Operating Instructions

Operating Instructions
Diesel engine
12 V 2000 G25, G45, G65, G85, G25 TB, G45 TB, G65 TB, G85 TB
16 V 2000 G25, G45, G65, G85, G25 TB, G45 TB, G65 TB, G85 TB
18 V 2000 G65, G85, G65 TB, G85 TB
Application group 3B
MS15019/02E
Printed in Germany
© 2013 Copyright MTU Friedrichshafen GmbH
This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior
written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, mi-
crofilming and storage or processing on electronic systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage
during operation.
Subject to alterations and amendments.
Table of Contents
1 Safety 5 Maintenance
1.1 Important provisions for all products 5 5.1 Maintenance task reference table [QL1] 53
1.2 Personnel and organizational requirements 6
1.3 Transport 7 6 Troubleshooting
1.4 Safety regulations for startup and operation 8
1.5 Safety regulations for maintenance and 6.1 Fault indication on SAM display – Genset
repair work 9 applications 54
1.6 Fire prevention and environmental 6.2 Troubleshooting 78
protection, fluids and lubricants, auxiliary
materials 12 7 Task Description
1.7 Standards for warning notices in the text 14
7.1 Engine 81
7.1.1 Engine – Barring manually 81
2 General Information 7.1.2 Engine – Barring with starting system 82
7.1.3 Engine – Test run 83
2.1 Engine side and cylinder designations 15
2.2 Engine - Overview 16 7.2 Cylinder Liner 84
2.3 Sensors, actuators and injectors – Overview 17 7.2.1 Cylinder liner – Endoscopic examination 84
7.2.2 Instructions and comments on endoscopic and
visual examination of cylinder liners 86
3 Technical Data
7.3 Crankcase Breather 88
3.1 12/16/18 V 2000 Gx5 engine data, 7.3.1 Crankcase breather – Oil separator element
optimized fuel consumption 21 replacement, diaphragm check and
3.2 12/16/18 V 2000 Gx5-TB engine data, replacement 88
optimized fuel consumption 25 7.3.2 Crankcase breather – Wire mesh cleaning 90
3.3 12V 2000 Gx5 engine data, optimized 7.4 Valve Drive 91
exhaust emission 29 7.4.1 Valve clearance – Check and adjustment 91
3.4 16/18V 2000 Gx5 engine data, optimized 7.4.2 Cylinder head cover – Removal and
exhaust emission 33 installation 94
3.5 12/16/18V 2000 Gx5-TB engine data,
7.5 Injection Pump / HP Pump 95
optimized exhaust emission 38
7.5.1 Injection pump – Replacement 95
3.6 Firing order 42 7.5.2 Injection pump – Removal and installation 96
3.7 Engine – Main dimensions 43
7.6 Injection Valve / Injector 99
7.6.1 Injector – Replacement 99
4 Operation
7.6.2 Injector – Removal and installation 100
4.1 Putting the engine into operation after 7.7 Fuel System 104
extended out-of-service periods (>3 months) 44 7.7.1 Fuel injection line – Pressure pipe neck
4.2 Putting the engine into operation after replacement 104
scheduled out-of-service-period 45 7.7.2 Fuel – Draining 106
4.3 Starting the engine in manual mode (test 7.7.3 Fuel system – Venting 108
run) 46
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7.8 Fuel Filter 110

4.4 Safety system – Override 47 7.8.1 Fuel filter – Replacement 110
4.5 Operational checks 48 7.8.2 Fuel prefilter – Differential pressure gauge
4.6 Stopping the engine in manual mode (test check and adjustment 111
run) 49 7.8.3 Fuel prefilter – Draining 112
4.7 Emergency stop 50 7.8.4 Fuel prefilter – Flushing 113
4.8 After stopping the engine – Engine remains 7.8.5 Fuel prefilter cleaning 115
ready for operation 51 7.8.6 Fuel prefilter – Filter element replacement 116
4.9 After stopping the engine – Putting the 7.9 Charge-Air Cooling General, Left-Hand Side 118
engine out of operation 52
MS15019/02E 2013-01 | Table of Contents | 3

7.9.1 Intercooler – Checking condensate drains for 7.16.4 Charge-air coolant – Level check 136
coolant discharge and obstructions 118
7.17 Battery-Charging Generator 137
7.10 Air Filter 119 7.17.1 Battery-charging generator drive – Drive-belt
7.10.1 Air filter – Replacement 119 check and adjustment 137
7.10.2 Air filter – Removal and installation 120 7.17.2 Battery-charging generator drive – Drive belt
replacement 139
7.11 Air Intake 121
7.11.1 Service indicator – Signal ring position check 121 7.18 Fan Drive 140
7.18.1 Fan drive – Drive-belt check and adjustment 140
7.12 Starting Equipment 122 7.18.2 Fan drive – Drive belt replacement 143
7.12.1 Air starter – Manual operation 122
7.19 Wiring (General) for Engine/Gearbox/Unit 145
7.13 Lube Oil System, Lube Oil Circuit 123 7.19.1 Engine wiring – Check 145
7.13.1 Engine oil – Level check 123
7.13.2 Engine oil – Change 124 7.20 Accessories for (Electronic) Engine
Governor / Control System 146
7.14 Oil Filtration / Cooling 125
7.20.1 Engine governor and connectors – Cleaning 146
7.14.1 Engine oil filter – Replacement 125
7.20.2 Engine governor plug connections – Check 147
7.15 Coolant Circuit, General, High-Temperature 7.20.3 ECU 7 engine governor – Removal and
Circuit 126 installation 148
7.15.1 Engine coolant – Level check 126
7.15.2 Engine coolant – Change 127
7.15.3 Engine coolant – Draining 128
8 Appendix A
7.15.4 Engine coolant – Filling 129
8.1 Abbreviations 149
7.15.5 Coolant pump – Relief bore check 131
8.2 MTU contact persons/service partners 152
7.16 Low-Temperature Circuit 132
7.16.1 Charge-air coolant – Filling 132 9 Appendix B
7.16.2 Charge-air coolant – Draining 134
7.16.3 Charge-air coolant – Change 135 9.1 Special Tools 153
9.2 Index 160
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4 | Table of Contents | MS15019/02E 2013-01

1 Safety
1.1 Important provisions for all products
Nameplate
The product is identified by nameplate, model designation or serial number and must match with the
information on the title page of this manual.
Nameplate, model designation or serial number can be found on the product.
General information
This product may pose a risk of injury or damage in the following cases:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Modifications or conversions
• Noncompliance with the safety instructions and warning notices
Correct use
The product is intended exclusively for the application specified in the contract or defined at the time of
delivery.
This means that the equipment must be operated:
• Within the permissible operating parameters in accordance with the (→ product data)
• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubri-
cants Specifications of the manufacturer)
• With spare parts approved by the manufacturer in accordance with the (→ applicable Spare Parts
Catalog)
• In the original as-delivered configuration or in a configuration approved by the manufacturer in writ-
ing (including engine control/parameters)
• In compliance with all safety instructions and in adherence to all warning notices in this manual
• In accordance with the maintenance requirements over the entire service life of the product (→ Main-
tenance Schedule)
• In compliance with the maintenance and repair instructions contained in this manual, in particular
with regard to the specified tightening torques
• With the exclusive use of technical personnel trained in commissioning, operation, maintenance and
repair
• By contracting only workshops authorized by the manufacturer to carry out repair and overhaul
Any other use is considered improper use and increases the risk of personnel injury or material damage
in product operation.The manufacturer will accept no liability for such damage.
Modifications or conversions
Unauthorized modifications to the product compromise safety.
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The manufacturer will accept no liability or warranty claims for any damage caused by unauthorized
modifications or conversions.
Spare parts
Only genuine spare parts must be used to replace components or assemblies.
The manufacturer will accept no liability or warranty claims for any damage caused by the use of other
spare parts.
MS15019/02E 2013-01 | Safety | 5

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

Wear proper protective clothing for all work.
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6 | Safety | MS15019/02E 2013-01

1.3 Transport
Transport
Lift the engine only with the lifting eyes provided.

Use only the transport and lifting equipment approved by MTU.
Take note of the engine center of gravity.
The engine must only be transported in installation position, max. permissible diagonal pull 10°.
In the case of special packaging with aluminum foil, suspend the engine on the lifting eyes of the trans-
port pallet or transport with equipment for heavy loads (forklift truck).
Prior to transporting the engine, it is imperative to install transportation locking devices for crankshaft
and engine mounts.
Secure the engine against tilting during transport. The engine must be especially secured against slip-
ping or tilting when going up or down inclines and ramps.
Setting the engine down after transport

Place the engine only on an even, firm surface.
Ensure appropriate consistency and load-bearing capacity of the ground or support surface.
Never place an engine on the oil pan, unless expressively authorized by MTU on a case-to-case basis to
do so.
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MS15019/02E 2013-01 | Safety | 7

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

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

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

When electrical equipment is in operation, certain components of these appliances are electrically live.
Observe the safety instructions for these devices.
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8 | Safety | MS15019/02E 2013-01

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

Take special care when removing ventilation or plug screws from the product. Cover the screw or plug
with a rag to prevent fluids escaping under pressure.
Take care when draining hot fluids and lubricants (risk of burning).
Use only proper and calibrated tools. Observe the specified tightening torques during assembly or dis-
assembly.
Carry out work only on assemblies or plants which are properly secured.
Never use lines for climbing.
Keep fuel injection lines and connections clean.
Always seal connections with caps or covers if a line is removed or opened.
Take care not to damage lines, in particular fuel lines, during maintenance and repair work.
Ensure that all retainers and dampers are installed correctly.
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Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent
contact with other components. Do not place fuel or oil lines near hot components.
Do not touch elastomeric seals if they have carbonized or resinous appearance unless hands are prop-
erly protected.
Note cooling time for components which are heated for installation or removal (risk of burning).
When working high on the equipment, always use suitable ladders and work platforms. Make sure com-
ponents or assemblies are placed on stable surfaces.
MS15019/02E 2013-01 | Safety | 9

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

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

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

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Observe the safety instructions of the battery manufacturer when working with batteries.
Gases emanating from the battery are explosive. Avoid sparks and naked flames.
Do not allow electrolyte to come in contact with skin or clothing.
Wear protective clothing and protective gloves.
Never place tools on the battery.
Before connecting the cable to the battery, check the battery polarity.Battery pole reversal may lead to
injury through the sudden discharge of acid or bursting of the battery body.
10 | Safety | MS15019/02E 2013-01

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

When working with laser equipment, always wear special laser-protection goggles (hazard due to heavi-
ly focused radiation).
Laser equipment must be fitted with the protective devices necessary for safe operation according to
type and application.
For conducting light-beam procedures and measurement work, only the following laser devices must be
used:
• Laser devices of classes 1, 2 or 3A.
• Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700
nm), a maximum output of 5 mW, and in which the beam axis and surface are designed to prevent
any risk to the eyes.
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MS15019/02E 2013-01 | Safety | 11

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

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

The Fluids and Lubricants Specifications will be amended or supplemented as necessary. Prior to opera-
tion, make sure that the latest version is used. The applicable version may be downloaded at: http://
www.mtu-online.com/mtu/mtu-valuecare/mtu-valueservice-Technische-Dokumentation.
Auxiliary materials, fluids and lubricants might be hazardous goods or toxic substances.When using flu-
ids, lubricants, auxiliary materials and other chemical substances, follow the safety instructions that ap-
ply to the product. Take special care when using hot, chilled or caustic materials. When using flamma-
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ble materials, avoid contact with ignition sources and do not smoke.
Used oil
Used oil contains harmful combustion residue.
Rub barrier cream into hands.
Wash hands after contact with used oil.
12 | Safety | MS15019/02E 2013-01

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

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

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• When working with acids and alkaline solutions, wear face mask, gloves and protective clothing.
• Do not inhale vapors.
• If urea solution was swallowed, rinse mouth and drink plenty of water.
• If the solutions was spilled onto clothing, remove the affected clothing immediately.
• In case of skin contact, rinse parts of the body thoroughly with clean water.
• Rinse eyes immediately with eyedrops or clean tap water. Seek medical attention as soon as possi-
ble.
MS15019/02E 2013-01 | Safety | 13

1.7 Standards for warning notices in the text
DANGER
In the event of immediate danger.
Consequences: Death, serious or irreversible injury
• Remedial action
WARNING
In the event of a situation involving potential danger.
Consequences: Death, serious or permanent injury
• Remedial action
CAUTION
In the event of possible danger.
Consequences: Minor or moderate injuries
• Remedial action
NOTICE
In the event of a situation involving potentially adverse effects on the product.
Consequences: Material damage.
• Remedial action
• Additional product information
Warning notices
u This manual with all safety instructions and waring notices must be issued to all personnel involved in
operation, maintenance, repair or transportation.
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14 | Safety | MS15019/02E 2013-01

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

2 KGS = Free end 4 KS = Driving end
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MS15019/02E 2013-01 | General Information | 15

2.2 Engine - Overview
Illustration is applicable to 12/16/18 V 2000 Gxy engines (with water-cooled
intercooler)
010 Crankcase and add-on 080 Fuel system (low pressure) 180 Lube oil system / lube oil
components 100 Exhaust turbocharger circuit
020 Gear train 110 Charge-air cooling 200 Coolant system
030 Running gear 120 Air intake/air supply 210 Power generation / sup-
040 Cylinder head 140 Exhaust system ply, engine side
050 Valve gear 170 Starting equipment 220 Cooling air system
070 Fuel system (high pres- 230 Mounting/support
sure) 500 Monitoring, control and
regulation equipment, gen-
eral electric equipment
Engine model designation

Key to the engine model designations 12/16/18V 2000 Gxy
12/16/18 Number of cylinders
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V Cylinder arrangement: V-engine

2000 Series
G Application
X Application segment (2, 4, 6, 8)
y Design index (0,1, 2,...)
16 | General Information | MS15019/02E 2013-01

2.3 Sensors, actuators and injectors – Overview
Engine with air-charge-air cooling version A
1 XF33 (H-engine coolant) 2 B01 (camshaft speed)
Illustration also applies to 12/16/18 V 2000 Gx5-TD

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1 B09 (T-charge-air) 4 B06 (T-engine coolant) 7 B05 (P-lubricant)
2 B10 (P-charge-air) 5 B33 (T-fuel)
3 B13 (crankshaft speed) 6 B07 (T-lube oil)
Illustration also applies to 12/16/18 V 2000 Gx5-TD
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Engine with water charge-air cooling version B
1 B10 (P-charge air)* 2 B09 (T-charge air) 3 B01 (camshaft speed)
to *
2 B10 12V and 18V
B09 16 V
3 B09 12V and 18V
B10 16 V
Illustration also applies to 12/16/18 V 2000 Gx5-TB

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1 B33 (T-fuel) 3 B13 (crankshaft speed) 5 B07 (T-lube oil)
2 XF33 (H-engine coolant) 4 B06 (T-engine coolant) 6 B05 (P-lubricant)
Illustration also applies to 12/16/18 V 2000 Gx5-TB
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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 16V 2000 18V 2000
G25 G65 G25 G65 G65
Application group 3B 3B 3B 3B 3B
Intake air temperature °C 25 25 25 25 25
Barometric pressure mbar 1000 1000 1000 1000 1000
Site altitude above sea level m 100 100 100 100 100
POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)
Number of cylinders 12 12 16 16 18
Rated engine speed A rpm 1500 1500 1500 1500 1500
Continuous power ISO 3046 A kW 580 695 810 890 1000
(10% overload capability, de-
sign power DIN 6280, ISO
8528)
GENERAL CONDITIONS (for maximum power)

Intake air depression (new fil- A mbar 15 15 15 15 15
ter)
Intake air depression, max. L mbar 50 50 50 50 50
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Exhaust pressure A mbar 30 30 30 30 30

Exhaust pressure, max. L mbar 85 85 85 85 85
MODEL RELATED DATA (basic design)

Engine with exhaust turbo- x x x x x
charging (ETC) and charge air
cooling (CAC)
Exhaust piping, non-cooled x x x x x
MS15019/02E 2013-01 | Technical Data | 21

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

Charge air pressure before R bar abs 2.8 3.2 3.0 3.2 3.1
cylinder - DL
COOLANT SYSTEM (HT circuit)

Coolant temperature (at en- A °C 95 95 95 95 95
gine connection: outlet to
cooling equipment)
TIM-ID: 0000010882 - 001
Coolant temperature after en- R °C 97 97 97 97 97

gine, alarm
Coolant temperature after en- L °C 102 102 102 102 102
gine, shutdown
Coolant antifreeze content, L % 50 50 50 50 50
max.
Pressure loss in off-engine L bar 0.7 0.7 0.7 0.7 0.7
cooling system, max.
22 | Technical Data | MS15019/02E 2013-01

LUBE-OIL SYSTEM
Lube oil operating tempera- R °C 88 88 88 88 88
ture before engine, from
Lube-oil operating tempera- R °C 98 98 98 98 98
ture before engine, to
Lube-oil temperature before R °C 100 100 100 100 100
engine, alarm
Lube-oil temperature before L °C 105 105 105 105 105
engine, shutdown
Lube-oil operating pressure R bar 6.2 6.2 5.5 5.5 6.0
before engine, from
before engine, to
Lube-oil pressure before en- R bar 4.4 4.4 4.4 4.4 4.4
gine, alarm
Lube-oil pressure before en- L bar 3.9 3.9 3.9 3.9 3.9
gine, shutdown
FUEL SYSTEM
Fuel pressure at engine sup- L bar -0.3 -0.3 -0.3 -0.3 -0.3
ply connection, min. (when
engine is starting)
Fuel pressure at engine sup- L bar +0.5 +0.5 +0.5 +0.5 +0.5
ply connection, max. (when
engine is starting)
GENERAL OPERATING DATA

Cold start capability: Air tem- R °C 0** 0** 0** 0** 0**
perature (w/o start aid, w/o
preheating) - (case A)
Coolant preheating: preheat- R °C 32 32 32 32 32
ing temperature (min.)
Firing speed, from R rpm 100 100 100 100 100
Firing speed, to R rpm 120 120 120 120 120
CAPACITIES
TIM-ID: 0000010882 - 001
Engine coolant capacity, en- R liters 90 90 110 130 120
gine side (without cooling
equipment)
Total engine oil capacity at ini- R liters 77 77 102 102 130
tial filling (standard oil sys-
tem) (Option: max. operating
inclinations)

Oil change capacity, max. R liters N N N N N
(standard oil system)
Oil change quantity, max. R liters 74 74 99 99 114
(standard oil system) (Option:
max. operating inclinations)
Oil pan capacity at dipstick L liters 50 50 69 69 87
mark "min." (standard oil sys-
inclinations)
mark "max." (standard oil sys-
inclinations)
WEIGHTS / MAIN DIMENSIONS

Engine weight, dry (basic en- R kg 2490 2490 3100 3100 3500
gine configuration acc. to
scope of supply specification)
ACOUSTICS
Exhaust noise, unsilenced - R dB(A) 120 127 119 120 120
DL (sound power level LW,
ISO 6798)
Engine surface noise with at- R dB(A) 117 118 120 121 123
tenuated intake noise filter) -
ISO 6798)
TIM-ID: 0000010882 - 001

3.2 12/16/18 V 2000 Gx5-TB engine data, optimized fuel
consumption
Explanation:
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable
G25-TB G65-TB G25-TB G65-TB G65-TB
Charge-air coolant tempera- °C 55 55 55 55 55
ture
Raw water inlet temperature °C - - - - -
8528)

ter)
TIM-ID: 0000010905 - 001


cooling (CAC)

fuel injection
water
gle
Bore mm 130 130 130 130 130
Stroke mm 150 150 150 150 150
der
ble
Flywheel interface DISC 18" 18" 18" 18" 18"

cylinder - DL

cooling equipment)
TIM-ID: 0000010905 - 001

gine, alarm
gine, shutdown
max.

COOLANT SYSTEM (LT circuit)
Coolant temperature before A °C 55 55 55 55 55
intercooler (at engine inlet
from cooling equipment)
max.
LUBE-OIL SYSTEM
engine, alarm
Lube-oil temperature before L °C 105 105 105 105 105
engine, shutdown
before engine, from
before engine, to
gine, alarm
gine, shutdown
FUEL SYSTEM
engine is starting)
engine is starting)

TIM-ID: 0000010905 - 001

CAPACITIES
equipment)
Charge-air coolant, engine R liters 20 20 20 20 20
side
inclinations)
inclinations)
inclinations)

ACOUSTICS
ISO 6798)
ISO 6798)
TIM-ID: 0000010905 - 001

3.3 12V 2000 Gx5 engine data, optimized exhaust emission
Explanation:
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable
Engine model 12V 2000 12V 2000 12V 2000 12V 2000
G25 G45 G65 G85
Application group 3B 3B 3B 3B
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
Number of cylinders 12 12 12 12
Rated engine speed A rpm 1500 1800 1500 1800
Continuous power ISO 3046 (10% over- A kW 580 710 695 810
load capability, design power DIN 6280,
ISO 8528)

Intake air depression (new filter) A mbar 15 15 15 15
Intake air depression, max. L mbar 30 50 30 50
Exhaust pressure A mbar 30 30 30 30
Exhaust pressure, max. L mbar 50 85 50 85

Engine with exhaust turbocharging (ETC) x x x x
TIM-ID: 0000010922 - 001
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 23.88 23.88
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"

Charge air pressure before cylinder - DL R bar abs 3.6 3.2 4.0 3.35

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
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
TIM-ID: 0000010922 - 001
gine, to
Lube-oil temperature before engine, alarm R °C 100 103 100 103
Lube-oil temperature before engine, shut- L °C 105 - 105 -
down
Lube-oil operating pressure before engine, R bar 6.2 6.5 6.2 6.5
from
Lube-oil operating pressure before engine, R bar 7.5 7.8 7.5 7.8
to

Lube-oil pressure before engine, alarm R bar 4.6 - 4.6 5.5
Lube-oil pressure before engine, shut- L bar 4.1 - 4.1 5.0
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)

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 90 90
(without cooling equipment)
Total engine oil capacity at initial filling R liters 77 77 77 77
(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 74 74
system) (Option: max. operating inclina-
tions)
Oil pan capacity at dipstick mark "min." L liters 50 50 50 50
ating inclinations)
Oil pan capacity at dipstick mark "max." L liters 67 67 67 67
ating inclinations)
TIM-ID: 0000010922 - 001

Engine weight, dry (basic engine configu- R kg 2490 2490 2490 2490
ration acc. to scope of supply specifica-
tion)

ACOUSTICS
Exhaust noise, unsilenced - DL (sound R dB(A) 123 126 126 129
power level LW, ISO 6798)
Engine surface noise with attenuated in- R dB(A) 117 117 118 120
take noise filter) - DL (sound power level
LW, ISO 6798)
TIM-ID: 0000010922 - 001

3.4 16/18V 2000 Gx5 engine data, optimized exhaust emission
Explanation:
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable
Engine model 16V 2000 16V 2000 16V 2000 16V 2000 18V 2000 18V 2000
G25 G45 G65 G85 G65 G85
Application group 3B 3B 3B 3B 3B 3B
Intake air temper- °C 25 25 25 25 25 25
ature
Barometric pres- mbar 1000 1000 1000 1000 1000 1000
sure
Site altitude m 100 100 100 100 100 100
above sea level
Number of cylin- 16 16 16 16 18 18
ders
Rated engine A rpm 1500 1800 1500 1800 1500 1800
speed
Continuous power A kW 810 915 890 1010 1000 1191
ISO 3046 (10%
overload capabili-
ty, design power
DIN 6280, ISO
8528)

Number of cylin- 16 16 16 16 18 18
ders
Intake air depres- A mbar 15 15 15 15 15 15
sion (new filter)
TIM-ID: 0000010936 - 001
Intake air depres- L mbar 30 50 30 50 30 50

sion, max.
Exhaust pressure A mbar 30 30 30 30 30 30
Exhaust pressure, L mbar 50 85 50 85 50 85
max.

Number of cylin- 16 16 16 16 18 18
ders
Engine with ex- x x x x x x
haust turbocharg-
ing (ETC) and
charge air cooling
(CAC)
Exhaust piping, x x x x x x
non-cooled
Working method: x x x x x x
four-cycle, diesel,
single-acting
Combustion x x x x x x
method: Direct
fuel injection
Cooling system: x x x x x x
conditioned water
Direction of rota- x x x x x x
tion: c.c.w. (fac-
ing driving end)
Number of cylin- 16 16 16 16 18 18
ders
Cylinder configu- Degrees 90 90 90 90 90 90
ration: V angle
Bore mm 130 130 130 130 130 130
Stroke mm 150 150 150 150 150 150
Displacement per liters 1.99 1.99 1.99 1.99 1.99 1.99
cylinder
Displacement, to- liters 31.84 31.84 31.84 31.84 35.82 35.82
tal
Compression ra- 16 16 16 16 16 16
tio
Cylinder heads: x x x x x x
single-cylinder
Cylinder liners: x x x x x x
wet, replaceable
Inlet valves per 2 2 2 2 2 2
cylinder
Exhaust valves 2 2 2 2 2 2
TIM-ID: 0000010936 - 001
per cylinder
Standard flywheel SAE 0 0 0 0 0 0
housing flange
(engine main PTO)
Flywheel interface DISC 18" 18" 18" 18" 18" 18"

Number of cylin- 16 16 16 16 18 18
ders
Charge air pres- R bar abs 3.6 3.2 3.8 3.4 3.9 3.3
sure before cylin-
der - DL

Number of cylin- 16 16 16 16 18 18
ders
Coolant tempera- A °C 95 95 95 95 95 95
ture (at engine
connection: outlet
to cooling equip-
ment)
Coolant tempera- R °C 97 97 97 97 97 97
ture after engine,
alarm
Coolant tempera- L °C 102 102 102 102 102 102
ture after engine,
shutdown
Coolant antifreeze L % 50 50 50 50 50 50
content, max.
Pressure loss in L bar 0.7 0.7 0.7 0.7 0.7 0.7
off-engine cooling
system, max.
LUBE-OIL SYSTEM
Number of cylin- 16 16 16 16 18 18
ders
Lube oil operating R °C 88 88 88 88 88 88
temperature be-
fore engine, from
Lube-oil operating R °C 98 98 98 98 98 98
temperature be-
fore engine, to
Lube-oil tempera- R °C 100 103 100 103 100 103
ture before en-
gine, alarm
Lube-oil tempera- L °C 105 - 105 - 105 -
ture before en-
TIM-ID: 0000010936 - 001
gine, shutdown
Lube-oil operating R bar 5.5 6.0 5.5 6.0 6.0 6.5
pressure before
engine, from
Lube-oil operating R bar 6.5 7.0 6.5 7.0 8.0 8.5
pressure before
engine, to

Number of cylin- 16 16 16 16 18 18
ders
Lube-oil pressure R bar 4.6 5.5 4.6 5.5 4.6 5.5
before engine,
alarm
Lube-oil pressure L bar 4.1 5.0 4.1 5.0 4.1 5.0
before engine,
shutdown
FUEL SYSTEM
Number of cylin- 16 16 16 16 18 18
ders
Fuel pressure at L bar -0.3 -0.3 -0.3 -0.3 -0.3 -0.3
engine supply
connection, min.
(when engine is
starting)
Fuel pressure at L bar +0.5 +0.5 +0.5 +0.5 +0.5 +0.5
engine supply
connection, max.
(when engine is
starting)

Number of cylin- 16 16 16 16 18 18
ders
Cold start capabil- R °C 0** 0** 0** 0** 0** 0**
ity: Air tempera-
ture (w/o start
aid, w/o preheat-
ing) - (case A)
Coolant preheat- R °C 32 32 32 32 32 32
ing: preheating
temperature
(min.)
Firing speed, from R rpm 100 100 100 100 100 100
Firing speed, to R rpm 120 120 120 120 120 120
CAPACITIES
Number of cylin- 16 16 16 16 18 18
ders
TIM-ID: 0000010936 - 001
Engine coolant R liters 110 110 110 110 120 120

capacity, engine
side (without
cooling equip-
ment)
Charge-air cool- R liters - - - - - -
ant, engine side

Number of cylin- 16 16 16 16 18 18
ders
Total engine oil R liters 102 102 102 102 130 130
capacity at initial
filling (standard
oil system) (Op-
tion: max. operat-
ing inclinations)
Oil change ca- R liters N N N N N N
pacity, max.
(standard oil sys-
tem)
Oil change quanti- R liters 99 99 99 99 114 114
ty, max. (standard
oil system) (Op-
tion: max. operat-
ing inclinations)
Oil pan capacity L liters 69 69 69 69 87 87
at dipstick mark
"min." (standard
oil system) (Op-
tion: max. operat-
ing inclinations)
Oil pan capacity L liters 92 88 92 88 110 110
at dipstick mark
"max." (standard
oil system) (Op-
tion: max. operat-
ing inclinations)

Number of cylin- 16 16 16 16 18 18
ders
Engine weight, R kg 3100 3150 3100 3150 3500 3500
dry (basic engine
configuration acc.
to scope of supply
specification)
ACOUSTICS
Number of cylin- 16 16 16 16 18 18
ders
Exhaust noise, un- R dB(A) 122 128 123 128 124 129
TIM-ID: 0000010936 - 001
silenced - DL
(sound power lev-
el LW, ISO 6798)
Engine surface R dB(A) 120 121 121 122 122 123
noise with attenu-
ated intake noise
filter) - DL (sound
power level LW,
ISO 6798)

3.5 12/16/18V 2000 Gx5-TB engine data, optimized exhaust
emission
Explanation:
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable
G45-TB G85-TB G45-TB G85-TB G85-TB
Charge-air coolant tempera- °C 45 45 45 45 55
ture
Raw water inlet temperature °C - - - - -
8528)

ter)
TIM-ID: 0000010949 - 001


cooling (CAC)

fuel injection
water
gle
Bore mm 130 130 130 130 130
Stroke mm 150 150 150 150 150
der
ble
Flywheel interface DISC 18" 18" 18" 18" 18"

cylinder - DL

cooling equipment)
TIM-ID: 0000010949 - 001

gine, alarm
gine, shutdown
max.

COOLANT SYSTEM (LT circuit)
Coolant temperature before A °C 45 45 45 45 45
intercooler (at engine inlet
from cooling equipment)
max.
LUBE-OIL SYSTEM
engine, alarm
Lube-oil temperature before L °C - - - - -
engine, shutdown
before engine, from
before engine, to
gine, alarm
gine, shutdown
FUEL SYSTEM
engine is starting)
engine is starting)

TIM-ID: 0000010949 - 001

CAPACITIES
equipment)
Charge-air coolant, engine R liters 20 20 20 20 20
side
inclinations)
inclinations)
inclinations)

ACOUSTICS
ISO 6798)
ISO 6798)
TIM-ID: 0000010949 - 001

3.6 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 - 001

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

12V 2000 Gxy approx. 1885 mm approx. 1580 mm approx. 1585 mm
TIM-ID: 0000010030 - 002

4 Operation
4.1 Putting the engine into operation after extended out-of-service
periods (>3 months)
Preconditions
☑Engine is stopped and starting disabled.
☑MTU Fluids and Lubricants Specifications (A001061/..) are available.
Putting the engine into operation after extended out-of-service-periods (>3

months)
Item Task
Engine Depreserve (→ MTU Fluids and Lubricants Specifications A001061/..).
Lube oil system Check engine oil level (→ Page 123);
Fuel prefilter Prime (→ Page 113).
Fuel prefilter, pressure Align adjustable pointer with position of pressure indicator (→ Page 111).
gauge
Fuel system Vent (→ Page 108).
Cooling system If engine is out of service for more than one year, change engine coolant
(→ Page 127);
Change charge-air coolant (→ Page 135).
Cooling system Check engine coolant level (→ Page 126);
Check charge-air coolant level (→ Page 136).
Cooling system Preheat coolant with preheating unit.
Engine Governor Check plug-in connections (→ Page 147).
Monitoring equipment 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 - 001
44 | Operation | MS15019/02E 2013-01

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 123);
Cooling system Check engine coolant level (→ Page 126);
Check charge-air coolant level (→ Page 136).
Cooling system Preheat coolant with preheating unit.
Fuel prefilter Drain (→ Page 112).
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
MS15019/02E 2013-01 | Operation | 45

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

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

reach operating temperature
Item Action
Switchgear cabinet, control Close the generator circuit breaker.
panel etc. (depending on
manufacturer)
TIM-ID: 0000002226 - 003
Engine Apply full load only after engine has reached operating temperature (coolant
temperature approx. 75 °C).
46 | Operation | MS15019/02E 2013-01

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

Item Action
Switchgear cabinet, control Activate pushbutton for Override input of the ECU.
panel etc. (depending on • Certain shutdown criteria and/or starting prerequisites are ignored.
manufacturer)
Switchgear cabinet, control Actuate start button, for further starting sequence, refer to engine start
panel etc. (depending on (→ Page 46).
manufacturer)
Control and display panels During operation, check the displayed operational data (speed, temperature,
pressures).
Constantly monitor plant limit values.
TIM-ID: 0000000984 - 002
MS15019/02E 2013-01 | Operation | 47

4.5 Operational checks
DANGER
• Take special care when working on a running engine.
WARNING
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 111).
Exhaust system Check exhaust color (→ Page 78).
Intercooler Check condensate drain(s) for water discharge and obstruction
(→ Page 118).
Air filter Check signal ring position of service indicator (→ Page 121).
Replace air filter (→ Page 119), if the signal ring is completely visible in the
red area of the service indicator control window.
Coolant pump Check relief bore (→ Page 131).
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
48 | Operation | MS15019/02E 2013-01

4.6 Stopping the engine in manual mode (test run)
Preconditions
☑Generator (if fitted) is not connected to network.
☑Engine is running in manual mode.
CAUTION
Stopping the engine when it is running at full load causes extreme stress to the engine.
Risk of overheating, damage to components!
• Before stopping the engine, operate it at idle speed until operating temperatures decrease and
stable values are indicated.
Preparing a generator drive (only if generator circuit breaker is provided)

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

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

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

Item Action
Coolant circulation pump Operate pump for a sufficient period of time after the engine was stopped.
TIM-ID: 0000002285 - 002
MS15019/02E 2013-01 | Operation | 49

4.7 Emergency stop
CAUTION
An emergency stop causes extreme stress to the engine.
Risk of overheating, damage to components!
• Initiate emergency stop only in emergency situations.
Emergency stop from LOP

Item Task
EMERGENCY STOP button Press.
• Engine is stopped by switching off power supply to ECU;
• Signalization (e.g. by horn, flashing lamp) is released.
After emergency stop from LOP

Item Task
Switching cabinet, control Press button for alarm acknowledgement.
panel etc. (depending on • Audible and visual signalization stops.
manufacturer)
TIM-ID: 0000002305 - 002
50 | Operation | MS15019/02E 2013-01

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
MS15019/02E 2013-01 | Operation | 51

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 128);
Drain charge-air coolant (→ Page 134) if:
• freezing temperatures are to be expected and the engine is to remain out
of service for an extended period and if no antifreeze has been added to
the coolant;
• the engine room is not heated;
• the coolant is not kept at a suitable temperature;
• the antifreeze concentration is insufficient for the engine-room tempera-
ture;
• antifreeze concentration is 50 % and engine-room temperature is below
-40 °C.
Engine/generator/pump Switch off.
control
Air intake and exhaust sys- If the engine is to remain out of service for more than 1 week, seal the en-
tem gine's air and exhaust sides. If the engine is to remain out of service for more
than 1 month, carry out preservation (→ Preservation and Represervation
Specifications A001070/..).
TIM-ID: 0000002706 - 003
52 | Operation | MS15019/02E 2013-01

5 Maintenance
5.1 Maintenance task reference table [QL1]
The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The
Maintenance Schedule is a stand-alone publication.
The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance
Schedule.
Task Option Maintenance tasks
W0500 Check engine oil level. (→ Page 48)
W0501 Visually inspect engine for leaks and general condition. (→ Page 48)
W0502 X Check intercooler drain(s). (→ Page 48)
W0503 Check signal ring position of service indicator on air filter. (→ Page 48)
W0505 Check relief bores of coolant pump(s). (→ Page 48)
W0506 Check engine for abnormal running noises, exhaust color and (→ Page 48)
vibrations.
W0507 X Drain water and contaminants from fuel prefilter. (→ Page 48)
W0508 X Check reading on differential pressure gage of fuel prefilter. (→ Page 48)
W0534 Carry out test run, minimum duration: until steady-state tem- (→ Page 83)
perature is reached, no less than 1/3 load (monthly).
W1001 Replace fuel filter or fuel filter element. (→ Page 110)
W1002 Check valve clearance. (→ Page 91)
W1003 Check belt condition and tension, replace if necessary. (→ Page 137)
W1005 Replace air filter. (→ Page 119)
W1006 Replace fuel injectors. (→ Page 99)
W1007 Replace fuel injection pump(s). (→ Page 95)
W1008 Replace engine oil filter when changing engine oil, or when (→ Page 125)
the interval (years) is reached, at the latest.
W1010 Coolant cooler: Check exterior of cooler elements for dirt. -
W1011 Perform endoscopic examination. (→ Page 84)
W1178 Replace pressure pipe neck in cylinder head. (→ Page 104)
Table 1: Maintenance task reference table [QL1]

TIM-ID: 0000034855 - 002
MS15019/02E 2013-01 | Maintenance | 53

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 - 002
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 (↓ ↑).
54 | Troubleshooting | MS15019/02E 2013-01

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

TIM-ID: 0000008508 - 002
Yellow alarm:
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.
MS15019/02E 2013-01 | Troubleshooting | 55

Fault and alarm messages
The fault code numbers are generated by the engine governor and transmitted to the display below.
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-
TIM-ID: 0000008508 - 002
ter, see PR 2.8008.100 for ed.

explanation).
004 SS T-Fuel Main warning: Fuel tempera- Check tank temper- 2.0122932
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
TIM-ID: 0000008508 - 002
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
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
TIM-ID: 0000008508 - 002
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.
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-
TIM-ID: 0000008508 - 002
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.
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).
TIM-ID: 0000008508 - 002
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).
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 - 002

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 - 002

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 - 002
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 necessa-
pulse not available, short cir- ry.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 - 002

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 - 002

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 - 002
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 - 002

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 - 002

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 - 002

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 - 002

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 - 002

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 - 002

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 - 002


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 - 002
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 - 002
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 - 002
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-
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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 145).
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 147).
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 108).
Engine Governor Defective Contact Service.
Engine fires unevenly

Fuel injection equip- Injector defective Replace (→ Page 99).
ment Injection pump defective Replace (→ Page 96).
Engine does not reach nominal speed

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Fuel supply Fuel prefilter clogged Replace (→ Page 116).

Easy-change fuel filter clogged Replace (→ Page 110).
Air supply Air filter clogged Check signal ring position of service in-
dicator (→ Page 121).
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

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Engine oil Too much oil in engine Drain engine oil (→ Page 124).
Oil separator of crankcase breather con- Replace (→ Page 88).
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 112).
Intercooler Leaking Contact Service.
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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 barring or starting the engine, ensure that nobody is in the danger zone.
• After working on the engine, check that all protective devices have been reinstalled and all tools
removed from the engine.
Barring the engine 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 abnormal re-
sistance.
Result: If the resistance exceeds the normal com-
pression resistance, contact Service.
4. For barring device removal, follow reverse
sequence of working steps.
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MS15019/02E 2013-01 | Task Description | 81

7.1.2 Engine – Barring with starting system
Preconditions
☑External pushbutton “Bar engine without starting” is provided.
DANGER
• Before barring or starting the engine, ensure that nobody is in the danger zone.
• After working on the engine, check that all protective devices have been reinstalled and all tools
removed from the engine.
Engine – Barring with starting system

1. 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.
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82 | Task Description | MS15019/02E 2013-01

7.1.3 Engine – Test run
DANGER
WARNING
Engine – Test run

1. Start engine (→ Page 46).
2. Perform test run not below 1/3 load and at least until steady-state temperature is reached.
3. Carry out operational checks (→ Page 48).
4. Stop engine (→ Page 49).
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7.2 Cylinder Liner
7.2.1 Cylinder liner – Endoscopic examination
Preconditions

Rigid endoscope Y20097353 1
Preparatory steps
1. Remove cylinder head cover (→ Page 94).
2. Remove injector (→ Page 100).
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 do tion required as part of mainte-
not cover the entire stroke area nance work
• Dark areas in the upper section of the cooling bore, remaining circum-
ference 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 top Service must be contacted
piston ring
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• Heat discoloration in the direction of stroke and honing pattern dam-

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

2. Use technical terms for description of the liner surface (→ Page 86).
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 100).
2. Install cylinder head cover (→ Page 94).
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7.2.2 Instructions and comments on endoscopic and visual examination of cylinder
liners
Terms used for endoscopic examination
Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic ex-
amination report.
Findings Action
Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing products,
particles, broken-off burrs). Removed cylinders clearly show such scoring on the
running surface under endoscope magnification. Cannot be felt with the fingernail.
Findings not critical.
Single scores Clearly visible scores caused by hard particles. They usually start in the TDC area
and cross through the hone pattern in the direction of stroke.
Scored area These areas consist of scores of different length and depth next to one another. In
most cases, they are found at the 6-o'clock and 12-o'clock positions (inlet/
exhaust) along the transverse engine axis.
Smoothened area Smoothened areas are on the running surface but almost the whole honing pattern
is still visible. Smoothened areas appear brighter and more brilliant than the sur-
rounding running surface.
Bright area Bright areas are on the running surface and show local removal of the honing pat-
tern. Grooves from honing process are not visible any more.
Discoloration This is caused by oxidation (surface discoloration through oil or fuel) and tempera-
ture differences around the liner. It appears rather darker within the honed struc-
ture in contrast to the bright metallic running surface. The honing pattern is undis-
turbed. Discolorations extend in stroke direction and may be interrupted.
Corrosion fields / Corrosion fields / spots result from water (condensed water) with the valves in the
spots overlap (open) position. They are clearly visible due to the dark color of the honing
groove bottom.
This corrosion is not critical unless there is corrosion pitting.
Black lines Black lines are a step towards heat discoloration. They are visible as a clear discol-
oration from TDC to BDC in the running surface and the start of localized damage
to the honing pattern.
Cylinder liners with a large number of black lines around the running surface have
limited service life and should be replaced.
Burn mark This is caused by a malfunction in the liner / ring tribosystem. Usually they run
over the whole ring-travel area (TDC/BDC), starting at the first TDC-ring and be-
coming more visible from the second TDC-ring 2 onwards and less pronounced
from TDC-ring 1. The honing pattern is usually no longer visible and displays a
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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.
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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.
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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.
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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
Risk of injury!
• Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
CAUTION
Excessive reaction time of cleaning agents on components.
Damage to component!
• 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 residual parts with cleaner.
8. Remove cleaner.
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
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(wire mesh) (3) into the oil separator cover

(7), ensuring correct installation sequence.
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 81).
3. Bar engine with barring device in engine di-
rection of rotation until TDC pointer and
TDC mark on the flywheel are aligned.
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Checking valve clearance at two
crankshaft positions
1. Check TDC position of piston in cylinder
A1:
• If the rocker arms are unloaded on cylin-
der A1, the piston is in firing TDC.
• If the rocker arms are under load on cyl-
inder A1, the piston is in overlap TDC.
2. Check valve clearance with cold engine:
• Inlet = 0.4 mm;
• Exhaust = 0.6 mm;
3. Check all valve clearances in two crank-
shaft 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.
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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 81).
3. Install end cover.
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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 with gasket
from cylinder head.
2. Clean installation surface.
3. Check condition of gasket in cylinder head
cover.
4. Replace damaged gasket(s).
5. Install cylinder head cover with screws.
Final steps
1. Slide rubber sleeves onto the relevant pipe connection.
2. Tighten all clamps.
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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 96).
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7.5.2 Injection pump – Removal and installation
Preconditions

Ratchet F30027340 1
Adapter F30006234 1
Crowfoot wrench, 19 mm F30027424 1
Torque wrench, 0.5-5 Nm 0015384230 1
Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 1
Engine oil
Seal (→ Spare Parts Catalog)
DANGER
Risk of serious injury – Danger to life!
• Before barring the engine, ensure that nobody is in the danger zone.
WARNING
• Do not smoke.
Preparatory steps
1. Shut off fuel supply line before fuel filter.
2. Drain fuel (→ Page 106).
3. Remove engine governor, if required (→ Page 148).
4. Remove charge-air manifolds and take off seals (only on engines with air-to-air charge-air cooling).
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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 pretensioned compression spring
presses the injection pump out of the
crankcase; if not:
• Turn crankshaft using barring device
(→ Page 81).The pump cam of the cam-
shaft presses the injection 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. Seal all openings with appropriate covers
after removal.
Installing injection pump

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 81), set pump
cam on camshaft to base circle.
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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
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1. Remove barring device (→ Page 81).

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 manifolds.
6. Install engine governor (→ Page 148).
7. Open fuel supply line.
8. Vent fuel system (→ Page 108)

7.6 Injection Valve / Injector
7.6.1 Injector – Replacement
Injector (→ Spare Parts Catalog)
Replacing injector
u Remove injector and install new injector (→ Page 100).
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7.6.2 Injector – Removal and installation
Preconditions

Impact extractor F30377999 1
Fuel suction device F30378207 1
Ratchet F30027340 1
Adapter F30006234 1
Socket wrench, 19 mm F30025897 1
Double box wrench F30011450 1
Engine oil
WARNING
• Do not smoke.
WARNING
Compressed air
Risk of injury!
Preparatory steps
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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. Seal all openings with appropriate covers
after removal.
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Installing injector
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.
Result: • The pin is at 11-o'clock position to the
transversal axis of the engine.
• The pin is engaged in the groove of the
clamp (4).
6. Install clamp (4) with screw (5), positioning
it correctly.
Result: • The pin is engaged in the groove of 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 rotated.
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
the 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.
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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.
16. Connect fuel line (2).

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

Ratchet F30027340 1
Adapter F30006234 1
Socket wrench, 19 mm F30025897 1
Double box wrench F30011450 1
Engine oil
Pressure pipe neck (→ Spare Parts Catalog)
WARNING
• Do not smoke.
WARNING
Compressed air
Risk of injury!
Preparatory steps
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Replacing pressure pipe neck
2. Blow out fuel line (2) with compressed air.
3. Remove thrust screw (4).
4. Pull off 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
the 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
10. Connect fuel line (2).
tightening torque.
tightening torque.
Final steps
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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.
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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.
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7.7.3 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.
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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.
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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. Install and tighten new filter by hand.
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7.8.2 Fuel prefilter – Differential pressure gauge check and adjustment
DANGER
WARNING
Adjusting differential pressure

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

1. With the engine running at full load or rated power, read off pressure at gauge (1).
2. If differential pressure as indicated between position of adjustable pointer (2) and pressure-indicating
pointer (3) of pressure gauge is ≥ 0.3 bar, flush filter element of the cut-in filter (→ Page 113).
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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.
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8. Place new gasket in cover (2).

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

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

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

1. Stop engine (→ Page 49) and disable engine start.
2. Remove screws for cover and take off cover (2).
5. Fit cover with gasket and secure it with screws.
6. Check differential pressure (→ Page 111).
Result: If flushing did not lead to an improvement of the differential pressure, replace filter element of fuel pre-
filter (→ Page 116).
TIM-ID: 0000004937 - 016

7.8.5 Fuel prefilter cleaning
Preconditions

Diesel fuel
WARNING
• Do not smoke.
Fuel prefilter cleaning

1. Shut off fuel supply.
2. Remove nuts from filter head.
3. Take off filter housing and drain fuel into
appropriate container.
4. Remove filter-element securing nut and re-
move filter element by pulling it down-
wards.
5. Wash filter element in clean fuel using a
smooth brush.
6. Wash filter housing with clean fuel.
7. Insert filter element into filter housing and
secure with nut.
8. Place new sealing ring into groove in filter
head.
9. Fit cover with seal and secure it with nuts
crosswise.
10. Open fuel supply.
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7.8.6 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 111).
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7.9 Charge-Air Cooling General, Left-Hand Side
7.9.1 Intercooler – Checking condensate drains for coolant discharge and
obstructions
Preconditions

WARNING
Compressed air
Risk of injury!
Intercooler – Checking condensate drains for coolant discharge and obstruc-

tions
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 intercooler. 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 100).
2. Bar the engine manually (→ Page 81).
3. Bar the engine with the starting system to blow out cylinder chambers (→ Page 82).
4. Install injectors (→ Page 100).
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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 120).
2. Reset signal ring of service indicator (→ Page 121).
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7.10.2 Air filter – Removal and installation
Preconditions
Variant A
1. Release clamp (2).
2. Remove air filter (3) and clamp (2) from
flange of intake housing (1).
3. Verify that there are no objects in the
flange of the intake housing (1) and clean
it.
4. Place new air filter (3) with clamp (2) onto
intake housing (1).
5. Tighten clamp (2).
Variant B
1. Release latches (1).
2. Remove 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.
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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 119).
2. After installation of new filter, press reset
button (1).
Result: Signal ring returns to initial position.
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7.12 Starting Equipment
7.12.1 Air starter – Manual operation
DANGER
WARNING
Air starter – Manual operation

1. Press pushbutton for manual start and hold
it.
2. Allow compressed air to enter the air start-
er, until the engine fires evenly.
3. Release pushbutton.
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7.13 Lube Oil System, Lube Oil Circuit
7.13.1 Engine oil – Level check
Preconditions
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." and
"max." marks.
4. Top up to "max." if required (→ Page 124).
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 124).
5. Insert oil dipstick into guide tube up to the stop.
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7.13.2 Engine oil – Change
Preconditions
☑Engine is at operating temperature.

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 125).
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 125).
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 123).
5. After oil change and filter replacement, bar
engine with starting system (→ Page 82).
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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 using the filter wrench.
2. Clean the sealing face of the filter head.
3. Check condition of the new oil filter sealing
ring and coat it with oil.
4. Install and tighten new oil filter by hand.
5. Replace further oil filters in the same way.
6. After each oil change and filter replace-
ment, bar engine with starting system
(→ Page 82).
7. Check oil level (→ Page 123).
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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 129).
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 129).
TIM-ID: 0000000037 - 004

7.15.2 Engine coolant – Change
Coolant
Engine coolant – Change

1. Drain engine coolant (→ Page 128).
2. Fill with engine coolant (→ Page 129).
TIM-ID: 0000000036 - 030

7.15.3 Engine coolant – Draining
Preconditions

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

1. Turn breather valve of filler neck on coolant
expansion tank counterclockwise to the
first stop and allow pressure to escape.
3. Draw off segregated corrosion inhibitor oil
in expansion tank through the filler neck.
4. Open drain valves and 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 - 002

7.15.4 Engine coolant – Filling
Preconditions

Coolant
WARNING
WARNING
CAUTION
Cold coolant in hot engine can cause thermal stress.
Formation of cracks in components!
• Fill / top up coolant only into cold engine.
Preparatory steps
TIM-ID: 0000000034 - 005
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 126), top up with coolant if required.
TIM-ID: 0000000034 - 005

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

check
1. Check relief bore for oil and water 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 49) and disable
engine start.
b) Clean relief bore with a wire.
c) Start the engine (→ Page 46) and oper-
ate it at idle speed for some minutes.
d) Check relief bore again for oil and cool-
ant discharge.
TIM-ID: 0000000038 - 001

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

Coolant
WARNING
WARNING
CAUTION
Cold coolant in hot engine can cause thermal stress.
Formation of cracks in components!
• Fill / top up coolant only into cold engine.
Preparatory steps
3. Remove plug screw from filling point on
coolant line to intercooler.
TIM-ID: 0000000039 - 003

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 136).
TIM-ID: 0000000039 - 003

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 - 002

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

1. Drain charge-air coolant (→ Page 134).
2. Fill with charge-air coolant (→ Page 132).
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 132).
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 132).
TIM-ID: 0000000042 - 007

7.17 Battery-Charging Generator
7.17.1 Battery-charging generator drive – Drive-belt check and adjustment
Preconditions

Belt-tension tester 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 139):
• 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. Place belt-tension tester onto drive belt
midway between the belt pulleys.
3. Press button uniformly down on drive-belt
surface until spring disengagement can be
heard and felt.
4. Do not press any further, otherwise the
reading is not exact.
TIM-ID: 0000000043 - 002
5. Take off belt-tension tester without chang-

ing the position of the indication arm.
6. Read off measuring value at the intersec-
tion of indication 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 and 3).
2. Tension drive belt with tensioning nut (1)
and check belt tension.
3. Tighten screw (2) with torque wrench to the specified tightening torque.
Screw M12 Tightening torque (Engine oil) 40 Nm +4 Nm
4. Tighten screw (3).
5. Check drive belt tension.
TIM-ID: 0000000043 - 002

7.17.2 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 143).
3. Release securing screws (2 and 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 137).
8. Tighten securing screw (2) with torque wrench to the specified tightening torque.
Screw M12 Tightening torque (Engine oil) 40 Nm + 4 Nm
9. Tighten securing screw (3).
10. Install drive belt for fan drive (→ Page 143).
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7.18 Fan Drive
7.18.1 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 143):
• 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
heard and felt.
5. Read off measured value at the intersec-
tion of indication arm and “KG” scale.
TIM-ID: 0000000045 - 002
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
heard and felt.
5. Read off measured value at the intersec-
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. Loosen screws (3).
2. Release locknut (2).
3. Screw in screw (1) to tension drive belt.
4. Tighten locknut (2).
6. Tighten screw (3) with torque wrench to the specified tightening torque.
TIM-ID: 0000000045 - 002

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 - 002

7.18.2 Fan drive – Drive belt replacement
Preconditions

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

iant A
1. Loosen securing screws (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 140).
Drive belt replacement, var-

iant B
1. Release securing screws (1 and 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
grooves as a set and without applying any
TIM-ID: 0000000046 - 002
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 140).

Final steps
1. Install fan.
TIM-ID: 0000000046 - 002

7.19 Wiring (General) for Engine/Gearbox/Unit
7.19.1 Engine wiring – Check
Preconditions

Isopropyl alcohol X00058037 1
Engine wiring – Check

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

7.20 Accessories for (Electronic) Engine Governor / Control System
7.20.1 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 with isopropyl alcohol.
2. Remove dirt from connector and cable surfaces with isopropyl alcohol.
3. Check legibility of cable labels. Clean or replace illegible labels.
Cleaning severely contaminated connectors on the engine governor

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

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

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

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

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

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

8 Appendix A
8.1 Abbreviations
Abbrevia- Meaning Explanation
tion
ADEC Advanced Diesel Engine Control Engine governor
AL Alarm Alarm (general)
ANSI American National Standards Institute Association of American standardization organiza-
tions
ATL Abgasturbolader Exhaust turbocharger (ETC)
BR Baureihe Series
BV Betriebsstoffvorschrift MTU Fluids and Lubricants Specifications, Publication
No. A01061/..
CAN Controller Area Network Data bus system, bus standard
CCG Cross Connection Gear Transfer gearbox
CODAG Combined Diesel (engine) And Gas (tur-
bine propulsion)
CPP Controllable Pitch Propeller
DAG Diesel (engine) And Gas (turbine)
DE Diesel Engine
DIN Deutsches Institut für Normung e. V. At the same time identifier of German standards (DIN
= “Deutsche Industrie-Norm”)
DIS Display unit
DL Default Lost Alarm: CAN bus missing
ECS Engine Control System
ECS-UNI Engine Control System UNIversal
ECU Engine Control Unit Engine governor
EDM Engine Data Module
EMU Engine Monitoring Unit
ETK Ersatzteilkatalog Spare Parts Catalog (SPC)
FPP Fixed Pitch Propeller
GCU Gear Control Unit
GMU Gear Monitoring Unit
GT Gas Turbine
HAT Harbor Acceptance Test
TIM-ID: 0000002049 - 005
HI High Alarm: Measured value exceeds 1st maximum limit

HIHI High High Alarm: Measured value exceeds 2nd maximum limit
value
HT High Temperature
ICFN ISO – Continuous rating – Fuel stop Power specification in accordance with DIN-ISO
power – Net 3046-7
IDM Interface Data Module
IMO International Maritime Organization
MS15019/02E 2013-01 | Appendix A | 149

tion
ISO International Organization for Stand- International umbrella organization for all national
ardization standardization institutes
KGS Kraftgegenseite Engine free end in accordance with DIN ISO 1204
KS Kraftseite Engine driving end in accordance with DIN ISO 1204
LCD Liquid Crystal Display, Liquid Crystal
Device
LCU Local Control Unit LOP subassembly
LED Light Emitting Diode
LMU Local Monitoring Unit LOP subassembly
LO Low Alarm: Measured value lower than 1st minimum limit
value
LOLO Low Low Alarm: Measured value lower than 2nd minimum limit
value
LOP Local Operating Panel Control console, control panel
LOS Local Operating Station
MCS Monitoring and Control System
MG Message
MPU Microprocessor Unit, Microprocessing
Unit
MRG Main Reduction Gear
OT Oberer Totpunkt Top Dead Center (TDC)
P-xyz Pressure-xyz Pressure measuring point xyz
PAN Panel Control panel
PCU Propeller Control Unit
PIM Peripheral Interface Module
PT Power Turbine
RCS Remote Control System
RL Redundancy Lost Alarm: Redundant CAN bus missing
SAE Society of Automotive Engineers U.S. standardization organization
SAT Sea Acceptance Test
SD Sensor Defect Alarm: Sensor failure
SDAF Shut Down Air Flaps Emergency-air shutoff flap(s)
SOLAS International Convention for the Safety
of Life at Sea
SS Safety System Safety system alarm
TIM-ID: 0000002049 - 005
SSK Schnellschlussklappe(n) Emergency air shut-off flaps

SSS Synchronized Self-Shifting (clutch)
STBD Starboard
T-xyz Temperature-xyz Temperature measuring point xyz
TD Transmitter Deviation Alarm: Deviation in transmitter values
UT Unterer Totpunkt Bottom Dead Center (BDC)
VS Voith Schneider Voith Schneider drive
WJ Water jet Water jet drive
150 | Appendix A | MS15019/02E 2013-01

tion
WZK Werkzeugkatalog Tool Catalog (TC)
ZKP Zugehörigkeit-Kategorie-Parameter Assignment category parameter; number scheme for
signals from the ADEC engine governor
TIM-ID: 0000002049 - 005
MS15019/02E 2013-01 | Appendix A | 151

8.2 MTU contact persons/service partners
Our worldwide sales network with its subsidiaries, sales offices, representatives and customer service
centers ensures fast and direct support on site and the high availability of our products.
Local support
Experienced and qualified specialists place their knowledge and expertise at your disposal.
For locally available support, go to the MTU Internet site: http://www.mtu-online.com
24h hotline
With our 24h hotline and the outstanding flexibility of our service staff, we are always ready to assist
you – either during operation, for preventive maintenance, corrective work in case of malfunction or
changed operating conditions, or for spare parts supply.
Your contact at Headquarters: Service-support@mtu-online.com
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
Phone: +49 7541 908555
Fax: +49 7541 908121
TIM-ID: 0000000873 - 014
152 | Appendix A | MS15019/02E 2013-01

9 Appendix B
9.1 Special Tools
Adapter
Part No.: F30006234
Qty.: 1
Used in: 7.5.2 Injection pump – Removal and installation
(→ Page 96)
Qty.: 1
Used in: 7.6.2 Injector – Removal and installation (→ Page 100)
Qty.: 1
Used in: 7.7.1 Fuel injection line – Pressure pipe neck replace-
ment (→ Page 104)
Barring device for 12V engines

Part No.: F6558556
Qty.: 1
Used in: 7.1.1 Engine – Barring manually (→ Page 81)
Barring device for 16V, 18V engines

Part No.: F6558557
Qty.: 1
Used in: 7.1.1 Engine – Barring manually (→ Page 81)
DCL-ID: 0000014859 - 003
MS15019/02E 2013-01 | Appendix B | 153

Belt tension tester
Part No.: 5505890119/00
Qty.: 1
Used in: 7.18.1 Fan drive – Drive-belt check and adjustment
(→ Page 140)
Belt-tension tester
Part No.: Y20097429
Qty.: 1
Used in: 7.17.1 Battery-charging generator drive – Drive-belt
check and adjustment (→ Page 137)
Box wrench, 17 mm
Part No.: F30028341
Qty.: 1
Used in: 7.7.2 Fuel – Draining (→ Page 106)
Crowfoot wrench, 19 mm
Part No.: F30027424
Qty.: 1
(→ Page 96)
Qty.: 1
DCL-ID: 0000014859 - 003

Qty.: 1
ment (→ Page 104)
154 | Appendix B | MS15019/02E 2013-01

Crowfoot wrench, 22 mm
Part No.: F30027425
Qty.: 1
(→ Page 96)
Qty.: 1
Qty.: 1
ment (→ Page 104)
Double box wrench

Part No.: F30011450
Qty.: 1
Qty.: 1
ment (→ Page 104)
Feeler gauge
Part No.: Y4342013
Qty.: 1
Used in: 7.4.1 Valve clearance – Check and adjustment
(→ Page 91)
Filter wrench
Part No.: F30379104
Qty.: 1
Used in: 7.8.1 Fuel filter – Replacement (→ Page 110)
Qty.: 1
Used in: 7.14.1 Engine oil filter – Replacement (→ Page 125)
DCL-ID: 0000014859 - 003
MS15019/02E 2013-01 | Appendix B | 155

Fuel suction device
Part No.: F30378207
Qty.: 1
Impact extractor
Part No.: F30377999
Qty.: 1
DCL-ID: 0000014859 - 003
156 | Appendix B | MS15019/02E 2013-01

Ratchet
Part No.: F30027340
Qty.: 1
Used in: 7.3.1 Crankcase breather – Oil separator element re-
placement, diaphragm check and replacement
(→ Page 88)
Qty.: 1
(→ Page 91)
Qty.: 1
Used in: 7.4.2 Cylinder head cover – Removal and installation
(→ Page 94)
Qty.: 1
(→ Page 96)
Qty.: 1
Qty.: 1
ment (→ Page 104)
Qty.: 1
Qty.: 1
Used in: 7.17.2 Battery-charging generator drive – Drive belt re-
placement (→ Page 139)
Qty.: 1
(→ Page 140)
Rigid endoscope
Part No.: Y20097353
Qty.: 1
Used in: 7.2.1 Cylinder liner – Endoscopic examination
(→ Page 84)
DCL-ID: 0000014859 - 003
MS15019/02E 2013-01 | Appendix B | 157

Socket wrench, 19 mm
Part No.: F30025897
Qty.: 1
Qty.: 1
ment (→ Page 104)
Torque wrench, 0.5-5 Nm

Part No.: 0015384230
Qty.: 1
(→ Page 96)
Torque wrench, 20-100 Nm

Part No.: F30026582
Qty.: 1
(→ Page 91)
Qty.: 1
(→ Page 96)
Qty.: 1
Qty.: 1
ment (→ Page 104)
Qty.: 1
Qty.: 1
Used in: 7.17.2 Battery-charging generator drive – Drive belt re-
DCL-ID: 0000014859 - 003
placement (→ Page 139)

Qty.: 1
(→ Page 140)
158 | Appendix B | MS15019/02E 2013-01

Part No.: F30027336
Qty.: 1
Used in: 7.3.1 Crankcase breather – Oil separator element re-
placement, diaphragm check and replacement
(→ Page 88)

Part No.: F30043446
Qty.: 1
Used in: 7.4.2 Cylinder head cover – Removal and installation
(→ Page 94)
Qty.: 1
Used in: 7.7.2 Fuel – Draining (→ Page 106)
DCL-ID: 0000014859 - 003
MS15019/02E 2013-01 | Appendix B | 159

9.2 Index
Numerics Cylinder liner
12/16/18 V 2000 Gx5 engine data, optimized fuel con- – Endoscopic examination 84
sumption 21 – Instructions and comments on endoscopic and visual
12/16/18 V 2000 Gx5-TB engine data, optimized fuel con- examination 86
sumption 25
E
12/16/18V 2000 Gx5-TB engine data, optimized exhaust
emission 38 ECU 7 engine governor
12V 2000 Gx5 engine data, optimized exhaust emission – Removal and installation 148
29 Emergency stop 50
16/18V 2000 Gx5 engine data, optimized exhaust emis- Engine
sion 33 – Barring manually 81
– Barring with starting system 82
A – Main dimensions 43
Abbreviations 149 – Overview 16
After stopping the engine – Starting in manual mode (test run) 46
– Engine remains ready for operation 51 – Stopping in manual mode (test run) 49
– Putting the engine out of operation 52 – Test run 83
Air filter – Wiring check 145
– Replacement 119 Engine coolant
Air filter – Removal and installation 120 – Change 127
Air starter – Draining 128
– Manual operation 122 – Filling 129
Engine coolant level
C – Check 126
Charge-air coolant Engine governor
– Change 135 – Cleaning 146
– Level check 136 – Plug connections
Charge-air coolant – Check 147
– Draining 134 Engine oil
– Filling 132 – Change 124
Charge-air coolant level Engine oil level
– Check 136 – Check 123
Connectors Engine side
– Cleaning 146 – Designation 15
Contact persons 152 Engine wiring
Coolant – Check 145
– Change 135
F
– Charge-air
– Draining 134 Fan drive
– Filling 132 – Drive belt replacement 143
– Filling 129 Fault indication on SAM display
Coolant level – Genset applications 54
– Check 126 Firing order 42
Coolant - charge air Fuel
– prefilter
DCL-ID: 0000014859 - 003
– Level check 136

Crankcase breather – Flushing 113
– Diaphragm check 88 Fuel prefilter
– Oil separator element replacement 88 – Differential pressure gauge
Crankcase breather – Wire mesh cleaning 90 – Check and adjustment 111
Cylinder – Draining 112
– Designation 15 – Filter element
Cylinder head cover – Replacement 116
– Removal and installation 94 – Flushing 113
Fuel prefilter cleaning 115
160 | Appendix B | MS15019/02E 2013-01

H V
Hotline 152 Valve clearance
– Adjustment 91
I – Check 91
Injection pump
– Removal and installation 96 W
– Replacement 95 Warning notices, standards 14
Injector Wiring - engine
– Replacement 99 – Check 145
Intercooler
– Condensate drains for coolant discharge
– Check 118
– Condensate drains for obstructions
– Check 118
M
Maintenance schedule
– Maintenance task reference table [QL1] 53
MTU contact persons 152
O
Operational checks 48
P
Putting the engine into operation after extended out-of-
service periods (>3 months) 44
Putting the engine into operation after scheduled out-of-
service-period 45
S
Safety regulation
– Environmental protection 12
Safety regulations
– Auxiliary materials 12
– Fire prevention 12
– Fluids and lubricants 12
– Important provisions 5
– Maintenance work 9
– Operation 8
– Organizational requirements 6
– Personnel requirements 6
– Repair work 9
– Startup 8
– Warning notices, standards 14
Safety system
– Override 47
SAM
DCL-ID: 0000014859 - 003
– Genset applications 54

Sensors, actuators and injectors
– Overview 17
Service partners 152
Spare parts service 152
T
Transport 7
Troubleshooting 78
MS15019/02E 2013-01 | Appendix B | 161

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7.8 Fuel Filter 110

MS15019/02E 2013-01 | Table of Contents | 3

DCL-ID: 0000014859 - 003

4 | Table of Contents | MS15019/02E 2013-01

MS15019/02E 2013-01 | Safety | 5

Working clothes and protective equipment

TIM-ID: 0000040531 - 001

6 | Safety | MS15019/02E 2013-01

Lift the engine only with the lifting eyes provided.

Setting the engine down after transport

MS15019/02E 2013-01 | Safety | 7

Safety regulations for equipment operation

Malfunctions and emergency stop

Operation of electrical equipment

8 | Safety | MS15019/02E 2013-01

Safety regulations during maintenance and repair work

MS15019/02E 2013-01 | Safety | 9

Safety regulations after completion of maintenance and repair work

Hydraulic installation and removal

Working with batteries

10 | Safety | MS15019/02E 2013-01

Working with laser equipment

MS15019/02E 2013-01 | Safety | 11

Environmental protection and disposal

Auxiliary materials, fluids and lubricants

12 | Safety | MS15019/02E 2013-01

Paints and lacquers

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

• Observe the relevant safety data sheet for all materials.

MS15019/02E 2013-01 | Safety | 13

TIM-ID: 0000040578 - 001

14 | Safety | MS15019/02E 2013-01

1 Left engine side 3 Right engine side

MS15019/02E 2013-01 | General Information | 15

Engine model designation

V Cylinder arrangement: V-engine

16 | General Information | MS15019/02E 2013-01

1 XF33 (H-engine coolant) 2 B01 (camshaft speed)

Illustration also applies to 12/16/18 V 2000 Gx5-TD

MS15019/02E 2013-01 | General Information | 17

Illustration also applies to 12/16/18 V 2000 Gx5-TD

TIM-ID: 0000022704 - 001

18 | General Information | MS15019/02E 2013-01

1 B10 (P-charge air)* 2 B09 (T-charge air) 3 B01 (camshaft speed)

Illustration also applies to 12/16/18 V 2000 Gx5-TB

MS15019/02E 2013-01 | General Information | 19

Illustration also applies to 12/16/18 V 2000 Gx5-TB

TIM-ID: 0000022704 - 001

20 | General Information | MS15019/02E 2013-01

GENERAL CONDITIONS (for maximum power)

Exhaust pressure A mbar 30 30 30 30 30

MODEL RELATED DATA (basic design)

MS15019/02E 2013-01 | Technical Data | 21

COMBUSTION AIR / EXHAUST GAS

COOLANT SYSTEM (HT circuit)

Coolant temperature after en- R °C 97 97 97 97 97

22 | Technical Data | MS15019/02E 2013-01

GENERAL OPERATING DATA