Mtu 16v2000g65 PDF

Operating Instructions
Diesel engine
12 V 2000 G25, G25 TB
12 V 2000 G45, G45 TB
12 V 2000 G65, G65 TB
12 V 2000 G85, G85 TB
16 V 2000 G25, G25 TB
16 V 2000 G45, G45 TB
16 V 2000 G65, G65 TB
16 V 2000 G85, G85 TB
18 V 2000 G25, G25 TB
18 V 2000 G45, G45 TB
18 V 2000 G65, G65 TB
18 V 2000 G85, G85 TB
Application group 3A
MS15018/02E
Table of Contents
1 Safety 6 Troubleshooting
1.1 Important provisions for all products 5 6.1 Fault indication on SAM display – Genset
1.2 Personnel and organizational requirements 6 applications 40
1.3 Transport 7 6.2 Troubleshooting 64
1.4 Safety regulations for startup and operation 8
1.5 Safety regulations for maintenance and 7 Task Description
repair work 9
1.6 Fire prevention and environmental 7.1 Engine 67
7.1.1 Engine – Barring manually 67
protection, fluids and lubricants, auxiliary
7.1.2 Engine – Barring with starting system 68
materials 12
7.1.3 Engine – Test run 69
1.7 Standards for safety notices in the text 14
7.2 Cylinder Liner 70
2 General Information 7.2.1 Cylinder liner – Endoscopic examination 70
7.2.2 Instructions and comments on endoscopic and
2.1 Engine side and cylinder designations 15 visual examination of cylinder liners 72
2.2 Engine – Overview 16 7.3 Crankcase Breather 74
2.3 Sensors and actuators – Overview 18 7.3.1 Crankcase breather – Oil separator element
replacement, diaphragm check and
3 Technical Data replacement 74
7.3.2 Crankcase breather – Wire mesh cleaning 76
3.1 12/16/18 V 2000 Gx5 engine data,
optimized fuel consumption 20 7.4 Valve Drive 77
7.4.1 Valve clearance – Check and adjustment 77
3.2 12/16/18 V 2000 Gx5-TB engine data,
7.4.2 Cylinder head cover – Removal and
optimized fuel consumption 24 installation 80
3.3 Firing order 28
3.4 Engine – Main dimensions 29 7.5 Injection Pump / HP Pump 81
7.5.1 Injection pump – Replacement 81
7.5.2 Injection pump – Removal and installation 82
4 Operation
7.6 Injection Valve / Injector 85
4.1 Putting the engine into operation after 7.6.1 Injector – Replacement 85
extended out-of-service periods (>3 months) 30 7.6.2 Injector – Removal and installation 86
4.2 Putting the engine into operation after
scheduled out-of-service-period 31 7.7 Fuel System 89
7.7.1 Fuel injection line – Pressure pipe neck
4.3 Engine – Starting in manual mode (test run) 32 replacement 89
4.4 Safety system – Override 33 7.7.2 Fuel – Draining 91
4.5 Operational checks 34 7.7.3 Fuel pressure maintaining valve – Removal
4.6 Engine – Stopping in manual mode (test and installation 93
run) 35 7.7.4 Fuel system – Venting 94
4.7 Engine – Emergency stop 36
7.8 Fuel Filter 96
4.8 After stopping the engine – Engine remains 7.8.1 Fuel filter – Replacement 96
ready for operation 37
DCL-ID: 0000019467 - 004
7.8.2 Fuel prefilter – Differential pressure check

4.9 After stopping the engine – Putting the and adjustment of gauge 97
engine out of operation 38 7.8.3 Fuel prefilter – Draining 98
7.8.4 Fuel prefilter – Flushing 99
5 Maintenance 7.8.5 Fuel prefilter – Cleaning 101
7.8.6 Fuel prefilter – Filter element replacement 102
5.1 Maintenance task reference table [QL1] 39
7.9 Charge-Air Cooling General, Left-Hand Side 104
7.9.1 Intercooler – Checking condensate drain for
coolant discharge and obstructions 104
MS15018/02E 2013-09 | Table of Contents | 3

7.10 Air Filter 105 7.17.2 Cooler – Cleaning cooler elements 124
7.10.1 Air filter – Replacement 105
7.18 Battery-Charging Generator 125
7.10.2 Air filter – Removal and installation 106
7.18.1 Battery-charging generator drive – Drive-belt
7.11 Air Intake 107 check and adjustment 125
7.11.1 Service indicator – Signal ring position check 107 7.18.2 Battery-charging generator drive – Drive belt
replacement 127
7.12 Starting Equipment 108
7.12.1 Air starter – Manual operation 108 7.19 Fan Drive 128
7.19.1 Fan drive – Drive-belt check and adjustment 128
7.13 Lube Oil System, Lube Oil Circuit 109 7.19.2 Fan drive – Belt replacement 131
7.13.1 Engine oil – Level check 109
7.13.2 Engine oil – Change 110 7.20 Wiring (General) for Engine/Gearbox/Unit 133
7.20.1 Engine wiring – Check 133
7.14 Oil Filtration / Cooling 111
7.14.1 Engine oil filter – Replacement 111 7.21 Accessories for (Electronic) Engine
Governor / Control System 134
7.15 Coolant Circuit, General, High-Temperature 7.21.1 Engine governor and connectors – Cleaning 134
Circuit 112 7.21.2 Engine governor plug connections – Check 135
7.15.1 Engine coolant – Level check 112 7.21.3 ECU 7 engine governor – Removal and
7.15.2 Engine coolant – Change 113 installation 136
7.15.3 Engine coolant – Draining 114
7.15.4 Engine coolant – Filling 115
7.15.5 Coolant pump – Relief bore check 117 8 Appendix A
7.16 Low-Temperature Circuit 118 8.1 Abbreviations 137
7.16.1 Charge-air coolant – Filling 118
8.2 MTU contact persons/service partners 140
7.16.2 Charge-air coolant – Draining 120
7.16.3 Charge-air coolant – Change 121
7.16.4 Charge-air coolant – Level check 122 9 Appendix B
7.17 Coolant System 123 9.1 Special Tools 141

7.17.1 Cooler – Checking cooler elements externally 9.2 Consumables 148
for dirt 123 9.3 Spare Parts 151
9.4 Index 154
DCL-ID: 0000019467 - 004
4 | Table of Contents | MS15018/02E 2013-09

2 General Information
2.1 Engine side and cylinder designations
Engine sides are always designated as viewed from the driving end (KS) (4).
For designation of the cylinders (to DIN ISO 1204) the letter "A" (1) is used to refer to the cylinders on
the left-hand side of the engine and the letter "B" (3) to refer to the cylinders on the right-hand side. The
cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end.
The numbering of other engine components also starts with no. 1 at the driving end.
1 Left-hand side of engine 3 Right-hand side of engine

2 Free end 4 Driving end
TIM-ID: 0000002185 - 012
MS15018/02E 2013-09 | General Information | 15

2.2 Engine – Overview
Illustration is applicable to 12/16/18 V 2000 Gxy engines (with water-cooled
intercooler TB)
010 Crankcase and add-on 7 Oil heat exchanger 14 Charge-air manifold

components 8 Oil filter 15 Cylinder head
1 Air filter 9 Coolant pump 16 Flywheel housing
2 Oil separator 10 Fuel priming pump 17 Starter
3 Intercooler 11 Air outlet 18 Mounting
4 Engine governor 12 Exhaust turbocharger 19 Oil pan
5 Fuel filter 13 Exhaust elbow 20 Crankcase breather
6 Fan drive
TIM-ID: 0000009973 - 004
16 | General Information | MS15018/02E 2013-09

Illustration is applicable to 12/16/18 V 2000 Gxy engines (with air-cooled
intercooler TD)
1 Air filter 7 Oil heat exchanger 13 Exhaust elbow

2 Oil separator 8 Oil filter 14 Charge-air manifold
3 Air outlet 9 Coolant pump 15 Cylinder head
4 Engine governor 10 Fuel priming pump 16 Flywheel housing
5 Fuel filter 11 Exhaust turbocharger 17 Mounting
6 Fan drive 12 Oil pan 18 Crankcase breather
Engine model designation

Key to the engine model designations 12/16/18V 2000 Gxy
12/16/18 Number of cylinders
V Cylinder arrangement: V-engine
2000 Series
G Application
X Application segment (2, 4, 6, 8)
y Design index (0,1, 2,...)
TIM-ID: 0000009973 - 004

2.3 Sensors and actuators – Overview
Engines with water-cooled intercooler TB
Item Name Monitoring of

1 B7 Lube oil temperature
2 B5 Lube oil pressure
3 B9 Charge-air coolant temperature
4 B10 Charge-air pressure
5 B1 Camshaft speed
6 B13 Crankshaft speed
7 B6 Coolant temperature
8 B33 Fuel temperature
The coolant level sensor F33 is located in the coolant expansion tank at the cooler
TIM-ID: 0000022704 - 003
18 | General Information | MS15018/02E 2013-09

Engine with air-cooled intercooler TD
Item Name Monitoring of

1 B7 Lube oil temperature
2 B5 Lube oil pressure
3 B9 Charge-air coolant temperature
4 B10 Charge-air pressure
5 B1 Camshaft speed
6 B13 Crankshaft speed
7 B6 Coolant temperature
8 B33 Fuel temperature
The coolant level sensor F33 is located in the coolant expansion tank at the cooler
TIM-ID: 0000022704 - 003

3 Technical Data
3.1 12/16/18 V 2000 Gx5 engine data, optimized fuel
consumption
Explanation:
DL Ref. value: Continuous power
BL Ref. value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power settings).
N Not yet defined value
- Not applicable
X Applicable
REFERENCE CONDITIONS
Engine model 12V 2000 12V 2000 16V 2000 18V 2000
G25 G65 G65 G65
Application group 3A 3A 3A 3A
Intake air temperature °C 25 25 25 25
Barometric pressure mbar 1000 1000 1000 1000
Site altitude above sea level m 100 100 100 100
POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)
Number of cylinders 12 12 16 18
Rated engine speed A rpm 1500 1500 1500 1500
Continuous power ISO 3046 (10% over- A kW 452 515 655 720
load capability, design power DIN 6280,
ISO 8528)
GENERAL CONDITIONS (for maximum power)

Intake air depression (new filter) A mbar 15 15 15 15
Intake air depression, max. L mbar 50 50 50 50
Exhaust pressure A mbar 30 30 30 30
Exhaust pressure, max. L mbar 85 85 85 85
TIM-ID: 0000010804 - 001
MODEL RELATED DATA (basic design)

Engine with exhaust turbocharging (ETC) x x x x
and charge air cooling (CAC)
Exhaust piping, non-cooled x x x x
Working method: four-cycle, diesel, single- x x x x
acting
20 | Technical Data | MS15018/02E 2013-09

Combustion method: Direct fuel injection x x x x
Cooling system: conditioned water x x x x
Direction of rotation: c.c.w. (facing driving x x x x
end)
Cylinder configuration: V angle Degrees 90 90 90 90
Bore mm 130 130 130 130
Stroke mm 150 150 150 150
Displacement per cylinder liters 1.99 1.99 1.99 1.99
Displacement, total liters 23.88 23.88 31.84 35.82
Compression ratio 16 16 16 16
Cylinder heads: single-cylinder x x x x
Cylinder liners: wet, replaceable x x x x
Inlet valves per cylinder 2 2 2 2
Exhaust valves per cylinder 2 2 2 2
Standard flywheel housing flange (engine SAE 0 0 0 0
main PTO)
Flywheel interface DISC 18" 18" 18" 18"
COMBUSTION AIR / EXHAUST GAS

Charge air pressure before cylinder - DL R bar abs 2.3 2.5 2.5 2.4
COOLANT SYSTEM (HT circuit)

Coolant temperature (at engine connec- A °C 95 95 95 95
tion: outlet to cooling equipment)
Coolant temperature after engine, alarm R °C 97 97 97 97
Coolant temperature after engine, shut- L °C 102 102 102 102
down
Coolant antifreeze content, max. L % 50 50 50 50
Pressure loss in off-engine cooling sys- L bar 0.7 0.7 0.7 0.7
tem, max.
LUBE-OIL SYSTEM
TIM-ID: 0000010804 - 001
Lube oil operating temperature before en- R °C 88 88 88 88
gine, from
Lube-oil operating temperature before en- R °C 98 98 98 98
gine, to
Lube-oil temperature before engine, alarm R °C 100 100 100 100
Lube-oil temperature before engine, shut- L °C 105 105 105 105
down
MS15018/02E 2013-09 | Technical Data | 21

Lube-oil operating pressure before engine, R bar 6.2 6.2 5.5 6.0
from
to
Lube-oil pressure before engine, alarm R bar 4.4 4.4 4.4 4.4
Lube-oil pressure before engine, shut- L bar 3.9 3.9 3.9 3.9
down
FUEL SYSTEM
Fuel pressure at engine supply connec- L bar -0.3 -0.3 -0.3 -0.3
tion, min. (when engine is starting)
Fuel pressure at engine supply connec- L bar +0.5 +0.5 +0.5 +0.5
tion, max. (when engine is starting)
GENERAL OPERATING DATA

Cold start capability: Air temperature R °C 0** 0** 0** 0**
(w/o start aid, w/o preheating) - (case A)
Coolant preheating: preheating tempera- R °C 32 32 32 32
ture (min.)
Firing speed, from R rpm 100 100 100 100
Firing speed, to R rpm 120 120 120 120
CAPACITIES
Engine coolant capacity, engine side R liters 90 90 110 120
(without cooling equipment)
Total engine oil capacity at initial filling R liters 77 77 102 130
(standard oil system) (Option: max. oper-
ating inclinations)
Oil change capacity, max. (standard oil R liters N N N N
system)
Oil change quantity, max. (standard oil R liters 74 74 99 114
system) (Option: max. operating inclina-
tions)
Oil pan capacity at dipstick mark "min." L liters 50 50 69 87
TIM-ID: 0000010804 - 001

ating inclinations)
Oil pan capacity at dipstick mark "max." L liters 67 67 92 110
ating inclinations)

WEIGHTS / MAIN DIMENSIONS
Engine weight, dry (basic engine configu- R kg 2490 2490 3100 3500
ration acc. to scope of supply specifica-
tion)
ACOUSTICS
Exhaust noise, unsilenced - DL (sound R dB(A) 119 119 116 116
power level LW, ISO 6798)
Engine surface noise with attenuated in- R dB(A) 114 115 119 119
take noise filter) - DL (sound power level
LW, ISO 6798)
TIM-ID: 0000010804 - 001

3.2 12/16/18 V 2000 Gx5-TB engine data, optimized fuel
consumption
Explanation:
DL Ref. value: Continuous power
BL Ref. value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power settings).
N Not yet defined value
- Not applicable
X Applicable
REFERENCE CONDITIONS
Engine model 12V 2000 12V 2000 16V 2000 18V 2000
G25-TB G65-TB G65-TB G65-TB
Application group 3A 3A 3A 3A
Intake air temperature °C 25 25 25 25
Charge-air coolant temperature °C 55 55 55 55
Raw water inlet temperature °C - - - -
Barometric pressure mbar 1000 1000 1000 1000
Site altitude above sea level m 100 100 100 100
POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)
Rated engine speed A rpm 1500 1500 1500 1500
Continuous power ISO 3046 (10% over- A kW 452 515 655 720
load capability, design power DIN 6280,
ISO 8528)
GENERAL CONDITIONS (for maximum power)

Intake air depression (new filter) A mbar 15 15 15 15
Intake air depression, max. L mbar 50 50 50 50
Exhaust pressure A mbar 30 30 30 30
Exhaust pressure, max. L mbar 85 85 85 85
TIM-ID: 0000010846 - 001
MODEL RELATED DATA (basic design)

Engine with exhaust turbocharging (ETC) x x x x
and charge air cooling (CAC)
Exhaust piping, non-cooled x x x x
Working method: four-cycle, diesel, single- x x x x
acting
Combustion method: Direct fuel injection x x x x

Cooling system: conditioned water x x x x
Direction of rotation: c.c.w. (facing driving x x x x
end)
Cylinder configuration: V angle Degrees 90 90 90 90
Bore mm 130 130 130 130
Stroke mm 150 150 150 150
Displacement per cylinder liters 1.99 1.99 1.99 1.99
Displacement, total liters 23.88 23.88 31.84 35.82
Compression ratio 16 16 16 16
Cylinder heads: single-cylinder x x x x
Cylinder liners: wet, replaceable x x x x
Inlet valves per cylinder 2 2 2 2
Exhaust valves per cylinder 2 2 2 2
Standard flywheel housing flange (engine SAE 0 0 0 0
main PTO)
Flywheel interface DISC 18" 18" 18" 18"
COMBUSTION AIR / EXHAUST GAS

Charge air pressure before cylinder - DL R bar abs 2.3 2.5 2.5 2.4
COOLANT SYSTEM (HT circuit)

Coolant temperature (at engine connec- A °C 95 95 95 95
tion: outlet to cooling equipment)
Coolant temperature after engine, alarm R °C 97 97 97 97
Coolant temperature after engine, shut- L °C 102 102 102 102
down
tem, max.
COOLANT SYSTEM (LT circuit)

TIM-ID: 0000010846 - 001
Coolant temperature before intercooler A °C 55 55 55 55

(at engine inlet from cooling equipment)
tem, max.

LUBE-OIL SYSTEM
Lube oil operating temperature before en- R °C 88 88 88 88
gine, from
Lube-oil operating temperature before en- R °C 98 98 98 98
gine, to
Lube-oil temperature before engine, alarm R °C 100 100 100 100
Lube-oil temperature before engine, shut- L °C 105 105 105 105
down
from
to
Lube-oil pressure before engine, alarm R bar 4.4 4.4 4.4 4.4
Lube-oil pressure before engine, shut- L bar 3.9 3.9 3.9 3.9
down
FUEL SYSTEM
Fuel pressure at engine supply connec- L bar -0.3 -0.3 -0.3 -0.3
tion, min. (when engine is starting)
Fuel pressure at engine supply connec- L bar +0.5 +0.5 +0.5 +0.5
tion, max. (when engine is starting)
GENERAL OPERATING DATA

Cold start capability: Air temperature R °C 0** 0** 0** 0**
(w/o start aid, w/o preheating) - (case A)
Coolant preheating: preheating tempera- R °C 32 32 32 32
ture (min.)
Firing speed, from R rpm 100 100 100 100
Firing speed, to R rpm 120 120 120 120
CAPACITIES
Engine coolant capacity, engine side R liters 110 110 130 140
(without cooling equipment)
TIM-ID: 0000010846 - 001
Charge-air coolant, engine side R liters 20 20 20 20

Total engine oil capacity at initial filling R liters 77 77 102 130
ating inclinations)
Oil change capacity, max. (standard oil R liters N N N N
system)
Oil change quantity, max. (standard oil R liters 74 74 99 114
system) (Option: max. operating inclina-
tions)

Oil pan capacity at dipstick mark "min." L liters 50 50 69 87
ating inclinations)
Oil pan capacity at dipstick mark "max." L liters 67 67 92 110
ating inclinations)
WEIGHTS / MAIN DIMENSIONS

Engine weight, dry (basic engine configu- R kg 2570 2570 3180 3580
ration acc. to scope of supply specifica-
tion)
ACOUSTICS
Exhaust noise, unsilenced - DL (sound R dB(A) 119 119 116 116
power level LW, ISO 6798)
Engine surface noise with attenuated in- R dB(A) 114 115 119 119
take noise filter) - DL (sound power level
LW, ISO 6798)
TIM-ID: 0000010846 - 001

3.3 Firing order
Firing order
12 V A1-B2-A5-B4-A3-B1-A6-B5-A2-B3-A4-B6
16 V A1-B5-A3-A5-B2-B8-A2-A8-B3-A7-B4-B6-A4-A6-B1-B7
18 V A1-B6-A3-B4-A5-B2-A7-B1-A9-B3-A8-B5-A6-B7-A4-B9-A2-B8
TIM-ID: 0000002793 - 002

3.4 Engine – Main dimensions
Engine model Length (A) Width (B) Height (C)

12 V 2000 Gxy approx. 1885 mm approx. 1580 mm approx. 1585 mm
TIM-ID: 0000010030 - 003

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

months)
Item Action
Engine Depreserve (→ MTU Preservation and Represervation Specifications
A001070/..).
Lube oil system Check engine oil level (→ Page 109);
Fuel prefilter Fill with fuel (→ Page 99).
Fuel prefilter, pressure Align adjustable pointer with position of pressure indicator (→ Page 97).
gauge
Fuel system Vent (→ Page 94).
Coolant circuit If engine is out of service for more than one year, change engine coolant
(→ Page 113).
Change charge-air coolant (→ Page 121).
Coolant circuit Check engine coolant level (→ Page 112);
Check charge-air coolant level (→ Page 122).
Coolant circuit Heat engine coolant with coolant preheating unit.
Engine governor Check plug-in connections (→ Page 135).
Monitoring system Carry out lamp test (see manufacturer's documentation).
Engine/generator control Switch ON;
system select operating mode, e.g. MANUAL, AUTOMATIC OPERATION.
TIM-ID: 0000002190 - 002
30 | Operation | MS15018/02E 2013-09

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

Item Task
Lube oil system Check oil level (→ Page 109);
Cooling system Check engine coolant level (→ Page 112);
Check charge-air coolant level (→ Page 122).
Cooling system Preheat coolant with preheating unit.
Fuel prefilter Drain (→ Page 98).
Monitoring equipment Carry out lamp test (see manufacturer's documentation).
Engine/generator control Switch ON;
system Select operating mode, e.g. MANUAL OPERATION, AUTOMATIC OPERATION.
TIM-ID: 0000002677 - 001
MS15018/02E 2013-09 | Operation | 31

4.3 Engine – Starting in manual mode (test run)
Preconditions
☑Generator (if fitted) is not connected to network.
☑External start interlock is not active.
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Before cranking the engine with starter system, make sure that there are no persons in the en-
gine's danger zone.
WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.
Preparation
Item Action
Operating mode switch (if Change to manual mode.
fitted)
Preheating pump (if fitted) Switch on.
Starting the engine

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

reach operating temperature
Item Action
Switchgear cabinet, control Close the generator circuit breaker.
panel etc. (depending on
manufacturer)
TIM-ID: 0000002226 - 004
Engine Apply full load only after engine has reached operating temperature (coolant
temperature approx. 75 °C).
32 | Operation | MS15018/02E 2013-09

4.4 Safety system – Override
NOTICE
Safety functions and engine shutdown alarms will be disregarded.
Severe material damage!
• Initiate emergency start only in emergency situations.
NOTICE
Inadmissible operating status.
Severe damage to property!
• Use override function only in hazardous situations to ensure full capability in the event of engine
faults.
Preparation
Note: This function is only available when a pushbutton is provided.
Safety system – Override

Item Action
Switchgear cabinet, control Activate pushbutton for Override input of the ECU.
panel etc. (depending on • Certain shutdown criteria and/or starting prerequisites are ignored.
manufacturer)
Switchgear cabinet, control Actuate start button, for further starting sequence, refer to engine start
panel etc. (depending on (→ Page 32).
manufacturer)
Control and display panels During operation, check the displayed operational data (speed, temperature,
pressures).
Constantly monitor plant limit values.
TIM-ID: 0000000984 - 003
MS15018/02E 2013-09 | Operation | 33

4.5 Operational checks
DANGER
Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
• Take special care when working on a running engine.
WARNING
Engine noise above 85 dB (A).
Operational checks
Item Task
Control and display panels Check indicated operating parameters (speed, temperatures, pressures).
Engine under load, Check engine/plant and pipework for leaks, rectify any leaks with the engine
Engine at nominal speed stopped;
Check for abnormal running noises and vibration.
Fuel prefilter Check whether indicated differential pressure is within the limit (→ Page 97).
Exhaust system Check exhaust color (→ Page 64).
Intercooler Check condensate drain(s) for water discharge and obstruction
(→ Page 104).
Air filter Check signal ring position of service indicator (→ Page 107).
Replace air filter (→ Page 105), if the signal ring is completely visible in the
red area of the service indicator control window.
Coolant pump Check relief bore (→ Page 117).
Compressed-air system (if Check operating pressure at pressure gauge;
installed) Fill compressed-air tank to maximum pressure;
Drain condensate from compressed-air tank, pressure drop must not exceed
1 bar.
TIM-ID: 0000010120 - 001
34 | Operation | MS15018/02E 2013-09

4.6 Engine – Stopping in manual mode (test run)
Preconditions
☑Generator (if fitted) is not connected to network
☑Engine in manual mode
NOTICE
Stopping the engine when it is running at full load subjects it to extreme thermal and mechanical
stresses.
Overheating of and, therefore, damage to components is possible!
• Before shutting down the engine, allow it to idle until the engine temperatures decrease and
constant levels are indicated.
Preparing a generator drive (only if generator circuit breaker is provided)

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

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

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

Item Action
Coolant circulation pump Operate pump for a sufficient period of time after the engine is stopped.
TIM-ID: 0000002285 - 004
MS15018/02E 2013-09 | Operation | 35

4.7 Engine – Emergency stop
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 stop from LOP

Item Action
Emergency stop pushbutton Press pushbutton.
• Engine is stopped by disconnecting the power supply to the ECU;
• signalization (e.g. by horn, flashing lamp) is released.
After emergency stop from LOP

Item Action
Switchgear cabinet, control Press pushbutton for alarm acknowledgement.
panel etc. (depending on • Audible and visual alarm signaling stops.
manufacturer)
TIM-ID: 0000002305 - 003
36 | Operation | MS15018/02E 2013-09

4.8 After stopping the engine – Engine remains ready for
operation

Item Action
Engine/generator/pump Select operating mode, e.g. MANUAL, AUTOMATIC OPERATION.
control
TIM-ID: 0000000983 - 003
MS15018/02E 2013-09 | Operation | 37

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

Item Action
Coolant circuit Drain engine coolant (→ Page 114);
Drain charge-air coolant (→ Page 120) 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 tem-
perature;
• antifreeze concentration is 50 % and engine-room temperature is be-
low -40 °C.
Engine/generator/pump Switch off.
control
Air intake and exhaust sys- If the engine is to remain out of service for more than 1 week, seal the en-
tem gine's air and exhaust sides. If the engine is to remain out of service for more
than 1 month, carry out preservation (→ Preservation and Represervation
Specifications A001070/..).
TIM-ID: 0000002706 - 003
38 | Operation | MS15018/02E 2013-09

5 Maintenance
5.1 Maintenance task reference table [QL1]
The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The
Maintenance Schedule is a stand-alone publication.
The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance
Schedule.
Task Maintenance tasks
W0500 Check engine oil level. (→ Page 109)
W0501 Visually inspect engine for leaks and general condition. (→ Page 34)
W0502 Check intercooler drain. (→ Page 34)
W0503 Check signal ring position of service indicator on air filter. (→ Page 34)
W0505 Check relief bores of water pump(s). (→ Page 34)
W0506 Check engine for abnormal running noises, exhaust color and (→ Page 34)
vibrations.
W0507 Drain water and contaminants from fuel prefilter. (→ Page 34)
W0508 Check reading on differential pressure gage of fuel prefilter. (→ Page 34)
W0534 Carry out test run, minimum duration: until steady-state tem- (→ Page 69)
perature is reached, no less than 1/3 load (monthly).
W1001 Replace fuel filter or fuel filter element. (→ Page 96)
W1002 Check valve clearance. (→ Page 77)
W1003 Check belt condition and tension, replace if necessary. (→ Page 125)
W1005 Replace air filter. (→ Page 105)
W1006 Replace fuel injectors. (→ Page 85)
W1007 Replace fuel injection pump(s). (→ Page 82)
W1008 Replace engine oil filter when changing engine oil, or when the (→ Page 111)
time limit (years) is reached, at the latest.
W1010 Coolant cooler: Check exterior of cooler elements for dirt. (→ Page 123)
W1011 Perform endoscopic examination. (→ Page 70)
W1056 Replace fuel pressure maintaining valve. (→ Page 93)
W1178 Replace pressure pipe neck in cylinder head. (→ Page 89)
TIM-ID: 0000037729 - 002
MS15018/02E 2013-09 | Maintenance | 39

6 Troubleshooting
6.1 Fault indication on SAM display – Genset applications
SAM fault messages
1 2-line LC display 3 Fault type

2 Time indicator for alarms 4 Node number
The structure of the display is as follows:
• First line
– Time indicator for alarms (e.g. #)
– Type of fault (e.g. SE03)
– Node number at which the fault occurred (e.g. nd11)
• Second line (option)
– Running text, providing more information about the fault currently displayed
Time indicator for alarms Meaning
# Alarm is no longer active, does not appear on next power-up.
TIM-ID: 0000008508 - 003
A Alarm is active.
B Alarm was active during the last hour.
C Alarm was active during the last four hours.
D Alarm was active during the last four to twelve hours.
E Alarm was active more than twelve hours ago.
Proceed to the next alarm by pressing key (↓ ↑).
40 | Troubleshooting | MS15018/02E 2013-09

Fault type – fault message text
SE no. Error message text
0 Sensor Temperatur Defect
1 Temperature failure
2 Sensor Voltage Defect
3 Voltage failure
4 CAN Bus- 1 Error/Bus Defec
5 CAN Bus- 1 Overrun
8 Temperatur Compensation Error
9 I/O-Module Slot2 Defect
12 Serial Conection Lost
15 S/A Bus Faulty
16 PAN 1 Defect
17 PAN 2 Defect
18 PAN 3 Defect
19 PAN 4 Defect
20 PAN 5 Defect
21 PAN 6 Defect
27 Download Server Collision
28 not projected node
Engine governor messages
Recommended action in case of alarm

Yellow alarm:
TIM-ID: 0000008508 - 003
The engine can still be operated providing that automatic engine shutdown to protect the engine has
not been configured or is not tripped. Contact Service immediately/start fault rectification.
Red alarm:
Caution, the engine is running at its limits. Shut down manually without further delay if the engine does
not shut itself down immediately after a red alarm is signaled.
Fault and alarm messages

The fault code numbers are generated by the engine governor and transmitted to the display below.
MS15018/02E 2013-09 | Troubleshooting | 41

The fault code (1) comprises three digits.
Fault messages can also be caused by faulty sensors/actuators. Contact Service to have sensors/
actuators checked and replaced as necessary if the troubleshooting measures listed in the table below
prove unsuccessful.
IMPORTANT NOTE:
The information provided in the columns “Meaning” and “Action” applies to the standard default state
of the genset on delivery. Differing system responses requiring different action may result when set-
tings are changed by the OEM. The OEM is responsible for documenting any changes and defining ap-
propriate counteraction.
The table below lists possible fault codes:
Fault Setting parame-
code no. Full designation Meaning Action ter no.
003 HI T-Fuel Prewarning: Fuel tempera- Check tank temper- 2.0122931
ture too high (limit value 1, ature, contact Serv-
alarm configuration parame- ice if no fault detect-
ter, see PR 2.8008.100 for ed.
explanation).
004 SS T-Fuel Main warning: Fuel tempera- Check tank temper- 2.0122932
TIM-ID: 0000008508 - 003
ture too high (limit value 2, ature, contact Serv-

alarm configuration parame- ice if no fault detect-
ter, see PR 2.8008.100 for ed.
explanation).
005 HI T-Charge Air Prewarning: Charge-air tem- Check cooler, check 2.0121.931
perature too high (limit value intercooler, contact
1, alarm configuration pa- Service if no fault
rameter, see PR 2.8008.100 detected.
for explanation).

006 SS T-Charge Air Main warning: Charge-air Check cooler, check 2.0121.932
temperature too high (limit intercooler, contact
value 2, alarm configuration Service if no fault
parameter, see PR detected.
2.8008.100 for explanation).
009 HI T-Coolant Intercool- Prewarning: Coolant temper- Check cooler, con- 2.0124.931
er ature in intercooler too high tact Service if no
(limit value 1, alarm configu- fault detected.
ration parameter, see PR
010 SS T-Coolant Intercool- Main warning: Coolant tem- Check cooler, con- 2.0124.932
er perature in intercooler too tact Service if no
high (limit value 2, alarm con- fault detected.
figuration parameter, see PR
015 LO P-Lube Oil Prewarning: Lube-oil pres- Check oil level, con- 2.0100.921
sure too low (limit value 1, tact Service if no
alarm configuration parame- fault detected.
ter, see PR 2.8008.100 for
explanation).
016 SS P-Lube Oil Main warning: Lube-oil pres- Check oil level, con- 2.0100.922
sure too low (limit value 2, tact Service.
alarm configuration parame-
explanation). Automatic en-
gine shutdown.
024 SS Coolant Level Coolant level too low (limit Check coolant level 2.0152.912
value 2, alarm configuration in expansion tank,
parameter, see PR check for leakage
2.8008.100 for explanation). and seal any leaks
Automatic engine shutdown. as necessary.
030 SS Engine Overspeed Engine overspeed (limit value Attempt to restart 2.2510.932
2, alarm configuration pa- engine.
rameter, see PR 2.8008.100
for explanation). Automatic
engine shutdown.
044 LO Coolant Level Inter- Intercooler coolant level too Check coolant level 2.0153.921
cooler low (limit value 1, alarm con- in expansion tank,
figuration parameter, see PR check for leakage
2.8008.100 for explanation). and seal any leaks
Automatic engine shutdown. as necessary.
051 HI T-Lube Oil Lube-oil temperature too Check cooling sys- 2.0125.931
TIM-ID: 0000008508 - 003
high (limit value 1, alarm con- tem.

Warning.
052 SS T-Lube Oil Lube-oil temperature too Check cooling sys- 2.0125.932
high (limit value 2, alarm con- tem, contact Service
figuration parameter, see PR if cooling system is
2.8008.100 for explanation). in order.
Automatic engine shutdown.

065 LO P-Fuel Fuel inlet pressure too low Check filter, check 2.0102.921
(limit value 1, alarm configu- genset fuel supply.
Warning.
066 SS P-Fuel Fuel inlet pressure too low Check filter, check 2.0102.922
(limit value 2, alarm configu- genset fuel supply.
Warning.
067 HI T-Coolant Coolant temperature too high Check cooling sys- 2.0120.931
(limit value 1, alarm configu- tem.
Warning.
068 SS T-Coolant Coolant temperature too high Check cooling sys- 2.0120.932
(limit value 2, alarm configu- tem. Contact Serv-
ration parameter, see PR ice if cooling system
2.8008.100 for explanation). is in order.
Automatic engine shutdown.
081 AL Rail Leakage Pressure gradient in rail too On stopping: Seal 1.8004.046
low on starting or too high on off system, contact
stopping, HP system leaking Service; On starting:
(alarm configuration parame- Check engine for
ter, see PR 2.8008.100 for leakage, if none
explanation). found, attempt re-
starting as per oper-
ating instructions
(air in system).
082 HI P-Fuel (Common Rail pressure is greater than Check HP fuel con- 2.0104.931
Rail) set value (alarm configura- trol block wiring, if
tion parameter, see PR no fault detected,
2.8008.100 for explanation). contact Service.
Warning.
083 LO P-Fuel (Common Rail pressure is less than set Check HP fuel con- 2.0104.921
Rail) value (alarm configuration trol block wiring,
parameter, see PR check HP system for
2.8008.100 for explanation). leakage, if no fault
Warning. detected, contact
Service.
089 SS Engine Speed too Engine speed too low (alarm Check for additional 2.2500.030
Low configuration parameter, see messages.
TIM-ID: 0000008508 - 003
PR 2.8008.100 for explana-

tion). Engine stop.
090 SS Idle Speed Not Idling speed not reached Check for additional 2.1090.925
Reached (alarm configuration parame- messages.
explanation). Start terminat-
ed.

091 SS Release Speed Not Runup speed not reached Check for additional 2.1090.924
Reached (alarm configuration parame- messages. Recharge
ter, see PR 2.8008.100 for battery. Engine un-
explanation). Start terminat- der load: Check fuel
ed. supply; if no fault
detected, contact
Service.
092 SS Starter Speed Not Starter speed not reached Check for additional 2.1090.923
Reached (alarm configuration parame- messages. Recharge
ter, see PR 2.8008.100 for battery. Engine un-
explanation). Start terminat- der load: Check fuel
ed. Starter does not turn or supply; if no fault
turns slowly. detected, contact
Service.
093 SS T-Preheat Preheating temperature too Engine start inter- 2.1090.922
low (limit value 2, alarm con- lock is active as
figuration parameter, see PR coolant temperature
2.8008.100 for explanation). is too low for engine
start, preheating
necessary.
094 LO T-Preheat Preheating temperature too Engine start inter- 2.1090.921
low (limit value 1, alarm con- lock is active as
figuration parameter, see PR coolant temperature
2.8008.100 for explanation). is too low for engine
start, preheating
necessary.
095 AL Prelubrication Fault Oil priming pressure not Contact Service. 2.1090.920
reached (alarm configuration
parameter, see PR
102 AL Fuel Cons. Counter Electronic fault: Consump- Replace engine gov- 1.8004.624
Defect tion counter faulty (alarm ernor at next oppor-
configuration parameter, see tunity.
tion).
104 AL Eng Hours Counter Electronic fault: Hour meter Replace engine gov- 1.8004.623
Defect faulty (alarm configuration ernor at next oppor-
parameter, see PR tunity.
118 LO ECU Power Supply Supply voltage too low (limit Check batteries and 2.0140.921
Voltage value 1, alarm configuration charge as necessa-
parameter, see PR ry; check generator.
TIM-ID: 0000008508 - 003

Warning.
119 LOLO ECU Power Sup- Supply voltage too low (limit Check batteries and 2.0140.922
ply Voltage value 2, alarm configuration charge as necessa-
parameter, see PR ry; check generator.
Warning.

120 HI ECU Power Supply Supply voltage too high (limit Check batteries and 2.0140.931
Voltage value 1, alarm configuration generator.
parameter, see PR
Warning.
121 HIHI ECU Power Sup- Supply voltage too high (limit Check batteries and 2.0140.932
ply Voltage value 2, alarm configuration generator.
parameter, see PR
Warning.
122 HI T-ECU Electronics temperature too Check engine room 2.0132.921
high (limit value 1, alarm con- ventilation.
Warning.
176 AL LifeData not availa- No (suitable) LifeData back- Contact Service. 2.4000.004
ble up system available, backup
system has no LifeData func-
tion when timeout following
ECU reset expires or CAN
bus to backup system is dis-
rupted (alarm configuration
parameter, see PR
177 AL LifeData restore in- This fault message is gener- Contact Service. 2.4000.006
complete ated when a CRC is faulty
(stated for each module) or
upload is incomplete during a
restore data upload process
(into ADEC) (alarm configura-
tion parameter, see PR
180 AL CAN1 Node Lost Connection to a node on Test devices con- 2.0500.680
CAN bus 1 has failed (alarm nected to CAN, test
configuration parameter, see wiring.
tion).
181 AL CAN2 Node Lost Connection to a node on Check devices con- 2.0500.681
CAN bus 2 has failed (alarm nected to CAN.
configuration parameter, see
tion).
TIM-ID: 0000008508 - 003
182 AL CAN Wrong Param- Incorrect parameter values 2.0500.682

eters entered in data record (alarm
PR 2.8008.100).

183 AL CAN No PU-Data The selected CAN mode initi- Check devices con- 2.0500.683
alizes communication by nected to CAN.
means of the PU data mod-
ule. However, the required
PU data module is unavaila-
ble or invalid (alarm configu-
184 AL CAN PU-Data Flash Programming error on at- Contact Service. 2.0500.684
Error tempting to copy a received
PU data module into the
Flash module (alarm configu-
186 AL CAN1 Bus Off CAN controller 1 is in "Bus Contact Service. 2.0500.686
Off" state, automatic switch-
ing to CAN2 results. Causes
are e.g. short circuit, massive
disruptions or baud rate in-
compatibility (alarm configu-
187 AL CAN1 Error Passive CAN controller 1 has indicat- Contact Service. 2.0500.687
ed a warning. Causes are e.g.
missing associate nodes, mi-
nor disruptions and tempora-
ry bus overload (alarm con-
188 AL CAN2 Bus Off CAN controller 2 is in "Bus Contact Service. 2.0500.688
Off" state, automatic switch-
ing to CAN1 results. Causes
are e.g. short circuit, massive
disruptions or baud rate in-
compatibility (alarm configu-
189 AL CAN2 Error Passive CAN controller 2 has indicat- Contact Service. 2.0500.689
ed a warning. Causes are e.g.
missing associate nodes, mi-
nor disruptions and tempora-
ry bus overload (alarm con-
TIM-ID: 0000008508 - 003

201 SD T-Coolant SD alarm configuration, cool- Check sensor and 1.8004.570
ant temperature sensor faul- wiring (B6), replace
ty, short circuit or wire break. as necessary.
202 SD T-Fuel SD alarm configuration, fuel Check sensor and 1.8004.572
temperature sensor faulty, wiring (B33), replace
short circuit or wire break. as necessary.

203 SD T-Charge Air SD alarm configuration, Check sensor and 1.8004.571
charge-air temperature sen- wiring (B9), replace
sor faulty, short circuit or as necessary.
wire break.
205 SD T-Coolant Intercool- SD alarm configuration, cool- Check sensor and 1.8004.574
er ant temperature sensor of in- wiring (B26), replace
tercooler faulty, short circuit as necessary.
or wire break.
208 SD P-Charge Air SD alarm configuration, Check sensor and 1.8004.566
charge-air pressure sensor wiring (B10), replace
faulty, short circuit or wire as necessary.
break.
211 SD P-Lube Oil SD alarm configuration, lube- Check sensor and 1.8004.563
oil pressure sensor faulty, wiring (B5), replace
215 SD P-HD SD alarm configuration, rail Check sensor and 1.8004.567
pressure sensor faulty, HP wiring (B48), replace
controller in emergency as necessary.
mode, short circuit or wire
break.
216 SD T-Lube Oil SD alarm configuration, lube- Check sensor and 1.8004.575
oil temperature sensor faulty, wiring (B7), replace
219 SD T-Intake Air SD alarm configuration, in- Check sensor and 1.8004.573
take air temperature sensor wiring (B3), replace
faulty, short circuit or wire as necessary.
break.
220 SD Level Coolant Wa- SD alarm configuration, cool- Check sensor and 1.8004.584
ter ant level sensor faulty, short wiring (F33), replace
circuit or wire break. as necessary. Fault
is rectified when
electronics are
switched back on
223 SD Level Coolant Inter- SD alarm configuration, cool- Check sensor and 1.8004.583
cooler ant level sensor faulty, short wiring (F57), replace
circuit or wire break. as necessary. Fault
is rectified when
electronics are
switched back on.
TIM-ID: 0000008508 - 003

229 AL Stop Camshaft Sen- Engine stop due to camshaft Check connector 1.8004.562
sor Defect sensor fault (and a previous and wiring to sensor
crankshaft sensor fault in the B1, replace as nec-
same operating cycle). Alarm essary. Fault is rec-
configuration parameter, see tified when engine is
PR 2.8008.100 for explana- restarted. If cam-
tion. shaft and crankshaft
sensor are both faul-
ty, check connector
and wiring to sensor
B1 and B13. Re-
start. Fault is recti-
fied when engine is
restarted, contact
Service if this is not
the case.
230 SD Crankshaft Speed SD alarm configuration, Check sensor and 1.8004.498
crankshaft sensor faulty, wiring (B13), at-
short circuit or wiring dam- tempt restart, fault
age, engine remains opera- may be rectified
tional. when engine is re-
started. Contact
Service if this is not
the case
231 SD Camshaft Speed SD alarm configuration, cam- Check sensor and 1.8004.499
shaft sensor faulty, short cir- wiring (B1), attempt
cuit or wiring damage, engine restart, fault may be
remains operational. rectified when en-
gine is restarted.
Contact Service if
this is not the case.
240 SD P-Fuel SD alarm configuration, en- Check sensor and 1.8004.565
gine remains operational, wiring (B34), replace
fuel pressure sensor faulty, as necessary.
short circuit or wiring dam-
age.
245 SD ECU Power Supply SD alarm configuration, inter- Execute engine gov- 2.8006.589
Voltage nal engine governor fault. ernor self-test, re-
place engine gover-
nor in case of fault.
266 SD Speed Demand SD alarm configuration, ana- Check speed setting 2.8006.586
log speed setting faulty, transmitter and wir-
short circuit or wiring dam- ing, replace as nec-
TIM-ID: 0000008508 - 003
age. essary. Fault is rec-

tified when engine is
restarted.
269 SD Loadp.Analog filt. SD alarm configuration, fil- Check wiring, re- 2.8006.588
tered analog signal of load place as necessary.
pulse not available, short cir- Fault is rectified
cuit or wiring damage when engine is re-
started.

270 SD Frequency Input SD alarm configuration, fre- Contact Service. 2.8006.590
quency input faulty, short cir-
cuit or wiring damage.
301 AL Timing Cylinder A1 Time-of-flight measuring fault Replace plug-in 1.8004.500
injector cylinder A1: Time-of- pump if this occurs
flight value measured ex- frequently.
tremely small or large (alarm
tion).
injector cylinder A2 Time-of- pump if this occurs
tion).
injector cylinder A3: Time-of- pump if this occurs
tion).
tion).
tion).
TIM-ID: 0000008508 - 003

tion).
tion).

tion).
tion).
injector cylinder A10: Time- pump if this occurs
of-flight value measured ex- frequently.
tion).
311 AL Timing Cylinder B1 Time-of-flight measuring fault Replace plug-in 1.8004.510
injector cylinder B1: Time-of- pump if this occurs
tion).
tion).
313 AL Timing Cylinder B3 Time-of-flight measuring fault Replace plug-in 18004.512
tion).
TIM-ID: 0000008508 - 003

tion).

tion).
tion).
tion).
tion).
tion).
injector cylinder B10: Time- pump if this occurs
of-flight value measured ex- frequently.
tion).
321 AL Wiring Cylinder A1 Wiring fault in injector wiring Check injector wir- 1.8004.520
TIM-ID: 0000008508 - 003
cylinder A1. Result: Misfiring ing, rectify injector

(alarm configuration parame- solenoid valve short
ter, see PR 2.8008.100 for circuit (positive to
explanation). negative) (e.g. by
exchanging injec-
tors). Fault rectifica-
tion: When engine is
restarted.

exchanging injec-
restarted.
exchanging injec-
restarted.
exchanging injec-
restarted.
exchanging injec-
restarted.
exchanging injec-
TIM-ID: 0000008508 - 003

restarted.
exchanging injec-
restarted.

exchanging injec-
restarted.
exchanging injec-
restarted.
cylinder A10. Result: Misfir- ing, rectify injector
ing (alarm configuration pa- solenoid valve short
rameter, see PR 2.8008.100 circuit (positive to
for explanation). negative) (e.g. by
exchanging injec-
restarted.
331 AL Wiring Cylinder B1 Wiring fault in injector wiring Check injector wir- 1.8004.530
cylinder B1. Result: Misfiring ing, rectify injector
exchanging injec-
restarted.
exchanging injec-
TIM-ID: 0000008508 - 003

restarted.
exchanging injec-
restarted.

exchanging injec-
restarted.
exchanging injec-
restarted.
336 AL Wiring Cylinder B6 Wiring fault in injector wiring Check injector wir- 1.8004535
exchanging injec-
restarted.
exchanging injec-
restarted.
exchanging injec-
TIM-ID: 0000008508 - 003

restarted.
exchanging injec-
restarted.

340 AL Wiring Cylinder B10 Wiring fault in injector wiring Check injector wir- 1.8004539
cylinder B10. Result: Misfir- ing, rectify injector
ing (alarm configuration pa- solenoid valve short
rameter, see PR 2.8008.100 circuit (positive to
for explanation). negative) (e.g. by
exchanging injec-
restarted.
341 AL Open Load Cylinder Disruption fault in injector Check injector wir- 1.8004.540
A1 wiring to cylinder A1. Result: ing, exclude disrup-
Misfiring (alarm configuration tion in solenoid
parameter, see PR valve (e.g. by injec-
2.8008.100 for explanation). tor replacement).
Fault rectification:
After each working
cycle.
A2 wiring cylinder A2. Result: ing, exclude disrup-
After each working
cycle.
After each working
cycle.
After each working
cycle.
TIM-ID: 0000008508 - 003

After each working
cycle.

After each working
cycle.
After each working
cycle.
After each working
cycle.
After each working
cycle.
After each working
cycle.
B1 wiring cylinder B1. Result: ing, exclude disrup-
TIM-ID: 0000008508 - 003

After each working
cycle.

After each working
cycle.
After each working
cycle.
After each working
cycle.
After each working
cycle.
After each working
cycle.
TIM-ID: 0000008508 - 003

After each working
cycle.

After each working
cycle.
After each working
cycle.
After each working
cycle.
361 AL Power Stage Low Internal electronic fault (elec- Start engine gover- 1.8004.496
tronics may be defective). If nor self-test. Re-
parameter 1.1020.021 (Pow- place engine gover-
er Stage Failure: Stop En- nor in case of fault;
gine) is set, engine is stop- if self-test diagnoses
ped here additionally (alarm “Electronics OK”
configuration parameter, see check for additional
PR 2.8008.100 for explana- fault messages (e.g.
tion). wiring fault).
362 AL Power Stage high Internal electronic fault (elec- Start engine gover- 1.8004.497
363 AL Stop Power Stage Internal electronic fault (elec- Start engine gover- 1.8004.560
TIM-ID: 0000008508 - 003


365 AL Stop MV-Wiring Injector wiring fault. Engine Check wiring, re- 1.8004.561
Ground stop configurable (alarm con- place wiring harness
figuration parameter, see PR as necessary.
Possible causes: 1. Short cir-
cuit of injector positive con-
nection to ground of one or
more injectors. 2. Short cir-
cuit of injector negative con-
nection to ground of one or
more injectors.
381 AL Wiring TOP 1 Short circuit or wire break at Check wiring. 2.8006.638
transistor output 1 plant side
(TOP 1, alarm configuration
parameter, see PR
parameter, see PR
parameter, see PR
parameter, see PR
390 AL MCR exceeded DBR/MCR function: MCR None. 1.1085.009
(maximum continuous rate)
exceeded. Engine power is
limited to admissible continu-
ous power (alarm configura-
400 AL Open Load Digital Line disruption at digital in- Check wiring. 2.8006.625
Input 1 put 1, wiring faulty or no re-
sistance via switch, (alarm
TIM-ID: 0000008508 - 003
tion).
tion).

402 AL Open Load Digital Line disruption at digital in- Check wiring. 2.8006627
tion).
tion).
tion).
tion).
tion).
tion).
408 AL Open Load Emerg. Line disruption at input for Check wiring. 2.8006.633
Stop Input ESI emergency stop, wiring faulty
or no resistance via switch
410 LO U-PDU Injector voltage too low (limit Execute engine gov- 2.0141.921
value 1, alarm configuration ernor self-test, re-
parameter, see PR place engine gover-
TIM-ID: 0000008508 - 003
2.8008.100 for explanation). nor in case of fault.

411 LOLO U-PDU Injector voltage too low (limit Execute engine gov- 2.0141.922
value 2, alarm configuration ernor self-test, re-
parameter, see PR place engine gover-
412 HI U-PDU Injector voltage too high (lim- Execute engine gov- 2.0141.931
it value 1, alarm configura- ernor self-test, re-
tion parameter, see PR place engine gover-

413 HIHI U-PDU Injector voltage too high (lim- Execute engine gov- 2.0141.932
it value 2, alarm configura- ernor self-test, re-
tion parameter, see PR place engine gover-
444 SD U-PDU SD alarm configuration, sen- Replace engine gov- 1.8004.578
sor fault at injector output ernor.
stage. Engine governor inter-
nal fault. Engine governor re-
placement.
450 SD Idle/End-Torque In- SD alarm configuration, input Check signal trans- 2.8006.592
put [%] signal for initial/final torque mitter and wiring,
faulty, short circuit or wiring replace as necessa-
damage ry. Fault is rectified
when engine is re-
started.
454 SS Power Reduction Power reduction activated, None. 2.7000.011
Active engine operating outside
standard limits. The following
variables may also combine
to lead to this message: In-
take depression, exhaust
back pressure, charge-air
coolant temperature, intake
air temperature. Alarm con-
2.8008.100 for explanation.
463 SD AUX 2 SD alarm configuration, ana- Check signal trans- 1.8004.591
log input signal for Aux 2 mitter and wiring,
damage. ry.
464 SD P-AUX 1 SD alarm configuration, ana- Check pressure 1.8004.589
log input signal for pressure transmitter and wir-
Aux 1 faulty, short circuit or ing, replace as nec-
wiring damage. essary.
468 SD T-AUX 1 Analog input for temperature Check signal trans- 1.8004.579
Aux 1 faulty, short circuit or mitter and wiring,
wiring damage replace as necessa-
ry.
469 SD AUX 1 SD alarm configuration, ana- Check signal trans- 1.8004.590
log input signal for Aux 1 mitter and wiring,
damage. ry.
TIM-ID: 0000008508 - 003
470 SD T-ECU Engine governor defective. Replace engine gov- 1.8004.587

ernor at next oppor-
tunity.
471 SD Coil Current SD alarm configuration, HP Check sensor and 1.8004.592
fuel control block activation, wiring, replace as
short circuit or wiring dam- necessary. Fault is
age. rectified when en-
gine is restarted.

472 AL Stop SD Engine stop as shutdown Contact Service. 2.8006.593
channels have "sensor fault"
(alarm configuration parame-
explanation).
474 AL Wiring FO Line break or short circuit at Contact Service. 2.8006.655
channel FO (alarm configura-
475 AL CR Trigger Engine Tripped by crash recorder Replace engine gov- 1.8010.009
Stop triggering due to engine shut- ernor at next oppor-
down. tunity.
476 AL Crash Rec. Init. Er- Initialization error of crash re- Contact Service. 1.8010.007
ror corder.
478 AL Comb. Alarm Yel YELLOW combined alarm Contact Service. 2.8006.001
(Plant) from plant (alarm configura-
479 AL Comb. Alarm Red RED combined alarm from Contact Service. 2.8006.002
(Plant) plant (alarm configuration pa-
rameter, see PR 2.8008.100
for explanation).
480 AL Ext. Engine Protec- External engine protection Contact Service. 2.0291.921
tion function active (alarm config-
uration parameter, see PR
555 AL Call MTU Field Serv- Power reduction caused by Contact Service. 2.0555.001
ice maintenance function (main-
tenance concept, alarm con-
TIM-ID: 0000008508 - 003

6.2 Troubleshooting
Engine does not turn when starter is actuated

Component Probable Cause Task
Battery Low or defective Charge or replace (see manufacturer's
documentation).
Cable connections defective Check if cable connections are properly
secured (see manufacturer's documen-
tation).
Starter Engine wiring or starter defective Check if cable connections are properly
secured, contact Service.
Engine wiring Defective Check (→ Page 133).
Engine/generator Secure seating of assemblies or connec- Perform visual inspection (see manufac-
control system tors not provided turer's documentation).
Engine Governor Plug-in connections are loose Check plug-in connections (→ Page 135).
Engine Running gear blocked (engine cannot be Contact Service.
barred manually)
Engine turns but does not fire

Starter Poor rotation by starter: Battery low or Charge or replace battery (see manufac-
defective turer's documentation).
Fuel system Not vented Vent fuel system (→ Page 94).
Engine Governor Defective Contact Service.
Engine fires unevenly

Fuel injection equip- Injector defective Replace (→ Page 85).
ment Injection pump defective Replace (→ Page 82).
Engine does not reach nominal speed

TIM-ID: 0000002534 - 002
Fuel supply Fuel prefilter clogged Replace (→ Page 102).

Easy-change fuel filter clogged Replace (→ Page 96).
Air supply Air filter clogged Check signal ring position of service in-
dicator (→ Page 107).
Engine Overloaded Contact Service.

Engine speed not steady
Speed sensor Defective Contact Service.
Charge-air temperature too high

Coolant Incorrect coolant concentration Check (MTU test kit).
Intercooler Contaminated Contact Service.
Engine room Air-intake temperature too high Check fans and air supply / ventilation
ducts.
Charge-air pressure too low

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

Intercooler Leaking, major coolant discharge Contact Service.
Exhaust gas black

Engine Overloaded Contact Service.
Exhaust gas blue

TIM-ID: 0000002534 - 002
Engine oil Too much oil in engine Drain engine oil (→ Page 110).
Oil separator of crankcase breather con- Replace (→ Page 74).
taminated
Exhaust turbocharger, Defective Contact Service.
cylinder head, piston
rings, cylinder liner

Exhaust gas white
Engine Not at operating temperature Run engine to reach operating tempera-
ture.
Fuel system Water in fuel Check fuel system on fuel prefilter.
Drain fuel prefilter (→ Page 98).
Intercooler Leaking Contact Service.
TIM-ID: 0000002534 - 002

7 Task Description
7.1 Engine
7.1.1 Engine – Barring manually
Preconditions
Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Barring device for 12V engines F6558556 1
Barring device for 16V, 18V engines F6558557 1
DANGER
• Before cranking 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 removed from the engine.
Engine – Barring manually

1. Remove access cover from flywheel hous-
ing.
2. Install barring device (arrow) on flywheel
housing.
3. Rotate crankshaft in engine direction of ro-
tation. Apart from the normal compression
resistance, there should be no resistance.
Result: If the resistance exceeds the normal com-
pression resistance, contact Service.
4. For barring device removal, follow reverse
sequence of working steps.
TIM-ID: 0000000012 - 003
MS15018/02E 2013-09 | Task Description | 67

7.1.2 Engine – Barring with starting system
Preconditions
☑External pushbutton “Bar engine without starting” is provided.
DANGER
gine's danger zone.
Engine – Barring with starting system

1. Press pushbutton “Bar engine without starting” and keep depressed.
2. Let the crankshaft rotate until oil pressure is indicated, but not longer than 10 seconds.
3. Repeat this procedure after approx. 20 seconds if required.
TIM-ID: 0000000013 - 004
68 | Task Description | MS15018/02E 2013-09

7.1.3 Engine – Test run
DANGER
gine's danger zone.
WARNING
Engine – Test run

1. Start engine (→ Page 32).
2. Perform test run not below 1/3 load and at least until steady-state temperature is reached.
3. Carry out operational checks (→ Page 34).
4. Stop engine (→ Page 35).
TIM-ID: 0000000870 - 008

7.2 Cylinder Liner
7.2.1 Cylinder liner – Endoscopic examination
Preconditions

Rigid endoscope Y20097353 1
Preparatory steps
1. Remove cylinder head cover (→ Page 80).
2. Remove injector (→ Page 86).
Positioning crankshaft at BDC

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

Findings Action
• Thin carbon coating on circumference of carbon scraper ring No action required
• Slight localized additive deposits at top edge
• Singular smooth areas at lower edge
• Carbon deposits on circumference in clearance 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
• Consistent honing pattern without objections
• 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 tion required as part of mainte-
do not cover the entire stroke area nance work
• Dark areas in the upper section of the cooling bore, remaining cir-
cumference without objections
• Piston rings without objections
• On the entire circumference, apart from light areas of discoloration Cylinder liner must be replaced;
(that do not impair operation) clearly darker stripes that start at the Service must be contacted
top piston ring
TIM-ID: 0000000015 - 014
• Heat discoloration in the direction of stroke and honing pattern

damage
• Heat discoloration of piston rings
1. Compile endoscopy report using the table.

2. Use technical terms for description of the liner surface (→ Page 72).
3. Depending on findings:
• do not take any action or
• carry out a further endoscopic examination as part of maintenance work or
• contact Service; cylinder liner must be replaced.

Final steps
1. Install injector (→ Page 86).
2. Install cylinder head cover (→ Page 80).
TIM-ID: 0000000015 - 014

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

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

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

Torque wrench, 6-50 Nm F30027336 1
Ratchet F30027340 1
Engine oil
Filter element (→ Spare Parts Catalog)
Diaphragm (→ Spare Parts Catalog)
Gasket (→ Spare Parts Catalog)
WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Wear protective clothing, gloves, and goggles / safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.
Replacing oil separator element

1. Remove cover (2) with O-ring (3).
2. Remove filter element (1) from housing (4).
3. Insert new filter element in housing (4).
4. Install cover (2) with new O-ring.
TIM-ID: 0000000017 - 008
5. Use torque wrench to tighten the screws of cover (2) to the specified torque.
Name Size Type Lubricant Value/Standard
Screw Tightening torque (Engine oil) 10 Nm −2 Nm
6. Replace further oil separator elements in the same way.

Checking diaphragm
1. Remove cover (4).
2. Remove spring (5), gasket (2) and dia-
phragm (3).
3. Check diaphragm (3) for damage, fit new
diaphragm if used one is damaged.
4. Install diaphragm (3) on housing (1).
5. Install new seal (2) and spring (5) together
with cover (4).
6. Use torque wrench to tighten the screws of cover (4) to the specified torque.
Screw Tightening torque (Engine oil) 10 Nm −2 Nm
7. Check diaphragms in further oil separators in the same way.
TIM-ID: 0000000017 - 008

7.3.2 Crankcase breather – Wire mesh cleaning
Cleaner
Diesel fuel
Petroleum jelly
Sealing ring (→ Spare Parts Catalog)
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
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.
NOTICE
Cleaning agents should not be left to take effect for too long.
Damage to components is possible!
• Observe manufacturer's instructions.
Crankcase breather – Wire mesh

cleaning
1. Remove hose.
2. Loosen clamp (5).
3. Remove oil separator cover (7).
4. Remove individual parts from oil separator
cover (7).
5. Wash filter element (wire mesh) (3) with
diesel fuel.
6. Blow out filter element (wire mesh) (3) with
compressed air.
7. Clean remaining components with cleaner.
8. Remove cleaning agent.
9. Coat sealing ring (6) with petroleum jelly
and insert in groove in the oil separator
cover (7).
10. Insert both holders (2, 4) and filter element
TIM-ID: 0000003469 - 002
(wire mesh) (3) into the oil separator cov-

er (7), ensuring correct installation se-
quence.
11. Install oil separator cover (7) with clamp (5)
on cylinder head cover (1).
12. Install hose, ensuring that it is not subject-
ed to tension.

7.4 Valve Drive
7.4.1 Valve clearance – Check and adjustment
Preconditions
☑Engine coolant temperature is max. 40 °C.
☑Valves are closed.

Feeler gauge Y4342013 1
Ratchet F30027340 1
Engine oil
Preparatory steps
2. Install barring device (→ Page 67).
3. Bar engine with barring device in engine di-
rection of rotation until TDC pointer and
TDC mark on the flywheel are aligned.
Diagram for 12V engines (two

crankshaft positions)
TIM-ID: 0000000018 - 005


Checking valve clearance at two crankshaft positions

1. Check TDC position of piston in cylinder A1:
• If the rocker arms are unloaded on cylinder A1, the piston is in firing TDC.
• If the rocker arms are under load on cylinder A1, the piston is in overlap TDC.
2. Check valve clearance with cold engine:
• Inlet = 0.4 mm;
• Exhaust = 0.6 mm;
TIM-ID: 0000000018 - 005
3. Check all valve clearances in two crankshaft positions (firing TDC and overlap TDC of cylinder A1) as
per diagram:
1 Cylinder A1 is in firing TDC
2 Cylinder A1 is in overlap TDC
I Inlet valve
X Exhaust valve
4. Use feeler gauge to determine the distance between valve bridge and rocker arm.
5. If the deviation from the reference value exceeds 0.1 mm, adjust valve clearance.

Adjusting valve clearance
1. Loosen locknut (1) and unscrew adjusting
screw (2) by a few threads.
2. Insert feeler gauge between valve bridge
and rocker arm.
3. Readjust adjusting screw (2) so that the
feeler gauge just passes through the gap.
4. Tighten locknut (1) with torque wrench to the specified tightening torque while holding adjusting
screw (2) firmly with screw driver.
Locknut M12 x 1 Tightening torque (Engine oil) 50 Nm
5. Insert feeler gauge between valve bridge and rocker arm to verify that the gauge just passes through
the gap.
Result: If not, adjust valve clearance.
Final steps
1. Remove barring device (→ Page 67).
3. Install access cover.
TIM-ID: 0000000018 - 005

7.4.2 Cylinder head cover – Removal and installation
Preconditions

Ratchet F30027340 1
Preparatory steps
1. On cylinder head covers with crankcase breather: Loosen clamps.
2. Slide rubber sleeves onto the pipe.
Cylinder head cover – Removal

and installation
1. Remove cylinder head cover (2) with gas-
ket (1) from cylinder head.
2. Clean installation surface.
3. Check condition of gasket (1) in cylinder
head cover (1).
4. Replace damaged gasket(s) (1).
5. Install cylinder head cover (2) with
screws (4) and washers (3).
Final steps
1. Slide rubber sleeves onto the relevant pipe connection.
2. Tighten all clamps.
TIM-ID: 0000000019 - 004

7.5 Injection Pump / HP Pump
7.5.1 Injection pump – Replacement
Injection pump (→ Spare Parts Catalog)
Injection pump – Replacement

u Remove injection pump and install new one (→ Page 82).
TIM-ID: 0000000020 - 004

7.5.2 Injection pump – Removal and installation
Preconditions

Ratchet F30027340 1
Adapter F30006234 1
Crowfoot wrench, 19 mm F30027424 1
Crowfoot box wrench, 22 mm F30027425 1
Torque wrench, 0.5-5 Nm 0015384230 1
Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 1
Engine oil
DANGER
gine's danger zone.
WARNING
• Do not smoke.
Preparatory steps
1. Close fuel supply line upstream of fuel filter.
2. Drain fuel (→ Page 91).
3. Remove engine governor, if required (→ Page 136).
4. Remove charge-air manifolds and take off seals (only on engines with air-to-air charge-air cooling).
TIM-ID: 0000000021 - 004

Removing injection pump
1. Mark installation position of injection
pump.
2. Disconnect wiring (1) from injection pump.
3. Disconnect fuel line (2).
4. Unscrew securing screws of injection pump
by approx. 6 mm.
Result: The preloaded compression spring presses
the injection pump out of the crankcase. If
not:
• Turn crankshaft with barring device
(→ Page 67) .
Pump cam of camshaft presses the in-
jection pump out of the crankcase. If
not:
• Carefully press out injection pump at the
recess in the injection pump head.
5. Remove injection pump securing screws.
6. Remove injection pump.
7. Remove sealing rings from injection pump.
8. After removal, seal all openings with suita-
ble covers.
Injection pump – Installation

1. Remove all blanking plugs and covers.
2. Clean mating face of injection pump and
roller.
Note: Sealing ring (1) Ø47 mm
3. Coat sealing ring (1) with grease and fit on-
to injection pump.
Note: Sealing ring (2) Ø45 mm
to injection pump.
5. Coat roller (arrow) with engine oil.
6. Clean sealing face and fuel bores in crank-
case.
7. Using barring device (→ Page 67), set pump
cam on camshaft to base circle.
TIM-ID: 0000000021 - 004

8. Install injection pump, observing marked
installation position.
9. Install securing screws of injection pump and tighten with torque wrench to the specified torque.
Screw M10 Tightening torque (Engine oil) 60 Nm +12 Nm
10. Coat the mating face between union nut and fuel line, ball seal and thread on both ends of the fuel
line (3) with engine oil.
11. Install fuel line (3).
Note: Observe the inscription on the union nuts (2, 4).
12. Tighten union nuts (2, 4) marked with “35 +3 Nm” (see arrow) with torque wrench to the specified tight-
ening torque.
Union nut M14 Tightening torque (Engine oil) 35 Nm +3 Nm
13. Tighten union nuts (2, 4) marked with “30 +3 Nm” (see arrow) with torque wrench to the specified tight-
ening torque.
14. Install injection pump wiring (1).
15. Use torque wrench to tighten screws to the specified tightening torque.
Screw Tightening torque (Engine oil) 1.5 Nm ±0.2 Nm
Final steps
TIM-ID: 0000000021 - 004
1. Remove barring device (→ Page 67).

2. Clean mating faces on cylinder head and charge-air manifold.
3. Check gaskets for damage and replace them, if required.
4. Coat gaskets with grease and place onto cylinder head.
5. Install charge-air pipes.
6. Install engine governor (→ Page 136).
7. Open fuel supply line.
8. Vent fuel system (→ Page 94)

7.6 Injection Valve / Injector
7.6.1 Injector – Replacement
Injector (→ Spare Parts Catalog)
Replacing injector
u Remove injector and install new injector (→ Page 86).
TIM-ID: 0000000022 - 013

7.6.2 Injector – Removal and installation
Preconditions

Impact extractor F30377999 1
Fuel suction device F30378207 1
Ratchet F30027340 1
Adapter F30006234 1
Plug-in open-end wrench, 19 mm F30025897 1
Double-head box wrench F30011450 1
Engine oil
WARNING
• Do not smoke.
WARNING
Preparatory steps
TIM-ID: 0000000023 - 003

Removing injector
1. Disconnect leak-off fuel line from cylinder
head.
3. Remove thrust screw (2).
4. Pull off pressure pipe neck (3).
5. Extract fuel from the exposed bores using
the suction device.
6. Remove screw (2).

7. Take off clamp (1).
8. Screw impact extractor into injector.
9. Remove injector using the impact extrac-
tor.
10. Remove injector sealing ring using a self-
made hook.
11. After removal, seal all openings with suita-
ble covers.
Injector – Installation
1. Remove all covers before installation.
2. Clean sealing surface on cylinder head and
protective sleeve.
to injector.
to injector.
5. Press injector into cylinder head by hand.
TIM-ID: 0000000023 - 003
Result: • The pin is at 11-o'clock position to the

transversal axis of the engine.
• Pin is in recess of clamp (4).
6. Install clamp (4) with screw (5), positioning
it correctly.
Result: • Pin on injector is in the recess in the
clamp.
• Forked clamp end is engaged in the cov-
er recess.
7. Tighten screw (5) of the clamp by hand.
Result: Injector can still be turned.

8. Blow out fuel line (2) and pressure pipe
neck (5) with compressed air.
9. Coat sealing ring with grease and fit onto
pressure pipe neck (5).
10. Coat the tape of the pressure pipe neck (5)
with engine oil.
11. Insert pressure pipe neck (5) into cylinder
head until the sealing ring is in contact with
cylinder head.
12. Fully press in pressure pipe neck (5) by
hand.
13. Tighten thrust screw (4) with torque wrench to the specified tightening torque.
Thrust screw M22 x 1.5 Tightening torque (Engine oil) 40 Nm ±5 Nm
14. Use torque wrench to tighten screw for clamp at injector to the specified tightening torque.
Screw M10 Tightening torque (Engine oil) 50 Nm
15. Coat the mating face between union nut and fuel line, ball seal and thread on both ends of the fuel
line (2) with engine oil.
17. Tighten union nuts (1, 3) marked with “35 +3 Nm” (see arrows) with torque wrench to the specified
tightening torque.
tightening torque.
19. Connect leak-off fuel line to cylinder head.
Final steps
TIM-ID: 0000000023 - 003


7.7 Fuel System
7.7.1 Fuel injection line – Pressure pipe neck replacement
Preconditions

Ratchet F30027340 1
Adapter F30006234 1
Plug-in open-end wrench, 19 mm F30025897 1
Double-head box wrench F30011450 1
Engine oil
Pressure pipe tube (→ Spare Parts Catalog)
WARNING
• Do not smoke.
WARNING
Preparatory steps
TIM-ID: 0000000024 - 003

Replacing pressure pipe neck
2. Blow out fuel line (2) with compressed air.
3. Remove thrust screw (4).
4. Withdraw pressure pipe neck (5).
5. Coat sealing ring with grease and fit on
new pressure pipe neck (5).
6. Coat the tape of the pressure pipe neck (5)
with engine oil.
7. Insert pressure pipe neck (5) into cylinder
head until the sealing ring is in contact with
cylinder head.
8. Fully press in pressure pipe neck (5) by
hand.
9. Tighten thrust screw (4) with torque wrench to the specified tightening torque.
Thrust screw M22 x 1.5 Tightening torque (Engine oil) 40 Nm ±5 Nm
tightening torque.
tightening torque.
Final steps
TIM-ID: 0000000024 - 003

7.7.2 Fuel – Draining
Preconditions

Box wrench, 17 mm F30028341 1
Engine oil
WARNING
• Do not smoke.
Fuel – Draining
1. Loosen nut (arrow) on banjo union.
2. Disconnect fuel line on non-return valve

(arrow).
3. Remove non-return valve and collet emerg-
ing fuel in a suitable container.
TIM-ID: 0000000025 - 003

4. If fuel no longer emerges, install non-return valve and tighten with torque wrench to the specified tight-
ening torque.
Non-return valve Tightening torque (Engine oil) 10 Nm +1 Nm
5. Connect fuel line.
6. Tighten nut on banjo union.
TIM-ID: 0000000025 - 003

7.7.3 Fuel pressure maintaining valve – Removal and installation
Preconditions

Pressure relief valve (→ Spare Parts Catalog)
WARNING
• Do not smoke.
Fuel pressure maintaining valve

– Removal and installation
1. Shut off fuel supply.
2. Remove fuel line (6).
3. Remove banjo screws (1) and (3).
4. Remove sealing rings (2) and (4).
5. Remove screws (9) with washer (8).
6. Remove screws (7) and take off holder.
7. Install new pressure relief valve (5) with
new sealing rings (2) and (4), following the
reverse sequence of working steps.
8. Open fuel supply.
TIM-ID: 0000000028 - 002

7.7.4 Fuel system – Venting
Preconditions

Engine oil
WARNING
• Do not smoke.
Fuel system – Venting

1. Unlock fuel priming pump, unscrew handle.
2. Loosen nut (arrow) on banjo union.

3. Operate the pump with the handle until
bubble-free fuel emerges.
4. Tighten nut on banjo union.
TIM-ID: 0000000026 - 002

5. Loosen banjo screw (arrow).
7. Tighten banjo screw.
8. Loosen union nut of fuel return line.

9. Loosen non-return valve (arrow).
11. Use torque wrench to non-return valve to the specified tightening torque.
Non-return valve Tightening torque (Engine oil) 10 Nm +1 Nm
12. Tighten union nut of fuel return line.
13. Lock fuel priming pump, screw in handle.
TIM-ID: 0000000026 - 002

7.8 Fuel Filter
7.8.1 Fuel filter – Replacement
Preconditions

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

1. Remove easy-change filter using the filter
wrench.
2. Clean the sealing surface on the bracket.
3. Fill the new easy-change filter with clean
fuel.
4. Screw on easy-change filter and tighten by
hand.
TIM-ID: 0000000027 - 002

7.8.2 Fuel prefilter – Differential pressure check and adjustment of gauge
DANGER
• Only run the engine at low power. Keep away from the engine's danger zone.
WARNING
Setting adjustable pointer of dif-

ferential pressure gauge
1. After installation of a new filter element,
align adjustable pointer (2) with pressure-
indicating 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
pointer (3) of pressure gauge is ≥ 0.3 bar, flush filter element of the cut-in filter (→ Page 99).
TIM-ID: 0000004925 - 008

7.8.3 Fuel prefilter – Draining
Preconditions

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

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

drained.
3. Unlock drain valve (6) by pressing toggle
and open it.
4. Drain water and contaminants from filter
until pure fuel emerges.
5. Close drain valve (6).
6. Remove screws for cover and take off cov-
er (2).
7. Fill filter housing with clean fuel.
TIM-ID: 0000004929 - 004
8. Place new gasket in cover (2).

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

7.8.4 Fuel prefilter – Flushing
Fuel
Seal (→ Spare Parts Catalog)
DANGER
WARNING
• Do not smoke.
WARNING
Fuel prefilter – Flushing

1. Cut out the contaminated filter.
1 Left filter cut in
2 Right filter cut in
TIM-ID: 0000004937 - 017

2. Open vent plug (5) of the filter to be flush-
ed.
3. Unlock drain cock (6) by pressing toggle,
open it and drain fuel.
Result: Fuel flows from filtered side back to the un-
filtered side, flushing the filter deposits
downwards out of the filter.
4. Close vent plug (5) and drain cock (6).
Fuel prefilter – Filling with fuel

1. Stop engine (→ Page 35) and disable engine start.
2. Remove screws securing the cover and take off cover (2).
5. Fit cover with gasket and secure it with screws.
6. Check differential pressure (→ Page 97).
Result: If flushing did not lead to an improvement of the differential pressure, replace filter element of fuel pre-
filter (→ Page 102).
TIM-ID: 0000004937 - 017

7.8.5 Fuel prefilter – Cleaning
Preconditions

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

1. Close fuel supply.
2. Remove nuts from filter head.
3. Unscrew filter bowl and drain fuel into a
suitable container.
4. Remove securing nut for filter element and
pull off filter element downwards.
5. Wash filter element in clean fuel using a
soft brush.
6. Wash filter bowl with clean fuel.
7. Insert filter element in filter head and se-
cure with nut.
8. Place new sealing ring in filter head groove.
9. Fit cover with seal and tighten nuts cross-
wise.
10. Open fuel supply.
TIM-ID: 0000004936 - 002

7.8.6 Fuel prefilter – Filter element replacement
Preconditions

Diesel fuel
WARNING
• Do not smoke.
Replacing filter element

1. Cut out filter to be drained.
I Left filter cut in
II Right filter cut in
TIM-ID: 0000004944 - 005

2. Open threaded vent plug (5) of contaminat-
ed filter.
3. Unlock drain valve (6) by pressing toggle
and open it.
4. Drain water and dirt from filter.
5. Close drain valve (6).
6. Remove screws securing the cover and
take off cover (2).
7. Remove spring housing (4) and filter ele-
ment (3).
8. Insert new filter element (3) and spring
housing (4).
11. Fit cover with gasket and secure it with
screws.
12. Cut in the cut-out filter again.
13. Close threaded vent plug (5) when fuel
emerges.
14. Adjust the differential pressure gauge
(→ Page 97).
TIM-ID: 0000004944 - 005

7.9 Charge-Air Cooling General, Left-Hand Side
7.9.1 Intercooler – Checking condensate drain for coolant discharge and obstructions
Preconditions

WARNING
Checking intercooler condensate drain for coolant discharge and obstructions

1. Remove plug screw(s) from charge-air manifold.
2. Check drain bore(s) for air discharge. If no air escapes:
3. Clean drain bore(s) and blow out with compressed air.
4. More significant coolant leakage indicates a leaking charge-air cooler. Contact Service.
5. Install plug screw(s) with new sealing ring and tighten.
Emergency measures prior to engine start with a leaking intercooler

1. Remove injectors (→ Page 86).
2. Bar engine manually (→ Page 67).
3. Bar engine with the starting system to blow out cylinder chambers (→ Page 68).
4. Install injectors (→ Page 86).
TIM-ID: 0000000030 - 003

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

1. Remove air filter(s) and install new one(s) (→ Page 106).
2. Reset signal ring of service indicator (→ Page 107).
TIM-ID: 0000013385 - 002

7.10.2 Air filter – Removal and installation
Preconditions
Variant A
1. Loosen clamp (2).
2. Remove air filter (1) and clamp (2) from
connecting flange of intake housing (3).
3. Verify that there are no objects in the
flange of the intake housing (3) and clean
it.
4. Fit air filter (1) and clamp (2) on connecting
flange of intake housing (3).
5. Tighten clamp (2).
Variant B
1. Release latches (1).
2. Take off cover (2).
3. Remove filter insert (3) and filter ele-
ment (4).
4. Wipe out filter housing (5) and cover (2)
with moist cloth.
5. Insert new filter element (4) and filter in-
sert (3).
6. For installation, follow reverse sequence of
working steps.
TIM-ID: 0000013395 - 002

7.11 Air Intake
7.11.1 Service indicator – Signal ring position check
Preconditions
Checking signal ring position

1. Replace air filter, if the signal ring (2) is
completely visible in the red area of the
service indicator control window (3)
(→ Page 105).
2. After installation of new filter, press reset
button (1).
Result: Signal ring returns to initial position.
TIM-ID: 0000000985 - 003

7.12 Starting Equipment
7.12.1 Air starter – Manual operation
DANGER
gine's danger zone.
WARNING
Air starter – Manual operation

1. Press pushbutton for manual start and hold
it.
2. Allow compressed air to enter the starter
until the engine fires evenly.
3. Release pushbutton.
TIM-ID: 0000006076 - 005

7.13 Lube Oil System, Lube Oil Circuit
7.13.1 Engine oil – Level check
Preconditions
Oil level check prior to engine

start
1. Withdraw oil dipstick from guide tube and
wipe it.
2. Insert oil dipstick into guide tube up to the
stop, withdraw after approx. 10 seconds
and check oil level.
3. Oil level must be between "min." (2) and
"max." (1) marks.
4. Top up with oil up to the "max" (1) mark
(→ Page 110) if required.
5. Insert oil dipstick into guide tube up to the
stop.
Oil level check after the engine is stopped

1. 5 minutes after stopping the engine, remove oil dipstick from the guide tube and wipe it.
2. Insert oil dipstick into guide tube up to the stop, withdraw after approx. 10 seconds and check oil level.
3. Oil level must be between "min." and "max." marks.
4. Top up to "max." if required (→ Page 110).
5. Insert oil dipstick into guide tube up to the stop.
TIM-ID: 0000000032 - 003

7.13.2 Engine oil – Change
Preconditions
☑Engine is at operating temperature.
☑MTU Fluids and Lubricants Specifications (A001061/..) are available.

Engine oil
WARNING
Hot oil.
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 111).
Oil change with 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 111).
Filling with new oil

1. Open cover on filler neck.
2. Pour oil in at filler neck up to "max." mark
at oil dipstick.
3. Close cover on filler neck.
4. Check engine oil level (→ Page 109).
5. After oil change and filter replacement, bar
engine with starting system (→ Page 68).
TIM-ID: 0000000031 - 006

7.14 Oil Filtration / Cooling
7.14.1 Engine oil filter – Replacement
Preconditions

Filter wrench F30379104 1
Engine oil
Oil filter (→ Spare Parts Catalog)
WARNING
Hot oil.
Engine oil filter – Replacement

1. Remove oil filter with filter wrench.
2. Clean the sealing face on the adapter.
3. Check condition of the new sealing ring
and coat it with oil.
4. Screw on and tighten new engine oil filter
by hand.
5. Replace other engine oil filters in the same
way.
6. After each oil change and filter replace-
ment, bar engine with starting system
(→ Page 68).
7. Check oil level (→ Page 109).
TIM-ID: 0000000033 - 002

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

neck:
1. Turn breather valve on coolant expansion
tank counterclockwise to the first stop and
allow pressure to escape.
2. Continue to turn breather valve counter-
clockwise and remove.
3. Check coolant level (coolant must be visi-
ble at the lower edge of the cast-in eye or
at the marking plate).
4. Top up with treated coolant as necessary
(→ Page 115).
5. Check and clean breather valve.
6. Place breather valve on filler neck and
close.
Coolant-level check by means of level sensor:

1. Switch on engine control system and check readings on the display.
2. Top up with treated coolant as necessary (→ Page 115).
TIM-ID: 0000000037 - 004

7.15.2 Engine coolant – Change
Engine coolant
Engine coolant – Change

1. Drain engine coolant (→ Page 114).
2. Fill with engine coolant (→ Page 115).
TIM-ID: 0000035998 - 001

7.15.3 Engine coolant – Draining
Preconditions

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

3. Draw off precipitated corrosion inhibitor oil
from the expansion tank through filler
neck.
4. Open drain valves and/or drain plugs and
drain coolant at the following points:
• At the preheating unit;
• At the engine coolant pump;
• At the crankcase, left and right sides;
• At oil heat exchanger.
5. Close all open drain points.
close.
TIM-ID: 0000000035 - 003

7.15.4 Engine coolant – Filling
Preconditions

Coolant
WARNING
WARNING
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
TIM-ID: 0000000034 - 007
Engine coolant – Filling

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

Final steps
1. Start the engine and operate it at idle speed for some minutes.
2. Check coolant level (→ Page 112), top up with coolant if required.
TIM-ID: 0000000034 - 007

7.15.5 Coolant pump – Relief bore check
DANGER
WARNING
Coolant pump – Relief bore

check
1. Check relief bore for oil and coolant dis-
charge.
2. Permissible discharge:
• Up to 10 drops of coolant per hour
• Up to 5 drops of oil per hour
3. If discharge exceeds the specified limits,
contact Service.
4. If relief bore is dirty:
a) Stop engine (→ Page 35) and disable
engine start.
b) Clean relief bore with a wire.
c) Start engine (→ Page 32) and operate it
at idle speed for some minutes.
d) Check relief bore again for oil and cool-
ant discharge.
TIM-ID: 0000000038 - 002

7.16 Low-Temperature Circuit
7.16.1 Charge-air coolant – Filling
Preconditions

Coolant
WARNING
WARNING
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
3. Remove plug screw from filling point on
coolant line to intercooler.
TIM-ID: 0000000039 - 005

Charge-air coolant – Filling
1. Fill treated coolant through filling line or through filler neck of coolant expansion tank until coolant level
reaches marking plate.
2. Install plug screws of filling points with new sealing rings.
3. Check proper condition of breather valve, clean sealing faces if required.
Final steps
1. Start the engine and operate it at idle speed for some minutes.
2. Check coolant level (→ Page 122).
TIM-ID: 0000000039 - 005

7.16.2 Charge-air coolant – Draining
Preconditions

WARNING
Charge-air coolant – Draining

1. Provide an appropriate container to drain
the coolant into.
4. Draw off precipitated corrosion inhibitor oil
from the expansion tank through filler
neck.
5. Open drain plugs and drain coolant at the
following points:
• At the charge-air coolant pump;
• At the intercooler, engine driving end
and free end sides.
6. Screw in drain plugs with new sealing rings.
close. TIM-ID: 0000000040 - 003

7.16.3 Charge-air coolant – Change
Coolant
Charge-air coolant – Change

1. Drain charge-air coolant (→ Page 120).
2. Fill with charge-air coolant (→ Page 118).
TIM-ID: 0000000041 - 011

7.16.4 Charge-air coolant – Level check
Preconditions
WARNING
Checking charge-air coolant lev-

el at filler neck:
3. Check coolant level (coolant must be visi-
ble at marking plate).
4. Top up coolant if necessary (→ Page 118).
5. Check proper condition of breather valve,
clean sealing faces if required.
Checking charge-air coolant level by means of level sensor:

1. Switch on engine control system and check display (coolant level is automatically monitored by engine
control system).
2. Top up coolant if necessary (→ Page 118).
TIM-ID: 0000000042 - 007

7.17 Coolant System
7.17.1 Cooler – Checking cooler elements externally for dirt
Preconditions
Check cooler elements externally for dirt

1. Inspect cooler elements visually for dirt.
2. Clean badly soiled cooler elements (→ Page 124).
TIM-ID: 0000015785 - 001

7.17.2 Cooler – Cleaning cooler elements
Preconditions
WARNING
Compressed air
Risk of injury!
• Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
WARNING
Chemical substances in cleaners.
Risk of irritation and chemical burns!
• Always obey manufacturer's instructions before use!
CAUTION
Excessive reaction time of cleaning agents on components.
Damage to component!
CAUTION
Unsuitable cleaning tool.
Damage to component!
• Use appropriate cleaning tool.
Cleaning cooler elements

1. Blow out the cooler elements with a jet of compressed air working against the direction of the cooling
air parallel to the cooling fins.
2. If cooler elements are badly soiled, treat cooling fins with a hot, grease-dissolving alkaline cleaning
agent before cleaning.
TIM-ID: 0000015784 - 001

7.18 Battery-Charging Generator
7.18.1 Battery-charging generator drive – Drive-belt check and adjustment
Preconditions

Pre-tension gauge Y20097429 1
Ratchet F30027340 1
Engine oil
Drive belt – Condition check

1. Remove protective cover.
2. Check condition of drive belt visually.
3. Replace drive belt (→ Page 127):
• If belt is oily;
• If belt shows signs of overheating;
• If ribs are broken around the entire cir-
cumference (A);
• If rib material is broken off in some pla-
ces (B).
4. Install protective cover.
Drive belt – Tension check

2. Position pretension gauge on drive belt
midway between belt pulleys.
3. Actuate pushbutton to press the tester uni-
formly on the drive belt surface until the
spring disengages.
4. Do not press any further, otherwise the dis-
play value will be falsified.
TIM-ID: 0000000043 - 003
5. Take off tension tester without changing

the position of the display arm.
6. Read off measured value at the intersec-
tion of display arm and "KG" scale.
7. If the measured value deviates from the
specified setting, readjust belt tension.

Setting (new drive belt) 450 N - 50 N
Setting (used drive belt) 350 N - 50 N
Drive belt – Tension adjustment

1. Release screws (2, 3).
2. Tension drive belt with tensioning nut (1)
and check belt tension.
3. Tighten screw (2) to specified torque using a torque wrench.

Screw M18 Tightening torque (Engine oil) 40 Nm +4 Nm
4. Tighten screw (3).
5. Check drive belt tension.
TIM-ID: 0000000043 - 003

7.18.2 Battery-charging generator drive – Drive belt replacement
Preconditions

Ratchet F30027340 1
Engine oil
Drive belt (→ Spare Parts Catalog)
Battery-charging generator drive

– Drive belt replacement
2. Remove drive belt for fan drive
(→ Page 131).
3. Release securing screws (2, 3).
4. Release tensioning screw (1) until the drive
belt can be removed.
5. Check belt pulleys for cleanliness, remove
dirt, if any.
6. Fit new drive belt.
7. Tension drive belt with tensioning nut (1)
and check belt tension (→ Page 125).
8. Tighten securing screw (2) with torque wrench to the specified tightening torque.
Screw M18 Tightening torque (Engine oil) 40 Nm + 4 Nm
9. Tighten securing screw (3).
10. Install drive belt for fan drive (→ Page 131).
TIM-ID: 0000000044 - 003

7.19 Fan Drive
7.19.1 Fan drive – Drive-belt check and adjustment
Preconditions

Belt tension tester 5505890119/00 1
Ratchet F30027340 1
Engine oil
Preparatory steps
1. Remove screws from protective cover.
Drive belt – Condition check

1. Check condition of drive belt visually.
2. Replace drive belt (→ Page 131):
• If belt is oily;
• If belt shows signs of overheating;
• If belt is cracked;
• If belt is worn;
• If cracks are found: .
Drive belt – Tension check, var-

iant A
1. Place belt-tension tester onto drive midway
between the belt pulleys (arrow).
2. Press button uniformly against drive belt
surface until spring disengagement can be
heard and felt.
4. Take off belt-tension tester without chang-
ing the position of the indication arm.
tion of indication arm and "KG" scale.
TIM-ID: 0000000045 - 003
6. If the measured value deviates from the specified setting, readjust belt tension.
Setting (new drive belt) 660 N
Setting (used drive belt) 510 N

Drive belt – Tension check, var-
iant B
1. Place belt-tension tester onto drive midway
between the belt pulleys (arrow).
2. Press button uniformly against drive belt
surface until spring disengagement can be
heard and felt.
4. Take off belt-tension tester without chang-
ing the position of the indication arm.
tion of indication arm and "KG" scale.
6. If the measured value deviates from the specified setting, readjust belt tension.
Setting (new drive belt) 670 N - 50 N
Setting (used drive belt) 570 N - 50 N
Drive belt – Tension adjustment,

variant A
1. Release screws (3).
2. Release locknut (2).
3. Screw in screw (1) to tension drive belt.
4. Tighten locknut (2).
6. Use torque wrench to tighten screws (3) to specified tightening torque.

TIM-ID: 0000000045 - 003

Drive belt – Tension adjustment,
variant B
1. Release screws (1, 4).
Note: Bolt (3) is in position A for variant 50 Hz,
and in position B for variant 60 Hz.
2. Screw in screw (2) to tension drive belt.
4. Tighten screws (1, 4) with torque wrench to the specified tightening torque.
Final steps
2. Fit screws and tighten.
TIM-ID: 0000000045 - 003

7.19.2 Fan drive – Belt replacement
Preconditions

Drive belt (→ Spare Parts Catalog)
Preparatory steps
1. Remove protective cover from radiator.
2. Remove fan.
Drive belt replacement, variant

A
1. Loosen securing screwsBelt replace-
ment (3).
2. Release locknut (2).
3. Screw out tensioning screw (1) until drive
belts can be removed.
4. Check belt pulley on fan bearing pedestal
and crankshaft for contamination, clean if
necessary.
Note: Drive belts must only be fitted in the
grooves as a set and without applying any
force.
5. Fit new set of drive belts.
6. To check drive tension, the fan bearing
pedestal must rest against the gearcase.
7. Adjust and check drive belt tension
(→ Page 128).
Drive belt replacement, variant

B
1. Release securing screws (1, 4).
2. Unscrew tensioning screw (2) with bolt (3)
until the drive belts can be removed.
3. Check belt pulley on fan bearing pedestal
and crankshaft for contamination, clean if
necessary.
Note: Drive belts must only be fitted in the
TIM-ID: 0000000046 - 003
grooves as a set and without applying any

force.
4. Fit new set of drive belts.
5. To check drive tension, the fan bearing
pedestal must rest against the gearcase.
6. Adjust and check drive belt tension
(→ Page 128).

Final steps
1. Install fan.
TIM-ID: 0000000046 - 003

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

Isopropyl alcohol X00058037 1
Checking engine wiring

1. Check securing screws of cable clamps on engine and tighten loose threaded connections.
2. Ensure that cables are fixed in their clamps and cannot swing freely.
3. Check that cable clamps are firm, tighten loose cable clamps.
4. Replace faulty cable clamps.
5. 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.
6. Clean dirty connector housings, sockets and contacts using isopropyl alcohol.
7. Ensure that all sensor connectors are securely engaged.
TIM-ID: 0000000029 - 019

7.21 Accessories for (Electronic) Engine Governor / Control System
7.21.1 Engine governor and connectors – Cleaning
Preconditions

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

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

Note: Seal unused connectors with the supplied protective cap.
1. Release the latch and pull off connectors.
2. Clean connector housings, connector socket housings and all contacts with isopropyl alcohol.
3. When connectors, sockets and all contacts are dry: Fit connectors and lock them.
TIM-ID: 0000000047 - 010

7.21.2 Engine governor plug connections – Check
Preconditions
☑Engine stopped and starting disabled.
NOTICE
Insertion of unsuitable test probe, e.g. test prod.
The contacts in the plug connection can be bent!
• Carry out check of plug connection only with test connectors.
Checking plug connections at engine governor

1. Check all plug connections for secure seating.
2. Latch loose connectors.
TIM-ID: 0000000048 - 008

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

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

1. Install in reverse order. Ensure correct assignment of connectors and sockets in so doing.
2. Check resilient mount before installing.
Result: Replace resilient mount if porous or defective.
TIM-ID: 0000000049 - 007

8 Appendix A
8.1 Abbreviations
Abbre- Meaning Explanation
viation
A/D Analog/Digital Transformer: transforms sensor voltages into numer-
ic values
ADEC Advanced Diesel Engine Controller Engine management system
AFRS Air Filter Restriction Sensor
AGR Abgasrückführung Exhaust gas recirculation
AL Alarm
ANSI American National Standards Institute Association of American standardization organiza-
tions
ATL Abgasturbolader/Abgasturboaufladung Exhaust turbocharger/exhaust turbocharging
ATS Air Temperature Sensor
BR Baureihe Series
BV Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU Publica-
tion No. A01061/..
CAN Controller Area Network Data bus system, bus standard
CDC Calibration Drift Compensation Setting of drift compensation in engine governor
with DiaSys
CEL Stop engine light 1st function: Warning lamp (rectify fault as soon as
possible)
2nd function: Read out fault codes
CKT Circuit
CLS Coolant Level Sensor Monitors coolant level
CM Current Measurement Current measured value
CPS Coolant Pressure Sensor Monitors coolant pressure
CR Common Rail
CTS Coolant Temperature Sensor Monitors coolant temperature
DDEC Detroit Diesel Electronic Controls Engine control system made by Detroit Diesel
DDL Diagnostic Data Link Diagnostic lines
DDR Diagnostic Data Reader Diagnostic unit
Dia Electronic dialog system
Sys®
DIN Deutsches Institut für Normung e. V. At the same time identifier of German standards
TIM-ID: 0000000858 - 011
(DIN = “Deutsche Industrie-Norm”)

DL Default Lost Alarm: Default CAN bus failure
DOC Diesel Oxidation Catalyst Oxidation catalyst upstream of the diesel particulate
filter
DPF Dieselpartikelfilter Diesel particulate filter
DT Diagnostic Tool Diagnostic unit
ECM Electronic Control Module Electronic control unit of the DDEC system
ECU Engine Control Unit Engine governor
MS15018/02E 2013-09 | Appendix A | 137

viation
EDM Engine Data Module Memory module for engine data
EE- Electrically Erasable Programmable Read Electrically Erasable Programmable Read Only Mem-
PROM Only Memory ory
EFPA Electronic Foot Pedal Assembly Electronic Foot Pedal Assembly
EGR Exhaust Gas Recirculation Exhaust gas recirculation
EIL Engine Ident Label
EMU Engine Monitoring Unit Engine monitoring unit
ESCM Extreme Site Condition Management Power reduction in the case of extreme site condi-
tions
ETK Ersatzteilkatalog Spare Parts Catalog
EUI Electronic Unit Injector Electronic Unit Injector
FO Frequency Output
FPS Fuel Pressure Sensor Monitors fuel pressure
FRS Fuel Restriction Sensor
FTS Fuel Temperature Sensor Monitors fuel temperature
FWCP Fire Water Control Panel Governor cabinet
GND Ground
HD High pressure
(HP)
HI High Alarm: Measured value exceeds 1st maximum limit
value
HIHI High High Alarm: Measured value exceeds 2nd maximum limit
value
HT High Temperature High temperature
IDM Interface Data Module Memory module for interface data
INJ Injector
ISO International Organization for Standardiza- International umbrella organization for all national
tion standardization institutes
KGS Kraftgegenseite Engine free end in accordance with DIN ISO 1204
KS Kraftseite Engine driving end in accordance with DIN ISO 1204
L1 Limit 1 Limit value 1
L2 Limit 2 Limit value 2
LED Light Emitting Diode Light emitting diode
LLK Ladeluftkühlung Intercooler
LO Low Alarm: Measured value lower than 1st minimum limit
value
TIM-ID: 0000000858 - 011
LOLO Low Low Alarm: Measured value lower than 2nd minimum lim-
it value
LSG Maximum-speed governor
LSU Lambda Sonde Universal Universal lambda probe
LT Low Temperature Low temperature
MCR Maximum Continuous Rating Torque limiting curve
N/A Not Applicable
ND Niederdruck Low pressure
138 | Appendix A | MS15018/02E 2013-09

viation
NN Normal Null Reference surface for height above sea level
NT Niedertemperatur
OEM Original Equipment Manufacturer
OI Optimized Idle
OLS Oil Level Sensor Monitors oil level
OPS Oil pressure sensor Monitors oil pressure
OTS Oil Temperature Sensor Monitors oil temperature
OT Oberer Totpunkt Top Dead Center
PAN Panel Control panel
PIM Peripheral Interface Module Peripheral interface module
PWM Pulse Width Modulation Modulated signal
P-xyz Pressure-xyz Pressure measuring point, xyz specifies the measur-
ing point designation
RL Redundancy Lost Alarm: Redundant CAN bus failure
SAE Society of Automotive Engineers U.S. standardization organization
SD Sensor Defect Alarm: Sensor failure
SEL Stop EngineLlight 1st function: Warning lamp (stop engine and rectify
fault)
2nd function: Read out fault codes
SID System Identification
SRS Synchronous Reference Sensor OT cylinder 1
SS Safety System / Security Shutdown Safety system alarm
TBS Turbocharger Boost Sensor Monitors charge-air pressure
TCI Turbo Compressor Inlet
TCO Turbo Compressor Outlet
TD Transmitter Deviation Alarm: Deviation in transmitter values
TPS Throttle Position Sensor
TRS Timing Reference Sensor
T-xyz Temperature-xyz Temperature measuring point, xyz specifies the
measuring point designation
U_PDU Voltage Power Driver Unit Solenoid valve output stage supply voltage
UDV Überdruckventil Pressure relief valve
UT Unterer Totpunkt Bottom Dead Center
VNT Variable Nozzle Turbine
VSG Variable-Speed Governor
TIM-ID: 0000000858 - 011
VSS Vehicle Speed Sensor

WZK Werkzeugkatalog Tool Catalog
ZKP Zuordnung - Kategorie - Parameter A number assigned to a parameter describing func-
tion and allocation
MS15018/02E 2013-09 | Appendix A | 139

8.2 MTU contact persons/service partners
Our worldwide sales network with its subsidiaries, sales offices, representatives and customer service
centers ensures fast and direct support on site and the high availability of our products.
Local support
Experienced and qualified specialists place their knowledge and expertise at your disposal.
For locally available support, go to the MTU Internet site: http://www.mtu-online.com
24h hotline
With our 24h hotline and the outstanding flexibility of our service staff, we are always ready to assist
you – either during operation, for preventive maintenance, corrective work in case of malfunction or
changed operating conditions, or for spare parts supply.
Your contact 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 908555
Fax: +49 7541 908121
TIM-ID: 0000000873 - 015
140 | Appendix A | MS15018/02E 2013-09

9 Appendix B
9.1 Special Tools
Adapter
Part No.: F30006234
Qty.: 1
Used in: 7.5.2 Injection pump – Removal and installation
(→ Page 82)
Qty.: 1
Used in: 7.6.2 Injector – Removal and installation (→ Page 86)
Qty.: 1
Used in: 7.7.1 Fuel injection line – Pressure pipe neck replace-
ment (→ Page 89)
Barring device for 12V engines

Part No.: F6558556
Qty.: 1
Used in: 7.1.1 Engine – Barring manually (→ Page 67)
Barring device for 16V, 18V engines

Part No.: F6558557
Qty.: 1
Used in: 7.1.1 Engine – Barring manually (→ Page 67)
DCL-ID: 0000019467 - 004
MS15018/02E 2013-09 | Appendix B | 141

Belt tension tester
Part No.: 5505890119/00
Qty.: 1
Used in: 7.19.1 Fan drive – Drive-belt check and adjustment
(→ Page 128)
Box wrench, 17 mm
Part No.: F30028341
Qty.: 1
Used in: 7.7.2 Fuel – Draining (→ Page 91)
Crowfoot box wrench, 22 mm

Part No.: F30027425
Qty.: 1
(→ Page 82)
Qty.: 1
Qty.: 1
ment (→ Page 89)
Crowfoot wrench, 19 mm
Part No.: F30027424
Qty.: 1
(→ Page 82)
Qty.: 1
DCL-ID: 0000019467 - 004

Qty.: 1
ment (→ Page 89)
142 | Appendix B | MS15018/02E 2013-09

Double-head box wrench
Part No.: F30011450
Qty.: 1
Qty.: 1
ment (→ Page 89)
Feeler gauge
Part No.: Y4342013
Qty.: 1
Used in: 7.4.1 Valve clearance – Check and adjustment
(→ Page 77)
Filter wrench
Part No.: F30379104
Qty.: 1
Used in: 7.8.1 Fuel filter – Replacement (→ Page 96)
Qty.: 1
Used in: 7.14.1 Engine oil filter – Replacement (→ Page 111)
Fuel suction device

Part No.: F30378207
Qty.: 1
DCL-ID: 0000019467 - 004
MS15018/02E 2013-09 | Appendix B | 143

Impact extractor
Part No.: F30377999
Qty.: 1
Plug-in open-end wrench, 19 mm

Part No.: F30025897
Qty.: 1
Qty.: 1
ment (→ Page 89)
Pre-tension gauge
Part No.: Y20097429
Qty.: 1
Used in: 7.18.1 Battery-charging generator drive – Drive-belt
check and adjustment (→ Page 125)
DCL-ID: 0000019467 - 004
144 | Appendix B | MS15018/02E 2013-09

Ratchet
Part No.: F30027340
Qty.: 1
Used in: 7.3.1 Crankcase breather – Oil separator element re-
placement, diaphragm check and replacement
(→ Page 74)
Qty.: 1
(→ Page 77)
Qty.: 1
Used in: 7.4.2 Cylinder head cover – Removal and installation
(→ Page 80)
Qty.: 1
(→ Page 82)
Qty.: 1
Qty.: 1
ment (→ Page 89)
Qty.: 1
Qty.: 1
Used in: 7.18.2 Battery-charging generator drive – Drive belt re-
placement (→ Page 127)
Qty.: 1
(→ Page 128)
Rigid endoscope
Part No.: Y20097353
Qty.: 1
Used in: 7.2.1 Cylinder liner – Endoscopic examination
(→ Page 70)
DCL-ID: 0000019467 - 004
MS15018/02E 2013-09 | Appendix B | 145

Torque wrench, 0.5-5 Nm
Part No.: 0015384230
Qty.: 1
(→ Page 82)
Torque wrench, 20-100 Nm

Part No.: F30026582
Qty.: 1
(→ Page 77)
Qty.: 1
(→ Page 82)
Qty.: 1
Qty.: 1
ment (→ Page 89)
Qty.: 1
Qty.: 1
Used in: 7.18.2 Battery-charging generator drive – Drive belt re-
placement (→ Page 127)
Qty.: 1
(→ Page 128)

Part No.: F30027336
Qty.: 1
Used in: 7.3.1 Crankcase breather – Oil separator element re-
placement, diaphragm check and replacement
(→ Page 74)
DCL-ID: 0000019467 - 004
146 | Appendix B | MS15018/02E 2013-09

Part No.: F30043446
Qty.: 1
Used in: 7.4.2 Cylinder head cover – Removal and installation
(→ Page 80)
Qty.: 1
DCL-ID: 0000019467 - 004
MS15018/02E 2013-09 | Appendix B | 147

9.2 Consumables
Cleaner
Part No.:
Qty.:
Used in: 7.3.2 Crankcase breather – Wire mesh cleaning (→ Page 76)
Coolant
Part No.:
Qty.:
Used in: 7.15.4 Engine coolant – Filling (→ Page 115)
Qty.:
Used in: 7.16.1 Charge-air coolant – Filling (→ Page 118)
Qty.:
Used in: 7.16.3 Charge-air coolant – Change (→ Page 121)
Diesel fuel
Part No.:
Qty.:
Qty.:
Qty.:
Used in: 7.8.3 Fuel prefilter – Draining (→ Page 98)
Qty.:
Used in: 7.8.5 Fuel prefilter – Cleaning (→ Page 101)
Qty.:
Used in: 7.8.6 Fuel prefilter – Filter element replacement (→ Page 102)
Engine coolant
Part No.:
Qty.:
Used in: 7.15.2 Engine coolant – Change (→ Page 113)
DCL-ID: 0000019467 - 004
148 | Appendix B | MS15018/02E 2013-09

Engine oil
Part No.:
Qty.:
Used in: 7.3.1 Crankcase breather – Oil separator element replacement, diaphragm check and
replacement (→ Page 74)
Qty.:
Used in: 7.4.1 Valve clearance – Check and adjustment (→ Page 77)
Qty.:
Used in: 7.5.2 Injection pump – Removal and installation (→ Page 82)
Qty.:
Qty.:
Used in: 7.7.1 Fuel injection line – Pressure pipe neck replacement (→ Page 89)
Qty.:
Qty.:
Used in: 7.7.4 Fuel system – Venting (→ Page 94)
Qty.:
Used in: 7.13.2 Engine oil – Change (→ Page 110)
Qty.:
Qty.:
Used in: 7.18.1 Battery-charging generator drive – Drive-belt check and adjustment
(→ Page 125)
Qty.:
Used in: 7.18.2 Battery-charging generator drive – Drive belt replacement (→ Page 127)
Qty.:
Used in: 7.19.1 Fan drive – Drive-belt check and adjustment (→ Page 128)
Fuel
Part No.:
Qty.:
Used in: 7.8.4 Fuel prefilter – Flushing (→ Page 99)
Grease (Kluthe Hakuform 30-10/Emulgier)

Part No.: X00029933
Qty.: 1
Qty.: 1
DCL-ID: 0000019467 - 004
Qty.: 1
Isopropyl alcohol
Part No.: X00058037
Qty.: 1
Used in: 7.20.1 Engine wiring – Check (→ Page 133)
Qty.: 1
Used in: 7.21.1 Engine governor and connectors – Cleaning (→ Page 134)
MS15018/02E 2013-09 | Appendix B | 149

Petroleum jelly
Part No.:
Qty.:
DCL-ID: 0000019467 - 004
150 | Appendix B | MS15018/02E 2013-09

9.3 Spare Parts
Air filter
Part No.:
Qty.:
Used in: 7.10.1 Air filter – Replacement (→ Page 105)
Diaphragm
Part No.:
Qty.:
Drive belt
Part No.:
Qty.:
Used in: 7.18.2 Battery-charging generator drive – Drive belt replacement (→ Page 127)
Qty.:
Used in: 7.19.2 Fan drive – Belt replacement (→ Page 131)
Easy-change filter
Part No.:
Qty.:
Filter element
Part No.:
Qty.:
Qty.:
Qty.:
Filter insert
Part No.:
Qty.:
DCL-ID: 0000019467 - 004
MS15018/02E 2013-09 | Appendix B | 151

Gasket
Part No.:
Qty.:
Qty.:
Used in: 7.4.2 Cylinder head cover – Removal and installation (→ Page 80)
Qty.:
Qty.:
Qty.:
Qty.:
Used in: 7.8.3 Fuel prefilter – Draining (→ Page 98)
Qty.:
Injection pump
Part No.:
Qty.:
Used in: 7.5.1 Injection pump – Replacement (→ Page 81)
Injector
Part No.:
Qty.:
Used in: 7.6.1 Injector – Replacement (→ Page 85)
Oil filter
Part No.:
Qty.:
Pressure pipe tube

Part No.:
Qty.:
Pressure relief valve

DCL-ID: 0000019467 - 004
Part No.:
Qty.:
Used in: 7.7.3 Fuel pressure maintaining valve – Removal and installation (→ Page 93)
Seal
Part No.:
Qty.:
Used in: 7.8.4 Fuel prefilter – Flushing (→ Page 99)
152 | Appendix B | MS15018/02E 2013-09

Sealing ring
Part No.:
Qty.:
Qty.:
Qty.:
Qty.:
Qty.:
Qty.:
Qty.:
Qty.:
Used in: 7.8.5 Fuel prefilter – Cleaning (→ Page 101)
Qty.:
Used in: 7.9.1 Intercooler – Checking condensate drain for coolant discharge and obstructions
(→ Page 104)
Qty.:
Used in: 7.13.2 Engine oil – Change (→ Page 110)
Qty.:
Used in: 7.15.3 Engine coolant – Draining (→ Page 114)
Qty.:
Used in: 7.15.3 Engine coolant – Draining (→ Page 114)
Qty.:
Used in: 7.16.1 Charge-air coolant – Filling (→ Page 118)
Qty.:
Used in: 7.16.2 Charge-air coolant – Draining (→ Page 120)
Qty.:
Used in: 7.16.2 Charge-air coolant – Draining (→ Page 120)
DCL-ID: 0000019467 - 004
MS15018/02E 2013-09 | Appendix B | 153

9.4 Index
Numerics D
12/16/18 V 2000 Gx5 engine data, optimized fuel con- Designations
sumption 20 – Engine sides and cylinders 15
12/16/18 V 2000 Gx5-TB engine data, optimized fuel con- Drive belt
sumption 24 – Check and adjustment 125, 128
– Replacement 127
A
Abbreviations 137 E
After stopping the engine ECU 7
– Engine remains ready for operation 37 – Installation 136
– Putting the engine out of operation 38 – Removal 136
Air filter ECU 7 engine governor
– Removal and installation 106 – Installation 136
– Replacement 105 – Removal 136
Air starter Engine
– Manual operation 108 – Barring manually 67
– Barring with starting system 68
C – Emergency stop 36
Charge-air coolant – Main dimensions 29
– Change 121 – Overview 16
– Draining 120 – Starting in manual mode (test run) 32
– Filling 118 – Stopping in manual mode (test run) 35
– Level check 122 – Test run 69
Charge-air coolant level – Wiring check 133
– Check 122 Engine coolant
Connectors – Change 113
– Cleaning 134 – Draining 114
Contact persons 140 – Filling 115
Coolant Engine coolant level
– Change 121 – Check 112
– Charge air Engine governor
– Draining 120 – Cleaning 134
– Filling 118 – Plug connections
– Filling 115 – Check 135
Coolant level Engine oil
– Check 112 – Change 110
Coolant pump Engine oil filter
– Relief bore check 117 – Replacement 111
Coolant - charge air Engine oil level
– Level check 122 – Check 109
Cooler – Checking cooler elements externally for dirt 123 Engine sides
Cooler – Cleaning cooler elements 124 – Designation 15
Crankcase breather Engine wiring
– Diaphragm check 74 – Check 133
DCL-ID: 0000019467 - 004
– Oil separator element replacement 74

– Wire mesh cleaning 76 F
Cylinder Fan drive
– Designation 15 – Drive belt replacement 131
Cylinder head cover Fault indication on SAM display
– Removal and installation 80 – Genset applications 40
Cylinder liner Firing order 28
– Endoscopic examination 70 Fuel
– Instructions and comments on endoscopic and visual – Draining 91
examination 72 – Prefilter
– Flushing 99
154 | Appendix B | MS15018/02E 2013-09

Fuel filter Safety regulations
– Replacement 96 – Consumables 12
Fuel injection line – Environmental protection 12
– Pressure pipe neck replacement 89 – Fire prevention 12
Fuel prefilter – Fluids and lubricants 12
– Cleaning 101 – Important provisions 5
– Draining 98 – Maintenance work 9
– Filter element – Operation 8
– Replacement 102 – Organizational requirements 6
– Flushing 99 – Personnel requirements 6
Fuel prefilter – Differential pressure gauge – Repair work 9
– Adjustment 97 – Safety notices, standards 14
– Check 97 – Startup 8
Fuel pressure maintaining valve Safety system
– Removal and installation 93 – Override 33
Fuel system SAM
– Venting 94 – Genset applications 40
Sensors and actuators
H – Overview 18
Hotline 140 Service partners 140
Spare parts service 140
I
Injection pump T
– Removal and installation 82 Transport 7
– Replacement 81 Troubleshooting 64
Injector
– Removal and installation 86 V
– Replacement 85 Valve clearance
Intercooler – Adjustment 77
– Condensate drain for coolant discharge – Check 77
– Check 104
– Condensate drain for obstructions
– Check 104
M
MTU contact persons 140
O
Operational checks 34
P
Putting the engine into operation after extended out-of-
service periods (>3 months) 30
Putting the engine into operation after scheduled out-of-
service-period 31
S
Safety notices, standards 14
DCL-ID: 0000019467 - 004
MS15018/02E 2013-09 | Appendix B | 155

Mtu 16v2000g65 PDF

Uploaded by

Copyright:

Available Formats

Mtu 16v2000g65 PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Mtu 16v2000g65 PDF

Uploaded by

Copyright:

Available Formats

Operating Instructions

7.8.2 Fuel prefilter – Differential pressure check

MS15018/02E 2013-09 | Table of Contents | 3

7.17 Coolant System 123 9.1 Special Tools 141

DCL-ID: 0000019467 - 004

4 | Table of Contents | MS15018/02E 2013-09

1 Left-hand side of engine 3 Right-hand side of engine

MS15018/02E 2013-09 | General Information | 15

010 Crankcase and add-on 7 Oil heat exchanger 14 Charge-air manifold

16 | General Information | MS15018/02E 2013-09

1 Air filter 7 Oil heat exchanger 13 Exhaust elbow

Engine model designation

MS15018/02E 2013-09 | General Information | 17

Item Name Monitoring of

18 | General Information | MS15018/02E 2013-09

Item Name Monitoring of

MS15018/02E 2013-09 | General Information | 19

GENERAL CONDITIONS (for maximum power)

MODEL RELATED DATA (basic design)

20 | Technical Data | MS15018/02E 2013-09

COMBUSTION AIR / EXHAUST GAS

COOLANT SYSTEM (HT circuit)

MS15018/02E 2013-09 | Technical Data | 21

GENERAL OPERATING DATA

(standard oil system) (Option: max. oper-

22 | Technical Data | MS15018/02E 2013-09

MS15018/02E 2013-09 | Technical Data | 23

GENERAL CONDITIONS (for maximum power)

MODEL RELATED DATA (basic design)

24 | Technical Data | MS15018/02E 2013-09

COMBUSTION AIR / EXHAUST GAS

COOLANT SYSTEM (HT circuit)

COOLANT SYSTEM (LT circuit)

Coolant temperature before intercooler A °C 55 55 55 55

MS15018/02E 2013-09 | Technical Data | 25

GENERAL OPERATING DATA

Charge-air coolant, engine side R liters 20 20 20 20

26 | Technical Data | MS15018/02E 2013-09

WEIGHTS / MAIN DIMENSIONS

MS15018/02E 2013-09 | Technical Data | 27

TIM-ID: 0000002793 - 002

28 | Technical Data | MS15018/02E 2013-09

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

MS15018/02E 2013-09 | Technical Data | 29

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

30 | Operation | MS15018/02E 2013-09

Putting the engine into operation

MS15018/02E 2013-09 | Operation | 31

Starting the engine

Connecting the generator (if fitted) to network, engine warm-up procedure to

32 | Operation | MS15018/02E 2013-09

Safety system – Override

MS15018/02E 2013-09 | Operation | 33

TIM-ID: 0000010120 - 001

34 | Operation | MS15018/02E 2013-09

Preparing a generator drive (only if generator circuit breaker is provided)

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

Stopping the engine

After stopping the engine