow alarm
Cause Corrective action
Rail pressure > Set value => DBR u Check wiring of HP fuel control block. Contact Service if no fault
reduction, later BOI (==> HP fuel can be detected.
control block faulty or HP fuel
control block wiring).

441 – AL System 2 Leaky

ZKP-Number: 1.8004.047
TIM-ID: 0000040293 - 002

Yellow alarm
Cause Corrective action
Pressure gradient in rail is too low 1. On stopping: Seal system. Contact Service.
during engine start or too high 2. On starting: Check engine for leakage, if none found, attempt
when engine stops (==> high- restarting as per operating instructions.
pressure system leaking, air in
system).

112 | Troubleshooting | MS150102/04E 2015-11

 444 – SD U-PDU
ZKP-Number: 1.8004.578
Yellow alarm
Cause Corrective action
Sensor of injector output stage u Replace Engine Control Unit.
faulty. ==> ECU internal fault.

446 – SD P-HP 2
ZKP-Number: 1.8004.599
Yellow alarm
Cause Corrective action
Rail pressure sensor faulty. ==> u Check sensor and wiring (B48.2), replace as necessary.
HP governor emergency mode
==> Short circuit or wire break.

448 – HI P-Charge Air

ZKP-Number: 2.0103.931
Yellow alarm
Cause Corrective action
Charge-air pressure too high (limit u Contact Service.
value 1).

449 – SS P-Charge Air

ZKP-Number: 2.0103.932
Red alarm
Cause Corrective action
Charge-air pressure too high (limit u Contact Service.
value 2).

454 – SS Power Limitation Active

ZKP-Number: 2.7000.011
Red alarm
Cause Corrective action
TIM-ID: 0000040293 - 002

Power reduction activated. u None.

460 – HI T-Exhaust EMU

ZKP-Number: 2.8006.652
Yellow alarm
Cause Corrective action
Exhaust temperature of EMU too u Contact Service.
high (limit value 1).

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 461 – LO T-Exhaust EMU
ZKP-Number: 2.8006.653
Yellow alarm
Cause Corrective action
Exhaust temperature of EMU too u Contact Service.
low (limit value 1).

462 – HI T-Coolant EMU

ZKP-Number: 2.8006.654
Yellow alarm
Cause Corrective action
Coolant temperature of EMU u Contact Service.
violated limit value 1.

470 – SD T-ECU
ZKP-Number: 1.8004.587
Yellow alarm
Cause Corrective action
Temperature sensor for ECU u Replace Engine Control Unit.
faulty. ==> Short circuit or wire
break.

472 – AL Stop SD
ZKP-Number: 2.8006.593
Yellow alarm
Cause Corrective action
Engine stop because shutdown u Contact Service.
channels detect “sensor defect".

478 – AL Comb. Alarm Yel (Plant)

ZKP-Number: 2.8006.001
Yellow alarm
Cause Corrective action
TIM-ID: 0000040293 - 002

YELLOW summary alarm from u Contact Service.

plant.

479 – AL Comb. Alarm Red (Plant)

ZKP-Number: 2.8006.002
Red alarm
Cause Corrective action
RED summary alarm from plant. u Contact Service.

114 | Troubleshooting | MS150102/04E 2015-11

 480 – AL Ext. Engine Protection
ZKP-Number: 2.0291.921
Yellow alarm
Cause Corrective action
External engine protection u Contact Service.
function active.

488 – HI ETC3 Overspeed

ZKP-Number: 2.3014.931
Yellow alarm
Cause Corrective action
Speed of 2nd secondary u Contact Service.
turbocharger too high (1st limit
value).

489 – SS ETC3 Overspeed

ZKP-Number: 2.3014.932
Red alarm
Cause Corrective action
Speed of 2nd secondary u Contact Service.
turbocharger too high (2nd limit
value).

490 – HI ETC4 Overspeed

ZKP-Number: 2.3015.931
Yellow alarm
Cause Corrective action
Speed of the 3rd secondary u Contact Service.
turbocharger too high (limit value
1).

491 – SS ETC4 Overspeed

ZKP-Number: 2.3015.932
Red alarm
TIM-ID: 0000040293 - 002

Cause Corrective action

Speed of the 3rd secondary u Contact Service.
turbocharger too high (limit value
2).

MS150102/04E 2015-11 | Troubleshooting | 115

 492 – AL ETC4 Cut-in Fault
ZKP-Number: 1.8004.202
Yellow alarm
Cause Corrective action
ETC4 failed to cut in. u Contact Service.

493 – AL ETC3 Cut-in Fault

ZKP-Number: 1.8004.203
Yellow alarm
Cause Corrective action
ETC3 failed to cut in. u Contact Service.

510 – AL Override applied

ZKP-Number: 2.7002.010
Yellow alarm
Cause Corrective action
Override actuated. u Contact Service.

520 – SD P-Intake Air after Filter A

ZKP-Number: 1.0186.900
Yellow alarm
Cause Corrective action
Intake air pressure sensor faulty. u Check sensor and wiring (B81.1), replace as necessary.
==> Short circuit or wire break.

536 – AL Wiring PWM_CM1

ZKP-Number: 1.1041.921
Yellow alarm
Cause Corrective action
Wire break or short circuit on u Check HP fuel control block and wiring (M8.1 and M8.3), replace
channel PWM_CM1. as necessary.
TIM-ID: 0000040293 - 002

116 | Troubleshooting | MS150102/04E 2015-11

 549 – AL Power Cut-Off detected
ZKP-Number: 2.7001.952
Yellow alarm
Cause Corrective action
This is an alarm from the u Contact Service.
emergency stop counting feature.
ECU operating voltage was
switched off while the engine was
running. This may lead to
overpressure in the HP system
which can damage the engine.

558 – AL Wiring PWM_CM2

ZKP-Number: 1.1041.922
Yellow alarm
Cause Corrective action
Wire break or short circuit on u Check HP fuel control block and wiring (M8.2 and M8.4), replace
channel PWM_CM2. as necessary.

565 – AL L1 P-Intake Air after Filter A

ZKP-Number: 2.0186.921
Yellow alarm
Cause Corrective action
Limit violation for intake air after u None.
filter A

576 – AL ESCM Override

ZKP-Number: 1.1075.083
Yellow alarm
Cause Corrective action
Violation of corrected MCR or u Contact Service.
DBR/MCR curve. Engine overload!

581 – AL Wiring PWM_CM3

ZKP-Number: 1.1041.923
TIM-ID: 0000040293 - 002

Yellow alarm
Cause Corrective action
Wire break or short circuit on u Check HP fuel control block and wiring (M8.5 and M8.7), replace
channel PWM_CM3. as necessary.

MS150102/04E 2015-11 | Troubleshooting | 117

 582 – AL Emergency Stop Failure
ZKP-Number: 1.1005.006
Yellow alarm
Cause Corrective action
The emergency stop failure alarm u Contact Service.
is raised if the engine fails to
come to a standstill during a
programmable time after the
emergency stop signal is received.
The delay from emergency stop to
alarm signaling is set by
parameter 1.1005.004.

586 – LO P-Oil Refill Pump

ZKP-Number: 2.0159.911
Yellow alarm
Cause Corrective action
Oil refill pump pressure too low u Check level at oil replenishment tank.
(limit value 1).

587 – AL Wiring PWM_CM4

ZKP-Number: 1.1041.924
Yellow alarm
Cause Corrective action
Wire break or short circuit on u Check HP fuel control block and wiring (M8.6 and M8.8), replace
channel PWM_CM4. as necessary.

594 – AL L1 PRV Defect

ZKP-Number: 1.1301.900
Yellow alarm
Cause Corrective action
Yellow alarm, pressure relief u Contact Service.
valve, first rail.

595 – AL L2 PRV Defect

TIM-ID: 0000040293 - 002

ZKP-Number: 1.1301.901
Yellow alarm
Cause Corrective action
Red alarm, pressure relief valve, u Contact Service.
second rail.

118 | Troubleshooting | MS150102/04E 2015-11

 596 – AL Test Parameters
ZKP-Number: 1.8004.645
Yellow alarm
Cause Corrective action
The parameter set is used for u Contact Service.
trials. The alarm remains set until
a series parameter set is loaded.

597 – AL Wiring PWM_CM5

ZKP-Number: 1.1041.925
Yellow alarm
Cause Corrective action
Wire break or short circuit on u Check pressure regulating valve and wiring (B45.1), replace as
channel PWM_CM5. necessary.

598 – AL L1 PRV Defect

ZKP-Number: 1.1302.900
Yellow alarm
Cause Corrective action
Yellow alarm, pressure relief u Contact Service.
valve, second rail.

599 – AL L2 PRV Defect

ZKP-Number: 1.1302.901
Yellow alarm
Cause Corrective action
Red alarm, pressure relief valve, u Contact Service.
second rail.

606 – AL Double Nodes Lost CAN 1+2

ZKP-Number: 2.0500.691
Yellow alarm
Cause Corrective action
TIM-ID: 0000040293 - 002

A node has failed on both CANs. u Contact Service.

608 – AL Wiring PWM_CM6

ZKP-Number: 1.1041.926
Yellow alarm
Cause Corrective action
Wire break or short circuit on u Check sensor and wiring (B45.2), replace as necessary.
channel PWM_CM6.

MS150102/04E 2015-11 | Troubleshooting | 119

 609 – AL Wiring PWM_CM7
ZKP-Number: 1.1041.927
Yellow alarm
Cause Corrective action
Wire break or short circuit on u Check wiring (X14), replace as necessary.
channel PWM_CM7.

615 – AL EIL Protection

ZKP-Number: 2.0610.951
Yellow alarm
Cause Corrective action
Alarm for Protection Module in u Contact Service.
response to faulty or manipulated
EIL.

616 – AL EIL Fault

ZKP-Number: 1.0610.952
Yellow alarm
Cause Corrective action
Alarm in case of faulty or u Contact Service.
manipulated EIL.

626 – AL Wiring PWM_CM8

ZKP-Number: 1.1041.928
Yellow alarm
Cause Corrective action
Wire break or short circuit on u Check valve and wiring (X14), replace as necessary.
channel PWM_CM8.

627 – AL Wiring PWM_CM9

ZKP-Number: 1.1041.929
Yellow alarm
Cause Corrective action
TIM-ID: 0000040293 - 002

Wire break or short circuit on u Check valve and wiring (X14), replace as necessary.
channel PWM_CM9.

120 | Troubleshooting | MS150102/04E 2015-11

 628 – AL Wiring PWM_CM10
ZKP-Number: 1.1041.930
Yellow alarm
Cause Corrective action
Wire break or short circuit on u Check valve and wiring (X14), replace as necessary.
channel PWM_CM10.

648 – SD P-Charge Air B

ZKP-Number: 1.0149.900
Yellow alarm
Cause Corrective action
Charge-air pressure sensor B-side 1. Check sensor and wiring (B10.2), replace as necessary.
faulty. ==> Short circuit or wire 2. Fault is rectified when engine is restarted.
break.

761 – SD T-Coolant b.Engine

ZKP-Number: 1.0080.900
Yellow alarm
Cause Corrective action
Oil pan temperature sensor faulty. u Check sensor and wiring (B38), replace as necessary.
==> Short circuit or wire break.

768 – SD T-Exhaust b. HP Turbine

ZKP-Number: 1.0212.920
Yellow alarm
Cause Corrective action
SD T-Exhaust b. HP Turbine A1. u Check sensor and wiring (B4.25), replace as necessary.

769 – SD T-Exhaust After Engine

ZKP-Number: 1.0213.920
Yellow alarm
Cause Corrective action
SD T-Exhaust after Engine. u Check sensor and wiring (B4.26), replace as necessary.
TIM-ID: 0000040293 - 002

771 – SD-Fuel B
ZKP-Number: 1.0215.920
Yellow alarm
Cause Corrective action
SD Fuel Temperature Tank B. u Check sensor and wiring (B33.6), replace as necessary.

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 772 – SD Level Oil Refill Tank
ZKP-Number: 1.0216.920
Yellow alarm
Cause Corrective action
SD Level Oil Refill Tank. u Check sensor and wiring (F50), replace as necessary.

773 – SD Fuel Return

ZKP-Number: 1.0217.920
Yellow alarm
Cause Corrective action
Fuel return pressure sensor faulty. u Check sensor and wiring (B35), replace as necessary.

774 – SD P-Fuel Before Engine

ZKP-Number: 1.0218.920
Yellow alarm
Cause Corrective action
SD Fuel Pressure b. Engine. u Check sensor and wiring (B34.4), replace as necessary.

775 – SD P-Lube Oil After Level Pump

ZKP-Number: 1.0219.920
Yellow alarm
Cause Corrective action
SD Lube oil pressure after level u Check sensor and wiring (B54), replace as necessary.
pump.

776 – SD P-Lube Oil at HP Pump A

ZKP-Number: 1.0220.920
Yellow alarm
Cause Corrective action
SD P-Lube Oil at HP Pump A. u Check sensor and wiring (B5.5), replace as necessary.

777 – SD P-Lube Oil at HP Pump B

TIM-ID: 0000040293 - 002

ZKP-Number: 1.0221.920
Yellow alarm
Cause Corrective action
SD P-Lube Oil at HP Pump B. u Check sensor and wiring (B5.5), replace as necessary.

122 | Troubleshooting | MS150102/04E 2015-11

 782 – SD-P-Lube Oil Turbocharger
ZKP-Number: 1.0222.920
Yellow alarm
Cause Corrective action
SD Lube OIl Pressure u Check sensor and wiring (B5.8), replace as necessary.
Turbocharger.

783 – AL L1 P-Oil Before ETC

ZKP-Number: 2.0222.921
Yellow alarm
Cause Corrective action
L1 L1 P-Oil Before ETC. u Contact Service.

784 – AL L2 P-Oil Before ETC

ZKP-Number: 2.0222.922
Yellow alarm
Cause Corrective action
L2 P-Oil Before ETC. u Contact Service.

785 – AL L1 P-Oil Before HP Pump A

ZKP-Number: 2.0220.921
Yellow alarm
Cause Corrective action
L1 L1 P-Oil Before HP Pump A. u Contact Service.

786 – AL L1 P-Oil Before HP Pump B

ZKP-Number: 2.0221.922
Yellow alarm
Cause Corrective action
L1 L1 P-Oil Before HP Pump B. u Contact Service.

787 – AL L1 P-Oil Level Pump

TIM-ID: 0000040293 - 002

ZKP-Number: 2.0219.921
Yellow alarm
Cause Corrective action
L1 L1 P-Oil Level Pump u Contact Service.

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 792 – AL L1 P-Charge Air B
ZKP-Number: 2.0149.921
Yellow alarm
Cause Corrective action
L1 L1 P-Oil Before ETC. u Contact Service.

793 – AL L2 P-Charge Air B

ZKP-Number: 2.0149.922
Yellow alarm
Cause Corrective action
L2 P-Charge Air B. u Contact Service.

794 – AL L1 P-Fuel Before Engine

ZKP-Number: 2.0218.921
Yellow alarm
Cause Corrective action
L1 P-Fuel Before Engine. u Contact Service.

795 – AL L1 P-Fuel Return (p high)

ZKP-Number: 2.0217.931
Yellow alarm
Cause Corrective action
L1 P-Fuel Return. u Contact Service.

796 – AL HI T-Charge Air B

ZKP-Number: 2.0146.931
Yellow alarm
Cause Corrective action
L1 T-Charge Air B. u Contact Service.

797 – AL HIHI T-Charge Air B

ZKP-Number: 2.0146.932
TIM-ID: 0000040293 - 002

Yellow alarm
Cause Corrective action
L2 T-Charge Air B. u Contact Service.

124 | Troubleshooting | MS150102/04E 2015-11

 798 – AL L1 T-Exhaust b. HP Turbine A1
ZKP-Number: 2.0212.931
Yellow alarm
Cause Corrective action
L1 T-Exhaust b. HP Turbine. u Contact Service.

799 – AL L2 T-Exhaust b. HP Turbine A1

ZKP-Number: 2.0212.932
Yellow alarm
Cause Corrective action
L2 T-Exhaust b. HP Turbine. u Contact Service.

800 – AL L1 T-Exhaust After Engine

ZKP-Number: 2.0213.931
Yellow alarm
Cause Corrective action
L1 T-Exhaust After Engine. u Contact Service.

801 – AL L1 T-Raw Water After Pump (p too low)

ZKP-Number: 2.0214.931
Yellow alarm
Cause Corrective action
L1 T-Raw Water After Pump. u Contact Service.

802 – AL L1 T-Fuel Before Engine

ZKP-Number: 2.0148.921
Yellow alarm
Cause Corrective action
L1 T-Fuel Before Engine. u Contact Service.

803 – HI T-Fuel B
ZKP-Number: 2.0215.931
TIM-ID: 0000040293 - 002

Yellow alarm
Cause Corrective action
Fuel temperature too high (limit u Contact Service.
value 1).

MS150102/04E 2015-11 | Troubleshooting | 125

 804 – SS T-Fuel B
ZKP-Number: 2.0215.932
Red alarm
Cause Corrective action
Fuel temperature too high (limit u Contact Service.
value 2).

805 – LO Level Oil Tank

ZKP-Number: 2.0216.921
Yellow alarm
Cause Corrective action
Oil replenishment tank level too 1. Check oil level in replenishment tank, fill with oil as necessary.
low (limit value 1). 2. Contact Service.

806 – SD ETC Speed 3

ZKP-Number: 1.3010.901
Yellow alarm
Cause Corrective action
Speed sensor of secondary 1. Check sensor and wiring (B44.3), replace as necessary.
turbocharger faulty. ==> Short 2. Fault is rectified when engine is restarted.
circuit or wire break.

807 – SD ETC Speed 4

ZKP-Number: 1.3010.903
Yellow alarm
Cause Corrective action
Speed sensor of secondary 1. Check sensor and wiring (B44.4), replace as necessary.
turbocharger faulty. ==> Short 2. Fault is rectified when engine is restarted.
circuit or wire break.

808 – SD ETC Speed 5

ZKP-Number: 1.3010.905
Yellow alarm
TIM-ID: 0000040293 - 002

Cause Corrective action

Speed sensor of secondary 1. Check sensor and wiring (B44.5), replace as necessary.
turbocharger faulty. ==> Short 2. Fault is rectified when engine is restarted.
circuit or wire break.

126 | Troubleshooting | MS150102/04E 2015-11

 821 – HI ETC1 Idle Speed too High.
ZKP-Number: 1.3010.907
Yellow alarm
Cause Corrective action
HI ETC1 Idle Speed too High. u Contact Service.

822 – HI ETC2 Idle Speed too High.

ZKP-Number: 1.3010.909
Yellow alarm
Cause Corrective action
HI ETC2 Idle Speed too High. u Contact Service.

823 – HI ETC3 Idle Speed too High.

ZKP-Number: 1.3010.911
Yellow alarm
Cause Corrective action
HI ETC3 Idle Speed too High. u Contact Service.

824 – HI ETC4 Idle Speed too High.

ZKP-Number: 1.3010.913
Yellow alarm
Cause Corrective action
HI ETC4 Idle Speed too High. u Contact Service.

825 – HI ETC5 Idle Speed too High.

ZKP-Number: 1.3010.915
Yellow alarm
Cause Corrective action
HI ETC5 Idle Speed too High. u Contact Service.

826 – AL ETC1 Synchro Fault.

ZKP-Number: 1.3010.917
TIM-ID: 0000040293 - 002

Yellow alarm
Cause Corrective action
AL ETC1 Synchro Fault. u Contact Service.

MS150102/04E 2015-11 | Troubleshooting | 127

 827 – AL ETC2 Synchro Fault.
ZKP-Number: 1.3010.919
Yellow alarm
Cause Corrective action
AL ETC2 Synchro Fault. u Contact Service.

828 – AL ETC3 Synchro Fault.

ZKP-Number: 1.3010.921
Yellow alarm
Cause Corrective action
AL ETC3 Synchro Fault. u Contact Service.

829 – AL ETC4 Synchro Fault.

ZKP-Number: 1.3010.923
Yellow alarm
Cause Corrective action
AL ETC4 Synchro Fault. u Contact Service.

830 – AL ETC5 Synchro Fault.

ZKP-Number: 1.3010.925
Yellow alarm
Cause Corrective action
AL ETC5 Synchro Fault. u Contact Service.

831 – AL ETC Switch Change.

ZKP-Number: 1.3010.927
Yellow alarm
Cause Corrective action
AL ETC Switch Change. u Contact Service.
TIM-ID: 0000040293 - 002

128 | Troubleshooting | MS150102/04E 2015-11

 8 Task Description
8.1 SOLAS
8.1.1 SOLAS shielding as per MTN 5233 – Installation
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
SOLAS cover X00009628 6
Cover A4 40
Cover A5 37
Cover A6 1
Cover A7 1
Cover A8 5
Cover E5 1

Installing SOLAS shielding

1. Pinpoint installation location (→ Page 132).
2. Install suitable shielding.
3. Press shielding until locked.
TIM-ID: 0000056275 - 001

MS150102/04E 2015-11 | Task Description | 129

 Installing SOLAS covers
1. Pinpoint installation location (→ Page 132)
2. Install suitable shielding.

TIM-ID: 0000056275 - 001

130 | Task Description | MS150102/04E 2015-11

 8.1.2 Adhesive tape for SOLAS shielding – Application
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Adhesive tape 1

Applying adhesive tape – gener-

al information
Note: Use the cable clamp to make a drainage
channel. This allows fluid to flow out without
pressure in case of leakage.
1. Place cable clamp (3) on union.
2. Affix adhesive tape (1) such that lettering (2)
faces out.
3. Wrap adhesive tape without tensioning.
4. Pull out cable clamp (3) after affixing adhe-
sive tape.

Sealing cone unions

Note: For installation positions of sealing cone un-
ions, see (→ Page 132).
1. Wrap three layers of adhesive tape from the
middle of the sealing cone union to area (A)
for at least 30 mm, ensuring that the adhe-
sive tape overlaps at least half its own width.
2. Wrap three layers of adhesive tape from the
middle of the sealing cone union to area (B)
for at least 30 mm, ensuring that the adhe-
sive tape overlaps at least half its own width.
TIM-ID: 0000038330 - 001

Plug-in connections
Note: For installation positions of plug-in connections, see (→ Page 132).
1. Apply adhesive tape flush.
2. Apply three layers of adhesive tape such that at least 30mm are covered from the middle of the screw to the
line.

MS150102/04E 2015-11 | Task Description | 131

 8.1.3 Installation locations for SOLAS shielding
General information
Primarily fit SOLAS shielding as per MTN 5233 (→ Page 129).
Shield unions with adhesive tape if SOLAS shielding as per MTN 5233 is not feasible (→ Page 131).
When affixing adhesive connections ensure that escaping fluid can flow out without pressure (→ Page 131).

Fuel filter head (A side, B side, free end)

Item Type of shielding Comments

1 SOLAS cover 2 for each fuel filter head
2 Adhesive tape On fuel filter head, free end
Must be fitted during assembly!

Table 6: SOLAS fuel filter head

TIM-ID: 0000042597 - 002

132 | Task Description | MS150102/04E 2015-11

 Item Type of shielding Comments
1 Adhesive tape On fuel filter head, A side and B side
Must be fitted during assembly!
2 Adhesive tape On fuel filter head, A side and B side

Table 7: SOLAS fuel filter head A+B

TIM-ID: 0000042597 - 002

MS150102/04E 2015-11 | Task Description | 133

 Measurement block (upper)

Item Type of shielding Comments

1 Cover (A4) Connection 7,
Piston cooling-oil pressure
2 Cover (A4) Connection 4,
Lube oil pressure before last turbocharger, left side
3 Cover (A4) Connection 3,
Lube oil pressure before last turbocharger, right side
4 Cover (A4) Connection 8,
Lube oil pressure before HP pump, B side
5 Cover (A4) Connection 13,
Lube oil pressure before HP pump, A side
6 Cover (A4) Connection 14,
Measurement block for lube oil, last crankshaft bear-
ing

Table 8: SOLAS measurement block (upper)

TIM-ID: 0000042597 - 002

134 | Task Description | MS150102/04E 2015-11

 Pressure sensor box

Item Type of shielding Comments

1 Adhesive tape Upper measurement block,
Connections 3, 4, 7, 8, 13 and 14
2 Adhesive tape Measurement block and connections on pressure
sensor box

Table 9: SOLAS pressure sensor box

TIM-ID: 0000042597 - 002

MS150102/04E 2015-11 | Task Description | 135

 Lube oil pressure monitoring - turbocharger, B side

Item Type of shielding Comments

1 Cover (A4) On pressure line, free end, B side
2 Adhesive tape Driving end, B side then, measurement block

Table 10: SOLAS lube oil pressure monitoring - turbochargers, B side

TIM-ID: 0000042597 - 002

136 | Task Description | MS150102/04E 2015-11

 Lube oil pressure monitoring - turbocharger, A side

Item Type of shielding Comments

1 Cover (A4) On pressure line, free end, A side
2 Adhesive tape Driving end, turbocharger group A1, transition to
hose line
3 Adhesive tape Driving end, A side then, measurement block

Table 11: SOLAS lube oil pressure monitoring - turbochargers, A side

TIM-ID: 0000042597 - 002

MS150102/04E 2015-11 | Task Description | 137

 Piston cooling-oil filter

Item Type of shielding Comments

1 Cover Cover on piston cooling-oil filter

TIM-ID: 0000042597 - 002

138 | Task Description | MS150102/04E 2015-11

 Piston cooling-oil pressure monitoring

Item Type of shielding Comments

1 Cover (A4) Oil filter, free end A-side
1 Adhesive tape Below coolant pump, A side

Table 12: SOLAS piston cooling-oil pressure monitoring - 1

TIM-ID: 0000042597 - 002

MS150102/04E 2015-11 | Task Description | 139

 Item Type of shielding Comments
1 Adhesive tape Along engine A side
2 Adhesive tape Driving end, A side then, measurement block

Table 13: SOLAS piston cooling-oil pressure monitoring - 2

TIM-ID: 0000042597 - 002

140 | Task Description | MS150102/04E 2015-11

 Monitoring of lube oil pressure before HP pumps, B side

Item Type of shielding Comments

1 Cover (A4) On camshaft cover, driving end, B side
2 Adhesive tape Driving end, B side then, measurement block

Table 14: SOLAS monitoring of lube oil pressure before HP pumps, B side
TIM-ID: 0000042597 - 002

MS150102/04E 2015-11 | Task Description | 141

 Monitoring of lube oil pressure before HP pumps, A side

Item Type of shielding Comments

1 Cover (A4) On camshaft cover, driving end, A side
1 Adhesive tape Driving end, A side then, measurement block

Table 15: SOLAS monitoring of lube oil pressure before HP pumps, A side

TIM-ID: 0000042597 - 002

142 | Task Description | MS150102/04E 2015-11

 Monitoring of lube oil pressure – last crankshaft bearing

Item Type of shielding Comments

1 Cover (A5) Driving end, center of engine
2 Cover (A4) T-piece to oil pumps
3 Cover (A4) Branch directly to the measurement block

Table 16: SOLAS monitoring of lube oil pressure – last crankshaft bearing
TIM-ID: 0000042597 - 002

MS150102/04E 2015-11 | Task Description | 143

 Item Type of shielding Comments
1 Adhesive tape Along engine B side
2 Adhesive tape Along engine B side, on gearcase

Table 17: SOLAS monitoring of lube oil pressure – last crankshaft bearing-2

TIM-ID: 0000042597 - 002

144 | Task Description | MS150102/04E 2015-11

 Turbocharger oil supply

Item Type of shielding Comments

1 Cover (E5) Pipe elbow on pressure relief valve
2 Adhesive tape Driving end, fit after painting

Table 18: SOLAS turbocharger oil supply

TIM-ID: 0000042597 - 002

MS150102/04E 2015-11 | Task Description | 145

 Valve-seat lubrication system

Item Type of shielding Comments

1 Cover (A4) Driving end, center of engine
2 Cover (A5) Driving end, center of engine
3 Adhesive tape Camshaft vibration damper, A side
4 Cover (A4) Camshaft vibration damper, A side

Table 19: SOLAS valve-seat lubrication - 1

TIM-ID: 0000042597 - 002

146 | Task Description | MS150102/04E 2015-11

 Item Type of shielding Comments
1 Adhesive tape Charge-air elbow, A side
2 Cover (A4) Charge-air elbow, A side
3 Cover (A4) Charge-air elbow, B side

Table 20: SOLAS valve-seat lubrication - 2

TIM-ID: 0000042597 - 002

MS150102/04E 2015-11 | Task Description | 147

 Seawater pump oil supply

Item Type of shielding Comments

1 Cover (A4) Oil distribution housing on gearcase, free end
2 Cover (A4) Behind seawater pump

Table 21: SOLAS seawater pump

TIM-ID: 0000042597 - 002

148 | Task Description | MS150102/04E 2015-11

 Additional gearcase lubrication

Item Type of shielding Comments

1 Cover (A4) On distribution housing, free end
2 Cover (A4) On gearcase, A side
3 Cover (A4) On gearcase, B side
4 Adhesive tape On gearcase, free end

Table 22: SOLAS gearcase lubrication

TIM-ID: 0000042597 - 002

MS150102/04E 2015-11 | Task Description | 149

 H.P. oil line

Item Type of shielding Comments

1 Cover (A8) On centrifugal oil filters
2 Cover (A8) On oil pumps
3 Cover (A4) On oil pumps

Table 23: SOLAS centrifugal oil filter 1

TIM-ID: 0000042597 - 002

150 | Task Description | MS150102/04E 2015-11

 Item Type of shielding Comments
1 Adhesive tape Free end, B side
2 Cover (A8) Free end, B side
3 Cover (A6) Free end, B side
4 Cover (A7) Free end, B side

Table 24: SOLAS centrifugal oil filter 2

TIM-ID: 0000042597 - 002

MS150102/04E 2015-11 | Task Description | 151

 HP pumps

Item Type of shielding Comments

1 Cover (A4) Lube oil supply,
2 on 6 HP pumps each
2 Cover (A8) LP fuel system,
4 on 6 HP pumps each

Table 25: SOLAS HP pumps

TIM-ID: 0000042597 - 002

152 | Task Description | MS150102/04E 2015-11

 LP fuel system

Item Type of shielding Comments

1 Adhesive tape On LP fuel pump
2 Adhesive tape On fuel distributor, free end
Must be fitted during assembly!

Table 26: SOLAS LP fuel system 1

TIM-ID: 0000042597 - 002

MS150102/04E 2015-11 | Task Description | 153

 Item Type of shielding Comments
1 Adhesive tape On connecting piece, A side, driving end
2 Adhesive tape On connecting piece, A side, free end

Table 27: SOLAS connection A

TIM-ID: 0000042597 - 002

154 | Task Description | MS150102/04E 2015-11

 Item Type of shielding Comments
1 Adhesive tape On connecting piece, B side, free end
2 Adhesive tape On connecting piece, B side, driving end

Table 28: SOLAS connection B

Item Type of shielding Comments

1 Adhesive tape On non-return valve, A side, driving end
2 Adhesive tape On fuel connection, driving end, engine center
Fit after painting!

Table 29: SOLAS LP fuel system, driving end, A

TIM-ID: 0000042597 - 002

MS150102/04E 2015-11 | Task Description | 155

 HP accumulator, A side, B side, free end

Item Type of shielding Comments

1 Adhesive tape Fuel pressure relief valve
1 each at HP accumulator, A side, driving end and B
side, free end
2 Cover (A5) Fuel pressure relief valve
1 each at HP accumulator, A side, driving end and B
side, free end

Table 30: SOLAS HP accumulator

TIM-ID: 0000042597 - 002

156 | Task Description | MS150102/04E 2015-11

 Injector leak fuel

Item Type of shielding Comments

1 Cover (A5) On cylinder head, A and B sides
2 Cover (A5) On injector leak fuel collecting line

Table 31: SOLAS injector leak fuel 1

TIM-ID: 0000042597 - 002

MS150102/04E 2015-11 | Task Description | 157

 Item Type of shielding Comments
1 Adhesive tape At A7,A8
Must be fitted during assembly!
2 Adhesive tape Along the engine, at A1 and B1
Must be fitted during assembly!
3 Adhesive tape At A2, A3, B6, B7
Must be fitted during assembly!

Table 32: SOLAS injector leak fuel 2

TIM-ID: 0000042597 - 002

158 | Task Description | MS150102/04E 2015-11

 Item Type of shielding Comments
1 Cover (A7) Non-return valve on leak-fuel tank, A side, free end
2 Adhesive tape Non-return valve near leak-fuel tank, A side, free end
Must be fitted during assembly!

Table 33: SOLAS injector leak fuel 3

TIM-ID: 0000042597 - 002

MS150102/04E 2015-11 | Task Description | 159

 Item Type of shielding Comments
1 Adhesive tape Gearcase, near B side, free end
2 Adhesive tape Injector leak fuel, B side, free end

Table 34: SOLAS injector leak fuel 4

TIM-ID: 0000042597 - 002

160 | Task Description | MS150102/04E 2015-11

 Item Type of shielding Comments
1 Adhesive tape Injector leak fuel, A side, free end
2 Cover (A7) Injector leak fuel, A side, free end

Table 35: SOLAS injector leak fuel 5

TIM-ID: 0000042597 - 002

MS150102/04E 2015-11 | Task Description | 161

 8.2 Engine
8.2.1 Disabling engine start
WARNING
Compressed-air pipes may still be under pressure, although the shut-off valve is closed.
Risk of injury!
• Before starting work, release pressure from pipework.

Disabling engine start

1. Close main valve of compressed-air system .
2. Open drain valve and depressurize compressed-air lines.
3. Switch off power supply with key switch.
4. Remove key.
5. Attach “Do not start engine, work on engine in progress” sign to main valve and key switch.

TIM-ID: 0000056667 - 001

162 | Task Description | MS150102/04E 2015-11

 8.2.2 Engine – Barring manually
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Torque multiplier F30030459 1
Ratchet F30006211 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.

Engine – Barring manually

1. Disable engine start (→ Page 162)
2. Remove cover (1).
Result: Limit switch (2) is in rest position. Start inter-
lock is active.

3. Fit torque multiplier (2) in the recessed

square of flange (1).
Result: The extension is located between the
stops (4).
4. Mount ratchet (3).
5. Switch on oil priming pump and operate for
at least 10 minutes (→ Page 55).
6. Open decompression valves (→ Page 167).
7. Rotate crankshaft with barring tool in engine
TIM-ID: 0000056666 - 001

direction of rotation.
Result: If the resistance exceeds the normal com-
pression resistance, contact Service.
8. Close decompression valves (→ Page 167).
9. Switch off oil priming pump (→ Page 55).
10. Continue to move ratchet (3) in the same di-
rection of rotation until the change-over lever
at the torque multiplier (2) can be switched
over to the opposite direction of rotation.
11. Remove ratchet (3) and torque multiplier (2)
from bore in cover.

MS150102/04E 2015-11 | Task Description | 163

 12. Fit cover (1).
13. Make sure that the limit switch (2) is actuat-
ed (→ Page 264).
14. Enable engine start (→ Page 165).

TIM-ID: 0000056666 - 001

164 | Task Description | MS150102/04E 2015-11

 8.2.3 Enabling engine start
Preconditions
☑ Remove “Do not start engine, work on engine in progress” sign from main valve and key switch.

WARNING
Compressed-air pipes may still be under pressure, although the shut-off valve is closed.
Risk of injury!
• Before starting work, release pressure from pipework.

Enabling engine start

1. Close drain valve.
2. Open main valve of compressed-air system .
3. Switch on power supply at key switch.
TIM-ID: 0000056668 - 001

MS150102/04E 2015-11 | Task Description | 165

 8.2.4 Coupling condition – Check
Preconditions
☑ Engine is stopped and starting disabled.

WARNING
Discharged fibers or dusts from a damaged coupling with components made of fiber-reinforced compo-
sites containing e.g. carbon or glass fibers.
Risk of injury to respiratory tract or irritation of skin!
• Wear protective clothing, protective gloves, and safety glasses / facial protection.
• Wear breathing mask of protective class FFP2 or higher.
• Avoid contact with skin.

Coupling condition – Check

1. Remove guard.
2. Wipe rubber elements with a dry cloth.
3. Visually inspect rubber elements for cracks and deformation.
Result: Hairline cracks are admissible
4. If a considerable number of deeper cracks or places with broken-off rubber are found, replace coupling
(→ Maintenance Manual).
5. Install guard.

TIM-ID: 0000007654 - 003

166 | Task Description | MS150102/04E 2015-11

 8.3 Cylinder Liner
8.3.1 Combustion chambers – Draining condensate
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Engine oil

Draining condensate for com-

bustion chambers
1. Release valve stem (arrow) by three turns on
all cylinders.
2. Press TURN ENGINE key on LOP (→ Page 52).
Result: Crankshaft rotates for approx. 10 seconds
with zero fuel injection.
3. Check whether fluid emerges.
• If the quantity of emerging fluid is abnor-
mally high, contact Service.
4. Disable engine start.

5. Tighten valve stem (arrow) on all cylinders to specified torque using a torque wrench.
Name Size Type Lubricant Value/Standard
Valve stem M12 X 1.5 Tightening torque (Engine oil) 20 Nm +2 Nm
TIM-ID: 0000042960 - 003

MS150102/04E 2015-11 | Task Description | 167

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

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Barring device F6555766 1
Ratchet with extension F30006212 1
Endoscope Y20097353 1

Preparatory steps
1. Remove cylinder head cover (→ Page 174).
2. Remove injector (→ Page 180).

Positioning crankshaft at BDC

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

Endoscopic examination of cylinder liner

Findings Measure
• 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.
• Dark areas in the upper section of the cooling bore, remaining circum-
ference are faultless
• Piston rings are 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-
TIM-ID: 0000003304 - 006

age
• Heat discoloration of piston rings

1. Compile endoscopic report using the table.

2. Use technical terms to describe the liner surface (→ Page 170).
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.

168 | Task Description | MS150102/04E 2015-11

 Final steps
1. Install injector (→ Page 180).
2. Install cylinder head cover (→ Page 174).
TIM-ID: 0000003304 - 006

MS150102/04E 2015-11 | Task Description | 169

 8.3.3 Instructions and comments on endoscopic and visual examination of cylinder
liners
Terms used for endoscopic examination
Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic examina-
tion report.
Findings 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 hone 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.
Smoothened area Smoothened areas are on the running surface but almost the whole honing pattern
is still visible. Smoothened areas appear brighter and more brilliant than the sur-
rounding running surface.
Findings not critical.
Bright area Bright areas are on the running surface and show local removal of the honing pat-
tern. Grooves from honing process are not visible any more.
Discoloration This is caused by oxidation (surface discoloration through oil or fuel) and tempera-
ture differences around the liner. It appears rather darker within the honed struc-
ture in contrast to the bright metallic running surface. The honing pattern is undis-
turbed. Discolorations extend in stroke direction and may be interrupted.
Findings not critical.
Corrosion fields / Corrosion fields / spots result from water (condensed water) with the valves in the
spots overlap (open) position. They are clearly visible due to the dark color of the honing
groove bottom.
This corrosion is not critical unless there is corrosion pitting.
Black lines Black lines are a step towards heat discoloration. They are visible as a clear discol-
oration from TDC to BDC in the running surface and the start of localized damage
to the honing pattern.
Cylinder liners with a large number of black lines around the running surface have
limited service life and should be replaced.
Burn mark This is caused by a malfunction in the liner / ring tribosystem. Usually they run
over the whole ring-travel area (TDC/BDC), starting at the first TDC-ring and be-
coming more visible from the second TDC-ring 2 onwards and less pronounced
from TDC-ring 1. The honing pattern is usually no longer visible and displays a
TIM-ID: 0000000014 - 015

clearly defined (straight) edge to the undisturbed surface. The damaged surface is
usually discolored. The circumferential length varies.
Liners with burn marks, or heat discoloration, starting in TDC-ring 1 have to be re-
placed.
Seizure marks, scuff- Irregular circumference lengths and depths. Can be caused either by the piston
ing skirt or the piston crown. Material deposits on the liner (smear), heavy discolora-
tion. Severe, visible scoring.
Replace liner.

170 | Task Description | MS150102/04E 2015-11

 Evaluation of findings and further measures
The findings in the start phase of oxidation discoloration and heat discoloration are similar. A thorough inves-
tigation and compliance with the above evaluation criteria allow an unambiguous evaluation. To avoid unnec-
essary disassembly work, it is recommended that another inspection be carried out after further operation of
the engine.
TIM-ID: 0000000014 - 015

MS150102/04E 2015-11 | Task Description | 171

 8.4 Valve Drive
8.4.1 Valve clearance – Check and adjustment
Preconditions
☑ Engine is stopped and starting disabled.
☑ Coolant temperature is max. 40 °C.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Valve adjustment gauge Y4099505 1
Valve adjustment wrench F30371153 1
Torque wrench, 40–200 Nm F30027337 1
Ratchet adapter F30027341 1
Engine oil

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.

Preparatory steps
1. Install barring device (→ Page 163).
2. Remove cylinder head cover (→ Page 174).
3. Open decompression valves (→ Page 167).

Checking valve clearance in two crankshaft positions

1. Rotate crankshaft in the normal direction of rotation until the A1 piston is at firing TDC.
2. Check firing TDC position.
Result: Rocker arms of cylinder A1 are freely movable.
3. Using a valve setting gauge, check the clearance between valve and adjusting screw.
• Inlet = 0.30 mm
• Exhaust = 0.50 mm
4. If the deviation from the specified value exceeds 0.1 mm, adjust valve clearance.
5. Set the other pistons successively to firing TDC and check valve clearance in the same way.
TIM-ID: 0000045551 - 003

172 | Task Description | MS150102/04E 2015-11

 Adjusting valve clearance
1. Release locknut (3) and unscrew adjusting
screw (2) slightly using valve wrench (1).
2. Insert valve setting gauge (4) between valve
and adjusting screw (2).
3. Readjust adjusting screw (2) with valve
wrench (1) so that the valve setting gauge
just passes through the gap (4).
4. Lubricate locknut (3) with engine oil.

5. Tighten locknut (3) to specified tightening torque with a torque wrench.

Name Size Type Lubricant Value/Standard
Locknut Tightening torque (Engine oil) 90 Nm +9 Nm

6. Check whether the valve setting gauge (4) just passes through between valve and adjusting screw (2).
Result: If not, adjust valve clearance.

Final steps
1. Remove barring device (→ Page 163).
2. Install cylinder head cover (→ Page 174).
3. Close decompression valves (→ Page 167).
TIM-ID: 0000045551 - 003

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

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Torque wrench, 6–50 Nm F30027336 1
Ratchet adapter F30027340 1
Engine oil
Pattex adhesive 40162 1
Grease X00029933 1
O-ring (→ Spare Parts Catalog)
O-ring (→ Spare Parts Catalog)

Removing and installing cylin-

der head cover
1. Release screws (1, 3) with washers (2).
2. Remove upper section of cylinder head cov-
er (4) with O-ring (5).
3. Remove cable (6) and lower section of cylin-
der head cover (7) with O-ring (5).
4. Clean sealing faces.
5. Check condition of O-rings.
6. Replace damaged O-rings.
a) Clean groove of upper and lower sec-
tion (4, 7) of cylinder head cover.
b) Coat groove with Pattex.
c) Insert O-ring.
7. Coat O-ring with grease.
8. Insert cable (6) and position lower section of
cylinder head cover (7) with O-ring on cylin-
der head.
9. Place upper section of cylinder head cover (4)
in position and screw in screws (1, 3) with
washers (2) and tighten hand-tight.
10. Tighten cylinder head cover and screws (1) to specified tightening torque using a torque wrench.
Name Size Type Lubricant Value/Standard
Screw Tightening torque (Engine oil) 50 Nm + 5 Nm
TIM-ID: 0000042601 - 001

11. Tighten cylinder head cover and screws (3) to specified tightening torque using a torque wrench.
Name Size Type Lubricant Value/Standard
Screw Tightening torque (Engine oil) 30 Nm + 3 Nm

174 | Task Description | MS150102/04E 2015-11

 8.4.3 Roller tappets – Check
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Outside micrometer, 0–25 mm Y20000083 1
Outside micrometer, 25–50 mm Y20000432 1
Bore gauge, 18–100 mm Y20091481 1
Roller tappet (→ Spare Parts Catalog)
Bushing (→ Spare Parts Catalog)
Pin (→ Spare Parts Catalog)
Roller (→ Spare Parts Catalog)

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

Checking roller tappets

Item Findings Task
Check outer diameter of roller tap- Dimensions out of tolerance. Replace
pet and pin with micrometer. Val-
ues (→ Page 176)
Check guide pin for damage. Damaged Replace
Check for easy movement and ex- • Sluggish Replace roller tappet.
cessive tappet roller clearance. • Excessive clearance.
Check roller tappet for damage • Damaged Replace
and wear. • Wear
visible
TIM-ID: 0000045571 - 001

MS150102/04E 2015-11 | Task Description | 175

 8.4.4 Roller tappets, tappet guide – Tolerances
Roller tappets and tappet guide

Item Designation Stage Toleranced Deviation Clearance Interference Wear limit

size Lower Upper Min. Max. Min. Max.
Basic size
1 Guide bore - 50.000 0 +0.052 0.030 0.102 - - Clearance
- installed max. 0.120
Tappet OD - 50.000 −0.050 −0.030
2 Roller bore - 29.000H6 0 +0.013 0.050 0.093 - - Clearance
max. 0.100
Bushing OD - 28.950 −0.030 0
3 Bushing bore - 21.070 0 +0.020 0.033 0.072 - - Clearance
Pin OD - 21.000r5 +0.028 +0.037 max. 0.080

4 Tappet bore - 21.000 H6 0 +0.013 - - 0.015 0.037 Test force F

min. 8000
Pin OD - 21.000r5 +0.028 +0.037
N
TIM-ID: 0000004311 - 006

5 Tappet slot width - 23.000 0 +0.400 0.300 0.750 - - Axial clear-

Roller width - 22.700 −0.050 0 (axial) (axial) ance max.
0.600
Bushing width - 22.700 −0.050 0
6 Roller OD - 44.000 -0.200 0 - - - - -

Table 36: Tolerances for roller tappets and tappet guide

176 | Task Description | MS150102/04E 2015-11

 Reconditioning notes:
Re 1 Smooth scores: Expansion at top and bottom (non-pressed area) max. wear limit +0.020.
Re 2 Running surfaces scored or rough: Replace parts. Regrinding bushing is not admissible. Deviation
from roundness out of tolerated fit size: Replace parts.
Re 3 Wear on pin
- less than 0.01: Smooth pin / greater than 0.01: Replace pin.
- scores on running surfaces: Replace parts. Regrinding bushing is not admissible.
Re 4 Wear on pin
- less than 0.01: Smooth pin / greater than 0.01: Replace pin.
- wear limit not reached: Replace parts.
Re 6 Roller running surfaces mat or scored: Replace roller.
TIM-ID: 0000004311 - 006

MS150102/04E 2015-11 | Task Description | 177

 8.5 Injector
8.5.1 Checking injector
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Injector (→ Spare Parts Catalog)
Hold-down clamp (→ Spare Parts Catalog)
Screw (→ Spare Parts Catalog)

Checking injector
Item Findings Task
Check injector externally for dam- Damaged Replace
age.
Check contact surfaces of hold- Damaged • Rework: Smooth with oilstone.
down clamp. • Replace
Inspect sealing cone of fuel injec- Damaged Exchange injector.
tor for damage.
Check cable connections for dam- Damaged Replace wiring harness.
age.
Check thread on screw and injec- Sluggish • Rework
tor for ease of movement. • Replace

TIM-ID: 0000032367 - 003

178 | Task Description | MS150102/04E 2015-11

 8.5.2 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 180).
TIM-ID: 0000042329 - 002

MS150102/04E 2015-11 | Task Description | 179

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

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Installation/removal device F6795329 1
Milling cutter F30454782 1
Torque wrench, 20–100 Nm F30026582 1
Ratchet adapter F30027340 1
Torque wrench, 80 to 400 Nm F30027338 1
Ratchet adapter F30027341 1
Assembly paste (Optimoly Paste White T) 40477 1
Grease (Kluthe Hakuform 30-10/emulsifier) X00029933 1
Engine oil
O-ring (→ Spare Parts Catalog)

WARNING
Escaping vapors of highly volatile media, e.g. fuel or ether. Contact with these substances causes irrita-
tion of eyes and skin.
Risk of poisoning and injury!
• Allow engine to cool down.
• Ventilate the workspace.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.
• Do not inhale vapors and smoke.

WARNING
Internal tension and residual pressure in the HP fuel system.Parts can be ejected when loosening them.
Risk of injury by ejected parts!
• Only use specified tools and devices.
• Wear goggles/facial protection.

WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.

WARNING
The component is very heavy and may fall or tip over if unstable.
Risk of crushing injuries to persons or limbs!
• Use appropriate lifting gear and equipment.
TIM-ID: 0000042600 - 004

• Wear safety footwear.

NOTICE
Removing all injectors.
Component damage possible!
• Ensure that the HP accumulator is secured on the engine through two HP lines.

180 | Task Description | MS150102/04E 2015-11

 Preparatory steps
1. Shut off fuel supply to engine.
2. Remove cylinder head cover (→ Page 174).

Removing injector
Note: When the injector line is unscrewed, the stor-
ed volume in the injector is emptied
1. Release union nut (3, 4) on injector line. Re-
move injector line.
2. Remove screw (2) and take off hold-down
clamp (1).

3. Install installation/removal device on cylinder

head.
4. Remove injector with installation/removal
device.
5. Remove installation/removal device.
TIM-ID: 0000042600 - 004

MS150102/04E 2015-11 | Task Description | 181

 6. Remove sealing ring (3) from injector.
7. Remove O-ring (2) and damping ring (1) from
injector.
8. Clean all mating and sealing surfaces.
9. Cover all connections and installation bores,
or seal with suitable plugs.

Installing injector
1. Remove plug before installing the injec-
tor. (Do not remove the plug from the injector
line until the line is installed.)
2. Coat injector with assembly paste in the area
of the nozzle clamping nut.
3. Secure new sealing ring with grease on injec-
tor, observing installation position of sealing
ring.

4. Fit new O-rings (2, 3) and damping ring (1) on

injector and coat with grease.
5. Clean sealing surface on the cylinder head
using the milling cutter to remove carbon.
6. Insert injector in cylinder head, ensuring cor-
rect alignment of injector line connection
(connection faces outwards).
TIM-ID: 0000042600 - 004

182 | Task Description | MS150102/04E 2015-11

 7. Press in injector with installation/removal de-
vice.
8. Remove installation/removal device.

9. Coat screw head mating face (2) and thread

with engine oil.
10. Position injector with hold-down clamp (1) in
cylinder head.
11. Place screw (2) for hold-down clamp (1) in
position.
Note: Ensure special cleanness.
12. Grease O-ring on injector line with assembly
paste.
13. Coat thread and sealing cone of injection line
and contact surface of thrust piece with en-
gine oil.
14. Carefully insert and position injector line with
union nut (4) at cylinder head.
15. Carefully insert and position injector line with
union nut (3) at HP accumulator.
16. Tighten both retaining screws (3, 4) hand-
tight.
17. Tighten screw (2) for hold-down clamp (1) with torque wrench to final tightening torque.
Name Size Type Lubricant Value/Standard
Screw Tightening torque 220 Nm + 20 Nm

18. Tighten injector line first at injector and then at HP accumulator to specified torque.
Name Size Type Lubricant Value/Standard
Retaining screw M32 Preload torque 100 Nm + 10 Nm
TIM-ID: 0000042600 - 004

19. Release line and then tighten once again first at injector and then at HP accumulator to final torque.
Name Size Type Lubricant Value/Standard
Retaining screw M32 Tightening torque 100 Nm + 10 Nm

20. Fit cable connector onto injector.

Final steps
1. Install cylinder head cover (→ Page 174).
2. Open fuel supply to engine.

MS150102/04E 2015-11 | Task Description | 183

 8.5.4 Limiting valve – Replacement
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Engine oil
Assembly compound according to MTH5108

WARNING
Escaping vapors of highly volatile media, e.g. fuel or ether. Contact with these substances causes irrita-
tion of eyes and skin.
Risk of poisoning and injury!
• Allow engine to cool down.
• Ventilate the workspace.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.
• Do not inhale vapors and smoke.

WARNING
Internal tension and residual pressure in the HP fuel system.Parts can be ejected when loosening them.
Risk of injury by ejected parts!
• Only use specified tools and devices.
• Wear goggles/facial protection.

WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.

Preparatory steps
1. Shut off fuel supply to engine.
2. Unscrew step protection.
3. Unscrew jacket.

Removing limiting valve

1. Release retaining screws (3) of injector
line (2) at HP accumulator and unscrew it.
2. Carefully release retaining screw (1) of injec-
tor line (2) on injector / cylinder head and
unscrew it.
TIM-ID: 0000042565 - 004

184 | Task Description | MS150102/04E 2015-11

 3. Carefully remove injector line (1).
4. Unscrew retaining screw (2).
5. Remove compensating disk (3).
6. Take out limiting valve (4).

Installing limiting valve

Note: Before installing the limiting valve and injector line:
• Coat O-rings and compensating disk with assembly compound according to MTH.
• Coat sealing ball, sealing cone, threads and thrust pad support with engine oil.
1. Insert new limiting valve in HP accumulator.
2. Lubricate compensating disk and insert in housing.
3. Screw on limiting valve with retaining screw.
Name Size Type Lubricant Value/Standard
Retaining screw M62x1.5 Tightening torque 150 Nm + 10 Nm

4. Carefully insert and position injector line with union nut at cylinder head.
5. Carefully insert and position injector line with union nut at HP accumulator.
6. Tighten both retaining screws hand-tight.
7. Tighten injector line first at injector and then at limiting valve of HP accumulator to specified torque.
Name Size Type Lubricant Value/Standard
Retaining screw M32 Preload torque 100 Nm + 10 Nm

8. Release line and then tighten once again first at injector and then at HP accumulator to final torque.
Name Size Type Lubricant Value/Standard
Retaining screw M32 Tightening torque 100 Nm + 10 Nm

Final steps
TIM-ID: 0000042565 - 004

1. Open fuel supply to engine.

2. Install step protection.
3. Install jacket.

MS150102/04E 2015-11 | Task Description | 185

 8.6 Fuel System
8.6.1 Fuel system – Venting
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Torque wrench, 6–50 Nm F30027336 1
Ratchet adapter F30027340 1
Engine oil

WARNING
Escaping vapors of highly volatile media, e.g. fuel or ether. Contact with these substances causes irrita-
tion of eyes and skin.
Risk of poisoning and injury!
• Allow engine to cool down.
• Ventilate the workspace.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.
• Do not inhale vapors and smoke.

WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.

Fuel system – Venting

1. Release the fuel priming pump (arrow).
2. Operate fuel priming pump until fuel system
is fully primed.
3. Turn valve stems of vent valves by two turns
to open them (→ Page 236).
4. Operate fuel priming pump until bubble-free
fuel emerges from the vent valves.
TIM-ID: 0000045552 - 002

5. Close valve stems and tighten to specified torque using a torque wrench.
Name Size Type Lubricant Value/Standard
Screw M10 x 1 Tightening torque (Engine oil) 15 Nm +5 Nm

6. Operate fuel priming pump with approx. 50 strokes.

Result: Fuel filters are vented.
7. Secure the fuel priming pump (arrow).

186 | Task Description | MS150102/04E 2015-11

 8.6.2 Leak fuel tank – Draining
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

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

WARNING
Escaping vapors of highly volatile media, e.g. fuel or ether. Contact with these substances causes irrita-
tion of eyes and skin.
Risk of poisoning and injury!
• Allow engine to cool down.
• Ventilate the workspace.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.
• Do not inhale vapors and smoke.

WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.

Leak fuel tank – Draining

1. Remove drain plug from leak-fuel tank.
2. Catch leak fuel in a suitable container.
3. Insert drain plug with new sealing ring and tighten.
4. Eliminate any leaks in fuel system, contact Service.
TIM-ID: 0000005021 - 006

MS150102/04E 2015-11 | Task Description | 187

 8.7 Fuel Filter
8.7.1 Fuel prefilter ‒ Draining
Preconditions
☑ Engine is stopped and starting disabled.

WARNING
Escaping vapors of highly volatile media, e.g. fuel or ether. Contact with these substances causes irrita-
tion of eyes and skin.
Risk of poisoning and injury!
• Allow engine to cool down.
• Ventilate the workspace.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.
• Do not inhale vapors and smoke.

WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.

Fuel prefilter ‒ Draining

1. Switch off filter which is to be drained (A or
B):
1 Filter A cut out
2 Filter B cut out

TIM-ID: 0000045553 - 003

188 | Task Description | MS150102/04E 2015-11

 2. Open threaded vent plug (1) of the filter to be
drained.
3. Open drain valve (2).
4. Drain water and contaminants from the filter
until pure fuel emerges.
5. Close drain valve (2).

6. Connect filling pump to filling connection (1)

on the intake side of the filter.
7. Open vent valve (2) and fill with fuel until fuel
emerges from the vent pipe (3).
8. Close vent valve (2).
9. Open rotary slide valve (4) a little (by approx.
30°) and open vent valve(s) (2), until fuel
emerges from the vent pipe (3).
10. Close vent valve(s) (2).
11. Turn rotary slide valve (4) back to locked po-
sition.
TIM-ID: 0000045553 - 003

MS150102/04E 2015-11 | Task Description | 189

 8.7.2 Fuel prefilter – Filter element replacement
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

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

WARNING
Escaping vapors of highly volatile media, e.g. fuel or ether. Contact with these substances causes irrita-
tion of eyes and skin.
Risk of poisoning and injury!
• Allow engine to cool down.
• Ventilate the workspace.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.
• Do not inhale vapors and smoke.

WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.

Replacing filter element

1. Cut out the filter to be replaced (A or B).
1 Filter A cut out
2 Filter B cut out

TIM-ID: 0000045554 - 003

190 | Task Description | MS150102/04E 2015-11

 2. Open threaded vent plug (1) of contaminated
filter.
3. Unlock drain valve (5) by pressing toggle and
open it.
4. Drain water and dirt from filter.
5. Close drain valve (5).
6. Remove screws securing cover (2) and take
off cover.
7. Remove spring cartridge (3) and filter ele-
ment (4).
8. Insert new filter element (4) and spring car-
tridge (3).
9. Fill filter housing with clean fuel.
10. Place new seal in cover.
11. Fit cover with gasket and secure it with
screws (2).
12. Cut in the cut-out filter again.
13. Close threaded vent plug (1) when fuel
emerges.
14. Set adjustable pointer of differential pressure
gage (→ Page 192).
TIM-ID: 0000045554 - 003

MS150102/04E 2015-11 | Task Description | 191

 8.7.3 Fuel prefilter – Differential pressure check and adjustment of gauge
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

Setting adjustable pointer of dif-

ferential pressure gauge
1. After installation of a new filter element, align
adjustable pointer (2) with pressure-indicat-
ing pointer (3) of pressure gauge (1).
2. Verify that differential pressure is within the
limit.

Fuel prefilter – checking differential pressure

1. With the engine running at full load or rated power, read off pressure at gauge (1).
2. If differential pressure as indicated between position of adjustable pointer (2) and pressure-indicating point-
er (3) of pressure gauge is ≥ 0.3 bar, flush filter element of the cut-in filter (→ Page 193).
TIM-ID: 0000045555 - 001

192 | Task Description | MS150102/04E 2015-11

 8.7.4 Fuel prefilter – Flushing
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Diesel fuel

DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING
Escaping vapors of highly volatile media, e.g. fuel or ether. Contact with these substances causes irrita-
tion of eyes and skin.
Risk of poisoning and injury!
• Allow engine to cool down.
• Ventilate the workspace.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.
• Do not inhale vapors and smoke.

WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

Fuel prefilter – Flushing

1. Cut out contaminated filter (A or B):
1 Filter A cut out
2 Filter B cut out
TIM-ID: 0000042959 - 004

MS150102/04E 2015-11 | Task Description | 193

 2. Open threaded vent plug (1) of filter to be
flushed.
3. Open drain valve (2) and drain fuel.
Result: Fuel flows from filtered side back to the unfil-
tered side, flushing the filter deposits down-
wards out of the filter.
4. Close threaded vent plug (1) and drain
valve (2).

Filling fuel prefilter with fuel

1. Stop engine (→ Page 60) and disable engine start.
2. Connect filling pump to filling connection (1)
on the intake side of the filter.
3. Open vent valve (2) and fill with fuel until fuel
emerges from the vent pipe (3).
4. Close vent valve (2).
5. Open rotary slide valve (4) a little (by approx.
30°) and open vent valve(s) (2), until fuel
emerges from the vent pipe (3).
6. Close vent valve(s) (2).
7. Turn rotary slide valve (4) back to locked po-
sition.
8. Check differential pressure (→ Page 192).
Result: If flushing did not improve differential pres-
sure, replace filter element in fuel prefilter
(→ Page 190).
TIM-ID: 0000042959 - 004

194 | Task Description | MS150102/04E 2015-11

 8.7.5 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)
Synthetic ring (→ Spare Parts Catalog)

DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING
Escaping vapors of highly volatile media, e.g. fuel or ether. Contact with these substances causes irrita-
tion of eyes and skin.
Risk of poisoning and injury!
• Allow engine to cool down.
• Ventilate the workspace.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.
• Do not inhale vapors and smoke.

WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

NOTICE
Damage to component due to contamination.
An emergency stop during filter replacement with the engine running at full load causes extreme stress
to the engine.
Risk of severe material damage!
• Do not fill filter prior to installation. Remove protective foil of the filter directly before screwing it on.
TIM-ID: 0000042598 - 005

• Replace filter with the engine running at partial load at engine speeds up to max. 600 rpm.

MS150102/04E 2015-11 | Task Description | 195

 Replacing fuel filter with the en-
gine stopped
A Both filters cut in
B Left filter cut out
C Right filter cut out
1 Fuel vent
2 Fuel filter
3 Control lever on three-way cock

1. Cut out the filter to be replaced.

2. Unscrew cut-out easy-change filter with filter wrench.
3. Clean sealing surface on filter head.
4. Check sealing ring on new easy-change filter and moisten with fuel.
5. Fit SOLAS shield (→ Page 23).
6. Screw on easy-change filter and tighten by hand.
7. Set three-way cock to normal operating position (both filters cut in).
8. Replace other fuel filters in the same way.
9. Vent fuel system (1).

Replacing fuel filter with the engine running

1. Cut out the filter to be replaced.
2. Unscrew cut-out easy-change filter with filter wrench.
3. Clean sealing surface on filter head.
4. Check sealing ring on new easy-change filter and moisten with fuel.
5. Fit SOLAS shield (→ Page 23).
6. Remove protective foil of easy-change filter.
7. Screw on easy-change filter and tighten by hand.
8. Set three-way cock to normal operating position (both filters cut in).
9. Replace other fuel filters in the same way.
TIM-ID: 0000042598 - 005

196 | Task Description | MS150102/04E 2015-11

 8.8 Preheater
8.8.1 Preheating unit
Control elements
1 Group switch
2 On/off switch

Group switch (1) in switch position 0

Rated voltage Unit Heating
output
380 V kW 6.7
400 V kW 7.4
440 V kW 9.0

Group switch (1) in switch position 1

Rated voltage Unit Heating
output
380 V kW 13.4
400 V kW 14.8
440 V kW 18.0

Group switch (1) in switch position 2

Rated voltage Unit Heating
TIM-ID: 0000045556 - 001

output
380 V kW 17.9
400 V kW 19.8
440 V kW 24.0

MS150102/04E 2015-11 | Task Description | 197

 Structure
1 Coolant inlet
2 Junction box
3 Coolant outlet
4 Non-return flap
5 Drain
6 Continuous flow heater
7 Heating element with thermostat
8 Electric pump

Operation
The preheating unit is intended to warm up the engine coolant. The electric pump (8) ensures the circulation
of the preheated coolant through the engine.
A heating element is installed in the continuous flow heater (6). A non-return flap (4) prevents coolant from
flowing through the preheating unit when the engine is running.
When the coolant temperature has reached the value of the thermostat setting (7), the thermostat (7)
switches off the preheating unit via contactors.
In the event of excessive coolant temperature, the temperature limiter of the thermostat (7) opens the con-
trol loop. The preheating unit is switched off.
The system is reset manually after the fault has been eliminated.

TIM-ID: 0000045556 - 001

198 | Task Description | MS150102/04E 2015-11

 8.8.2 Preheater – Function and leak-tightness check
Preconditions
☑ Preheater is switched on.

Checking operation
Note: The coolant temperature must be within the range of the thermostat when the preheater is ready for opera-
tion.
1. Check coolant preheating temperature.
2. Set the thermostat to the relevant temperatures if they are out of range.

Checking heating element(s) (electrical)

u (→ Page 200)

Checking for leaks

1. Check leak-tightness at coolant inlet and outlet.
2. Tighten any leaking unions.
TIM-ID: 0000030251 - 003

MS150102/04E 2015-11 | Task Description | 199

 8.8.3 Heating element(s) – Electrical check
Preconditions
☑ Preheater must be switched on.

Note: Work on electrical systems must only be carried out by qualified personnel.

Heating element(s) – Electrical check

1. Use a clip-on measuring instrument at an accessible point (e.g. in switchgear cabinet) to carry out one cur-
rent measurement per phase.
2. For power consumption, see electrical systems documentation or use formula: I = P / (√3 * U), I in Ampere,
P in Watt, U in Volt.
• lt is only permissible for the actual power consumption to be slightly less than the specified value. No
other deviations are permissible.
• If power consumption is significantly less, the heating element(s) must be replaced, contact Service

TIM-ID: 0000030452 - 001

200 | Task Description | MS150102/04E 2015-11

 8.9 Charge-Air Cooling
8.9.1 Intercooler drain lines – Check
Preconditions
☑ Engine is stopped and starting disabled.

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.

Intercooler drain lines – Check

1. Immediately after shutting down the engine,
check whether condensate emerges at the
drain lines on the left and right engine side,
driving end.
2. If a large amount of water is discharged, a in-
tercooler is leaking, (→ contact Service).

Emergency measures prior to engine start with a leaking intercooler

1. Open decompression valves (→ Page 167).
2. Bar engine manually (→ Page 163).
3. Close decompression valves (→ Page 167).
TIM-ID: 0000045557 - 003

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 8.9.2 Charge-air cooler – Checking condensate drain line for coolant discharge and
obstruction
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

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 ear defenders.

Checking charge-air cooler drain

line
1. With the engine running, verify that air
emerges from the condensate drain lines on
left and right engine sides. If no air escapes:
2. Remove drain line(s) and blow out with com-
pressed air.
3. Replace clogged condensate drain line(s) by
new one(s).
4. Install condensate drain line(s).
5. If a large amount of coolant is discharged,
the charge-air cooler is leaking. Contact Serv-
ice.

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

1. Blow out condensate from cylinders (→ Page 167).
2. If the quantity of emerging fluid is abnormally high, do not operate engine any longer and contact Service.
TIM-ID: 0000045558 - 001

202 | Task Description | MS150102/04E 2015-11

 8.10 Air Filter
8.10.1 Service indicator – Signal ring position check
Preconditions
☑ Engine is stopped and starting disabled.

Checking signal ring position

1. If the signal ring is completely visible in the
control window (2), replace air filter
(→ Page 204).
2. After installation of new filter, press reset
button (1).
Result: Engaged piston with signal ring moves back
to initial position.
TIM-ID: 0000005484 - 009

MS150102/04E 2015-11 | Task Description | 203

 8.10.2 Air filter – Replacement
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Air filter (→ Spare Parts Catalog)

Replacing the air filter

1. Remove old air filter and install new air filter (→ Page 205).
2. Reset signal ring of contamination indicator (→ Page 203).

TIM-ID: 0000005447 - 009

204 | Task Description | MS150102/04E 2015-11

 8.10.3 Air filter – Removal and installation
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Torque wrench, 4–20 Nm F30044239 1

Air filter – Removal and installa-

tion
1. Remove prefilter (1) from air filter (2).
2. Loosen clamp (3).
3. Remove air filter (2) and clamp (3) from con-
necting flange of intake housing (4).
4. Verify that there are no objects in the con-
necting flange of the intake housing (4) and
clean it.
5. Place new air filter (2) with clamp (3) onto in-
take housing (4).

6. Tighten screw on clamp (3) with torque wrench to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw - Tightening torque 5 Nm

7. Install prefilter (1) on air filter.

TIM-ID: 0000045559 - 001

MS150102/04E 2015-11 | Task Description | 205

 8.10.4 Air filter element – Cleaning
Preconditions
☑ Engine stopped and starting disabled.

Special tools, Material, Spare parts

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

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 ear defenders.

Cleaning air filter element

Note: Clean paper filter element dry only.
1. Open air filter and remove filter element
(→ Page 205).
2. Check seal for damage and cleanness, re-
place if necessary.
3. Clean all sealing and contact surfaces.
4. Blow out filter element with compressed air
(max. 3 bar) from the inside out, until no
more dust is blown out.
5. Fit new filter element if old one is heavily
contaminated or damaged (→ Page 204).

Visual inspection
1. Use inspection lamp to check cleaned filter
element for damage.
2. Fit new filter element if old one is damaged
(→ Page 204).
TIM-ID: 0000045560 - 002

206 | Task Description | MS150102/04E 2015-11

 8.11 Starting Equipment
8.11.1 3-way solenoid valve – Manual operation
Preconditions
☑ Operating voltage is switched on.
☑ Operating voltage is switched on.
☑ Oil priming pump is ready for operation.

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.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

3-way solenoid valve – Manual

operation
1. Switch on oil priming pump and operate for
at least 10 minutes (→ Page 55)
Note: Make sure that the pressure at the last bear-
ing or before turbocharger respectively is
0.3 bar.
2. Remove seal wire (1) from knurled screw (2)
and keep it for later use.
3. Turn knurled screw (1) on 3-way solenoid
valve clockwise (3) and hold it in this posi-
tion.
4. Allow compressed air to enter the starter un-
til the engine fires evenly.
5. Turn knurled screw (2) counterclockwise (4)
and release it.
6. Switch off oil priming pump.
7. Fasten seal wire (1) as shown in the illustra-
tion, i.e. lead it through the bore of the
knurled screw (2) and secure it safely to the
3-way solenoid valve.
TIM-ID: 0000042584 - 003

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 8.11.2 Pressure reducing station – Putting into operation
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 ear defenders.

Switching on pressure reducing

station

Item Designation
1 Pressure line is shut off and working-air line vented
2 Right-hand air filter and right-hand pressure reduc-
ing valve are cut in
3 Operating position: Both air filters and both pressure
reducing valves are cut in
4 Left-hand air filter and left-hand pressure reducing
valve are cut in

1. Set lever to position 3.

Result: Both air filters and both pressure reducing valves are cut in.
2. Check pressure at pressure gauge.

Pressure reducing station – Adjusting outlet pressure

1. Make sure that the main valve of the compressed-air supply is open.
2. Cut out left-hand pressure reducing valve.
3. Adjust outlet pressure at adjusting screws of right-hand pressure reducing valve.
TIM-ID: 0000006096 - 004

4. Cut in left-hand pressure reducing valve.

5. Cut out right-hand pressure reducing valve.
6. Adjust outlet pressure at adjusting screws of left-hand pressure reducing valve.
7. Cut in right-hand pressure reducing valve.

208 | Task Description | MS150102/04E 2015-11

 Pressure reducing station –
Checking safety valve
1. Press manual control knob (arrow) down-
ward.
Result: Safety valve (located below safety valve on
the right) is raised.
2. If safety valve does not trip, contact Service.
TIM-ID: 0000006096 - 004

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 8.11.3 Pressure reducing station – Venting and shutdown
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 ear defenders.

Pressure reducing station –

Venting and shutdown

Item Designation
1 Pressure line is shut off and working-air line vented
2 Right-hand air filter and right-hand pressure reduc-
ing valve are cut in
3 Operating position: Both air filters and both pressure
reducing valves are cut in
4 Left-hand air filter and left-hand pressure reducing
valve are cut in

1. Close the main valve of the compressed-air supply line.

2. Set lever to position 1.
Result: Pressure line is shut off and working-air line vented.
TIM-ID: 0000006099 - 005

210 | Task Description | MS150102/04E 2015-11

 8.11.4 Pressure reducing station – Filter cleaning
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Cleaner (Hakupur 312) 30390 1
O-ring (→ Spare Parts Catalog)
Filter element (→ Spare Parts Catalog)

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 ear defenders.

Cleaning filter
1. Depressurize and shut down the pressure re-
ducing station (→ Page 210).
2. Remove filter elements from housing and
take off (arrowed).
3. Check filter elements.
Result: Fit new filter elements if damaged.
4. Clean filter elements with cleaner and blow
out with compressed air.
5. Install filter elements with new O-rings in
housing.
6. Put pressure reducing station into operation
(→ Page 208).
TIM-ID: 0000006103 - 007

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 8.11.5 Compressed-air tank – Draining condensate
Preconditions
☑ Engine is stopped and starting disabled.

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 ear defenders.

Compressed-air tank – Draining

condensate
1. Provide an appropriate container to collect
the fluid.
2. Press in pin on condensate drain valve to
open the valve.
3. Release the pin to close the valve.

TIM-ID: 0000034696 - 003

212 | Task Description | MS150102/04E 2015-11

 8.11.6 Starter – Condition check
Preconditions
☑ Engine is stopped and starting disabled.

Checking starter condition

1. Check securing screws of starter for secure seating and tighten if required.
2. Check wiring (→ Page 259).
TIM-ID: 0000000905 - 017

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 8.11.7 Start pilot – Fluid level check

Checking fluid level

1 Tank cover
2 Boring bar bit
3 Sealing ring
4 Handle

u Fluid level must be at the height of the mark (arrowed), top up if necessary.

TIM-ID: 0000053519 - 001

214 | Task Description | MS150102/04E 2015-11

 8.11.8 Start pilot filter – Cleaning
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Fuel
Compressed air

DANGER
Leaks in the start pilot system may cause a deflagration.
Risk of explosion!
• Fit warning signs in the engine room.
• Observe the maintenance intervals of the start pilot system.

WARNING
Escaping vapors of highly volatile media, e.g. fuel or ether. Contact with these substances causes irrita-
tion of eyes and skin.
Risk of poisoning and injury!
• Allow engine to cool down.
• Ventilate the workspace.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.
• Do not inhale vapors and smoke.

Cleaning filter
1. Unscrew securing nut (4).
2. Remove decantation container (3) and fil-
ter (1).
3. Clean filter (1) with diesel fuel and blow out
with compressed air.
4. Mount filter (1) and decantation container (3)
with sealing ring (2) in perfect condition.
5. Screw on securing nut (4).
6. Fill container.
TIM-ID: 0000042586 - 004

MS150102/04E 2015-11 | Task Description | 215

 8.11.9 Compressor – Greasing
Preconditions
☑ Engine stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Lube oil HLP ISO VG15

Greasing compressor
1. Open grease nipple.
Note: Never use engine oil or high-viscosity oil be-
cause the compressor would become inoper-
able at low temperatures.
2. Fill oil with oil spray can into grease nipple
opening (A).
Note: If viscous oil was used by mistake, clean
compressor.
3. Close grease nipple.

TIM-ID: 0000042585 - 001

216 | Task Description | MS150102/04E 2015-11

 8.12 Exhaust Flap with Actuator
8.12.1 Exhaust turbocharger control linkage – Lubrication
Preconditions
☑ Engine is stopped and starting disabled.
☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Grease gun F30006433 1
Grease (Retinax EP2) 40388 1

DANGER
Missing protective devices after working on the engine.
Risk of severe injuries and danger to life due to ejected parts!
• Disable engine start.
• After working on the engine, check that all protective devices have been reinstalled.

WARNING
Exhaust flaps/air flaps close abruptly.
Risk of crushing hands!
• Before actuating, ensure that nobody is in the danger zone.

Lubricating control linkage

1. Clean grease nipple (1).
2. Press in grease.
3. Clean and oil joints.
TIM-ID: 0000042582 - 003

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 8.12.2 Air and exhaust flaps – Functional test
Preconditions
☑ Engine is stopped and starting disabled.
☑ Minimum compressed air pressure of 6 bar available at the valve block.

DANGER
Missing protective devices after working on the engine.
Risk of severe injuries and danger to life due to ejected parts!
• Disable engine start.
• After working on the engine, check that all protective devices have been reinstalled.

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 ear defenders.

WARNING
Exhaust flaps/air flaps close abruptly.
Risk of crushing hands!
• Before actuating, ensure that nobody is in the danger zone.

Checking function of air and ex-

haust flap actuating cylinders
1. Set 5/2-way solenoid valve (arrow) to posi-
tion 1.
Result: Open air and exhaust flaps.
2. Check position of flaps.
3. Set 5/2-way solenoid valve (arrow) to posi-
tion 0.
Result: Close air and exhaust flaps.
4. Check position of flaps.
5. Set all 5/2-way solenoid valves (arrow) to ini-
tial position 0.
TIM-ID: 0000042583 - 003

218 | Task Description | MS150102/04E 2015-11

 Checking position of air and ex-
haust flap actuating cylinders
1. Check position of actuating cylinder for air-
flow control flap (2):
• Piston rod (1) retracted - air flap (2) open
• Piston rod (1) extended - air flap (2) closed
2. Check position of actuating cylinder for ex-
haust flap (3):
• Piston rod (1) retracted - exhaust flap (3)
closed
• Piston rod (1) extended - exhaust flap (3)
closed
TIM-ID: 0000042583 - 003

MS150102/04E 2015-11 | Task Description | 219

 8.13 Lube Oil System, Lube Oil Circuit
8.13.1 Engine oil level – Check
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Engine oil

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Wear protective clothing, gloves, and goggles / safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.

CAUTION
Rotating, moving parts.
Risk of injury!
• Wear protective clothing, gloves, and goggles / safety mask.
• Wear hairnet.
• Vacuum dust from grinding.

Checking engine oil level on ini-

tial oil filling
Note: The oil dipstick is additionally marked as fol-
lows on the front and rear side:
• 0 rpm
• 1000 rpm
1. Fill engine with oil until oil level reaches the
'max' mark on the '0 rpm' side of the dipstick
(→ Page 222).
2. Switch on oil priming pump and operate for
at least 10 minutes (→ Page 55).
TIM-ID: 0000006164 - 007

3. Check oil level and top up with oil up to the

'max.' mark (→ Page 222).
4. Run the engine for some minutes at idling
speed.
5. Stop the engine.
6. Check oil level after approx. 5 minutes of
standstill and top up to 'max' mark
(→ Page 222).
7. Top up oil replenishment tank to “max” mark.

220 | Task Description | MS150102/04E 2015-11

 Checking engine oil level prior to engine start
1. Withdraw dipstick from guide tube and wipe it.
2. Insert dipstick into guide tube up to the stop, withdraw after approx. 10 seconds and check oil level.
3. Oil level must reach the 'max' mark on the '0 rpm' side of the oil dipstick.
4. If necessary, top up to 'max' mark (→ Page 222).
5. Insert dipstick into guide tube up to the stop.
6. Top up oil replenishment tank to “max” mark.

Checking engine oil level after the engine is shut down

1. Five minutes after stopping the engine, remove oil dipstick from the guide tube and wipe it.
2. Insert dipstick into guide tube up to the stop, withdraw after approx. 10 seconds and check oil level.
3. Oil level must reach the 'max' mark on the '0 rpm' side of the oil dipstick.
4. If necessary, top up to 'max' mark (→ Page 222).
5. Insert dipstick into guide tube up to the stop.

Checking engine oil level with the engine running

1. Run the engine at constant speed of 1000 rpm for 10 minutes.
2. Withdraw dipstick from guide tube and wipe it.
3. Insert dipstick into guide tube up to the stop, withdraw after approx. 10 seconds and check oil level.
4. Oil level must not be below the 'min' mark on the '1000 rpm' side of the oil dipstick.
5. Check oil replenishment system if required.

Oil replenishment system, checking oil level

1. Check oil level at sight glass of oil storage tank, tank must be filled to minimum 2/3 of tank capacity.
2. Top up if required.
TIM-ID: 0000006164 - 007

MS150102/04E 2015-11 | Task Description | 221

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

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Engine oil

WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Wear protective clothing, gloves, and goggles / safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.

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. Install drain plug with new sealing ring.
4. Replace engine oil filter (→ Page 228).

Oil change using semirotary hand pump: Oil extraction

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 228).

Filling with new oil

1. Determine amount of engine oil required for
oil change (Product Summary - Technical Da-
ta).
2. Open cover on filler neck.
3. Pour oil in at filler neck up to "max." mark at
oil dipstick.
4. Close cover on filler neck.
5. Check engine oil level (→ Page 220).
TIM-ID: 0000045562 - 001

222 | Task Description | MS150102/04E 2015-11

 8.13.3 Engine oil – Sample extraction and analysis
Preconditions
☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.
☑ Engine is at operating temperature.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
MTU test kit 5605892099/00 1
WT05 solution 5605892099/23 1

DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Wear protective clothing, gloves, and goggles / safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.

Extracting and analyzing engine oil sample

1. Drain approx. 2 l of engine oil from the drain cock of the engine oil filter.
Result: Oil sludge in the drain cock is flushed out.
2. Drain approx. 1 liter engine oil into a clean container.
3. Using the equipment and chemicals of the MTU test kit, examine oil for:
• Dispersion capability (spot test);
• Water content;
• Dilution by fuel.
TIM-ID: 0000006173 - 006

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 8.13.4 Engine oil sludge – Check for metallic residue
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Grease-solvent cleaner or fuel
Filter paper
Filter funnel 1
Collecting vessel 1

WARNING
Escaping vapors of highly volatile media, e.g. fuel or ether. Contact with these substances causes irrita-
tion of eyes and skin.
Risk of poisoning and injury!
• Allow engine to cool down.
• Ventilate the workspace.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.
• Do not inhale vapors and smoke.

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

Oil sludge analysis

1. Dilute oil sludge with grease-solvent cleaner or fuel.
2. Place filter paper into filter funnel. Filter out solid oil sludge constituents, collecting the solvent in a contain-
er.
3. If the filter paper shows metallic residue, monitor engine carefully during further engine operation and in-
spect oil sludge daily.
4. If metallic residue is still detected, check the engine.

TIM-ID: 0000006178 - 006

224 | Task Description | MS150102/04E 2015-11

 8.13.5 Engine oil bypass filter – Replacement
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

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

WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Wear protective clothing, gloves, and goggles / safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.

Replacing filter elements

1. Close shut-off valve upstream of engine oil
bypass filter.
2. Remove screw (1) countering screw (3) in so
doing.
3. Remove drain screw from housing lower sec-
tion.
4. Drain oil sludge.
Note: Filter cover (5) is spring-loaded.
5. Remove screw (3).
6. Remove filter cover with sealing ring (4),
spring (7) and washer (8).
7. Clean components.
TIM-ID: 0000006525 - 003

MS150102/04E 2015-11 | Task Description | 225

 8. Lift up grip (arrow).
9. Rotate filter element backward and forward
to withdraw it at the grip (arrowed).
10. Rotate lower filter element backward and for-
ward and withdraw it using the hook.
11. Clean filter housing.
12. Insert the new filter elements using the hook.

13. Place washer (8) onto upper filter element.

14. Fit spring (7).
15. Fit cover (5) with new sealing ring (6).
16. Compress cover (5) to install screw (3) with
new sealing ring (4).
17. Tighten screw (3).
18. Install screw (1) with sealing ring (2) and
tighten.
19. Install drain screw with new sealing ring in
housing lower section and tighten.
20. Replace further filter elements in the same
way.
21. Open shut-off valve upstream of engine oil
bypass filter.

TIM-ID: 0000006525 - 003

226 | Task Description | MS150102/04E 2015-11

 8.13.6 Oil priming pump – Checking direction of rotation
Preconditions
☑ Engine is stopped.

DANGER
Electric voltage supply for operation.
Danger of burns and fatal electric shock!
• Make certain that the power supply to the product is switched off before starting work. Secure
against unintentional switching on!

Oil priming pump – Checking direction of rotation

1. Switch on lube oil priming pump briefly (→ Page 55) and check direction of rotation.
Result: Pump rotor rotates in accordance with the arrow on the pump housing. If this is not the case:
2. Change polarity of electric leads.
3. Check direction of rotation.
TIM-ID: 0000006265 - 005

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

Special tools, Material, Spare parts

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

WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Wear protective clothing, gloves, and goggles / safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.

Replacing filter elements

1. Drain oil at oil drain valve (7) and oil drain
cock (9) and collect in suitable container.
2. Remove nuts (1) and washers (2).
3. Remove filter cover (3).
4. Remove filter elements (5).
5. Install new filter elements (5).
6. Coat O-rings (4) and (8) with engine oil and
insert.
7. Fit filter cover (3).
8. Install nuts (1) with washers (2) and tighten
crosswise.
9. Check oil level (→ Page 220).
TIM-ID: 0000045563 - 001

228 | Task Description | MS150102/04E 2015-11

 8.14.2 Engine oil filter – Cleaning edge-type filter element
Preconditions
☑ Engine is stopped and starting disabled.

Cleaning the edge-type filter element

1. Rotate the handle on the engine oil filter through one or two turns.
2. Repeat this procedure for each engine oil filter.
TIM-ID: 0000006314 - 004

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 8.14.3 Piston cooling-oil filter – Replacement
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Filter wrench F30379104 1
Engine oil
Oil filter (→ Spare Parts Catalog)

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.

DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Wear protective clothing, gloves, and goggles / safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.

NOTICE
Damage to component due to contamination.
An emergency stop during filter replacement with the engine running at full load causes extreme stress
to the engine.
Risk of severe material damage!
• Do not fill filter prior to installation. Remove protective foil of the filter directly before screwing it on.
• Replace filter with the engine running at partial load at engine speeds up to max. 600 rpm.
TIM-ID: 0000045564 - 002

230 | Task Description | MS150102/04E 2015-11

 Oil filter replacement with the
engine stopped
1. Stop engine (→ Page 60) and disable engine
start.
2. Cut out the filter to be replaced at diverter
valve (1).
3. Unscrew cut-out oil filter (3) using oil filter
wrench.
4. Clean the sealing face (2) on the connecting
piece.
5. Check sealing ring of new oil filter and coat
with engine oil.
6. Screw on and tighten new engine oil filter by
hand.
7. Replace other oil filters in the same way.
8. After each oil change and filter replacement,
bar engine manually with barring device
(→ Page 163).
9. Check oil level (→ Page 220).

Oil filter replacement with the

engine running
1. Cut out the filter to be replaced at diverter
valve (1).
2. Unscrew cut-out oil filter (3) using oil filter
wrench.
3. Clean the sealing face (2) on the connecting
piece.
4. Check sealing ring of new oil filter and coat
with engine oil.
5. Fit SOLAS shield (→ Page 23).
6. Remove protective foil of oil filter.
7. Screw on and tighten new engine oil filter by
hand.
8. Replace other oil filters in the same way.
TIM-ID: 0000045564 - 002

MS150102/04E 2015-11 | Task Description | 231

 8.14.4 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, 6–50 Nm F30027336 1
Ratchet adapter F30027340 1
Engine oil
Cleaning agent (Hakutex 60) 50602 1
Filter sleeve (→ Spare Parts Catalog)
O-ring (→ Spare Parts Catalog)
O-ring (→ Spare Parts Catalog)

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 ear defenders.

Removing centrifugal oil filter bracket

u (→ Page 235).

Removing rotor and rotor cap

1. Remove cover (1).
2. Remove O-ring (2).
3. Carefully remove rotor (3) from housing lower
section (4).

TIM-ID: 0000006419 - 006

232 | Task Description | MS150102/04E 2015-11

 4. Secure lower part of rotor lightly in a bench
vise.
5. Mark relative positions of rotor cap and lower
part of rotor.
6. Remove nut (arrowed).
Result: Rotor cap is detached from lower part of ro-
tor.
7. Carefully remove rotor cap.

8. Remove filter sleeve (2) from rotor cap (1).

9. Measure thickness of oil residue on filter
sleeve (2).
10. If maximum layer thickness (25 mm) is ex-
ceeded, shorten maintenance interval.
11. Wash rotor parts with cleaning agent and
blow out with compressed air, ensuring that
the centrifuge nozzles are not obstructed.
12. Fit new O-ring (6) on lower part of rotor (4).
13. Place the oil guide tube onto the lower part of
the rotor, ensuring that it is seated with the
guide pin (5) engaged.
14. Insert new filter sleeve (2) in rotor cap (1).
15. Carefully position rotor cap (1) on lower part
of rotor taking into account marks made dur-
ing removal.
16. Screw in nut.
Result: Rotor cap is pressed down onto metallic
stop.
17. Tighten nut to specified torque using a torque wrench.
Name Size Type Lubricant Value/Standard
Nut Tightening torque (Engine oil) 18 Nm ± 2 Nm
TIM-ID: 0000006419 - 006

MS150102/04E 2015-11 | Task Description | 233

 18. Clean cover (1) and housing lower section (4)
with a clean cloth.
19. Insert new O-ring in groove in housing lower
section.
20. Insert rotor (3) carefully into housing lower
section.
21. Check rotor (3) for ease of movement.
22. Install cover (1).

Installing centrifugal oil filter bracket

u (→ Page 235).

TIM-ID: 0000006419 - 006

234 | Task Description | MS150102/04E 2015-11

 8.14.5 Centrifugal oil filter bracket – Removal and installation
Preconditions
☑ Engine is stopped and starting disabled.

Removing centrifugal oil filter

bracket
1. Release screws (2) and (5).
2. Swing holder (1) up.
3. Release nut (3) on cover (4).
4. Swing screws outwards.

Installing centrifugal oil filter

bracket
1. Turn screws up to place them in grooves.
2. Tighten nuts (3) crosswise.
3. Swing holder (1) down to place it in the
grooves of the cover (4).
4. Tighten screws (5).
5. Tighten screws (2).
6. Check centrifugal oil filter for leaks during en-
gine operation.
TIM-ID: 0000006451 - 004

MS150102/04E 2015-11 | Task Description | 235

 8.15 Coolant Circuit, General, High-Temperature Circuit
8.15.1 Drain and venting points
Also valid for 16 V engines

1 Vent line, raw water circuit 4 Piston cooling oil filter 7 Oil filler neck
2 Connection, engine coolant 5 Connection, engine coolant
vent line sample extraction
3 Fuel filter 6 Centrifugal oil filter

TIM-ID: 0000042587 - 002

236 | Task Description | MS150102/04E 2015-11

 Free end (KGS)

1 Fuel filter 4 Connection, engine coolant 7 Engine coolant thermostat

2 Oil sampling connection sample extraction 8 Connection for automatic
3 Piston cooling oil filter 5 Connection, engine coolant seawater inductor
vent line 9 Centrifugal oil filter
6 Connection, engine coolant
drain point
TIM-ID: 0000042587 - 002

MS150102/04E 2015-11 | Task Description | 237

 Side view

1 Vent line, raw water circuit 6 Oil filter 11 Oil filler neck
2 Connection, coolant vent 7 Edge-type filter, drain point 12 Oil dipstick
line for contaminants 13 Crankcase safety valve
3 Fuel filter 8 Fuel priming pump 14 Connection, engine coolant
4 Fuel vent valve 9 Centrifugal oil filter drain point
5 Three-way cock, fuel filter 10 Connection for barring de-
vice

TIM-ID: 0000042587 - 002

238 | Task Description | MS150102/04E 2015-11

 Driving end (KS)

1 Oil filler neck 2 Engine oil system vent valve

TIM-ID: 0000042587 - 002

MS150102/04E 2015-11 | Task Description | 239

 8.15.2 Water drain valve – Check

Water drain valve – Check

1. Open water drain valve.
2. Check water outlet for obstructions.
3. Close water drain valve.

TIM-ID: 0000007733 - 007

240 | Task Description | MS150102/04E 2015-11

 8.15.3 Vent line – Obstruction check
Preconditions
☑ Engine is stopped and starting disabled.

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 ear defenders.

Checking vent line for obstructions

1. Remove vent line (→ Page 236).
2. Blow out vent line with compressed air. If vent line is blocked, fit new one.
3. Install vent line.
4. Repeat this procedure for all vent lines (→ Page 236).
TIM-ID: 0000006709 - 005

MS150102/04E 2015-11 | Task Description | 241

 8.15.4 Heat exchanger – Venting
WARNING
Escaping vapors of highly volatile media, e.g. fuel or ether. Contact with these substances causes irrita-
tion of eyes and skin.
Risk of poisoning and injury!
• Allow engine to cool down.
• Ventilate the workspace.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.
• Do not inhale vapors and smoke.

WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.

Heat exchanger – Venting

1. Open shut-off valve in fuel vent line upstream and downstream of heat exchanger.
2. Vent until bubble-free fuel emerges.
3. Close shut-off valves.

TIM-ID: 0000006702 - 004

242 | Task Description | MS150102/04E 2015-11

 8.15.5 Engine coolant level – Check
Preconditions
☑ Engine is stopped and starting disabled.
☑ Coolant temperature is below 40 °C.
☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.

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.

Checking engine coolant level at

coolant expansion tank
1. Engine coolant level must lie between 'min.'
and 'max.' marks.
2. If required, top up to 'max.' mark with treated
coolant (→ Page 246).
TIM-ID: 0000045565 - 001

MS150102/04E 2015-11 | Task Description | 243

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

Engine coolant change

1. Drain engine coolant (→ Page 245).
2. Fill with engine coolant (→ Page 246).

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244 | Task Description | MS150102/04E 2015-11

 8.15.7 Draining engine coolant
Preconditions
☑ Engine is stopped and starting disabled.
☑ Engine coolant temperature is max. 40 °C.

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.

Preparatory steps
1. Make sure that all drain lines are connected to the drain points (→ Page 236).
2. Switch off preheating unit.

Draining engine coolant

1. Turn breather valve of coolant expansion tank counterclockwise until the first stop and allow pressure to es-
cape.
2. Continue to turn breather valve counterclockwise and remove.
3. Draw off precipitated corrosion inhibitor oil from the expansion tank through filler neck.
4. Draw off engine coolant into dirty water tank (→ ship-side draining and filling equipment).
5. Place breather valve on filler neck and close.
TIM-ID: 0000006750 - 005

MS150102/04E 2015-11 | Task Description | 245

 8.15.8 Engine coolant – Filling
Preconditions
☑ Engine is stopped and starting disabled.
☑ Engine coolant temperature is below 40 °C.
☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Engine coolant

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.

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.

Preparatory steps
1. Turn valve cover (1) on expansion tank to the
left to the first lock and release pressure.
2. Continue to turn valve cover (1) counter-
clockwise and remove.

Filling coolant with pump

TIM-ID: 0000045567 - 001

1. Make sure that the filling line is connected to (→ ship-side draining/filling equipment).
2. Operate pump to fill engine with treated coolant until the required coolant level is reached at the coolant
expansion tank (→ Page 243).

246 | Task Description | MS150102/04E 2015-11

 Final steps
1. Start engine and operate it at idling speed for some minutes.
2. Vent engine coolant system.
a) Open vent point (→ Page 236).
b) Close vent point when bubble-free coolant emerges.
c) Repeat this procedure for all vent points.
d) Close breather valve (arrow) on coolant expansion tank.
3. Check engine coolant level (→ Page 243).
TIM-ID: 0000045567 - 001

MS150102/04E 2015-11 | Task Description | 247

 8.15.9 Engine coolant pump – Relief bore check
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

Engine coolant pump – Relief

bore check
1. Check relief bore for oil and coolant dis-
charge.
2. Stop engine (→ Page 60) and disable engine
start, observe general safety instructions for
maintenance and repair.
3. Clean the relief bore with a wire if it is dirty.
• Permissible coolant discharge: up to 10
drops per hour.
• Permissible oil discharge: up to 5 drops
per hour.
4. If discharge exceeds the specified limits:
Contact Service.

TIM-ID: 0000000961 - 013

248 | Task Description | MS150102/04E 2015-11

 8.15.10 Engine coolant – Sample extraction and analysis
Preconditions
☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.

Special tools, Material, Spare parts

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

DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.

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
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

Engine coolant – Sample extraction and analysis

1. Draw off approx. 1 liter of coolant from expansion tank.
2. Using the equipment and chemicals in the MTU test kit, examine coolant for:
• Antifreeze concentration;
• Corrosion inhibitor concentration;
• pH value.
TIM-ID: 0000006776 - 006

MS150102/04E 2015-11 | Task Description | 249

 8.15.11 Coolant system – Strainer removal
Preconditions
☑ Engine is stopped and starting disabled.
☑ Coolant temperature is below 40 °C

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Grease X00029933 1
O-ring (→ Spare Parts Catalog)
Seal (→ Spare Parts Catalog)

Removing strainer
1. Drain engine coolant (→ Page 245).
2. Remove screws from elbow (6).
3. Remove elbow (6) from receptacle (3).
Note: Store the strainer for future use after compo-
nent maintenance or extended component
maintenance.
4. Remove strainer (7).
5. Coat flange (4) with grease and insert.
6. Slide elbow (6) onto receptacle (3).
7. Screw elbow (6) onto holder (1) and coolant
line (2).
8. Tighten screws.
9. Fill with coolant (→ Page 246).

TIM-ID: 0000045568 - 001

250 | Task Description | MS150102/04E 2015-11

 8.16 Raw Water Pump with Connections
8.16.1 Raw water pump – Check
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Outside micrometer, 25–50 mm Y20000432 1
Outside micrometer, 50–75 mm Y20000088 1
Outside micrometer, 75–100 mm Y20000169 1
Outside micrometer, 100–125 mm Y20000219 1
Bore gauge, 18–100 mm Y20091481 1
Bore gauge, 100–160 mm Y20091482 1
Bearing housing (→ Spare Parts Catalog)
Volute (→ Spare Parts Catalog)
Impeller (→ Spare Parts Catalog)
Sealing ring carrier (→ Spare Parts Catalog)
Bellows - rotary seal (→ Spare Parts Catalog)
O-ring (→ Spare Parts Catalog)
Pump shaft (→ Spare Parts Catalog)
Snap ring (→ Spare Parts Catalog)

WARNING
Components have sharp edges.
Risk of injury!
• Wear protective gloves.

WARNING
The component is very heavy and may fall or tip over if unstable.
Risk of crushing injuries to persons or limbs!
• Use appropriate lifting gear and equipment.
• Wear safety footwear.

Checking raw water pump

Item Findings Task
Check volute and impeller for cavi- Cavitation visible. Replace
tation.
Check pump shaft for wear and • Signs of wear • Rework: Smooth minor signs of
damage. • Damage wear with oilstone.
TIM-ID: 0000045569 - 001

visible • Replace
Visually inspect sealing surfaces • Wear • Rework: Smooth with oilstone.
for signs of wear, pitting and cavi- • Pitting • Replace
tation. • Cavitation
visible
Check gear for indentations, signs • Indentations • Rework: Smooth with oilstone.
of wear and damage. • Signs of wear • Replace drive shaft
• Damage
visible
Check taper seats with gauge. Not true to gauge. Replace pump shaft.

MS150102/04E 2015-11 | Task Description | 251

 Item Findings Task
Measure pump shaft with outside Values not attained. Replace
micrometer. Values (→ Page 253)
Measure bearing housing. Values Values exceeded. Replace
(→ Page 253)

TIM-ID: 0000045569 - 001

252 | Task Description | MS150102/04E 2015-11

 8.16.2 Raw water pump – Tolerances

Item Designation Stage Toleranced Deviation Clearance Interference Wear limit

size Lower Upper Min. Max. Min. Max.
Basic size
1 Bearing bore - 45.000 –0.012 0 - - 0.009 0.037 Interfer-
Shaft OD - 45.000 m6 +0.009 +0.025 ence min.
0.005
2 Housing bore - 100.000 K7 –0.025 +0.010 - 0.025 - 0.025 Clearance
max. 0.030
Bearing OD - 100.000 –0.015 0
3 Bearing bore - 60.000 –0.015 0 - - 0.011 0.045 Interfer-
Shaft OD - +0.011 +0.030 ence min.
60.000 m6
0.011
4 Housing bore - 110.000 J7 –0.013 +0.022 - 0.037 - 0.013 Clearance
max. 0.040
Bearing OD - 110.000 –0.015 0
5 Impeller projection - 3.200 to - - - - - - -
- impeller fitted loosely 5.000
TIM-ID: 0000007277 - 003

6 Rotary seal - - - - - - - - -
Counterring - - - -
7 Seal carrier bore - 85.000 H8 0 +0.054 - - 0.146 0.350 -
Shaft seal - 85.000 +0.200 +0.350
OD
8 Running surface OD - 55.000 h11 –0.190 0 - - - - -

MS150102/04E 2015-11 | Task Description | 253

Item Designation Stage Toleranced Deviation Clearance Interference Wear limit
size Lower Upper Min. Max. Min. Max.
Basic size
9 Gear projection - 4.000 to - - - - - - -
- gear loosely fitted 5.300
Reconditioning notes:
Re 6: If wear traces are found: Replace components together.
Re 8: If running surface is worn: Recondition pump shaft by spray-metallizing and plunge-cut grinding.

Table 37: Tolerances for raw water pump

TIM-ID: 0000007277 - 003

254 | Task Description | MS150102/04E 2015-11

 8.16.3 Raw water pump – Relief bore check
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

Raw water pump – Relief bore

check
1. Check relief bore for oil and raw water dis-
charge.
2. Stop engine (→ Page 60) and disable engine
start, observe general safety instructions for
maintenance and repair.
3. Clean the relief bore with a wire if it is dirty.
• Permissible raw water discharge: up to 10
drops per hour;
• Permissible oil discharge: up to 5 drops
per hour.
4. If discharge exceeds the specified limits:
Contact Service.
TIM-ID: 0000007282 - 006

MS150102/04E 2015-11 | Task Description | 255

 8.16.4 Automatic seawater inductor – Function check
Preconditions
☑ Engine is stopped.

Note: During engine operation, the automatic seawater inductor is controlled and monitored by the electronic en-
gine management system.
Automatic seawater inductor –
Function check
Note: The automatic seawater inductor is supplied
with compressed air from the starting air sys-
tem. Carry out functional check once only.
1. Press pushbutton (1) on solenoid valve of au-
tomatic seawater inductor (→ Page 236).
Result: • Raw-water pump is vented.
• Raw water emerges from the opening (ar-
row).
2. Release pushbutton (1).
3. Remove any dirt.

TIM-ID: 0000007343 - 004

256 | Task Description | MS150102/04E 2015-11

 8.17 Engine Mounting / Support
8.17.1 Engine mounts – Checking securing screws for firm seating
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Torque wrench, 80 to 400 Nm F30027338 1

Engine mounts – Checking se-

curing screws for firm seating
1. Check securing screws for firm seating.
2. Tighten loose screw connections.

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

Name Size Type Lubricant Value/Standard
Screw M16 x60 Tightening torque 250 Nm +25 Nm

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

Name Size Type Lubricant Value/Standard
Screw M16 x 13 Tightening torque 250 Nm +25 Nm
0

5. Use torque wrench to tighten screws (2) to specified tightening torque.

Name Size Type Lubricant Value/Standard
TIM-ID: 0000049950 - 001

Screw M22 x 70 Tightening torque 380 Nm

6. Tighten hex nut (4) with torque wrench to specified tightening torque.
Name Size Type Lubricant Value/Standard
M42 Tightening torque 400 Nm + 40 Nm

MS150102/04E 2015-11 | Task Description | 257

 8.17.2 Engine mounting – Cleaning
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 ear defenders.

Engine mounting – Cleaning

Note: Do not allow resilient rubber mounts to come into contact with oil and fuel.
1. Wipe rubber surfaces with a dry cloth only; never clean with organic detergents.
2. Blow off all components thoroughly with compressed air.

TIM-ID: 0000007479 - 004

258 | Task Description | MS150102/04E 2015-11

 8.18 Wiring (General) for Engine/Gearbox/Unit
8.18.1 Еngine cabling ‒ Check
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

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

Еngine cabling ‒ Check

1. Check securing screws of cable clamps on engine and tighten loose threaded connections.
2. Ensure that cables are fixed in their clamps and cannot swing freely.
3. Check if all cable clips are closed and intact.
4. Replace faulty cable clips.
5. Check that cable clamps are firm, tighten loose cable clamps.
6. Replace faulty cable clamps.
7. Visually inspect the following electrical line components for damage:
• Connector housing
• Contacts
• Sockets
• Cables and terminals
• Plug-in contacts
Result: Contact Service if cable conductors are damaged.
Note: Close male connectors that are not plugged in with the protective cap supplied.
8. Clean dirty connector housings, sockets and contacts using isopropyl alcohol.
9. Ensure that all sensor connectors are securely engaged.
TIM-ID: 0000000029 - 022

MS150102/04E 2015-11 | Task Description | 259

 8.19 Accessories for (Electronic) Engine Governor / Control System
8.19.1 Connectors and housing – Cleaning
Preconditions
☑ Engine is stopped and starting disabled.
☑ Power supply is switched off.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Connector pliers 0135315483 1
Isopropyl alcohol X00058037 1

Cleaning ECS housing and connectors

1. Remove coarse dirt on housing surface using (Isopropyl alcohol).
2. Remove dirt from surface of connectors, connector sockets and shrink sleeves using (Isopropyl alcohol).
3. Check legibility of cable labels. Clean or replace illegible labels.

Cleaning heavily soiled ECS connectors

1. Use connector pliers to unlock bayonet union nut and withdraw connector.
2. Clean connector housings, connector socket housings and all contacts with (Isopropyl alcohol).
3. When connectors, sockets and all contacts are dry: Install connectors and check plug-in connections
(→ Page 261).

TIM-ID: 0000008477 - 007

260 | Task Description | MS150102/04E 2015-11

 8.19.2 Plug-in connections – Check
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Connector pliers 0135315483 1

Checking plug-in connections

1. Use connector pliers to make certain that all plug-in connections are securely seated.
2. Tighten loose bayonet union nuts with connector pliers by turning them clockwise until they lock into place.
3. Ensure that unassigned connector sockets are protected with covering caps.
4. If bayonet couplings are defective, contact Service.
TIM-ID: 0000008480 - 003

MS150102/04E 2015-11 | Task Description | 261

 8.19.3 Indicator lamp – LED replacement
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Cap puller 0015383730 1
LED, yellow (→ Spare Parts Catalog)
LED, red (→ Spare Parts Catalog)
LED, green (→ Spare Parts Catalog)

NOTICE
Faulty LED installation can destroy contacts.
Damage to component!
• Fit LED with correct polarity.

Removing LED
1. Insert small screwdriver (6) between glass
cover (5) and lamp housing (4).
2. Pry out glass cover together with inscription
label (2). Take care not to brake lugs (1).
3. Insert screwdriver between lamp housing and
edge of lens (3).
4. Carefully withdraw lens from lamp housing.
Result: The LED is visible.

5. Position cap puller (1) on LED and remove

LED. Record orientation of contact sur-
face (2) marked “+24V”.
TIM-ID: 0000008436 - 008

262 | Task Description | MS150102/04E 2015-11

 Installing LED
1. Insert new LED with correct polarization (note orientation of the contact surface marked “+24V”).
2. Latch LED in position.
3. Insert lens (2) into lamp housing. Recess-
es (1) must be positioned horizontally oppo-
site one another.
4. Press inscription label onto lower side of
glass cover (3) and set on both together, en-
suring that lugs (4) engage in recesses (5) of
the lens.
5. Press glass cover slightly to latch into posi-
tion.
TIM-ID: 0000008436 - 008

MS150102/04E 2015-11 | Task Description | 263

 8.20 Control and Display Elements, General
8.20.1 Limit switch – Check
Preconditions
☑ Engine is stopped and starting disabled.

Limit switch – Check

1. Verify that cover (1) is fitted.
2. Verify that limit switch (2) is activated.

TIM-ID: 0000007917 - 003

264 | Task Description | MS150102/04E 2015-11

 8.20.2 Fluid level monitor – Check
Preconditions
☑ Monitoring system is switched on.
☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.

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
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Wear protective clothing, gloves, and goggles / safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.

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

Checking function
1. Open tank cap.
2. Drain or extract fluid until monitoring system responds.
Result: Fit new fluid level monitor if monitoring system does not respond.
3. Top up with fluid.
4. Close tank cap.
TIM-ID: 0000009037 - 004

MS150102/04E 2015-11 | Task Description | 265

 8.21 Emergency Instrumentation (Local Operating Panel)
8.21.1 Engine control system – Operational tests
Preconditions
☑ Engine is stopped.

Screen test
1. Use the function keys to actuate 'NEXT PAGE' at the display.
Result: The next page is displayed.
2. Press the PREVIOUS PAGE key.
Result: The previous page is displayed.

Barring test
1. Press LOCAL MODE key.
2. Press TURN ENGINE key.
Result: • Spot of the key flashes.
• Key is not lit.
• All components involved in the Engine start function are checked without starting the engine.

Emergency stop test

1. Press EMERGENCY STOP button.
Result: • Engine is stopped by interrupting fuel injection
2. Alarm acknowledgment at LOP display via function keys.
3. Make plant ready for operation again.

Overspeed test
1. Start engine (→ Page 59).
Result: • Engine runs at idling speed.
• Gearbox disengaged.
2. Select engine speed indicator at LOP display.
3. Press and hold down pushbutton TEST OVERSPEED.
Result: • Key lights up.
• Limit overspeed (bargraph chart on LOP display) is reduced.
4. Increase engine speed to test speed (admissible speed minus 100 rpm).
Result: • Engine shuts down via the emergency shutdown function when the reduced overspeed limit is reached.
5. Shut down engine.

Checking oil priming pump operation

1. Turn selector switch of oil priming pump to position MAN and hold.
Result: • Indicator lamp lights up.
• Oil priming pump is running.
TIM-ID: 0000042957 - 001

2. Turn selector switch of oil priming pump to position AUTO.

Checking preheating unit operation

1. Turn selector switch of oil preheater unit to position MANUAL and hold.
Result: • Indicator lamp lights up.
• Preheating unit is in operation.
2. Turn selector switch of preheating unit to position AUTOMATIC.

266 | Task Description | MS150102/04E 2015-11

 9 Appendix A
9.1 Abbreviations
Abbre- Meaning Explanation
viation
ADEC Advanced Diesel Engine Controller Engine management system
EGR Exhaust Gas Recirculation
AL Alarm Alarm (general)
ANSI American National Standards Institute Association of American standardization organiza-
tions
ETC Exhaust turbocharger
BDM Backup Data Module Data backup module
BR (Baureihe) Series
BV (Betriebsstoffvorschrift) Fluids and Lubri- MTU Publication No. A001061/..
cants Specifications
CAN Controller Area Network Data bus system, bus standard
CPP Controllable Pitch Propeller
CR Common Rail
DIN Deutsches Institut für Normung e. V. At the same time identifier of German standards
(DIN = “Deutsche Industrie-Norm”)
DIS Display Unit Display panel
DL Default Lost Alarm: Default CAN bus failure
DOC Diesel Oxidation Catalyst
DPF Diesel Particulate Filter
ECS Engine Control System Engine management system
ECU Engine Control Unit Engine governor
EDM Engine Data Module Memory module for engine data
EIL Engine Ident Label
EMU Engine Monitoring Unit
SPC Spare Parts Catalog
FPP Fixed Pitch Propeller
GCU Gear Control Unit
GMU Gear Monitoring Unit
HI High Alarm: Measured value exceeds 1st maximum limit
HIHI High High Alarm: Measured value exceeds 2nd maximum limit
TIM-ID: 0000002045 - 019

value
HT High Temperature
ICFN ISO – Continuous rating – Fuel stop power Power specifications acc. to DIN-ISO 3046-7
– Net
IDM Interface Data Module Memory module for interface data
IMO International Maritime Organization
ISO International Organization for Standardiza- International umbrella organization of all standards
tion institutes
KGS Engine free end Engine free end in accordance with DIN ISO 1204

MS150102/04E 2015-11 | Appendix A | 267

 Abbre- Meaning Explanation
viation
KS Engine driving end 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
LPU Lubricating Oil Pump Control Unit Lube oil pump control
MCS Monitoring and Control System
MG Message
MPU Microprocessor Unit, Microprocessing Unit
TDC Top Dead Center
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
PCU Propeller Control Unit
PIM Peripheral Interface Module
UPS Unit Pump System
POM Power Output Module Module to control starter and battery-charging gen-
erator
PPC Priming Pump Control Oil priming pump
RCS Remote Control System
RL Redundancy Lost Alarm: Redundant CAN bus failure
SAE Society of Automotive Engineers U.S. standardization organization
SD Sensor Defect Alarm: Sensor failure
SDAF Shut Down Air Flaps Emergency-air shutoff flap(s)
SS Safety System Safety system alarm
SSK Emergency-air shutoff flap(s)
T-xyz Temperature-xyz Temperature measuring point xyz
TD Transmitter Deviation Alarm: Sensor comparison fault
TIM-ID: 0000002045 - 019

BDC Bottom Dead Center

VS Voith Schneider Voith Schneider drive
WJ Water jet Water jet drive
TC Tool Catalog

268 | Appendix A | MS150102/04E 2015-11

 9.2 MTU Contact/Service Partners
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 MTU Internet site: http://www.mtu-online.com

24h Hotline
With our 24h hotline and high flexibility, we're 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:
E-mail: info@mtu-online.com
Tel.: +49 7541 9077777
Fax.: +49 7541 9077778
Asia/Pacific: +65 6100 2688
North and Latin America: +1 248 560 8000

Spare Parts Service

Fast, simple and correct identification of spare parts for your drive system or vehicle fleet. The right spare
part at the right time at the right place.
With this aim in mind, we can call on a globally networked spares logistics system, a central warehouse at
headquarters and on-site stores at our subsidiary companies, agencies and service workshops.
Your contact at Headquarters:
E-mail: spare.parts@mtu-online.com
Tel.: +49 7541 9077777
Fax.: +49 7541 9077778
TIM-ID: 0000000873 - 016

MS150102/04E 2015-11 | Appendix A | 269

 10 Appendix B
10.1 Special Tools
Barring device
Part No.: F6555766
Qty.: 1
Used in: 8.3.2 Cylinder liner – Endoscopic examination
(→ Page 168)

Bore gauge, 100–160 mm

Part No.: Y20091482
Qty.: 1
Used in: 8.16.1 Raw water pump – Check (→ Page 251)

Bore gauge, 18–100 mm

Part No.: Y20091481
Qty.: 1
Used in: 8.4.3 Roller tappets – Check (→ Page 175)
Qty.: 1
Used in: 8.16.1 Raw water pump – Check (→ Page 251)
DCL-ID: 0000026046 - 007

270 | Appendix B | MS150102/04E 2015-11

 Cap puller
Part No.: 0015383730
Qty.: 1
Used in: 8.19.3 Indicator lamp – LED replacement (→ Page 262)

Connector pliers
Part No.: 0135315483
Qty.: 1
Used in: 8.19.1 Connectors and housing – Cleaning (→ Page 260)
Qty.: 1
Used in: 8.19.2 Plug-in connections – Check (→ Page 261)

Endoscope
Part No.: Y20097353
Qty.: 1
Used in: 8.3.2 Cylinder liner – Endoscopic examination
(→ Page 168)

Filter wrench
Part No.: F30379104
Qty.: 1
Used in: 8.7.5 Fuel filter – Replacement (→ Page 195)
Qty.: 1
Used in: 8.14.3 Piston cooling-oil filter – Replacement
DCL-ID: 0000026046 - 007

(→ Page 230)

MS150102/04E 2015-11 | Appendix B | 271

 Grease gun
Part No.: F30006433
Qty.: 1
Used in: 8.12.1 Exhaust turbocharger control linkage – Lubrication
(→ Page 217)

Installation/removal device
Part No.: F6795329
Qty.: 1
Used in: 8.5.3 Injector – Removal and installation (→ Page 180)

Milling cutter
Part No.: F30454782
Qty.: 1
Used in: 8.5.3 Injector – Removal and installation (→ Page 180)

MTU test kit

Part No.: 5605892099/00
Qty.: 1
Used in: 8.13.3 Engine oil – Sample extraction and analysis
(→ Page 223)
Qty.: 1
Used in: 8.15.10 Engine coolant – Sample extraction and analysis
(→ Page 249)
DCL-ID: 0000026046 - 007

272 | Appendix B | MS150102/04E 2015-11

 Outside micrometer, 0–25 mm
Part No.: Y20000083
Qty.: 1
Used in: 8.4.3 Roller tappets – Check (→ Page 175)

Outside micrometer, 100–125 mm

Part No.: Y20000219
Qty.: 1
Used in: 8.16.1 Raw water pump – Check (→ Page 251)

Outside micrometer, 25–50 mm

Part No.: Y20000432
Qty.: 1
Used in: 8.4.3 Roller tappets – Check (→ Page 175)
Qty.: 1
Used in: 8.16.1 Raw water pump – Check (→ Page 251)

Outside micrometer, 50–75 mm

Part No.: Y20000088
Qty.: 1
Used in: 8.16.1 Raw water pump – Check (→ Page 251)
DCL-ID: 0000026046 - 007

MS150102/04E 2015-11 | Appendix B | 273

 Outside micrometer, 75–100 mm
Part No.: Y20000169
Qty.: 1
Used in: 8.16.1 Raw water pump – Check (→ Page 251)

Ratchet
Part No.: F30006211
Qty.: 1
Used in: 8.2.2 Engine – Barring manually (→ Page 163)

Ratchet adapter
Part No.: F30027341
Qty.: 1
Used in: 8.4.1 Valve clearance – Check and adjustment
(→ Page 172)
Qty.: 1
Used in: 8.5.3 Injector – Removal and installation (→ Page 180)

Ratchet adapter
Part No.: F30027340
Qty.: 1
Used in: 8.4.2 Cylinder head cover – Removal and installation
(→ Page 174)
Qty.: 1
DCL-ID: 0000026046 - 007

Used in: 8.5.3 Injector – Removal and installation (→ Page 180)

Qty.: 1
Used in: 8.6.1 Fuel system – Venting (→ Page 186)
Qty.: 1
Used in: 8.14.4 Centrifugal oil filter – Cleaning and filter sleeve re-
placement (→ Page 232)

274 | Appendix B | MS150102/04E 2015-11

 Ratchet with extension
Part No.: F30006212
Qty.: 1
Used in: 8.3.2 Cylinder liner – Endoscopic examination
(→ Page 168)

Steam jet cleaner

Part No.: -
Qty.: 1
Used in: 4.12 Plant – Cleaning (→ Page 65)

Torque multiplier
Part No.: F30030459
Qty.: 1
Used in: 8.2.2 Engine – Barring manually (→ Page 163)

Torque wrench, 20–100 Nm

Part No.: F30026582
Qty.: 1
Used in: 8.5.3 Injector – Removal and installation (→ Page 180)
DCL-ID: 0000026046 - 007

MS150102/04E 2015-11 | Appendix B | 275

 Torque wrench, 40–200 Nm
Part No.: F30027337
Qty.: 1
Used in: 8.4.1 Valve clearance – Check and adjustment
(→ Page 172)

Torque wrench, 4–20 Nm

Part No.: F30044239
Qty.: 1
Used in: 8.10.3 Air filter – Removal and installation (→ Page 205)

Torque wrench, 6–50 Nm

Part No.: F30027336
Qty.: 1
Used in: 8.4.2 Cylinder head cover – Removal and installation
(→ Page 174)
Qty.: 1
Used in: 8.6.1 Fuel system – Venting (→ Page 186)
Qty.: 1
Used in: 8.14.4 Centrifugal oil filter – Cleaning and filter sleeve re-
placement (→ Page 232)

Torque wrench, 80 to 400 Nm

Part No.: F30027338
Qty.: 1
Used in: 8.5.3 Injector – Removal and installation (→ Page 180)
DCL-ID: 0000026046 - 007

276 | Appendix B | MS150102/04E 2015-11

 Torque wrench, 80 to 400 Nm
Part No.: F30027338
Qty.: 1
Used in: 8.17.1 Engine mounts – Checking securing screws for
firm seating (→ Page 257)

Valve adjustment gauge

Part No.: Y4099505
Qty.: 1
Used in: 8.4.1 Valve clearance – Check and adjustment
(→ Page 172)

Valve adjustment wrench

Part No.: F30371153
Qty.: 1
Used in: 8.4.1 Valve clearance – Check and adjustment
(→ Page 172)

WT05 solution
Part No.: 5605892099/23
Qty.: 1
Used in: 8.13.3 Engine oil – Sample extraction and analysis
(→ Page 223)
DCL-ID: 0000026046 - 007

MS150102/04E 2015-11 | Appendix B | 277

 10.2 Index
Numerics E
3-way solenoid valve  ECU 
– Manual operation  207 – Fault messages  83
50-hours service 69 Engine 
– Barring  
A – Manually  163
Adhesive tape for SOLAS shielding  – Disabling start  162
– Application  131 – Emergency shutdown at LOP  62
After stopping the engine 63 – Enabling start  165
Air and exhaust flaps  – Layout  27
– Functional test  218 – Main dimensions  51
Air filter  – Prelubricating after extended out-of-service periods  
– Air filter element cleaning  206 57
– Installation  205 – Starting at LOP  59
– Removal  205 – Stop at LOP  60
– Replacement  204 Engine cabling 
Automatic seawater inductor function  – Check  259
– Check  256 Engine control system – Operational tests 266
Engine coolant 
C – Change  244
Centrifugal oil filter  – Draining  245
– Cleaning  232 – Filling  246
Centrifugal oil filter bracket  – Sample extraction and analysis  249
– Removal and installation  235 – Vent line  
Changing engine speed  – Obstruction check  241
– At Local Operating Panel LOP 14  68 Engine coolant level 
Charge-air cooler  – Check  243
– Checking condensate drain line for coolant discharge Engine coolant pump 
and obstruction  202 – Relief bore check  248
Combustion chambers  Engine data 
– Draining condensate  167 – 16 V 1163 M84  35
Compressed-air tank – Draining condensate 212 – 16 V 1163 M94  38
Compressor   – 16V 1163 M74  32
– Greasing  216 – 20 V 1163 M74  41
Contact persons 269 – 20 V 1163 M84  44
Controls and displays  – 20 V 1163 M94  47
– Local Operating Panel LOP 14  52 Engine driving end 
Coolant  – Definition  22
– Change  244 Engine free end 
Coolant system  – Definition  22
– Strainer removal  250 Engine mounting 
Coupling condition  – Checking securing screws for firm seating  257
– Check  166 – Cleaning  258
Cylinder  Engine oil 
DCL-ID: 0000026046 - 007

– Designation  22 – Change  222

Cylinder head cover  – Oil sludge check for metallic residue  224
– Removal and installation  174 – Sample  
Cylinder liner  – Analysis  223
– Endoscopic examination  168 – Extraction  223
– Instructions and comments on endoscopic and visual Engine oil bypass filter – Replacement 225
examination  170 Engine oil filter 
– Cleaning edge-type filter element  229
D
– Replacement  228
Drain and venting points 236 Engine oil level 
– Check  220

278 | Appendix B | MS150102/04E 2015-11

 Engine sides  LED 
– Designation  22 – Indicator lamp  
Engine wiring  – Replacement  262
– Connectors and housing   Limit switch – Check 264
– Cleaning  260 Limiting valve 
Exhaust turbocharger control linkage  – Replacement  184
– Lubrication  217 List of abbreviations 267
Local Operating Panel LOP 14 
F – Changing engine speed  68
Fault messages  – Controls and displays  52
– Engine Control Unit ECU 9  83 – Gearbox  
Fiber-reinforced composites  – Engaging/disengaging  66
– General information  20 LOP 14 
Filter sleeve  – Controls and displays  52
– Replacement  232
Firing order 50 M
Fluid level monitor  Maintenance Schedule 
– Check  265 – Maintenance task reference table [QL1]  70
Fuel booster pump  Maintenance schedule - Additional information 72
– Troubleshooting  80 MTU contact persons 269
Fuel filter 
– Replacement  195 O
Fuel prefilter  Oil priming pump 
– Differential pressure gauge   – Direction of rotation  
– Adjustment  192 – Checking  227
– Check  192 – Troubleshooting  80
– Draining  188 Operational checks 61
– Filter element  
– Replacement  190 P
– Flushing  193 Piston cooling-oil filter 
Fuel system  – Replacement  230
– Venting  186 Plant 
– Cleaning  65
G Plug-in connections – Check 261
Gearbox  Preheater 
– Engaging/disengaging   – Function and leak-tightness check  199
– At Local Operating Panel LOP 14  66 Preheating unit 197
Prelubricating 
H – Engine after extended out-of-service periods  57
Heat exchanger  Pressure reducing station 
– Vent  242 – Filter cleaning  211
Heating element(s)  – Putting into operation  208
– Electrical check  200 – Venting and shutdown  210
Hotline 269 Product description 23
Pump control EPC 
I – Controls and displays  55
Injector  – Function check  64
– Check  178
DCL-ID: 0000026046 - 007

Putting the engine into operation 

– Removal and installation  180 – After extended out-of-service periods (>3 months)  56
– Replacement  179 – After scheduled out-of-service-period  58
Installation locations for SOLAS shielding 132
Intercooler  R
– Drain line check  201 Raw water pump 
– Check  251
L – Relief bore  
Leak fuel tank  – Check  255
– Draining  187 – Tolerances  253
Roller tappets 
– Check  175

MS150102/04E 2015-11 | Appendix B | 279

 Roller tappets, tappet guide 
– Tolerances  176

S
Safety notices, standards 15
Safety regulations 
– Auxiliary materials  13
– Environmental protection  13
– Fire prevention  13
– Fluids and lubricants  13
– Important provisions  5, 6
– Maintenance work  10
– Operation  8
– Organizational requirements  7
– Personnel requirements  7
– Repair work  10
– Startup  8
Safety requirements 
– Safety notices, standards  15
Sensors and actuators – Overview 28
Service indicator 
– Signal ring position check  203
Service partners 269
SOLAS 
– Installation locations for SOLAS shielding  132
SOLAS shielding as per MTN 5233 
– Installation  129
Spare parts service 269
Start pilot 
– Filter cleaning  215
– Fluid level check  214
Starter 
– Condition check  213

T
Transport 19
Transport locking devices – Crankshaft 16
Troubleshooting 73
– Oil priming pump, fuel booster pump  80

V
Valve clearance 
– Adjustment  172
– Check  172

W
Water drain valve 
– Check  240
DCL-ID: 0000026046 - 007

Wiring 
– Check  
– On engine  259
– Connectors and housing  
– Cleaning  260

280 | Appendix B | MS150102/04E 2015-11