MS15054 - 00e Mtu

Operating Instructions
Diesel engine
12V2000Gx6x
16V2000Gx6x
MS15054/00E
Engine model kW/cyl. Application group
12V2000G16S 59.7 kW/cyl. 3B, continuous operation, variable load, ICXN
3F, mains backup mode, unlimited, ICXN
3G, continuous operation, time-limited, ICXN
12V2000G76S 74.2 kW/cyl. 3D, standby power, fuel stop power, IFN
3H, mains backup mode, special qualifications
3F, mains backup mode, unlimited, ICXN
3G, continuous operation, time-limited, ICXN
Table 1: Applicability
© 2015 Copyright MTU Friedrichshafen GmbH

This publication is protected by copyright and may not be used in any way, whether in whole or in part, without the prior writ-
ten consent of MTU Friedrichshafen GmbH. This particularly applies to its reproduction, distribution, editing, translation, micro-
filming and storage or processing in electronic systems including databases and online services.
All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen GmbH
reserves the right to change, delete or supplement the information provided as and when required.
Table of Contents
1 Safety 3.10 Engine data 12V/16V2000Gx6S, 3H,
standby operation mode, special
1.1 Important provisions for all products 5 qualifications, EPA Nonroad T2 (40CFR89)
1.2 Personnel and organizational requirements 7 and EPA Stationary EMERG T2 (40CFR60)
1.3 Transport 8 (provisional) 55
1.4 Safety regulations for startup and operation 9 3.11 Firing order 59
1.5 Safety precautions when working on the 3.12 Engine – Main dimensions 60
engine 10
1.6 Fire prevention and environmental
4 Operation
protection, fluids and lubricants, auxiliary
materials 13 4.1 Putting the engine into operation after
1.7 Standards for safety notices in the text 15 extended out-of-service periods (>3 months) 61
4.2 Putting the engine into operation after
2 General Information scheduled out-of-service-period 62
4.3 Starting the engine 63
2.1 Engine side and cylinder designations 16 4.4 Operational checks 64
2.2 Engine – Overview 17 4.5 Emission label – Check 65
2.3 Sensors and actuators – Overview 18 4.6 Engine shutdown 66
4.7 Emergency engine stop 67
3 Technical Data 4.8 After stopping the engine 68
3.1 Engine data 12V/16V2000Gx6S, 3B, 4.9 Plant – Cleaning 69
continuous operation, variable load, ICXN,
optimized fuel consumption (provisional) 22 5 Maintenance
3.2 Engine data 12V/16V2000Gx6S, 3D, 5.1 Maintenance task reference table [QL1] 70
standby current, fuel stop power (IFN),
optimized fuel consumption (provisional) 26
6 Troubleshooting
3.3 Engine data 12V/16V2000Gx6S, 3F,
standby operation mode, unlimited, ICXN, 6.1 Troubleshooting 71
optimized fuel consumption (provisional) 30 6.2 Engine Control Unit – ECU9 fault messages 74
3.4 Engine data 12V/16V2000Gx6S, 3G,
continuous operation, time-limited, ICXN, 7 Task Description
optimized fuel consumption (provisional) 33
3.5 Engine data 12V/16V2000Gx6S, 3H, 7.1 Engine 102
standby operation mode, special 7.1.1 Engine – Cranking manually 102
7.1.2 Engine – Barring with starting system 103
qualifications, optimized fuel consumption
(provisional) 36 7.2 Crankcase Breather 104
3.6 Engine data 12V/16V2000Gx6S, 3B, 7.2.1 Crankcase breather – Oil mist fine separator
continuous operation, variable load, ICXN, replacement 104
EPA Nonroad T2 (40CFR89) (provisional) 40 7.3 Valve Drive 105
3.7 Engine data 12V/16V2000Gx6S, 3D, 7.3.1 Valve clearance – Check and adjustment 105
standby current, fuel stop power (IFN), EPA
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7.3.2 Cylinder head cover – Removal and

Nonroad T2 (40CFR89) (provisional) 44 installation 108
3.8 Engine data 12V/16V2000Gx6S, 3F,
7.4 Injector 109
standby operation mode, unlimited, ICXN, 7.4.1 Injector ‒ Replacement 109
EPA Nonroad T2 (40CFR89) and EPA 7.4.2 Injector – Removal and installation 110
Stationary EMERG T2 (40CFR60) 7.4.3 Injector functions 116
(provisional) 48
3.9 Engine data 12V/16V2000Gx6S, 3G, 7.5 Fuel System 117
7.5.1 Fuel system – Venting 117
continuous operation, time-limited, ICXN,
7.5.2 Fuel – Draining 118
EPA Nonroad T2 (40CFR89) (provisional) 52
MS15054/00E 2015-09 | Table of Contents | 3

7.6 Fuel Filter 119 7.13.4 Charge-air coolant – Level check 146
7.6.1 Fuel filter – Replacement 119 7.13.5 Charge-air coolant pump – Relief bore check 147
7.6.2 Fuel prefilter – Draining 120 7.13.6 Intercooler – Checking condensate drain for
7.6.3 Fuel prefilter – Filter element replacement 121 coolant discharge and obstructions 148
7.6.4 Fuel prefilter – Venting 123
7.14 Belt Drive 149
7.7 Air Filter 124 7.14.1 Drive belt – Condition check 149
7.7.1 Air filter – Replacement 124 7.14.2 Drive belt – Tension check 150
7.7.2 Air filter – Removal and installation 125 7.14.3 Drive belt ‒ Tension adjustment 152
7.14.4 Drive belt – Replacement 153
7.8 Air Intake 126
7.8.1 Service indicator – Signal ring position check 126 7.15 Battery-Charging Generator 154
7.15.1 Battery-charger drive – Drive belt replacement 154
7.9 Starting Equipment 127
7.9.1 Electric starter ‒ Overview 127 7.16 Fuel Supply System 156
7.9.2 Starter – Removal 128 7.16.1 Differential pressure gage – Check 156
7.9.3 Starter ‒ Installation 129 7.16.2 Coolant level sensor – Check 157
7.16.3 Pump capacity – Check 158
7.10 Lube Oil System, Lube Oil Circuit 130
7.10.1 Engine oil – Level check 130 7.17 Engine Governor 159
7.10.2 Engine oil – Change 131 7.17.1 Engine control system – Overview 159
7.17.2 Engine governor – Removal and installation 160
7.11 Oil Filtration / Cooling 132 7.17.3 Engine governor plug connections – Check 161
7.11.1 Engine oil filter – Replacement 132
7.11.2 Centrifugal oil filter – Cleaning and filter- 7.18 Wiring (General) for Engine/Gearbox/Unit 162
sleeve replacement 133 7.18.1 Engine cabling – Check 162
7.12 Coolant Circuit, General, High-Temperature 7.19 Accessories for (Electronic) Engine
Circuit 135 Governor / Control System 163
7.12.1 Engine coolant – Level check 135 7.19.1 Engine governor and connector – Cleaning 163
7.12.2 Engine coolant – Change 136
7.12.3 Engine coolant – Draining 137
7.12.4 Engine coolant – Filling 138 8 Appendix A
7.12.5 Engine coolant pump – Relief bore check 140
8.1 List of abbreviations 164
7.12.6 Engine coolant – Sample extraction and
analysis 141
8.2 MTU contact persons/service partners 166
7.13 Low-Temperature Circuit 142 9 Appendix B

7.13.1 Charge-air coolant – Filling 142
7.13.2 Charge-air coolant – Draining 144 9.1 Special Tools 167
7.13.3 Charge-air coolant – Change 145 9.2 Index 175
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4 | Table of Contents | MS15054/00E 2015-09

1 Safety
1.1 Important provisions for all products
Nameplate
The product is identified by nameplate, model designation or serial number and must match with the infor-
mation on the title page of this manual.
Nameplate, model designation or serial number can be found on the product.
All EU-certified engines delivered by MTU come with a second nameplate. When operating the machine in the
EU: The second nameplate must be affixed in a prominent position as described in the accompanying specifi-
cations.
General information
This product may pose a risk of injury or damage in the following cases:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Modifications or conversions
• Noncompliance with the safety instructions and warning notices
Correct use
The product is intended for use in accordance with its contractually-defined purpose as described in the rele-
vant technical documents only.
Intended use entails operation:
• Within the permissible operating parameters in accordance with the (→ Technical data)
• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubricants
Specifications of the manufacturer)
• With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU con-
tact/Service partner)
• In the original as-delivered configuration or in a configuration approved by the manufacturer in writing (in-
cluding engine control/parameters)
• In compliance with all safety regulations and in adherence with all warning notices in this manual
• With maintenance work performed in accordance with the (→ Maintenance Schedule) throughout the use-
ful life of the product
• In compliance with the maintenance and repair instructions contained in this manual, in particular with
regard to the specified tightening torques
• With the exclusive use of technical personnel trained in commissioning, operation, maintenance and re-
pair
• By contracting only workshops authorized by the manufacturer to carry out repair and overhaul
The product may only be operated in explosive atmospheres if it was certified for such operating conditions.
Any other use, in particular malpractice, shall be considered non-intended. Such improper use increases the
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risk of injury and damage when working with the product. The manufacturer shall not be held liable for any
damage resulting from improper, non-intended use.
Modifications or conversions
Unauthorized changes to the product represent a contravention of its intended use and compromise safety.
Changes or modifications shall only be considered to comply with the intended use when expressly author-
ized by the manufacturer. The manufacturer shall not be held liable for any damage resulting from unauthor-
ized changes or modifications.
MS15054/00E 2015-09 | Safety | 5

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

Emission labels are attached to all MTU engines. These must remain on the engine throughout its operational
life.
Engines used exclusively in land-based, military applications other than by US government agencies are ex-
cepted from this proviso.
Please note the following when replacing components with emission labels:
• Appropriate emission labels must be affixed on spare parts.
• Emission labels may not be transferred from old components to new ones.
• Emission labels on old components must be removed and destroyed.
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6 | Safety | MS15054/00E 2015-09

1.2 Personnel and organizational requirements
Organizational measures of the user/manufacturer
This manual must be issued to all personnel involved in operation, maintenance, repair, or transportation.
Keep this manual handy in the vicinity of the product such that it is accessible to operating, maintenance,
repair, and transport personnel at all times.
Personnel must receive instruction on product handling and maintenance based on this manual with a spe-
cial emphasis on safety requirements and warnings.
This is important in the case of personnel who only occasionally perform work on or around the product.
These personnel must be instructed repeatedly.
Personnel requirements
All work on the product shall be carried out by trained and qualified personnel only:
• Training at the Training Center of the manufacturer
• Technical personnel from the areas mechanical engineering, plant construction, and electrical engineering
The operator must define the responsibilities of the personnel involved in operation, maintenance, repair, and
transport.
Personnel must not be under the influence of alcohol, drugs, or strong medication.
Working clothes and personal protective equipment

When working, always wear the necessary personal protective equipment (for example safety shoes, ear pro-
tectors, protective gloves, goggles, breathing protection). Observe the information on personal protective
equipment in the respective activity description.
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MS15054/00E 2015-09 | Safety | 7

1.3 Transport
DANGER
Suspended load
Danger to life
• Never stand under suspended loads!
• Wear appropriate personal protective equipment.
Transport
Install the crankshaft locking device and the locking screws for the engine mounts prior to engine transporta-
tion.
Only use the lifting eyes provided to transport the engine.
Use only suitable transport and lifting gear.
Take the engine's center of gravity into account.
Transport the engine only in installation position: max. permissible diagonal pull 10 degrees.
Remove any loose parts from the engine.
Lift/lower the engine slowly. Ensure that lifting cables/chains do not touch the engine or any of its compo-
nents. Readjust lifting tackle as necessary.
If the engine is supplied with special aluminum foil packing: Lift the engine at the lifting eyes of the bearing
pedestal or use a means of transportation which is appropriate for the given weight (forklift truck).
Install the crankshaft locking device and the locking screws for the engine mounts prior to engine transporta-
tion (if applicable).
Secure the engine against tilting during transport. In particular when going down inclines or ramps, the en-
gine must be secured against moving and tilting.
Setting down the engine following transportation

Only set down engine on a firm, level surface.
Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate.
Never set down engines onto the oil pan unless expressly permitted by MTU on an engine-specific base.
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8 | Safety | MS15054/00E 2015-09

1.4 Safety regulations for startup and operation
Safety regulations for startup
Install the product correctly and carry out acceptance in accordance with the manufacturer's specifications
before putting the product into service. All necessary approvals must be granted by the relevant authorities
and all requirements for initial startup must be fulfilled.
When putting the product into operation, always ensure that:
• All personnel is clear of the danger zone surrounding moving parts of the machine.
Electrically-actuated linkages may be set in motion when the Engine Control Unit (governor) is switched
on.
• All maintenance and repair work has been completed.
• All loose parts have been removed from rotating machine components.
• All safety equipment is in place.
• No persons wearing pacemakers or any other technical body aids are present.
• The service room is adequately ventilated.
• Hazardous gases may occur as a result of the combustion of paints or oils in the first operating hours of
the product. Enter the service room only with a suitable breathing protection.
• The exhaust system is leak-tight and that the gases are vented to atmosphere.
• Protect battery terminals, generator terminals or cables against accidental contact.
• Check that all connections have been correctly allocated (e.g. +/- polarity, direction).
Immediately after putting the product into operation, make sure that all control and display instruments as
well as the monitoring, signaling and alarm systems are working properly.
Smoking is prohibited in the area of the product.
Safety regulations during operation

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

Practice the procedures for emergencies, in particular, emergency stop, on a regular basis.
The following steps must be taken if a malfunction of the system is detected or reported by the system:
• Inform supervisor(s) in charge.
• Analyze the message.
• Respond to the emergency appropriately, e.g. execute an emergency stop.
Operation
Do not remain in the operating room when the product is running for any longer than absolutely necessary.
Keep a safe distance away from the product if possible. Do not touch the product unless expressly instructed
to do so following a written procedure.
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Do not inhale the exhaust gases of the product.

The following requirements must be fulfilled before the product is started:
• Wear ear protection.
• Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binder agent.
Operation of electrical equipment

During operation of electrical devices, certain elements of these devices are live/under high voltage.
Observe the warning information applicable to the devices.
MS15054/00E 2015-09 | Safety | 9

1.5 Safety precautions when working on the engine
Safety regulations prior to maintenance and repair work
Have maintenance or repair work carried out by qualified and authorized personnel only.
Allow the product to cool down to less than 50 °C (risk of explosion for oil vapors, fluids and lubricants, risk
of burning).
Relieve pressure in fluid and lubricant systems and compressed-air lines which are to be opened. Use suita-
ble collecting vessels of adequate capacity to catch fluids and lubricants.
When changing the oil or working on the fuel system, ensure that the service room is adequately ventilated.
Never carry out maintenance and repair work with the product in operation, unless:
• It is expressly permitted to do so following a written procedure.
• The product is running in the low load range and only for as long as absolutely necessary.
Lock-out the product to preclude undesired starting, e.g.
• Start interlock
• Key switch
• With hydraulic starting system: shut off supply line.
Attach “Do not operate” sign in the operating area or to control equipment.
Disconnect the battery. Lock out circuit breakers.
Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic start-
ers are fitted.
Disconnect the control equipment from the product.
If special tools are specified, these special tools or other suitable tools must be used.
Elastomer components (e.g. engine mounts, damping elements, couplings and V-belts) must not be painted.
They may only be installed after painting the engine or must be covered before painting work is carried out.
The following applies to starters with copper-beryllium alloy pinions:
• Wear a respirator mask (filter class P3). Do not blow out the interior of the flywheel housing or the starter
with compressed air. Clean the flywheel housing inside with a class H dust extraction device.
• Observe the safety data sheet.
Safety regulations during maintenance and repair work

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

When working high on the equipment, always use suitable ladders and work platforms. Never work on en-
gines or components that are held in place by lifting equipment.
Keep fuel injection lines and connections clean.
Carry out appropriate cleaning procedures to clean and inspect components requiring special cleanness (e.g.
components carrying oil, fuel, or air).
Always seal connections with caps or covers if a line is removed or opened.
Fit new seals when re-installing lines.
10 | Safety | MS15054/00E 2015-09

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

Before barring, make sure that nobody is standing in the danger zone of the product.
Check that all access ports/apertures which have been opened to facilitate working are closed again.
Check that all safety equipment has been installed and that all tools and loose parts have been removed
(especially the barring gear).
Ensure that no unattached parts have been left in/on the product (e.g. including rags and cable straps).
Make sure the grounding device is properly connected.
Welding work
Welding operations on the product or mounted units are not permitted. Cover the product when welding in
its vicinity.
Before starting welding work:
• Switch off the power supply master switch.
• Disconnect the battery.
• Separate the electrical ground of electronic equipment from the ground of the unit.
No other maintenance or repair work must be carried out in the vicinity of the product while welding is going
on. Risk of explosion or fire due to oil vapors and highly flammable process materials.
Do not use product as ground terminal.
Never position the welding power supply cable adjacent to, or crossing wiring harnesses of the product. The
welding current may otherwise induce an interference voltage in the wiring harnesses which could conceiva-
bly damage the electrical system.
Remove components (e.g. exhaust pipe) from the product before performing necessary welding work .
Hydraulic installation and removal

Check satisfactory function and safe operating condition of tools, jigs and fixtures to be used. Use only the
specified jigs and fixtures for hydraulic removal/installation procedures.
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Observe the max. permissible force-on pressure specified for the jig/fixture.
Do not attempt to bend or exert force on H.P. lines.
Before starting work, pay attention to the following:
• Vent the installation/removal device, the pumps and the pipework at the relevant designated points.
• During the installation procedure, screw on device with pushed-in plunger.
• During the removal procedure, screw on device with retracted plunger.
For a hydraulic installation/removal device with central expansion pressure supply, screw spindle into shaft
end until correct sealing is established.
MS15054/00E 2015-09 | Safety | 11

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

Observe the safety instructions of the battery manufacturer when working with batteries.
Gases released from the battery are explosive. Avoid sparks and naked flames.
Do not allow battery acids to come into contact with skin or clothing.
Wear protective clothing, goggles and protective gloves.
Do not place tools on the battery.
Before connecting the cable to the battery, check the battery polarity. Battery pole reversal may lead to in-
jury through the sudden discharge of acid or bursting of the battery body.
Working on electrical and electronic assemblies

Always obtain the permission of the person in charge before commencing maintenance and repair work or
switching off any part of the electronic system required to do so.
De-energize the appropriate areas prior to working on assemblies.
Do not damage cabling during removal work. When reconnecting, ensure that cabling cannot be damaged
during operation by:
• Contact with sharp edges
• Chafing on components
• Contact with hot surfaces.
Do not secure cables on lines carrying fluids.
Do not use cable straps to secure cables.
Always use connector pliers to tighten union nuts on connectors.
Subject the device as well as the product to a functional testing on completion of all repair work. In particu-
lar, check the function of the emergency stop feature.
Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Package
faulty electronic components or assemblies properly before dispatching for repair:
• Moisture-proof
• Shock-proof
• Wrapped in antistatic foil if necessary.
Work with laser devices

Laser work must only be performed by authorized and trained personnel. When working with laser equip-
ment, always observe the safety instructions in the manufacturer's Operating Instructions.
When working with laser equipment, always wear special laser-protection goggles (hazard due to heavily fo-
cused radiation).
Laser devices must be equipped, in accordance with their class and usage, with protective devices for ensur-
ing safe operation.
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Measuring deviations on components

At a reference temperature of 20 °C, workpieces, components and measuring instrument are within the
specified tolerances.
12 | Safety | MS15054/00E 2015-09

1.6 Fire prevention and environmental protection, fluids and
lubricants, auxiliary materials
Fire prevention
Flames, naked light and smoking are prohibited.
When working with combustible indirect materials, e.g. cleaning agent, ensure area is well ventilated. The
resultant steam/air mixture must be sufficiently diluted to prevent a potentially explosive atmosphere.
Rectify any fuel or oil leaks immediately. Oil or fuel on hot components can cause fires – therefore always
keep the product in a clean condition. Do not leave rags saturated with fluids and lubricants on the product.
Do not store combustible materials near the product.
Do not carry out welding work on pipes and components carrying oil or fuel. Before welding, clean with a
nonflammable fluid.
When starting the engine with an external power source, connect the ground cable last and remove it first.
To avoid sparks in the vicinity of the battery, connect the ground cable from the external power source to the
ground cable of the engine or to the ground terminal of the starter.
Always have a suitable extinguishant (fire extinguisher) on hand and familiarize yourself fully with its han-
dling.
Noise
Noise can lead to an increased risk of accidents if acoustic signals, warning shouts or sounds indicating dan-
ger are drowned.
Wear ear protectors in workplaces with a sound pressure level in excess of 85 dB (A).
Environmental protection and disposal

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

The Fluids and Lubricants Specifications will be amended or supplemented as necessary. Prior to operation,
make sure that the latest version is used. The latest version can be found on the website on the “Technical
Info” or “Parts and Service” tabs at http://www.mtu-online.com.
Process materials may also be hazardous or toxic. When using consumables and auxiliary materials as well
as other chemical substances, observe the information contained in the safety data sheet for the product.
The safety data sheet may be obtained from the relevant manufacturer or from MTU.
Take special care when using hot, chilled or caustic materials.
Used oil
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Used oil contains combustion residues that are harmful to health.

Wear protective gloves!
Wash relevant areas after contact with used oil.
MS15054/00E 2015-09 | Safety | 13

Lead
• Adopt suitable measures to avoid the formation of lead dust.
• Switch on extraction system.
• When working with lead or pastes containing lead, avoid direct contact to the skin and do not inhale lead
vapors.
• Wash relevant areas 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 (hazard class AI, AII and B) out of con-
tainers, risks causing an explosion.
• Wear goggles when blowing dirt off workpieces or blowing away swarf.
• Blowing compressed air into thin-walled containers (e.g. containers made of sheet metal, plastic or glass)
for drying purposes or to check for leaks risks bursting them.
• Pay special attention to the pressure in the compressed air system or pressure vessel.
• Assemblies or products which are to be connected must be designed to withstand this pressure. Install
pressure-reducing or safety valves set to the admissible pressure if this is not the case.
• Hose couplings and connections must be securely attached.
• Provide the snout of the air nozzle with a protective disk (e.g. rubber disk).
• First shut off compressed air lines before compressed air device is disconnected from the supply line, or
before device or tool is to be replaced.
• Carry out leak test in accordance with the specifications.
Painting
• Observe the relevant safety data sheet for all materials.
• When carrying out painting work outside the spray stands provided with fume extraction systems, ensure
that the area is well ventilated. Make sure that neighboring work areas are not adversely affected.
• There must be no naked flames in the vicinity.
• No smoking.
• Observe fire-prevention regulations.
• Always wear a mask providing protection against paint and solvent vapors.
Liquid nitrogen
• Work with liquid nitrogen may be carried out only by qualified personnel.
• Store liquid nitrogen only in small quantities and always in specified containers without fixed covers.
• Avoid body contact (eyes, hands).
• Wear protective clothing, protective gloves, closed shoes and safety goggles.
• Make sure that working area is well ventilated.
• Avoid knocking or jolting the containers, valves and fittings or workpieces in any way.
Acids/alkaline solutions/urea (AdBlue®, DEF)

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• When working with acids and alkaline solutions, wear goggles or face mask, gloves and protective cloth-
ing.
• Do not inhale vapors.
• If urea solution is swallowed, rinse out mouth and drink plenty of water.
• Remove any wet clothing immediately.
• After contact skin, wash body areas with plenty of water.
• Rinse eyes immediately with eyedrops or clean tap water. Seek medical attention as soon as possible.
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1.7 Standards for safety notices in the text
DANGER
In the event of immediate danger.
Consequences: Death, serious or permanent injury!
• Remedial action.
WARNING
In the event of a situation involving potential danger.
Consequences: Death, serious or permanent injury!
CAUTION
In the event of a situation involving potential danger.
Consequences: Minor or moderate injuries!
NOTICE
In the event of a situation involving potentially adverse effects on the product.
Consequences: Material damage!
• Additional product information.
Safety notices
1. This manual with all safety instructions and safety notices must be issued to all personnel involved in opera-
tion, maintenance, repair or transportation.
2. The higher level warning notice is used if several hazards apply at the same time. Warnings related to person-
al injury shall be considered to include a warning of potential damage.
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MS15054/00E 2015-09 | Safety | 15

2 General Information
2.1 Engine side and cylinder designations
1 Left engine side (A-side) 3 Right engine side (B-side)

2 Engine free end in accord- 4 Engine driving end in ac-
ance with DIN ISO 1204 cordance with
(KGS = Kupplungsgegen- DIN ISO 1204 (KS = Kup-
seite) plungsseite)
Engine sides are always designated (in accordance with DIN ISO 1204) as viewed from driving end (4).
For cylinder designation (in accordance with DIN ISO 1204), the letter "Ax" refers to the cylinders on the left-
hand side of the engine (1) and letter "Bx" refers to the cylinders on the right-hand side (3). The cylinders of
each bank are numbered consecutively, starting with x=1 at driving end (4).
The numbering of other engine components also starts with 1 at driving end (4).
TIM-ID: 0000002185 - 013
16 | General Information | MS15054/00E 2015-09

2.2 Engine – Overview
12V2000Gx6S
Also valid for 16V engines
1 Air intake/air supply 6 Engine coolant pump 11 Exhaust turbocharger

2 Charge-air line 7 Charge-air coolant pump 12 Fuel system (high pressure)
3 Monitoring, control and reg- 8 Exhaust pipe 13 Starting equipment
ulation system 9 LP fuel system KS Driving end
4 Belt drive 10 Fuel filter
5 Charge air manifold
Explanation of engine model designation

12, 16 Number of cylinders
V Cylinder arrangement (Vee engine)
2000 Series
G Application (G = decentralized energy systems engineer-
ing)
x Application segment (0, 1, 2,...,9)
TIM-ID: 0000060297 - 002
6 Design index (0, 1, 2,...,9)

S Additional feature (S = 60 Hz)
Table 2: Explanation of engine model designation
MS15054/00E 2015-09 | General Information | 17

2.3 Sensors and actuators – Overview
Sensors and actuators – Driving end
Overview also applies to 12 V and 16 V engines.
Item Name Monitoring of

1 B3 Intake air temperature
Table 3: Sensors and actuators – Driving end
Sensors and actuators – A-side

Overview also applies to 12 V and 16 V engines.
TIM-ID: 0000060374 - 001

1 B5.1 Oil pressure after oil filter
2 B7 Oil temperature
3 B48.1 HP fuel, A-side
4 M8.1 Fuel pump pressure, A-side
Table 4: Sensors and actuators – A-side

TIM-ID: 0000060374 - 001

Sensors and actuators – Free end

1 B5.3 Oil pressure before oil filter (optional)
Table 5: Sensors and actuators – Free end
TIM-ID: 0000060374 - 001

Sensors and actuators – B-side

1 B9 Charge-air coolant temperature
2 B10 Charge-air pressure
3 XF70 Fuel filter level monitor (optional)
4 XF57 Coolant level, low temperature
5 XF33 Coolant level, high temperature
6 B6 Coolant temperature
7 A19 EIL, electronic label
8 B26 Coolant temperature
9 XF46 Leak fuel level (optional)
10 M8.2 Fuel pump pressure, B-side
11 B34.3 Fuel pressure after intermediate filter stage
(optional)
12 B34.2 Fuel pressure before main filter stage (op-
TIM-ID: 0000060374 - 001
tional)
13 B1 Camshaft speed
14 B13 Crankshaft speed
15 B48.2 HP fuel, B-side
Table 6: Sensors and actuators – B-side

3 Technical Data
3.1 Engine data 12V/16V2000Gx6S, 3B, continuous operation,
variable load, ICXN, optimized fuel consumption (provisional)
Legend
CP Ref. value: Continuous power. Continuous driving power under standard conditions
FSP Ref. value: Fuel stop power. Maximum engine power. In some applications, continuous power not pos-
sible (adjustment reserve)
A Design value. Value is required for configuration of an external system (plant)
R Guideline value. Typical average value for information; only conditionally suitable for configuration
L Limit value. Value that must not be undershot (lower limit, min. value) or exceeded (upper limit, max.
value); not suitable for configuration
N Value not yet defined. Value has not yet been, or will not be, named
- Not applicable. Module not relevant to this product type
X Applicable. Module relevant to this product type
> Actual value must be higher than specified value.
< Actual value must be lower than specified value.
* Value not sufficiently guaranteed (tolerance +/- 10%).
** Value not sufficiently guaranteed (tolerance +/- 5%).
ID Product type Application Engine speed Listed per-

formance
1 12V2000G16S Power generation 1800 rpm 716 kW Ref. 25 °C/55 °C; Wa-
3B continuous opera- 60 Hz 960 bhp ter charge air cooling
tion, variable load, (external)
ICXN Optimized fuel con-
sumption
sumption
sumption
TIM-ID: 0000065006 - 001
sumption
Reference condition
ID 1 2 3 4
Intake air temperature °C 25 25 25 25
Charge air coolant temperature °C 55 55 55 55
Barometric pressure mbar 1000 1000 1000 1000
Site altitude above sea level M 100 100 100 100
22 | Technical Data | MS15054/00E 2015-09

Performance data
ID 1 2 3 4
Rated engine speed A rpm 1800 1800 1800 1800
Continuous power ISO 3046 (10% over- A kW 716 810 898 998
load possible) (power range DIN 6280,
ISO 8528)
General conditions (for maximum power)

ID 1 2 3 4
Intake depression (new filter) A mbar 15 15 15 15
Intake depression, max. L mbar 40 40 40 40
Exhaust overpressure A mbar 30 30 30 30
Exhaust gas overpressure, max. L mbar 85 85 85 85
Model-related data (basic design)

ID 1 2 3 4
Engine with exhaust turbocharging (ETC) - X X X X
and charge-air cooling (CAC)
Combustion method: direct fuel injection - X X X X
Direction of rotation: c.c.w. (facing driv- - X X X X
ing end)
Cylinder arrangement: V-angle Degrees 90 90 90 90
(°)
Bore mm 135 135 135 135
Stroke mm 156 156 156 156
Displacement, cylinder Liters 2.233 2.233 2.233 2.233
Displacement, total Liters 26.8 26.8 26.8 35.7
Compression ratio - 16 16 16 16
Cylinder heads: Individual cylinder heads - X X X X
Cylinder liners: wet, replaceable - X X X X
Number of inlet valves per cylinder - 2 2 2 2
Number of exhaust valves per cylinder - 2 2 2 2
Standard housing connecting flange (en- SAE 0 0 0 0
gine main PTO side)
Flywheel connection (DISC) - 18" 18" 18" 18"
Air / exhaust
TIM-ID: 0000065006 - 001
ID 1 2 3 4
Charge-air pressure before cylinder - CP R bar abs 2.7 3.0 3.3 2.8
Coolant system (HT circuit)

ID 1 2 3 4
Coolant temperature (at engine connec- A °C 100 100 100 100
tion: outlet to cooling equipment)
Coolant temperature after engine, limit 1 L °C 102 102 102 102
MS15054/00E 2015-09 | Technical Data | 23

ID 1 2 3 4
Coolant antifreeze content, max. L % 50 50 50 50
Pressure loss in engine-external cooling L bar 1.0 1.0 1.0 1.0
system, max.
Coolant system (LT circuit)

ID 1 2 3 4
Coolant temperature before charge-air A °C 55 55 55 55
cooler (at engine inlet from cooling
equipment)
Pressure loss in engine-external cooling L bar 1.0 1.0 1.0 1
system, max.
Lube oil system

ID 1 2 3 4
Lube oil operating temperature before R °C 75 75 75 75
engine, from
engine, to
Lube oil temperature before engine, limit L °C 103 103 103 103
1
2
Lube oil operating pressure upstream of R bar 6.5 6.5 6.5 6.5
engine, from
Lube oil operating pressure before en- R bar 9.5 9.5 9.5 9.5
gine, to
Lube oil operating pressure before en- L bar 5.5 5.5 5.5 5.5
gine, warning
gine, shutdown
General operating data

ID 1 2 3 4
Cold start capability: air temperature R °C 0 0 0 0
(w/o start aid. w/o preheating) - (case A)
Coolant preheating: preheating tempera- L °C 32 32 32 32
TIM-ID: 0000065006 - 001
ture (min.)
Firing speed, from R rpm 100 100 100 100
Firing speed, to R rpm 120 120 120 120

Capacities
ID 1 2 3 4
Engine coolant capacity, engine side R Liters 63 63 63 70
(without cooling equipment)
Charge-air coolant, engine side R Liters 20 20 20 25
Engine oil capacity, initial filling (standard R Liters 92 92 92 114
oil system) (option: max. operating incli-
nations)
Oil change quantity, max. (standard oil R Liters 80 80 80 102
system) (option: max. operating inclina-
tions)
Weights / main dimensions

ID 1 2 3 4
Engine weight, dry (basic engine configu- R kg 2710 2710 2710 3180
ration acc. to scope of delivery specifica-
tion)
Sound
ID 1 2 3 4
Exhaust noise, not attenuated - DL R dB(A) 128 130 130
(sound power level LW, ISO 6798,
+3 dB(A) tolerance)
Engine surface noise with attenuated in- R dB(A) 125 122 123
take noise (filter) - DL (sound power level
LW, ISO 6798, +2 db(A) tolerance)
TIM-ID: 0000065006 - 001

3.2 Engine data 12V/16V2000Gx6S, 3D, standby current, fuel
stop power (IFN), optimized fuel consumption (provisional)
Legend

formance
3D standby current, 60 Hz 1193 bhp ter charge air cooling
fuel stop power (IFN) (external)
Optimized fuel con-
sumption
Optimized fuel con-
sumption
Optimized fuel con-
sumption,
Optimized fuel con-
sumption,
Reference condition
TIM-ID: 0000065009 - 001
ID 1 2 3 4

Performance data
ID 1 2 3 4
Fuel stop power ISO 3046 A kW 890 987 1097 1371

ID 1 2 3 4

ID 1 2 3 4
Uncooled exhaust lines - X X X X
Operating method: Four-stroke cycle, - X X X X
diesel, single-action
Cooling method: conditioned water - X X X X
ing end)
(°)
Bore mm 135 135 135 135
Stroke mm 156 156 156 156
gine main PTO side)
TIM-ID: 0000065009 - 001
Air / exhaust
ID 1 2 3 4
Charge-air pressure before cylinder - CP R bar abs - - - -

ID 1 2 3 4
system, max.

ID 1 2 3 4
equipment)
Pressure loss in engine-external cooling L bar 1.0 1.0 1 1.0
system, max.
Lube oil system

ID 1 2 3 4
Lube-oil operating temperature before R °C 75 75 75 75
engine, from
engine, to
1
2
engine, from
gine, to
gine, warning
gine, shutdown
Fuel system
TIM-ID: 0000065009 - 001
ID 1 2 3 4
Fuel pressure at engine inlet connection, L bar -
min. (when engine is starting)
Fuel pressure at engine inlet connection, L bar abs 1.5 1.5 1.5 1.5
max. (when engine is starting), absolute
pressure

ID 1 2 3 4
ture (min.)
Capacities
ID 1 2 3 4
nations)
tions)
Oil pan capacity at dipstick mark "min." R Liters 65 65 88 88
(standard oil system)
Oil pan capacity at dipstick mark "max." R Liters 70 70 94 94

ID 1 2 3 4
tion)
Sound
ID 1 2 3 4
Exhaust noise, not attenuated - DL R dB(A) 130 130 X
+3 dB(A) tolerance)
Engine surface noise with attenuated in- R dB(A) 122 121 X
TIM-ID: 0000065009 - 001

3.3 Engine data 12V/16V2000Gx6S, 3F, standby operation mode,
unlimited, ICXN, optimized fuel consumption (provisional)
Legend

formance
3F standby operation 60 Hz 1086 bhp ter charge air cooling
mode, unlimited, ICXN (external)
Optimized fuel con-
sumption
Optimized fuel con-
sumption
Reference condition
ID 1 2
Intake air temperature °C 25 25
Charge air coolant temperature °C 55 55
Barometric pressure mbar 1000 1000
Site altitude above sea level M 100 100
Performance data
ID 1 2
TIM-ID: 0000065011 - 001
Rated engine speed A rpm 1800 1800

Continuous power ISO 3046 (10% overload possible) (power A kW 810 998
range DIN 6280, ISO 8528)

ID 1 2
Intake depression (new filter) A mbar 15 15
Intake depression, max. L mbar 40 40

ID 1 2
Exhaust overpressure A mbar 30 30
Exhaust gas overpressure, max. L mbar 85 85

ID 1 2
Engine with exhaust turbocharging (ETC) and charge-air cooling - X X
(CAC)
Combustion method: direct fuel injection - X X
Direction of rotation: c.c.w. (facing driving end) - X X
Cylinder arrangement: V-angle Degrees 90 90
(°)
Bore mm 135 135
Stroke mm 156 156
Displacement, cylinder Liters 2.233 2.233
Displacement, total Liters 26.8 35.7
Compression ratio - 16 16
Cylinder heads: Individual cylinder heads - X X
Cylinder liners: wet, replaceable - X X
Number of inlet valves per cylinder - 2 2
Number of exhaust valves per cylinder - 2 2
Standard housing connecting flange (engine main PTO side) SAE 0 0
Flywheel connection (DISC) - 18" 18"
Air / exhaust
ID 1 2
Charge-air pressure before cylinder - DL R bar abs 3.0 2.8

ID 1 2
Coolant temperature (at engine connection: outlet to cooling A °C 100 100
equipment)
Coolant temperature after engine, limit 1 L °C 102 102
Coolant antifreeze content, max. L % 50 50
Pressure loss in engine-external cooling system, max. L bar 1.0 1.0
TIM-ID: 0000065011 - 001

ID 1 2
Coolant temperature before charge-air cooler (at engine inlet A °C 55 55
from cooling equipment)
Pressure loss in engine-external cooling system, max. L bar 1.0 1

Lube oil system
ID 1 2
Lube oil operating temperature before engine, from R °C 75 75
Lube oil operating temperature before engine, to R °C 100 100
Lube oil temperature before engine, limit 1 L °C 103 103
Lube oil operating pressure upstream of engine, from R bar 6.5 6.5
Lube oil operating pressure before engine, to R bar 9.5 9.5
Lube oil operating pressure before engine, warning L bar 5.5 5.5
Lube oil operating pressure before engine, shutdown L bar 5.0 5.0
Fuel system
ID 1 2
Fuel pressure at engine inlet connection, min. (when engine is L bar -
starting)

ID 1 2
Cold start capability: air temperature (w/o start aid. w/o preheat- R °C 0 0
ing) - (case A)
Coolant preheating: preheating temperature (min.) L °C 32 32
Firing speed, from R rpm 100 100
Firing speed, to R rpm 120 120
Capacities
ID 1 2
Engine coolant capacity, engine side (without cooling equipment) R Liters 63 70
Charge-air coolant, engine side R Liters 20 25
Engine oil capacity, initial filling (standard oil system) (option: R Liters 92 114
max. operating inclinations)
Oil change quantity, max. (standard oil system) (option: max. op- R Liters 80 102
erating inclinations)

ID 1 2
Engine weight, dry (basic engine configuration acc. to scope of R kg 2710 3180
delivery specification)
TIM-ID: 0000065011 - 001
Sound
ID 1 2
Exhaust noise, not attenuated - DL (sound power level LW, ISO R dB(A) 130
6798, +3 dB(A) tolerance)
Engine surface noise with attenuated intake noise (filter) - DL R dB(A) 122
(sound power level LW, ISO 6798, +2 db(A) tolerance)

3.4 Engine data 12V/16V2000Gx6S, 3G, continuous operation,
time-limited, ICXN, optimized fuel consumption (provisional)
Legend

formance
3G continuous opera- 60 Hz 1086 bhp ter charge air cooling
tion, time-limited, (external)
sumption
sumption
Reference condition
ID 1 2
Site altitude above sea level m 100 100
Performance data
ID 1 2
TIM-ID: 0000065013 - 001


ID 1 2

ID 1 2

ID 1 2
(CAC)
(°)
Bore mm 135 135
Stroke mm 156 156
Air / exhaust
ID 1 2
Charge-air pressure before cylinder - CP R bar abs 3.0 2.8

ID 1 2
equipment)
TIM-ID: 0000065013 - 001

ID 1 2

Lube oil system
ID 1 2
Fuel system
ID 1 2
Fuel pressure at engine inlet connection, min. (when engine is L bar -
starting)

ID 1 2
ing) - (case A)
Capacities
ID 1 2

ID 1 2
TIM-ID: 0000065013 - 001
Sound
ID 1 2

3.5 Engine data 12V/16V2000Gx6S, 3H, standby operation mode,
special qualifications, optimized fuel consumption
(provisional)
Legend

formance
3H standby operation 60 Hz 1193 bhp ter charge air cooling
mode, special qualifi- (external)
cations Optimized fuel con-
sumption
sumption,
sumption
Reference condition
ID 1 2 3
Intake air temperature °C 25 25 25
Charge air coolant temperature °C 55 55 55
TIM-ID: 0000065015 - 001
Barometric pressure mbar 1000 1000 1000

Site altitude above sea level M 100 100 100
Performance data
ID 1 2 3
Rated engine speed A rpm 1800 1800 1800
Fuel stop power ISO 3046 A kW 890 1097 1371

ID 1 2 3
Intake depression (new filter) A mbar 15 15 15
Intake depression, max. L mbar 40 40 40
Exhaust overpressure A mbar 30 30 30
Exhaust gas overpressure, max. L mbar 85 85 85

ID 1 2 3
Engine with exhaust turbocharging (ETC) and charge- - X X X
air cooling (CAC)
Uncooled exhaust lines - X X X
Operating method: Four-stroke cycle, diesel, single- - X X X
action
Combustion method: direct fuel injection - X X X
Cooling method: conditioned water - X X X
Direction of rotation: c.c.w. (facing driving end) - X X X
Cylinder arrangement: V-angle Degrees 90 90 90
(°)
Bore mm 135 135 135
Stroke mm 156 156 156
Displacement, cylinder Liters 2.233 2.233 2.233
Displacement, total Liters 26.8 35.7 35.7
Compression ratio - 16 16 16
Cylinder heads: Individual cylinder heads - X X X
Cylinder liners: wet, replaceable - X X X
Number of inlet valves per cylinder - 2 2 2
Number of exhaust valves per cylinder - 2 2 2
Standard housing connecting flange (engine main SAE 0 0 0
PTO side)
Flywheel connection (DISC) - 18" 18" 18"
Air / exhaust
ID 1 2 3
Charge-air pressure before cylinder - CP R bar abs - - -

TIM-ID: 0000065015 - 001
ID 1 2 3
Coolant temperature (at engine connection: outlet to A °C 100 100 100
cooling equipment)
Coolant temperature after engine, limit 1 L °C 102 102 102
Coolant antifreeze content, max. L % 50 50 50
Pressure loss in engine-external cooling system, max. L bar 1.0 1.0 1.0

ID 1 2 3
Coolant temperature before charge-air cooler (at en- A °C 55 55 55
gine inlet from cooling equipment)
Pressure loss in engine-external cooling system, max. L bar 1.0 1 1.0
Lube oil system

ID 1 2 3
Lube-oil operating temperature before engine, from R °C 75 75 75
Lube oil operating temperature before engine, to R °C 100 100 100
Lube oil temperature before engine, limit 1 L °C 103 103 103
Lube oil operating pressure upstream of engine, from R bar 6.5 6.5 6.5
Lube oil operating pressure before engine, to R bar 9.5 9.5 9.5
Lube oil operating pressure before engine, warning L bar 5.5 5.5 5.5
Lube oil operating pressure before engine, shutdown L bar 5.0 5.0 5.0
Fuel system
ID 1 2 3
Fuel pressure at engine inlet connection, min. (when L bar -
engine is starting)
Fuel pressure at engine inlet connection, max. (when L bar abs 1.5 1.5 1.5
engine is starting), absolute pressure

ID 1 2 3
Cold start capability: air temperature (w/o start aid. R °C 0 0 0
w/o preheating) - (case A)
Coolant preheating: preheating temperature (min.) L °C 32 32 32
Firing speed, from R rpm 100 100 100
Firing speed, to R rpm 120 120 120
Capacities
ID 1 2 3
Engine coolant capacity, engine side (without cooling R Liters 63 70 70
equipment)
TIM-ID: 0000065015 - 001
Charge-air coolant, engine side R Liters 20 25 25

Engine oil capacity, initial filling (standard oil system) R Liters 92 114 114
(option: max. operating inclinations)
Oil change quantity, max. (standard oil system) (op- R Liters 80 102 102
tion: max. operating inclinations)
Oil pan capacity at dipstick mark "min." (standard oil R Liters 65 88 88
system)
Oil pan capacity at dipstick mark "max." (standard oil R Liters 70 94 94
system)

ID 1 2 3
Engine weight, dry (basic engine configuration acc. to R kg 2710 3180 3180
scope of delivery specification)
Sound
ID 1 2 3
Exhaust noise, not attenuated - DL (sound power lev- R dB(A) 130 X
el LW, ISO 6798, +3 dB(A) tolerance)
Engine surface noise with attenuated intake noise (fil- R dB(A) 122 X
ter) - DL (sound power level LW, ISO 6798, +2 db(A)
tolerance)
TIM-ID: 0000065015 - 001

3.6 Engine data 12V/16V2000Gx6S, 3B, continuous operation,
variable load, ICXN, EPA Nonroad T2 (40CFR89) (provisional)
Legend

formance
ICXN EPA Nonroad T2 Comp
(40CFR89)
(40CFR89)
(40CFR89)
(40CFR89)
Reference condition
TIM-ID: 0000065007 - 001
ID 1 2 3 4

Performance data
ID 1 2 3 4
Continuous power ISO 3046 (10% over- A kW 716 810 898 998
load possible) (power range DIN 6280,
ISO 8528)

ID 1 2 3 4

ID 1 2 3 4
ing end)
(°)
Bore mm 135 135 135 135
Stroke mm 156 156 156 156
gine main PTO side)
Air / exhaust
TIM-ID: 0000065007 - 001
ID 1 2 3 4
Charge-air pressure before cylinder - CP R bar abs 3.0 3.3 3.5 3.2

ID 1 2 3 4

ID 1 2 3 4
system, max.

ID 1 2 3 4
equipment)
Pressure loss in engine-external cooling L bar 1.0 1.0 1.0 1
system, max.
Lube oil system

ID 1 2 3 4
engine, from
engine, to
1
2
engine, from
gine, to
gine, warning
gine, shutdown

ID 1 2 3 4
TIM-ID: 0000065007 - 001
ture (min.)

Capacities
ID 1 2 3 4
nations)
tions)

ID 1 2 3 4
tion)
Sound
ID 1 2 3 4
Exhaust noise, not attenuated - DL R dB(A) X 129 130 130
+3 dB(A) tolerance)
Engine surface noise with attenuated in- R dB(A) X 123 123 122
TIM-ID: 0000065007 - 001

3.7 Engine data 12V/16V2000Gx6S, 3D, standby current, fuel
stop power (IFN), EPA Nonroad T2 (40CFR89) (provisional)
Legend

formance
EPA Nonroad T2
(40CFR89)
EPA Nonroad T2 Comp
(40CFR89)
EPA Nonroad T2
(40CFR89)
EPA Nonroad T2 Comp
(40CFR89)
EPA Nonroad T2
(40CFR89)
EPA Nonroad T2 Comp
(40CFR89)
TIM-ID: 0000065010 - 001

EPA Nonroad T2
(40CFR89)
EPA Nonroad T2 Comp
(40CFR89)

Reference condition
ID 1 2 3 4
Performance data
ID 1 2 3 4
Fuel stop power ISO 3046 A kW 890 987 1097 1371

ID 1 2 3 4

ID 1 2 3 4
Uncooled exhaust lines - X X X X
Operating method: Four-stroke cycle, - X X X X
diesel, single-action
Cooling method: conditioned water - X X X X
ing end)
(°)
Bore mm 135 135 135 135
Stroke mm 156 156 156 156
TIM-ID: 0000065010 - 001
gine main PTO side)

Air / exhaust
ID 1 2 3 4
Charge-air pressure before cylinder - CP R bar abs - - - -

ID 1 2 3 4
system, max.

ID 1 2 3 4
equipment)
Pressure loss in engine-external cooling L bar 1.0 1.0 1 1
system, max.
Lube oil system

ID 1 2 3 4
Lube-oil operating temperature before R °C 75 75 75 75
engine, from
engine, to
1
2
engine, from
gine, to
TIM-ID: 0000065010 - 001
gine, warning
gine, shutdown
Fuel system
ID 1 2 3 4
Fuel pressure at engine inlet connection, L bar abs 1.5 1.5 1.5 1.5
max. (when engine is starting), absolute
pressure

ID 1 2 3 4
ture (min.)
Capacities
ID 1 2 3 4
nations)
tions)
Oil pan capacity at dipstick mark "min." R Liters 65 65 88 88
Oil pan capacity at dipstick mark "max." R Liters 70 70 94 94

ID 1 2 3 4
tion)
Sound
ID 1 2 3 4
Exhaust noise, not attenuated - DL R dB(A) 130 130 -
+3 dB(A) tolerance)
Engine surface noise with attenuated in- R dB(A) 121 121 -
TIM-ID: 0000065010 - 001

3.8 Engine data 12V/16V2000Gx6S, 3F, standby operation mode,
unlimited, ICXN, EPA Nonroad T2 (40CFR89) and EPA
Stationary EMERG T2 (40CFR60) (provisional)
Legend

formance
EPA Nonroad T2 Comp
(40CFR89)
EPA Stationary EMERG
T2 (40CFR60)
EPA Nonroad T2 Comp
(40CFR89)
Reference condition
ID 1 2
TIM-ID: 0000065012 - 001
Performance data
ID 1 2

ID 1 2

ID 1 2
(CAC)
(°)
Bore mm 135 135
Stroke mm 156 156
Air / exhaust
ID 1 2

ID 1 2
equipment)
TIM-ID: 0000065012 - 001


ID 1 2
Lube oil system

ID 1 2

ID 1 2
ing) - (case A)
Capacities
ID 1 2

TIM-ID: 0000065012 - 001
ID 1 2

Sound
ID 1 2
TIM-ID: 0000065012 - 001

3.9 Engine data 12V/16V2000Gx6S, 3G, continuous operation,
time-limited, ICXN, EPA Nonroad T2 (40CFR89) (provisional)
Legend

formance
(40CFR89)
(40CFR89)
Reference condition
ID 1 2
Performance data
ID 1 2
TIM-ID: 0000065014 - 001


ID 1 2

ID 1 2

ID 1 2
(CAC)
(°)
Bore mm 135 135
Stroke mm 156 156
Air / exhaust
ID 1 2

ID 1 2
equipment)
TIM-ID: 0000065014 - 001

ID 1 2

Lube oil system
ID 1 2

ID 1 2
ing) - (case A)
Capacities
ID 1 2

ID 1 2
Sound
ID 1 2
TIM-ID: 0000065014 - 001

3.10 Engine data 12V/16V2000Gx6S, 3H, standby operation mode,
special qualifications, EPA Nonroad T2 (40CFR89) and EPA
Stationary EMERG T2 (40CFR60) (provisional)
Legend

formance
cations EPA Nonroad T2 Comp
(40CFR89)
cations EPA Stationary EMERG
T2 (40CFR60)
EPA Nonroad T2 Comp
(40CFR89)
cations EPA Stationary EMERG
T2 (40CFR60)
EPA Nonroad T2 Comp
(40CFR89)
Reference condition
TIM-ID: 0000065016 - 001
ID 1 2 3
Intake air temperature °C 25 25 25
Charge air coolant temperature °C 45 45 45
Barometric pressure mbar 1000 1000 1000
Site altitude above sea level m 100 100 100

Performance data
ID 1 2 3
Rated engine speed A rpm 1800 1800 1800
Fuel stop power ISO 3046 A kW 890 1097 1371

ID 1 2 3
Intake depression (new filter) A mbar 15 15 15
Intake depression, max. L mbar 40 40 40
Exhaust overpressure A mbar 30 30 30
Exhaust gas overpressure, max. L mbar 85 85 85

ID 1 2 3
Engine with exhaust turbocharging (ETC) and charge- - X X X
air cooling (CAC)
Uncooled exhaust lines - X X X
Operating method: Four-stroke cycle, diesel, single- - X X X
action
Combustion method: direct fuel injection - X X X
Cooling method: conditioned water - X X X
Direction of rotation: c.c.w. (facing driving end) - X X X
Cylinder arrangement: V-angle Degrees 90 90 90
(°)
Bore mm 135 135 135
Stroke mm 156 156 156
Displacement, cylinder Liters 2.233 2.233 2.233
Displacement, total Liters 26.8 35.7 35.7
Compression ratio - 16 16 16
Cylinder heads: Individual cylinder heads - X X X
Cylinder liners: wet, replaceable - X X X
Number of inlet valves per cylinder - 2 2 2
Number of exhaust valves per cylinder - 2 2 2
Standard housing connecting flange (engine main SAE 0 0 0
PTO side)
Flywheel connection (DISC) - 18" 18" 18"
TIM-ID: 0000065016 - 001
Air / exhaust
ID 1 2 3
Charge-air pressure before cylinder - CP R bar abs - - -

ID 1 2 3
Coolant temperature (at engine connection: outlet to A °C 100 100 100
cooling equipment)
Pressure loss in engine-external cooling system, max. L bar 1.0 1.0 1.0

ID 1 2 3
Coolant temperature before charge-air cooler (at en- A °C 45 45 45
gine inlet from cooling equipment)
Pressure loss in engine-external cooling system, max. L bar 1.0 1 1
Lube oil system

ID 1 2 3
Lube oil operating temperature before engine, from R °C 75 75 75
Lube oil operating temperature before engine, to R °C 100 100 100
Lube oil operating pressure upstream of engine, from R bar 6.5 6.5 6.5
Lube-oil operating pressure before engine, to R bar 9.5 9.5 9.5
Lube oil operating pressure before engine, warning L bar 5.5 5.5 5.5
Lube oil operating pressure before engine, shutdown L bar 5.0 5.0 5.0
Fuel system
ID 1 2 3
Fuel pressure at engine inlet connection, max. (when L bar abs 1.5 1.5 1.5
engine is starting), absolute pressure

ID 1 2 3
Cold start capability: air temperature (w/o start aid. R °C 0 0 0
w/o preheating) - (case A)
TIM-ID: 0000065016 - 001
Coolant preheating: preheating temperature (min.) L °C 32 32 32

Firing speed, from R rpm 100 100 100
Firing speed, to R rpm 120 120 120
Capacities
ID 1 2 3
Engine coolant capacity, engine side (without cooling R Liters 63 70 70
equipment)
Charge-air coolant, engine side R Liters 20 25 25

ID 1 2 3
Engine oil capacity, initial filling (standard oil system) R Liters 92 114 114
(option: max. operating inclinations)
Oil change quantity, max. (standard oil system) (op- R Liters 80 102 102
tion: max. operating inclinations)
Oil pan capacity at dipstick mark "min." (standard oil R Liters 65 88 88
system)
Oil pan capacity at dipstick mark "max." (standard oil R Liters 70 94 94
system)

ID 1 2 3
Engine weight, dry (basic engine configuration acc. to R kg 2710 3180 3180
scope of delivery specification)
Sound
ID 1 2 3
Exhaust noise, not attenuated - DL (sound power lev- R dB(A) 130 -
el LW, ISO 6798, +3 dB(A) tolerance)
Engine surface noise with attenuated intake noise (fil- R dB(A) 121 -
ter) - DL (sound power level LW, ISO 6798, +2 db(A)
tolerance)
TIM-ID: 0000065016 - 001

3.11 Firing order
Firing order
Number of cylinders Firing order
12V A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1
16V A1-B5-A3-A5-B2-B8-A2-A8-B3-A7-B4-B6-A4-A6-B1-B7
18V A1-B6-A3-B4-A5-B2-A7-B1-A9-B3-A8-B5-A6-B7-A4-B9-A2-B8
TIM-ID: 0000053446 - 002

3.12 Engine – Main dimensions
Item Dimensions
Length (A) for 12V approx. 1885.2 mm
Length (A) for 16V approx. 2235.2 mm
Width (B) for 12V approx. 1588.3 mm
Width (B) for 16V approx. 1568.4 mm
Height (C) for 12V approx. 1420.2 mm
Height (C) for 16V approx. 1420.2 mm
Table 7: Main engine dimensions

TIM-ID: 0000060300 - 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 into operation after long out-of-service periods (>3 months)

Item Action
Engine Depreserve (→ Preservation and Represervation Specifications (A001070/
…)).
Lube oil system Check engine oil level (→ Page 130).
Fuel system Connect appropriate equipment to fuel supply line to fill the system.
Fuel system Vent (→ Page 117).
Coolant circuit If engine is out of service for more than one year, change engine coolant
(→ Page 136). Change charge-air coolant (→ Page 145).
Coolant circuit Check engine coolant level (→ Page 135); Check charge-air coolant level
(→ Page 146).
Coolant circuit Preheat engine coolant with coolant preheating unit (if fitted).
Engine governor Check plug-in connections (→ Page 161).
Engine control sstem Switch on.
TIM-ID: 0000010073 - 004
MS15054/00E 2015-09 | Operation | 61

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

Item Action
Lube oil system Check engine oil level (→ Page 130).
Coolant circuit Check engine coolant level (→ Page 135), check charge-air coolant level
(→ Page 146).
Coolant circuit Preheat engine coolant with coolant preheating unit, if fitted.
Fuel prefilter (if fitted) Drain water and contaminants, see manufacturer's documentation.
Engine control system Switch on.
TIM-ID: 0000010642 - 002
62 | Operation | MS15054/00E 2015-09

4.3 Starting the engine
Preconditions
☑ Engine with no load.
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Before cranking the engine with starter system, make sure that there are no persons in the engine's
danger zone.
WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.
Starting the engine

Item Measure
Engine Start the engine (→ documentation of the vehicle manufacturer/plant manu-
facturer).
TIM-ID: 0000010107 - 006
MS15054/00E 2015-09 | Operation | 63

4.4 Operational checks
DANGER
• Only run the engine at low power. Keep away from the engine's danger zone.
WARNING
Operational checks
Item Measure
Control and display panels Check readings of operational data (speed, temperature, pressures).
Engine operation Visually inspect engine for leaks and general condition;
Check engine for abnormal running noises, exhaust color and vibrations.
Air filter Check signal ring position of maintenance indicator on air filter
(→ Page 126).
Exhaust system Check exhaust color (→ Page 71).
Fuel prefilter (if fitted) Check reading at differential pressure gauge of fuel prefilter, see manufac-
turer's documentation.
Charge-air cooler Check drain for coolant discharge and obstruction (→ Page 148).
Engine coolant pump Check relief bore (→ Page 140).
Charge-air coolant pump Check relief bore (→ Page 147).
TIM-ID: 0000057107 - 002
64 | Operation | MS15054/00E 2015-09

4.5 Emission label – Check
Checking emission label

Note: If there are any irregularities, notify your MTU Service contact person without delay.
1. Check that emission labels are present (several are possible).
2. Does the label on the engine match the label document in the Business Portal/Equipment?
3. Check emission label for intactness.
4. Check content of emission label for complete readability
5. Does the engine number on the emission label match the engine identification plate?
6. Does the Manufacturing Date match the year of manufacture on the identification plate?
TIM-ID: 0000063752 - 001
MS15054/00E 2015-09 | Operation | 65

4.6 Engine shutdown
Preconditions
☑ Engine is not connected to load.
CAUTION
Shutting down from full-load operation may cause hot water to escape from the expansion tank.
Risk of scalding!
• Allow engine to cool down.
• Wear protective clothing, protective gloves, and safety goggles / safety mask.
NOTICE
Stopping the engine when it is running at full load subjects it to extreme thermal and mechanical stress-
es.
Overheating of and, therefore, damage to components is possible!
• Before shutting down the engine, allow it to idle until the engine temperatures decrease and constant
levels are indicated.
Preparation
Item Action
Engine Allow the engine to cool down by running it at idle speed for approx. 5 mi-
nutes.
Stopping the engine

Item Action
Engine Stopping (→ Documentation of the vehicle/plant manufacturer).
TIM-ID: 0000010138 - 007
66 | Operation | MS15054/00E 2015-09

4.7 Emergency engine stop
CAUTION
Shutting down from full-load operation may cause hot water to escape from the expansion tank.
Risk of scalding!
• Allow engine to cool down.
• Wear protective clothing, protective gloves, and safety goggles / safety mask.
NOTICE
An emergency stop causes extreme stress to the engine plant.
Risk of overheating, damage to components!
• Initiate emergency stop only in emergency situations.
Emergency engine stop

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

Item Action
Switch cabinet, operator Press pushbutton for alarm acknowledgment.
station etc. (depending on • Audible and visual signalization stops.
manufacturer)
Engine Manually open emergency-air shutoff flaps (if provided).
• Switch on ECU voltage supply
• Engine is ready for starting.
HP system Energize injectors (for pressure release in HP system using the function
„Blank Shot Afterrun“)
• Switch on ECU voltage supply
• Blank Shots are carried out (requires approx. 20 to 30 s.)
TIM-ID: 0000062460 - 001
MS15054/00E 2015-09 | Operation | 67

4.8 After stopping the engine
Preconditions
☑ MTU Preservation and Represervation Instructions (A001070/..) are available.
NOTICE
Engine coolant with inadequate freeze protection. Water remaining in the pressure sensors freezes at
temperatures below 0 °C.
Risk of sensor damage!
• Remove pressure sensors and shake off residual water.
After stopping the engine

Item Action
Coolant circuit Drain engine coolant (→ Page 137) if
• freezing temperatures are expected, the engine is to remain out of service
for an extended period, but engine coolant has no antifreeze additive.
• the engine room is not heated.
• the coolant is not kept at a suitable temperature.
• the antifreeze concentration is insufficient for the engine-room tempera-
ture.
• the antifreeze concentration is 50% and the engine-room temperature is
below -40 °C.
Engine control system Switch off (see manufacturer's documentation).
Air intake and exhaust sys- If the engine is to be taken out of service for longer than 1 week, seal the
tem engine on the air and exhaust side.
If the engine is to be taken out of service for longer than 1 month, it has to
be preserved (→ MTU Preservation and Represervation Instructions
A001070/..).
HP system (injector noise) The pressure is released in the system by means of the function "Blank Shot
Afterrun":
• Injectors are energized.
• A small injection quantity is diverted into the injector return line without
the nozzle needle opening (actuation of the servo valve on the injector
side, which does not result in injection into the combustion chamber).
Explanation: The injectors do not leak permanently, which is why the pres-
sure applied in the system during engine stop is maintained. Pressure is only
released through actuation of the injectors. When actuated, the switched
quantity of the servo valve and the injection quantity are discharged. This
procedure results in injector noise.
Depressurizing (pressure <400 bar) is necessary for the following reasons:
• Limitation of load on high-pressure pumps during start
• Safety during assembly activities
TIM-ID: 0000054740 - 002
68 | Operation | MS15054/00E 2015-09

4.9 Plant – Cleaning
Preconditions
☑ No operating voltage is applied.
Special tools, Material, Spare parts

Designation / Use Part No. Qty.
High-pressure cleaning unit - 1
Cleaner (Hakupur 50/136) X00056700 1
WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.
WARNING
Water jet from high-pressure cleaning unit.
Risk of eye injury, risk of scalding!
• Do not direct water jet at persons.
• Wear protective clothing, protective gloves, and goggles/safety mask.
NOTICE
Cleaning agents should not be left to take effect for too long.
Damage to components is possible!
• Observe manufacturer's instructions.
NOTICE
Blowing down product with compressed air.
Entry of dirt and damage to components is possible!
• Do not aim compressed air gun directly at seals or electronic components such as connectors or
ECUs.
Plant – Cleaning
1. Carry out plant cleaning only in areas where an appropriate oil separator is provided (environmental protec-
tion).
2. Prior to putting the cleaning unit into operation, read the operating instructions of the high-pressure cleaning
units carefully and observe the safety precautions.
3. The following requirements apply for cleaning the plant outside with a high-pressure cleaning unit:
• The pressure of the high-pressure jet (cleaning jet) must not exceed 50 bar.
• A minimum distance between spray nozzle and plant of 1 m must be observed.
TIM-ID: 0000010171 - 032
• The temperature of the cleaning medium must not exceed 80 °C.

4. For external cleaning with high-pressure jet, use a flat-mouth nozzle only.
Note: Never direct compressed air directly at electronic components.
5. Carry out external cleaning as follows:
a) Seal all openings in a suitable way.
b) Remove coarse dirt.
c) Spray on cleaner sparingly and leave it for 1 to 5 minutes.
d) Use the high-pressure jet to remove the loosened dirt.
e) Dry engine with compressed air.
MS15054/00E 2015-09 | Operation | 69

5 Maintenance
5.1 Maintenance task reference table [QL1]
The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Mainte-
nance Schedule is a stand-alone publication.
The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance
Schedule.
Option
Task Maintenance tasks
W0500 Check engine oil level. (→ Page 130)

W0501 Visually inspect engine for leaks and general condition. (→ Page 64)
W0503 Check service indicator of air filter. (→ Page 64)
W0505 Check relief bores of water pump(s) (→ Page 64)
W0506 Check engine for abnormal running noises, exhaust color (→ Page 64)
and vibrations.
W0507 X Drain water and contaminants from fuel prefilter. (→ Page 64)
W0508 X Check reading on vacuum gauge at fuel prefilter. (→ Page 64)
W0800 Check for presence of emission label(s) and check readabili- (→ Page 65)
ty and content.
W1001 Replace fuel filter or fuel filter element. (→ Page 119)
W1003 X Check belt condition and tension, replace if necessary. (→ Page 149)
W1005 Replace air filter. (→ Page 124)
W1006 Replace fuel injectors. (→ Page 109)
W1008 Replace engine oil filter when changing engine oil, or when (→ Page 132)
the interval (years) is reached, at the latest.
W1009 X Measure thickness of oil residue layer, clean and replace (→ Page 133)
sleeve at next engine oil change at the latest.
W1055 Replace oil separator. (→ Page 104)
W1178 Replace pressure pipe neck in cylinder head. (→ Page 110)
W1207 Check valve clearance, adjust if necessary. IMPORTANT! (→ Page 105)
First adjustment after 1,000 operating hours and after every
overhaul of cylinder heads after 1,000 operating hours.
W1244 X Check function of rod electrode. (→ Page 157)
W1245 X Check alarm function of differential pressure gauge. (→ Page 156)
TIM-ID: 0000064575 - 001
W1246 X Check pump capacity. (→ Page 158)

W1636 Reset parameters of drift correction (CDC) and enter coding (→ Page 116)
for injectors (IIG).
W1675 X Replace fuel prefilter or fuel prefilter element. (→ Page 121)
Table 8: Maintenance task reference table [QL1]
70 | Maintenance | MS15054/00E 2015-09

6 Troubleshooting
6.1 Troubleshooting
Engine does not turn when starter is actuated

Component Cause Action
Battery Low or faulty Charge or replace (see manufacturer's
documentation).
Cable connections faulty Check if cable connections are properly
secured (see manufacturer's documen-
tation).
Starter Engine cabling or starter faulty Check if cable connections are properly
secured, contact Service.
Engine cabling Faulty Check (→ Page 162).
Engine/generator Assemblies or connectors possibly loose Perform visual inspection (see manufac-
control system turer's documentation).
Engine governor Plug-in connections possibly loose Check plug connections (→ Page 161).
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-
faulty turer's documentation).
Fuel system Air in fuel system Vent fuel system (→ Page 117).
Engine governor Faulty Contact Service.
Engine fires unevenly

Fuel injection equip- Injector faulty Replace (→ Page 109).
ment Injection pump faulty Contact Service.
TIM-ID: 0000051898 - 002
Engine does not reach rated speed

Fuel supply Fuel prefilter clogged Replace (→ Page 121).
Easy-change fuel filter clogged Replace (→ Page 119).
Air supply Air filter clogged Check signal ring position of service in-
dicator (→ Page 126).
MS15054/00E 2015-09 | Troubleshooting | 71

Engine Overloaded Contact Service.
Engine speed not steady

Speed sensor Faulty Contact Service.
Charge-air temperature too high

Engine coolant Engine coolant treatment incorrect Check (MTU test kit).
Intercooler Contaminated Contact Service.
Engine room Air-intake temperature too high Check fans and intake/exhaust lines.
Charge-air pressure too low

Leaking Replace seals/nuts.
Intercooler Contaminated Contact Service.
Exhaust turbocharger Faulty Contact Service.
Coolant leaks at intercooler

Intercooler Leaking, major coolant discharge Contact Service.
Black exhaust gas

Component Probable Cause Action
TIM-ID: 0000051898 - 002
Engine Overloaded Contact Service.
72 | Troubleshooting | MS15054/00E 2015-09

Blue exhaust gas
Engine oil Too much engine oil in the engine Drain engine oil (→ Page 131).
Oil separator of crankcase breather con- Replace (→ Page 104).
taminated
Exhaust turbocharger, Faulty Contact Service.
cylinder head, piston
rings, cylinder liner
White exhaust gas

Engine Not at operating temperature Run engine to reach operating tempera-
ture.
Fuel system Water in fuel Check fuel system at fuel prefilter
Drain fuel prefilter (→ Page 120).
Intercooler Leaking Contact Service.
TIM-ID: 0000051898 - 002

6.2 Engine Control Unit – ECU9 fault messages
5 – HI T-Charge Air
Yellow alarm; warning
Cause Corrective action
Charge-air temperature too high 1. Check coolant cooler and intercooler.
(Level 1). 2. Contact Service if no malfunction can be detected.
6 – SS T-Charge Air
Yellow alarm; emergency stop
Charge-air temperature too high 1. Check coolant cooler and intercooler.
9 – HI T-Coolant Intercooler
Coolant temperature in 1. Check coolant cooler for leaks, contamination and operation.
intercooler too high (Level 1). 2. Contact Service if no malfunction can be detected.
10 – SS T-Coolant Intercooler
Red alarm; emergency stop
Coolant temperature in 1. Check coolant cooler for leaks, contamination and operation.
intercooler too high (Level 2). 2. Contact Service if no malfunction can be detected.
15 – LO P-Lube Oil
Lube oil pressure too low (Level 1. Check oil level, top up as necessary (→ Page 130).
1). 2. Contact Service if no malfunction can be detected.
16 – SS P-Lube Oil
TIM-ID: 0000060724 - 001

Lube oil pressure too low (Level 1. Check oil level, top up as necessary (→ Page 130).
2). 2. Contact Service if no malfunction can be detected.

23 – LO Coolant Level
Coolant level too low. 1. Check coolant circuit for leaks. Check coolant level in expansion
tank, top up as necessary.
2. Contact Service if no malfunction can be detected.
25 – HI P-Diff. Lube Oil

Differential oil pressure at oil filter u Check oil filter, replace as necessary.
too high (Level 1).
26 – SS P-Diff. Lube Oil

Differential oil pressure at oil filter u Check oil filter, replace as necessary.
too high (Level 2).
27 – HI Leak Fuel Level

Leak-fuel level too high. u Contact Service.
30 – SS Engine Overspeed
Engine speed too high. u Restart engine.
33 – HI P-Diff-Fuel
Differential pressure at fuel filter u Check fuel filter, replace as necessary.
too high (Level 1).
TIM-ID: 0000060724 - 001
34 – SS P-Diff-Fuel
Differential pressure at fuel filter u Check fuel filter, replace as necessary.
too high (Level 2).

44 – LO Coolant Level Intercooler
Intercooler coolant level too low. 1. Check coolant circuit for leaks.
2. Check coolant level in expansion tank, top up as necessary.
3. Contact Service if no malfunction can be detected.
51 – HI T-Lube Oil
Lube oil temperature too high 1. Check cooling system.
52 – SS T-Lube Oil
Lube oil temperature too high 1. Check cooling system.
53 – HI T-Intake Air
Intake air temperature too high u-
(Level 1).
54 – HIHI T-Intake Air

Intake air temperature too high u-
(Level 2).
59 – SS T-Coolant L3
Coolant temperature too high 1. Check cooling system.
TIM-ID: 0000060724 - 001
(Level 3). 2. Contact Service.

65 – LO P-Fuel
Fuel inlet pressure too low (Level 1. Check fuel lines for leakage.
1). 2. Drain fuel prefilter (→ Page 120).
3. Replace filter element of fuel prefilter (→ Page 121).
4. Replace fuel filter and, if required, intermediate fuel filter
(→ Page 119).
66 – SS P-Fuel
Fuel inlet pressure too low (Level 1. Check fuel lines for leakage.
2). 2. Drain fuel prefilter (→ Page 120).
3. Replace filter element of fuel prefilter (→ Page 121).
4. Replace fuel filter and, if required, intermediate fuel filter
(→ Page 119).
67 – HI T-Coolant
68 – SS T-Coolant
Red alarm; emergency stop (3 min. delay)
81 – AL Rail Leakage
Rail pressure gradient too low for 1. On engine stopping: Seal off system, contact Service
start or too high for stop => HP 2. On engine starting: Check engine for leakage, if none found,
fuel system leaky, air in system attempt restarting as per operating instructions (air in system).
TIM-ID: 0000060724 - 001
82 – HI P-Fuel (Common Rail)

Rail pressure > Set value => HP 1. Check wiring of HP fuel control block.
fuel control block jamming or 2. Contact Service if no fault can be detected.
wiring faulty

83 – LO P-Fuel (Common Rail)
Rail pressure < set value; HP fuel 1. Check wiring of HP fuel control block.
control block faulty or leakage in 2. Check high-pressure system for leaks.
HP fuel system. 3. Contact Service if no fault can be detected.
89 – SS Engine Speed too Low

Engine speed too low. 1. Restart engine (→ Page 63).
2. Observe additional messages.
90 – SS Idle Speed Not Reached

Idling speed not reached, start 1. Restart engine (→ Page 63).
aborted 2. Observe additional messages.
91 – SS Release Speed Not Reached

Run-up speed not reached, start 1. Restart engine (→ Page 63).
aborted 2. Observe additional messages.
92 – SS Starter Speed Mot Reached

Starter speed not reached; 1. Check battery.
termination of starting sequence; 2. Check wiring and voltage supply.
starter does not turn or turns 3. Check fuel supply.
slowly. 4. Restart engine (→ Page 63).
5. Observe additional messages.
93 – SS T-Preheat
Red alarm; engine start interlock
TIM-ID: 0000060724 - 001

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

94 – LO T-Preheat
Preheating temperature too low 1. Extend preheating period.
(Level 1); coolant temperature too 2. Check preheater.
low for engine start.
95 – AL Prelubrication Fault
Oil priming fault u Contact Service.
102 – AL Fuel Cons. Meter Defect

Consumption meter faulty. u Replace Engine Control Unit at next opportunity.
104 – AL Eng Hours Counter Defect

Hour meter faulty. u Replace Engine Control Unit at next opportunity.
118 – LO ECU Supply Voltage

Supply voltage too low (Level 1). u Check batteries, charge as necessary; check alternator.
119 – LOLO ECU Power Supply Voltage

Supply voltage too low (Level 2). u Check batteries, charge as necessary; check alternator.
120 – HI ECU Supply Voltage

TIM-ID: 0000060724 - 001

Supply voltage too high (Level 1). u Check batteries, charge as necessary; check alternator.
121 – HIHI ECU Power Supply Voltage

Supply voltage too high (Level 2). u Check batteries, charge as necessary; check alternator.

122 – HI T-ECU
Temperature of the electronics u Check engine room ventilation.
too high.
141 – AL Power too high

The average power rate over the u-
last 24 hours of engine operation
has exceeded the set maximum
value.
180 – AL CAN1 Node Lost

Connection to a node on CAN bus 1. Check devices connected to CAN.
1 failed. 2. Check wiring (termination resistor installed?).
181 – AL CAN2 Node Lost

Connection to a node on CAN bus 1. Check devices connected to CAN.
2 failed. 2. Check wiring (termination resistor installed?).
182 – AL CAN Wrong Parameters

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

TIM-ID: 0000060724 - 001
The selected CAN mode initializes 1. Check devices connected to CAN.

communication by means of the 2. Contact Service.
PU data module. However, the
required PU data module is not
available or not valid.

184 – AL CAN PU Data Flash Error
A programming error occurred u Contact Service.
when attempting to copy a
received PU data module into the
Flash module.
186 – AL CAN1 Bus Off

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

CAN controller 1 has signaled a 1. Check CAN bus for short circuit, rectify short circuit as necessary.
warning. 2. Check shielding, improve shielding as necessary.
3. Contact Service.
188 – AL CAN2 Bus Off

CAN controller 2 is in "Bus-Off" 1. Check CAN bus for short circuit, rectify short circuit as necessary.
status. 2. Check shielding, improve shielding as necessary.
3. Contact Service.
189 – AL CAN2 Error Passive

CAN controller 2 has signaled a 1. Check CAN bus for short circuit, rectify short circuit as necessary.
warning. 2. Check shielding, improve shielding as necessary.
3. Contact Service.
201 – SD T-Coolant
TIM-ID: 0000060724 - 001

Coolant temperature sensor u Check sensor B6 and wiring, replace as necessary (→ Page 162).
faulty.

203 – SD T-Charge Air
Charge air temperature sensor u Check sensor B9 and wiring, replace as necessary (→ Page 162).
faulty.
205 – SD T-Coolant Intercooler

Coolant pressure sensor of u Check sensor B26 and wiring, replace as necessary (→ Page 162).
intercooler faulty.
208 – SD P-Charge Air

Charge air pressure sensor faulty. u Check sensor B10 and wiring, replace as necessary (→ Page 162).
211 – SD P-Lube Oil

Lube-oil pressure sensor faulty. u Check sensor B5.1 and wiring, replace as necessary (→ Page 162).
215 – SD P-HD
Rail pressure sensor faulty; High u Check sensor B48.1 and wiring, replace as necessary
pressure regulator emergency (→ Page 162).
operation mode.
216 – SD T-Lube Oil

Lube-oil temperature sensor u Check sensor B7 and wiring, replace as necessary (→ Page 162).
faulty.
TIM-ID: 0000060724 - 001
219 – SD T-Intake Air

Intake air temperature sensor u Check sensor B3 and wiring, replace as necessary (→ Page 162).
faulty.

220 – SD Level Coolant Water
Coolant level sensor faulty. 1. Check sensor F33 and wiring, replace as necessary (→ Page 162).
2. Fault is rectified when electronics are switched back on.
221 – SD P-Diff Lube Oil

Lube oil differential pressure u Check sensor B5.1 and B5.3 and wiring, replace as necessary
sensor faulty. (→ Page 162).
222 – SD Leak Fuel Level

Leak-off fuel level sensor faulty. u Check sensor F46 and wiring, replace as necessary (→ Page 162).
223 – SD Level Coolant Intercooler

Coolant level sensor for 1. Check sensor F57 and wiring, replace as necessary (→ Page 162).
intercooler defective. 2. Fault is rectified when electronics are switched back on.
227 – SD P-Oil before Filter

Sensor for lube-oil pressure u Check sensor B5.3 and wiring, replace as necessary (→ Page 162).
before filter faulty.
228 – SD P-Fuel before Filter

Fuel pressure sensor (before main u Check sensor B34.2 and wiring, replace as necessary
filter) faulty. (→ Page 162).
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229 – AL Stop Camshaft Sensor Defect

Engine stop due to camshaft 1. Check sensor and wiring to connectors B1 and B13, replace as
sensor fault and a previous necessary (→ Page 162).
crankshaft sensor fault in the 2. Acknowledge alarm.
same operating cycle. 3. Restart engine (→ Page 63).

230 – SD Crankshaft Speed
Crankshaft sensor faulty. 1. Check sensor B13 and wiring, replace as necessary (→ Page 162).
2. Fault is rectified when engine is restarted, contact Service if this is
not the case.
231 – SD Camshaft Speed

Camshaft sensor faulty. 1. Check sensor B1 and wiring, replace as necessary (→ Page 162).
2. Fault is rectified when engine is restarted, contact Service if this is
not the case.
239 – SD P-Diff Fuel

Fuel pressure sensors faulty. u Check sensor B34.2, sensor 34.3 and wiring, replace as necessary
(→ Page 162).
240 – SD P-Fuel
Fuel pressure sensor before u Check sensor B34.3 and wiring, replace as necessary
intermediate filter faulty. (→ Page 162).
245 – SD ECU Supply Voltage

Internal ECU fault. u Replace Engine Control Unit.
266 – SD Speed Setting

Analog speed setting faulty. 1. Check speed setting transmitter and wiring, replace as necessary
TIM-ID: 0000060724 - 001
(→ Page 162).
2. Fault is rectified when engine is restarted.
269 – SD Loadp. Analog fil.

The filtered analog signal from the 1. Check wiring, replace as necessary.
load pulse is not present. 2. Fault is rectified when engine is restarted.

270 – SD Frequency Input
Frequency input faulty. 1. Check speed setting transmitter and wiring, replace as necessary
(→ Page 162).
321 – AL Wiring Cylinder A1

Short circuit in cylinder A1 1. Check injector wiring.
injector wiring. Result: Misfiring. 2. Rectify injector solenoid valve short circuit (positive to negative)
(e.g. by exchanging injectors).



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TIM-ID: 0000060724 - 001


331 – AL Wiring Cylinder B1
Short circuit in cylinder B1 1. Check injector wiring.




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341 – AL Open Load Cylinder A1

Open circuit in cylinder A1 1. Check injector wiring, exclude disruption in solenoid valve (e.g. by
injector wiring. Result: Misfiring. injector replacement).
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2. Fault is rectified after each working cycle.







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351 – AL Open Load Cylinder B1

Open circuit in cylinder B1 1. Check injector wiring, exclude disruption in solenoid valve (e.g. by




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361 – AL Injector Power Stage Low

Internal electronic fault, 1. Start Engine Control Unit self-test.
electronics possibly faulty. 2. Replace ECU in case of fault; if self-test diagnoses “Electronics OK”
check for additional fault messages (e.g. wiring fault).
362 – AL Injector Power Stage High

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363 – AL Stop Injector Power Stage
Red alarm; Self-restoring
365 – AL Stop SV-Wiring Ground

Red alarm; Self-restoring
Injector wiring fault. u Check wiring, replace wiring harness as necessary.
381 – AL Wiring TOP 1

Short circuit or wire break on u Check wiring (→ Page 162).
transistor output 1 plant-side
(TOP 1).

(TOP 2).

(TOP 3).

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(TOP 4).

390 – AL MCR exceeded
DBR/MCR function: MCR u-
(continuous maximum rate) was
exceeded.
400 – AL Open Load Digital Input 1

Line disruption at digital input 1. u Check wiring (→ Page 162).





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408 – AL Open Load Emerg. Stop Input ESI

Open circuit at input for u Check wiring (→ Page 162).
emergency stop.
410 – LO U-PDU
Injector voltage too low (Level 1). u Perform Engine Control Unit self-test, replace as necessary.
411 – LOLO U-PDU

Injector voltage too low (Level 2). u Perform Engine Control Unit self-test, replace as necessary.
412 – HI U-PDU
Injector voltage too high (Level 1). u Perform Engine Control Unit self-test, replace as necessary.
413 – HIHI U-PDU

Injector voltage too high (Level 2). u Perform Engine Control Unit self-test, replace as necessary.
414 – HI Level Water Fuel Prefilter

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

415 – LO P-Coolant Intercooler
Coolant pressure in intercooler 1. Check coolant level in expansion tank, top up as necessary.
too low (Level 1). 2. Check coolant circuit for leaks.
3. Check coolant pump.
416 – SS P-Coolant Intercooler

Coolant pressure in intercooler 1. Check coolant level in expansion tank, top up as necessary.
too low (Level 2). 2. Check coolant circuit for leaks.
3. Check coolant pump.
417 – SD Level Water Fuel Prefilter

Water level sensor of fuel prefilter u Check sensor F70 and wiring, replace as necessary .
faulty, short circuit or wire break.
438 – LO P-Fuel 2 (Common Rail)

Rail pressure below specified u Contact Service.
value.
HP fuel control block faulty or
leakage in HP fuel system.
439 – HI P-Fuel 2 (Common Rail)

Rail pressure above specified 1. Check wiring of HP fuel control block.
value. 2. Contact Service if no malfunction can be detected.
HP fuel control block jamming or
wiring faulty.
441 – AL System 2 Leaky

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

444 – SD U-PDU
Sensor of injector output stage u Replace Engine Control Unit.
faulty.
445 – SD P-Ambient Air

Ambient air pressure sensor u Replace Engine Control Unit (sensor is in the ECU).
faulty.
446 – SD P-HD2
Rail pressure sensor faulty, high- u Check sensor B48.2 and wiring, replace as necessary
pressure regulator emergency (→ Page 162).
mode;
450 – SD Idle/End-Torque Input [%]

Input signal for initial/final torque 1. Check signal transmitter and wiring, replace as necessary.
faulty. 2. Restart engine (→ Page 63).
454 – SS Power Reduction Active

Power reduction activated. u Observe any other messages.
470 – SD T-ECU
Temperature sensor for Engine u Replace Engine Control Unit at next opportunity.
Control Unit faulty.
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471 – SD HP fuel control block

Actuation of HP fuel control block 1. Check HP fuel control block and wiring, replace as necessary
faulty. (→ Page 162).

472 – AL Stop SD
Shutdown channels sensor fault. u Contact Service.
474 – AL Wiring FO
Wire break or short circuit at FO u Contact Service.
channel.
476 – AL Crash Rec. Init. Error

Initialization error of crash u Contact Service.
recorder.
478 – AL Comb. Alarm Yel (Plant)

Combined alarm initiated by plant u Observe any other fault messages.
(yellow).
479 – AL Comb. Alarm Red (Plant)

Combined alarm initiated by plant u Observe any other fault messages.
(red).
480 – AL Ext. Engine Protection

External engine protection u Contact Service.
function active.
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514 – Write Error Flash

Value was not accepted into flash. u Contact Service.

536 – AL Wiring PWM_CM1
Wire break or short circuit on u Check wiring to connected device or check connected device
channel PWM_CM1. (actuator/sensor), replace as necessary.
549 – AL Power Cut-Off detected

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

Red alarm, emergency stop
Engine overspeed, camshaft. u Restart engine (→ Page 63).
558 – AL Wiring PWM_CM2

Wire break or short circuit on u Check wiring to connected device or check connected device
channel PWM_CM2. (actuator/sensor), replace as necessary.
582 – AL Emergency Stop Failure

Entered in fault memory only.
Emergency stop command was u Contact Service.
not executed.
596 – AL Cons. Parameter Record

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

602 – AL CAN Engine Start Lock
Start interlock initiated by plant. 1. Check plant configuration.
2. Restart engine (→ Page 63).
610 – AL Wiring HP Control Block 1

Wire break or short circuit at PWM u Check wiring or HP fuel control block, replace as necessary .
channel HP fuel control block.
611 – AL Wiring HP Control Block 2

Fuel prefilter differential pressure u Check wiring or HP fuel control block, replace as necessary.
too high.
615 – AL EIL Protection

Yellow alarm; emergency stop (15 min. delay)
Alarm for Protection module as u Replace EIL.
reaction to faulty or manipulated
EIL.
616 – AL EIL Error

Alarm with faulty or manipulated u Replace EIL.
EIL.
762 – AL Smart Connect Lost

Smart Connect device has failed u Check wiring or Smart Connect, replace as necessary.
TIM-ID: 0000060724 - 001
on CAN bus.
832 – AL EIL Engine Number Differs

Alarm when fault numbers differ u Contact Service.
between ECU and EIL.

836 – AL Nominal Speed Setting Fail
Active analog speed setting faulty. u Check wiring (CAN MD).
851 – AL Extern Start and HD too high

Entered in fault memory only
An external start is pending and u Contact Service.
high pressure is too high.
852 – AL Max. Blankshot Time Expired

High pressure could not be u Contact Service.
released in the max. blankshot
time.
947 – AL Wrong LSI Channel Config

Data fault on allocating LSI u Contact Service.
channels.
973 – AL Checksum IIG

Checksum calculation or word u Contact Service.
limit check for one of the injectors
is not correct.
1130 – AL Short Circuit Analog Output 1

The value output at analog output u Check wiring.
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1 deviates excessively from the

value read back.

1131 – AL Short Circuit Analog Output 2
The value output at analog output u Check wiring.
2 deviates excessively from the
value read back.
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7 Task Description
7.1 Engine
7.1.1 Engine – Cranking manually
Preconditions

Barring tool F6792910 1
Ratchet F30006212 1
DANGER
• Before barring the engine, make sure that there are no persons in the engine's danger zone.
• After finishing work on the engine, make sure that all safety devices are put back in place and all
tools are removed from the engine.
Cranking engine manually (later-

al installation)
1. Remove starting equipment from flywheel
housing (→ Page 128).
2. Engage barring tool (2) with ring gear and in-
stall on flywheel housing.
3. Apply ratchet (1) to barring tool (2).
4. Rotate crankshaft in engine direction of rota-
tion. Apart from the normal compression re-
sistance, there should be no other resistance.
Result: If the resistance exceeds the normal com-
pression resistance, contact Service.
5. For removal, carry out reverse sequence.
6. Install starting equipment on flywheel hous-
ing (→ Page 129).
TIM-ID: 0000053448 - 001
102 | Task Description | MS15054/00E 2015-09

7.1.2 Engine – Barring with starting system
Preconditions
☑ External pushbutton “Bar engine without starting” is provided.
DANGER
• Before cranking the engine with starter system, make sure that there are no persons in the engine's
danger zone.
Barring engine with starting system

1. If fitted, 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 procedure after about 20 seconds if necessary.
TIM-ID: 0000061047 - 001
MS15054/00E 2015-09 | Task Description | 103

7.2 Crankcase Breather
7.2.1 Crankcase breather – Oil mist fine separator replacement
Preconditions

Engine oil
Oil mist fine separator (→ Spare Parts Catalog)
O-ring (→ Spare Parts Catalog)
WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Wear protective clothing, gloves, and goggles / safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.
Replacing oil mist fine separator

1. Unscrew screws (1) and remove together
with washers (2) and retainer (3).
2. Replace oil mist fine separator (4).
3. Replace O-ring (5) if necessary.
4. Screw in screws (1) with washers (2) and re-
tainer (3).
5. Replace further oil mist fine separators in the
same way.
TIM-ID: 0000053449 - 002

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

Valve clearance gauge Y4345893 1
Barring device F6792910 1
Ratchet F30006212 1
Double-head box wrench F30002800 1
Angular screw driver F30453001 1
Socket wrench F30030450 1
Torque wrench, 20-100 Nm F30026582 1
Measuring instrument Y4348409 1
Preparatory steps
1. Install barring tool (→ Page 102).
2. Remove cylinder head cover (→ Page 108).
Move piston of cylinder A1 to

TDC position (without marking
on flywheel)
Note: With cylinder head and valve gear installed.
1. Insert preloaded measuring gauge (2) into
measuring device (4) and secure using
screw (1).
2. Install measuring device (4) in cylinder head
and secure using knurled screw (3).
3. Set dial gauge (2) to zero.
4. Turn engine using barring device until piston
A1 reaches firing TDC.
Result: The piston is at firing TDC when both rocker
arms are unloaded, i.e. have clearance.
TIM-ID: 0000060301 - 002
Moving piston of cylinder A1 to TDC position (with marking on flywheel)

1. Unscrew plug screw on B-side of flywheel housing.
2. Turn engine in direction of rotation until marking on flywheel is visible in center.
Result: The piston is at firing TDC when both rocker arms are unloaded, i.e. have clearance.

Checking valve clearance at two crankshaft positions
1. Check TDC position of piston in cylinder 1 side A:
• When the rocker arms are relieved on cylinder 1 side A, the piston is at firing TDC.
• When the rocker arms are loaded on cylinder 1 side A, the piston is at overlap TDC.
2. Check valve clearance with engine cold (at max. 40 °C):
• Inlet (I) = 0.3 mm;
• Exhaust (X) = 0.4 mm.
3. Check all valve clearances at two crankshaft positions (firing TDC and overlap TDC) according to the table
below.
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.
Diagram for 12V/16V engines (two crankshaft positions)

Position Cylinder 1 2 3 4 5 6 7 8 9 10
12V
Firing TDC in cylinder A1 Side A IX I– –X I– –X ––
Side B I– –– –X I– IX –X
Overlap TDC in cylinder A1 Side A –– –X I– –X I– IX
Side B –X IX I– –X –– I–
16V
Firing TDC in cylinder A1 Side A IX –X –X I– –X I– –– ––
Side B I– –X –– I– IX I– IX –X
Overlap TDC in cylinder A1 Side A –– I– I– –X I– –X IX IX
Side B –X I– IX –X –– –X –– I–
I Inlet: Inlet valve adjustment permitted
X Exhaust: Exhaust valve adjustment permitted
– Valve adjustment not permitted
Table 9: Valve clearance adjustments
Adjusting valve clearance

1. Loosen locknut (1) and unscrew adjusting
screw (2) by a few threads.
2. Insert feeler gage between valve bridge and
rocker arm (3).
3. Readjust adjusting screw (2) so that the feel-
er gauge just passes through the gap.
TIM-ID: 0000060301 - 002

4. Tighten locknut (1) with torque wrench to the specified tightening torque, using an Allen wrench to hold the
adjusting screw (2) to prevent it from turning.
Name Size Type Lubricant Value/Standard
Locknut M12x1 Tightening torque 50 Nm +5 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.
2. Install cylinder head cover (→ Page 108).
TIM-ID: 0000060301 - 002

7.3.2 Cylinder head cover – Removal and installation
Preconditions

Torque wrench, 8–40 Nm F30043446 1
Torque wrench, 0.5–5 Nm 0015384230 1
Ratchet adapter F30027340 1
Engine oil
Gasket (→ Spare Parts Catalog)
Preparatory steps
1. Open wiring harness safety clips on cylinder head cover.
2. Disconnect wiring harness.
Removing and installing cylin-

der head cover
Note: Before removing the gasket, release injector
clamps and remove spade lugs.
1. Remove cylinder head cover (2) with gas-
ket (1) from cylinder head.
2. Clean mating face.
3. Check condition of gasket (1) in cylinder
head cover (2).
4. Replace gasket (1) if damaged.
5. Place gasket (1) in correct position on cylin-
der head.
6. Push spade lugs under the terminals on the injector and tighten with torque wrench to the specified tighten-
ing torque.
Nut M4 Tightening torque (Engine oil) 1.5 Nm ±0.25 Nm
7. Install cylinder head cover (2) with screws (4) and washer (3).
TIM-ID: 0000053452 - 002
Final steps
1. Connect wiring harness.
2. Close wiring harness safety clips on cylinder head cover.

7.4 Injector
7.4.1 Injector ‒ Replacement
Injector (→ Spare Parts Catalog)
Screw for hold-down clamp (→ Spare Parts Catalog)
Replacing injector
u Remove injector and install new one (→ Page 110).
TIM-ID: 0000053453 - 001

7.4.2 Injector – Removal and installation
Preconditions

Press-fitting tool F6790085 1
Puller F6790636 1
Fuel suction device F30378207 1
Torque wrench, 0.5–5 Nm 0015384230 1
Plug-in open-end wrench, 19 mm F30453236 1
Crowfoot wrench, 19 mm F30027424 1
Ring socket, 22 mm F30038494 1
Double-head box wrench F30011450 1
Socket wrench, 24 mm F30453238 1
Assembly compound (Kluthe Hakuform 30-15) X00067260 1
Engine oil
Sealing ring (→ Spare Parts Catalog)
WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.
WARNING
Residual pressure in HP fuel system.
Risk of injury due to fuel escaping at high pressure!
• Energize the Engine Control Unit for around 30 s after emergency stop or engine stall.
• Wear protective gloves and goggles/safety mask.
• Slowly open straight unions.
WARNING
Internal tension and residual pressure in the HP fuel system.Parts can be ejected when loosening them.
Risk of injury by ejected parts!
• Only use specified tools and devices.
• Wear goggles/facial protection.
TIM-ID: 0000050909 - 005
WARNING
Liquid or gaseous media, e.g. fuel, are poisonous.
Escaping vapors of highly volatile media, e.g. fuel or ether.
Risk of fatal injury through swallowing; risk of poisoning through inhalation; irritation to eyes
and skin!
• Seek medical attention immediately; do not induce vomiting.
• Do not inhale vapors or mist.
• Wear protective clothing, protective gloves, and safety glasses.
• If contact is made with skin, wash off with water and soap.

WARNING
Preparatory steps
1. Shut off fuel supply line.
2. Drain fuel (→ Page 118).
3. Remove cylinder head cover (→ Page 108).
Removing injector
1. Remove HP fuel line (1).
2. Unscrew union nut (2).
3. Pull off pressure pipe neck (3).
4. Extract fuel from the exposed bores using the
suction device.
5. Disconnect terminals (arrowed) on injector

and pull out cable lugs.
6. Remove gasket.
TIM-ID: 0000050909 - 005

7. Remove screw (3).
8. Take off hold-down clamp (2).
Note: Support ring on injector must likewise be re-
moved if it does not come out with the injec-
tor.
9. Use the puller to pull out injector (1).
10. After removal, seal all openings with suitable
covers.
Installing injector
1. Remove all covers before installation.
2. Clean sealing surface on cylinder head and
protective sleeve.
Note: Use a new sealing ring whenever the injector
is installed.
3. Coat sealing ring on injector (1) with assem-
bly compound.
Note: Use either the press-fitting tool or the hold-
down clamp (2) to press injector (1) into the
cylinder head.
4. Align faces on injector (1) for mounting in the
hold-down clamp (2) and insert injector by
hand in a straight line into the cylinder head.
5. Fit hold-down clamp (2) in correct position by
hand.
Installation without press-fitting tool

1. Screw in screw (3) and tighten screw (3) to carefully push injector (1) into cylinder head.
Screw M8 Preload torque (Engine oil) 5 Nm
2. Release screw (3) again and relieve hold-down clamp (2).

TIM-ID: 0000050909 - 005
Installation with press-fitting tool

1. Place press-fitting tool on hold-down clamp (2) to press injector (1) carefully into the cylinder head.
2. Place hold-down clamp (2) in correct position, screw in screw (3) and tighten hand-tight.

Installing pressure pipe neck
Note: Minimize contamination!
1. Visually inspect HP line (1) and replace if nec-
essary.
Note: Pressure pipe neck may be reused twice at
most.
2. Visually check sealing surfaces and pins on
pressure pipe neck for plastic deformation
and replace if necessary.
3. Coat sealing ring with assembly compound.
4. Coat sealing cone of pressure pipe neck (3)
with engine oil.
5. Slide pressure pipe neck (3) up to contact
point on sealing ring in cylinder head.
6. Press pressure pipe neck (3) in completely by
hand.
7. Align HP connection of injector with pressure
pipe neck (3).
8. Coat thread and shoulder of union nut (2) with engine oil and tighten to specified torque using a torque
wrench.
Retaining screw M24 Preload torque (Engine oil) 15 Nm +5 Nm
9. Tighten screw (3) for hold-down clamp (2) to specified torque using a torque wrench.
TIM-ID: 0000050909 - 005
Screw M8 Tightening torque (Engine oil) 40 Nm +4 Nm

10. Tighten union nut (2) on pressure pipe neck (3) to specified torque using a torque wrench.
Retaining screw M24 Tightening torque 50 Nm +5 Nm
Installing fuel line

1. Coat thread and shoulder of union nuts on HP fuel line (1) with engine oil.
Note: Position fuel line, ensuring it is free of tension.
2. Position HP fuel line (1) with union nut (2) in correct position between rail and pressure pipe neck (3), then
tighten by hand.
3. Tighten union nut of HP fuel line (1) on rail to specified torque using a torque wrench
a) In case of single-wall HP fuel system
Union nut M20 Tightening torque (Engine oil) 37 Nm +3 Nm
b) In case of double-wall (jacketed) HP fuel system

4. If the fuel system is jacketed, tighten retaining screw of HP fuel line (1) on pressure pipe neck (3) to speci-
fied tightening torque using torque wrench
Retaining screw M25 Tightening torque (Engine oil) 15 Nm +5 Nm
TIM-ID: 0000050909 - 005
5. Tighten union nut of HP fuel line (1) on pressure pipe neck (3) to specified torque using a torque wrench

Fitting gasket and connecting
injector cable
1. Place gasket on cylinder head, ensuring correct installation position.

2. Push cable lugs under the terminals (arrowed) on the injector and tighten to specified torque using a torque
wrench.
Nut M4 Tightening torque (Engine oil) 1.5 Nm ±0.25 Nm
Final steps
1. Install cylinder head cover (→ Page 108).
2. Open fuel supply line.
3. Vent fuel system (→ Page 117).
TIM-ID: 0000050909 - 005

7.4.3 Injector functions
Preconditions
Note: The engine will lose its emissions certification of the drift correction parameters (CDC) are not reset.
Resetting drift correction parameters (CDC) with DiaSys®

Note: After successful installation of DiaSys®, document can be found here: C:\DiaSys\Doku auf ihrem Service-
PC.
1. (→ Dialog system DiaSys® E531920/..).
2. If no DiaSys® is available, contact Service.
Entering injector coding (IIG)

Note: After successful installation of DiaSys®, document can be found here: C:\DiaSys\Doku auf ihrem Service-
PC.
1. (→ Dialog system DiaSys® E531920/..).
2. If no DiaSys® is available, contact Service.
TIM-ID: 0000045425 - 002

7.5 Fuel System
7.5.1 Fuel system – Venting
Preconditions
☑ Engine is stopped.

WARNING
• Do not smoke.
WARNING
and skin!
Fuel system – Venting

1. Open threaded vent plug (2) on filter head
and connect suitable hose.
2. Provide suitable container to collect escaping
fuel.
3. Actuate hand pump (1) until bubble-free fuel
emerges at the threaded vent plug.
TIM-ID: 0000043672 - 004
4. Close vent plug.

Threaded vent plug M16 Tightening torque 6 Nm +2 Nm
5. Lock hand pump (1).

7.5.2 Fuel – Draining
Preconditions
WARNING
• Do not smoke.
WARNING
and skin!
Fuel – Draining
1. Provide a suitable container in which to collect the fuel.
2. Remove fuel filter (→ Page 119).
3. Catch fuel as it runs out.
4. Install fuel filter (→ Page 119).
TIM-ID: 0000004702 - 004

7.6 Fuel Filter
7.6.1 Fuel filter – Replacement
Preconditions

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

1. Remove easy-change filter (3) with filter
wrench.
2. Clean sealing surface on retainer (1).
3. Slightly lubricate seal (2) on easy-change fil-
ter.
4. Install and tighten easy-change filter by hand.
5. Replace further easy-change filters in the
same way.
6. Vent fuel system (→ Page 117).
TIM-ID: 0000053454 - 003

7.6.2 Fuel prefilter – Draining
Preconditions
☑ Engine is stopped and starting disabled (non-switchable fuel prefilters only).
DANGER
WARNING
• Do not smoke.
WARNING
and skin!
WARNING
Fuel prefilter – Draining

1. Provide a suitable container to collect the wa-
ter.
2. Open drain screw (1).
3. Allow water to drain.
4. Close drain screw (2) again.
TIM-ID: 0000058151 - 003

7.6.3 Fuel prefilter – Filter element replacement
Preconditions

Diesel fuel
Filter parts kit (→ Spare Parts Catalog)
DANGER
WARNING
• Do not smoke.
WARNING
and skin!
WARNING
Preparatory step
u Provide a suitable container in which to collect the fuel.
TIM-ID: 0000058149 - 003

Replacing fuel prefilter
1. Close fuel supply.
2. Unscrew filter cover (1).
3. Remove filter element (3) from filter hous-
ing (4).
4. Install new O-ring (2) on filter cover (1).
5. Coat new O-ring (2) with fuel.
6. Insert new filter element (3) into filter hous-
ing (4).
7. Screw filter cover (1) into filter housing.
8. Tighten filter cover (1) with torque wrench to the specified tightening torque.
Filter cover Tightening torque 40 Nm
Final steps
1. Open fuel supply.
2. Vent fuel prefilter (→ Page 123).
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7.6.4 Fuel prefilter – Venting
Preconditions
DANGER
WARNING
• Do not smoke.
WARNING
and skin!
WARNING
Fuel prefilter – Venting

1. Unlock fuel priming pump, screw out han-
dle (1).
Note: Catch emerging fuel with a suitable cloth.
2. Unscrew the vent plug (2) approx. 3 to 4 rev-
olutions.
3. Operate the pump with the handle (1) until
bubble-free fuel emerges from the vent
plug (2).
4. Close vent plug (2) and tighten by hand.
Note: Catch emerging fuel with a suitable cloth.
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5. Unscrew vent plugs (3) approx. 3 to 4 revolu-

tions.
6. Operate the pump with the handle (1) until
bubble-free fuel emerges from the vent
plug (2).
7. Close vent plug (2) and tighten by hand.

7.7 Air Filter
7.7.1 Air filter – Replacement
Air filter (→ Spare Parts Catalog)
Filter insert (→ Spare Parts Catalog)
Filter element (→ Spare Parts Catalog)
Air filter – Replacement

1. Remove air filter(s) and install new one(s) (→ Page 125).
2. Reset signal ring of service indicator (→ Page 126).
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7.7.2 Air filter – Removal and installation
Preconditions
Air filter – Removal and installa-

tion
1. Release clamp (2).
2. Remove air filter (1) and clamp (2) from con-
necting flange of intake housing (3).
3. Clean the connecting flange of the intake
housing (3) and check it for free passage.
4. Fit air filter (1) and clamp (2) on connecting
flange of intake housing (3).
5. Tighten clamp (2).
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7.8 Air Intake
7.8.1 Service indicator – Signal ring position check
Preconditions
Checking signal ring position

1. If the signal ring is completely visible in the
control window (2), replace air filter
(→ Page 124).
2. After installation of new filter, press reset
button (1).
Result: Engaged piston with signal ring moves back
to initial position.
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7.9 Starting Equipment
7.9.1 Electric starter ‒ Overview
1 Starter 4 Gasket 7 Nut

2 Gasket 5 Stud
3 Flange 6 Washer
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7.9.2 Starter – Removal
Preconditions
DANGER
Electric voltage supply for operation.
Danger of burns and fatal electric shock!
• Make certain that the power supply to the product is switched off before starting work. Secure
against unintentional switching on!
WARNING
The component is very heavy and may fall or tip over if unstable.
Risk of crushing injuries to persons or limbs!
• Use appropriate lifting gear and equipment.
• Wear safety footwear.
Disconnecting and removing starter

1. Disconnect starter battery.
2. Prior to disconnection, mark all cables.
3. Remove all cables from starter.
4. Protect all cables from damage.
5. Remove starter nuts as shown in overview drawing (→ Page 127).
6. Remove starter.
7. Protect starter from damage.
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7.9.3 Starter ‒ Installation
Preconditions
DANGER
Electric voltage supply for operation.
Danger of burns and fatal electric shock!
• Make certain that the power supply to the product is switched off before starting work. Secure
against unintentional switching on!
WARNING
The component is very heavy and may fall or tip over if unstable.
Risk of crushing injuries to persons or limbs!
• Use appropriate lifting gear and equipment.
• Wear safety footwear.
Installing starter
1. Coat starter pinion with lubricating grease.
2. Install starter as per overview drawing (→ Page 127).
Starter, electrical connection

1. Connect cables in accordance with the marking.
2. Screw on nuts of connections and use torque wrench to tighten to specified tightening torque.
a) Terminal 30 (battery connection)
Nut M18 Tightening torque 24.7 to 27.5 Nm
b) Terminal 50 (switching connection)

Nut M6 Tightening torque 5 to 7 Nm
c) Terminal 31 (negative terminal)

Nut M10 Tightening torque 13.5 to 15.8 Nm
3. Check starter for correct operation.

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7.10 Lube Oil System, Lube Oil Circuit
7.10.1 Engine oil – Level check
Preconditions
Oil level check prior to engine

start
1. Withdraw oil dipstick from guide tube and
wipe it.
2. Insert oil dipstick into guide tube up to the
stop, withdraw after approx. 10 seconds and
check oil level.
3. Oil level must be between "min." (2) and
"max." (1) marks.
4. Top up with oil up to the "max" (1) mark
(→ Page 131) if required.
5. Insert oil dipstick into guide tube up to the
stop.
Oil level check after the engine is stopped

1. 5 minutes after stopping the engine, remove oil dipstick from the guide tube and wipe it.
2. Insert oil dipstick into guide tube up to the stop, withdraw after approx. 10 seconds and check oil level.
3. Oil level must be between "min." and "max." marks.
4. Top up to "max." if required (→ Page 131).
5. Insert oil dipstick into guide tube up to the stop.
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7.10.2 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 132).
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 132).
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 130).
5. After oil change and filter replacement, bar
engine with starting system (→ Page 103).
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7.11 Oil Filtration / Cooling
7.11.1 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 (2) with filter wrench.
2. Clean sealing face on connecting piece (1).
3. Check sealing ring (arrow) of new oil filter
and moisten with oil.
4. Screw on and tighten oil filter by hand.
5. Replace other oil filters in the same way.
6. After each oil change and filter replacement,
crank engine with starting equipment
(→ Page 103).
7. Check oil level (→ Page 130).
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7.11.2 Centrifugal oil filter – Cleaning and filter-sleeve replacement
Preconditions

Ratchet F30027340 1
Cold cleaner(Hakutex 60) X00056750 1
Filter sleeve (→ Spare Parts Catalog)
WARNING
Hot oil.
WARNING
Centrifugal oil filter – Cleaning

and filter-sleeve replacement
1. Slacken off nuts (4) crosswise.
2. Remove housing cover (1).
3. Carefully remove rotor (3) from lower part of
housing (5).
4. Remove nut (2).
5. Carefully remove rotor cap.
6. Remove filter sleeve from rotor cap.
7. Measure thickness of oil residues on filter
sleeve.
Result: If the oil residues exceed the maximum layer
thickness of 25 mm, shorten the mainte-
nance interval.
8. Disassemble rotor tube, filter cone and rotor
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bottom.
9. Wash out rotor cover, rotor tube, filter cone
and rotor bottom with cold cleaner.
10. Blow out with compressed air.
11. Check sealing ring, fit new one if necessary.
12. Insert new filter sleeve into rotor cap with the
smooth paper surface facing the outer wall.
13. Assemble rotor tube, filter cone and rotor
bottom with sealing ring.
14. Carefully insert rotor in lower part of housing.

15. Use torque wrench to tighten nut (2) to specified tightening torque.
Nut Tightening torque 8 Nm + 1 Nm
16. Fit housing cover (1).

17. Screw on nuts (4).
18. Use torque wrench to tighten nuts (4) crosswise to specified tightening torque.
Nut Tightening torque 12 Nm + 2 Nm
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7.12 Coolant Circuit, General, High-Temperature Circuit
7.12.1 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 counterclock-
wise and remove.
3. Check coolant level (coolant must be visible
at the lower edge of the cast-in eye or at the
marking plate).
4. Top up with treated coolant as necessary
(→ Page 138).
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 138).
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7.12.2 Engine coolant – Change
Coolant
Engine coolant change

1. Drain engine coolant (→ Page 137).
2. Fill with engine coolant (→ Page 138).
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7.12.3 Engine coolant – Draining
Preconditions
WARNING
Preparatory steps
1. Provide a suitable container to catch the coolant.
2. Switch off preheating unit.
Draining engine coolant

wise and remove.
3. Draw off precipitated corrosion inhibitor oil
from the coolant expansion tank through filler
neck.
4. Open drain screws and drain engine coolant
at the following drain points:
• At the preheating unit;
• At HT coolant pump (1);
• At crankcase (2) and (3), right side.
5. Close all open drain points.
6. Position breather valve on filler neck and
close.
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7.12.4 Engine coolant – Filling
Preconditions

Coolant
WARNING
WARNING
NOTICE
Cold coolant in hot engine can cause thermal stress.
Possible formation of cracks in the engine!
• Fill / top up coolant only into cold engine.
Preparatory steps
1. Turn breather valve (1) on coolant expansion
2. Continue to turn breather valve (1) counter-
clockwise and remove.
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Filling engine coolant

1. Pour in coolant via filler neck on expansion tank.
2. Check proper condition of breather valve (1), clean sealing faces if required.
3. Fit breather valve (1) and close it.

Final steps
1. Start the engine and operate it at idle speed for some minutes.
2. Check coolant level, top up coolant if necessary (→ Page 135).
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7.12.5 Engine coolant pump – Relief bore check
DANGER
WARNING
Engine coolant pump – Relief

bore check
1. Check relief bore for oil and coolant dis-
charge.
• Permissible coolant discharge: up to 10
drops per hour;
• Permissible oil discharge: up to 5 drops
per hour.
Result: If discharge exceeds the specified limits, con-
tact Service.
2. If relief bore is dirty:
• Stop engine (→ Page 66) and disable en-
gine start.
• Clean relief bore with a wire.
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7.12.6 Engine coolant – Sample extraction and analysis
Preconditions

MTU test kit 5605892099/00 1
WARNING
Engine coolant – Sample extraction and analysis

1. Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to es-
cape.
2. Continue to turn breather valve counterclockwise and remove.
3. Draw off precipitated corrosion inhibitor oil from expansion tank and dispose of oil.
4. Draw off approx. 1 liter coolant and drain into a clean container.
5. Using the equipment and chemicals from the MTU test kit, examine coolant for:
• antifreeze concentration;
• corrosion inhibitor concentration;
• pH value.
6. Fit breather valve and close it.
7. Engine coolant change intervals (→ MTU Fluids and Lubricants Specifications A001061/..).
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7.13 Low-Temperature Circuit
7.13.1 Charge-air coolant – Filling
Preconditions

Coolant
WARNING
WARNING
NOTICE
Cold coolant in hot engine can cause thermal stress.
Possible formation of cracks in the engine!
• Fill / top up coolant only into cold engine.
Preparatory steps
1. Turn breather valve (1) on coolant expansion
2. Continue to turn breather valve (1) counter-
clockwise and remove.
3. Remove plug screw from filling point on cool-
ant line to intercooler.
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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 (1), clean sealing faces if required.
4. Fit breather valve (1) and close it.
Final steps
1. Start the engine and operate it at idle speed for some minutes.
2. Check coolant level (→ Page 146).
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7.13.2 Charge-air coolant – Draining
Preconditions

WARNING
Draining charge-air coolant

1. Provide a suitable container to catch the
coolant.
wise and remove.
4. Draw off precipitated corrosion inhibitor oil
from the coolant expansion tank through filler
neck.
5. Open drain plug and drain coolant at charge-
air coolant pump (1).
6. Screw in all drain plugs with new sealing
rings.
7. Position breather valve on filler neck and
close.
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7.13.3 Charge-air coolant – Change
Coolant
Charge-air coolant – Change

1. Drain charge-air coolant (→ Page 144).
2. Fill with charge-air coolant (→ Page 142).
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7.13.4 Charge-air coolant – Level check
Preconditions
WARNING
Checking charge-air coolant level at filler neck:

1. Turn cap on coolant expansion tank counterclockwise to the first stop and allow pressure to escape.
2. Continue to turn cap counterclockwise and remove.
Note: Charge-air coolant must be visible at marker
plate.
3. Check charge-air coolant level.
4. Top up charge-air coolant as necessary
(→ Page 142).
5. Check that cap is in serviceable condition.
6. Clean sealing surfaces as necessary.
7. Fit cap and close tight.
Checking charge-air coolant level by means of level sensor:

Note: Coolant level is automatically monitored by engine control system.
1. Switch on engine control system and check readings on the display.
2. Top up charge-air coolant as necessary (→ Page 142).
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7.13.5 Charge-air coolant pump – Relief bore check
DANGER
WARNING
Charge-air coolant pump – Re-

lief bore check
1. Check relief bore for oil and coolant dis-
charge.
• Permissible coolant discharge: up to 10
drops per hour;
• Permissible oil discharge: Up to 5 drops/
hour;
Result: If discharge exceeds the specified limits, con-
tact Service.
2. If relief bore is dirty:
• Stop engine (→ Page 66) and disable en-
gine start.
• Clean relief bore with wire.
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7.13.6 Intercooler – Checking condensate drain for coolant discharge and obstructions
Preconditions

WARNING
Checking intercooler condensate drain 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 110).
2. Bar engine manually (→ Page 102).
3. Bar engine with the starting system to blow out cylinder chambers (→ Page 103).
4. Install injectors (→ Page 110).
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7.14 Belt Drive
7.14.1 Drive belt – Condition check
Preconditions
☑ Guard is removed.
Drive belt – Condition check
Item Findings Action

Drive belt A Singular cracks None
Drive belt B Cracks on entire circumference Replace (→ Page 153)
Drive belt C Chunking (→ Page 154)
Drive belt Belt is oily, shows signs of over-
heating
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7.14.2 Drive belt – Tension check
Preconditions

Tester Y4345711 1
Belt tension tester, 150–600 N Y20097429 1
Measuring depression depth with preload measuring device

Note: The frequency measurement procedure is the preferred one because it provides more exact measurement
results.
1. Remove protective cover.
2. Set preload measuring device onto the drive
belt in the middle between the belt pulleys
(arrow).
3. Using pushbutton, press vertically on top of
drive belt exerting even pressure until spring
can be heard or felt to engage.
4. Do not exert any more pressure as displayed
value will otherwise be falsified.
5. Remove preload measuring device without
changing the position of the display arm.
6. Read off measured value at the intersection
of display arm and “KG” scale. Refer to table
below for set-point value.
7. If the measured values deviate from the
specified values, adjust drive belt tension
(→ Page 152).
8. Install protective cover.
Belt length ‒ Application Measured value Measured value

Initial installation (new belt, (used belt, runtime 500 h)
runtime 0.5-2 h)
Drive belt 1800 mm – Fan Depression depth: 7 mm Depression depth: 8 mm
Test force: 188 N Test force: 188 N
Drive belt 1520 mm – Fan Depression depth: 6 mm Depression depth: 7 mm
Test force: 188 N Test force: 188 N
Table 10: Set-point values ‒ Measurement with preload measuring device

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Measuring belt tension with frequency meter

2. Tap against the belt with the handle of a hammer or with a wrench to initiate belt vibration.
3. Hold measuring tip of the frequency meter over belt drive.
4. The measured frequency value appears on the display of the frequency meter.
5. Compare measured value with value in the table.
6. If the measured values deviate from the specified values, adjust drive belt tension (→ Page 152).

Belt length ‒ Application Measured value Measured value
Initial installation (new belt) Operating tension (used belt)
Drive belt 1800 mm – Fan Frequency: 88 ±1 Hz Frequency: 77 ±1 Hz
Drive belt 1520 mm – Fan Frequency: 104 ±1 Hz Frequency: 92 ±1 Hz
Table 11: Set-point values ‒ Measurement with frequency meter

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7.14.3 Drive belt ‒ Tension adjustment
Preconditions

Engine oil
Drive belt ‒ Tension adjustment

1. Remove protective cover from cooler.
2. Remove protective grill from fan.
3. Loosen screws (2) slightly.
4. Adjust belt tension acc. to specifications with
screw (1) (→ Page 150).
5. Use torque wrench to tighten screws (2) to specified tightening torque.

Screw M16 x 50 Tightening torque (Engine oil) 180 Nm +18 Nm
6. Tighten screw (1) to specified torque using a torque wrench.

Screw M16 x Tightening torque (Engine oil) 50 Nm +5 Nm
200
7. Install protective grill on fan.

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8. Install protective cover on cooler.

7.14.4 Drive belt – Replacement
Preconditions

Drive belt (→ Spare Parts Catalog)
Replacing fan drive belt

1. Remove protective cover from cooler.
2. Remove protective grill from fan.
3. Remove fan.
4. Slacken off securing screws (2).
5. Screw out screw (1) until drive belt can be re-
moved.
6. Check belt pulley on cooler bearing mount
and crankshaft for contamination and clean if
necessary.
Note: When placing the drive belt in the grooves, no
force must be applied.
7. Fit new drive belt.
8. Adjust and check drive belt tension
(→ Page 152).
9. Install fan.
10. Install protective grill on fan.
11. Install protective cover on cooler.
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7.15 Battery-Charging Generator
7.15.1 Battery-charger drive – Drive belt replacement
Preconditions

Tester Y4345711 1
Belt tension tester, 150–600 N Y20097429 1
Engine oil
Drive belt (→ Spare Parts Catalog) 1
Preparatory steps
1. Remove safety equipment (if fitted).
2. Remove screws of protective cover (free end).
Replacing the drive belt

1. For initial installation: Moisten running surfa-
ces of the battery charger carrier (2) with oil.
2. For re-tensioning: Undo screws (1) and trickle
oil into the gap between gearcase (3) and
battery charger carrier (2).
3. Remove drive belt.
4. Check cleanness of belt pulleys.
5. Fit new drive belt on belt pulleys without ten-
sion.
6. Tighten screws (1) to torque.

Screw M10 Preload torque 10 Nm
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7. Insert and tighten clamping bolt (4) to torque and tension drive belt to specified set value.
Clamping bolt - Preload torque 8 Nm
Belt ‒ Application Measured value Measured value

Drive belt – Battery-charging gen- Frequency: 95.9 +2 Hz Frequency: 84.1 +2 Hz
erator
Table 12: Set-point values ‒ Measurement with frequency meter

Belt ‒ Application Measured value Measured value
Drive belt – Battery-charging gen- Depression depth: 7.8 mm Depression depth: 8.9 mm
erator Test force: 60 N Test force: 60 N
Table 13: Set-point values ‒ Measurement with preload measuring device

8. Tighten screws (1).
9. Use nut (5) to fasten the clamping bolt (4).
Final steps
2. Install screws of protective cover.
3. Install safety equipment (if fitted).
4. Check function of safety equipment (if fitted).
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7.16 Fuel Supply System
7.16.1 Differential pressure gage – Check
WARNING
• Do not smoke.
Checking differential pressure gage

1. Switch on fuel treatment system (optional).
2. Set both alarm points at the differential pressure gage to zero.
Result: Alarm is triggered after preset time.
3. Rest both alarm points at the differential pressure gage (see manufacturer's documentation).
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7.16.2 Coolant level sensor – Check
Preconditions
☑ Plant has been put out of operation.
WARNING
• Do not smoke.
Checking coolant level sensor

1. Drain coolant slowly.
Result: Alarm must be issued after the preset time.
2. Put plant into operation.
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7.16.3 Pump capacity – Check
WARNING
• Do not smoke.
Checking pump capacity

1. Install suitable pressure gage in the intake connection of the pump.
2. Check pump pressure.
a) Switch on fuel treatment system (optional).
Note: The pressure limiting valve at the pump might respond and open. Audible noise is caused by overflowing fuel
and can be disregarded.
b) Close ball valve at the outlet of the fuel treatment system.
c) Check pressure at the pressure gage in the inlet to the fuel treatment system and note down.
3. Checking pump pressure in throttled condition.
a) Reduce suction pressure of pump to -0.8 bar with the shut-off valve at the pump intake side.
b) Check pressure at the pressure gage in the inlet to the fuel treatment system and note down.
c) Open ball valve at inlet and outlet of fuel treatment system.
4. Calculate wear limit.
Example:
Measured value (normal condition). 3 bar
Measured value (throttled). 2.6 bar
If the determined pressure (throttled) is undershot by the determined pressure (normal) by 10%, the wear
limit is reached. Repair pump (inform Service).
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7.17 Engine Governor
7.17.1 Engine control system – Overview
1 Connector X2 3 Connector X3 5 Screw

2 Engine control system 4 Washer 6 Damper
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7.17.2 Engine governor – Removal and installation
Preconditions

Engine governor (→ Spare Parts Catalog) 1
Resilient mount (→ Spare Parts Catalog)
NOTICE
Wrong engine governor installed.
Engine damage!
• When reassembling an engine, make sure that the governor with the data record for the given engine
is installed.
Removing engine governor from

engine
1. Note or mark assignment of cables and con-
nectors.
2. Release latches on connectors (1) and (3).
3. Disconnect all connectors.
4. Remove all screws (5).
5. Remove engine governor (2).
Installing engine governor on engine

1. Install in reverse order. Ensure correct assignment of connectors and sockets in so doing.
2. Check resilient mount before installation.
Result: Replace resilient mount if porous or defective.
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7.17.3 Engine governor plug connections – Check
Preconditions
☑ Engine stopped and starting disabled.
☑ Electronic engine management system is de-energized.
NOTICE
Insertion of unsuitable test probe, e.g. test prod.
The contacts in the plug connection can be bent!
• Carry out check of plug connection only with test connectors.
Checking plug connections at engine governor

1. Check all plug connections for secure seating.
2. Lock loose connectors.
3. Check dust cap on ECU and EXU connectors for damage and correct seating.
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7.18 Wiring (General) for Engine/Gearbox/Unit
7.18.1 Engine cabling – Check
Preconditions

Solvent (isopropyl alcohol) X00058037 1
Engine cabling – Check

1. Check securing screws of cable clamps on engine and tighten loose screw connections.
2. Ensure that cables are securely seated in clamps and cannot move freely.
3. Check if all cable clips are closed and intact.
4. Replace faulty cable clips.
5. Check cable clamps for secure fit, tighten loose clamps.
6. Replace faulty cable clamps.
7. Visually inspect the following electrical components for damage:
• Connector housings
• Contacts
• Plug connectors
• Cables and terminals
• Plug-in contacts
Result: If cable conductors are damaged, contact Service.
Note: Close connectors that are not plugged in with the protective cap supplied.
8. Use isopropyl alcohol to clean dirty connector housings, plug connectors and contacts.
9. Ensure that all connecting plugs of the sensors are correctly engaged.
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7.19 Accessories for (Electronic) Engine Governor / Control System
7.19.1 Engine governor and connector – Cleaning
Preconditions

Solvent (isopropyl alcohol) X00058037 1
NOTICE
Insertion of unsuitable test probe, e.g. test prod.
The contacts in the plug connection can be bent!
• Carry out check of plug connection only with test connectors.
Engine governor and connector – Cleaning

1. Use isopropyl alcohol to remove coarse dirt from housing surface.
2. Use isopropyl alcohol to remove dirt from the connector and cable surfaces.
3. Check legibility of cable labels. Clean or replace illegible labels.
Heavily contaminated connectors on engine governor – Cleaning

Note: Close connectors that are not plugged in with the protective cap supplied.
1. Release latches of connectors and withdraw 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 latch them.
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8 Appendix A
8.1 List of abbreviations
Abbrevia- Meaning Explanation
tion
AL Alarm -
ANSI American National Standards Institute Association of American standardization organiza-
tions
ATL Abgasturbolader Exhaust turbocharger (ETC)
BDM Backup Data Module -
BR Baureihe Series
BV Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU Publication
No. A01061/..
CAN Controller Area Network Data bus system, bus standard
CPP Controllable Pitch Propeller
DIN Deutsches Institut für Normung e. V. At the same time identifier of German standards (DIN
= “Deutsche Industrie-Norm”)
DIS Display Unit Display panel
DL Default Lost Alarm: CAN bus missing
ECS Engine Control System Engine management system
ECU Engine Control Unit Engine governor
EDM Engine Data Module Memory module for engine data
EMU Engine Monitoring Unit
ETC Exhaust turbocharger
GCU Gear Control Unit
GMU Gear Monitoring Unit
HAT Harbor Acceptance Test
HI High Range violation alarm (1st upper limit value)
HIHI High High Range violation alarm (2nd upper limit value)
IDM Interface Data Module Memory module for interface data
ISO International Organization for Stand- International umbrella organization of all standards
ardization institutes
KGS Kupplungsgegenseite Engine free end in accordance with DIN ISO 1204
KS Kupplungsseite Engine driving end in accordance with DIN ISO 1204
LCD Liquid Crystal Display, Liquid Crystal
TIM-ID: 0000026477 - 004
Device
LCU Local Control Unit LOP subassembly
LED Light Emitting Diode
LO Low Range violation alarm (1st lower limit value)
LOLO Low Low Range violation alarm (2nd lower limit value)
LOP Local Operating Panel
LOS Local Operating Station Local control unit
LPU Oil refill pump
164 | Appendix A | MS15054/00E 2015-09

Abbrevia- Meaning Explanation
tion
MCS Monitoring and Control System
MG Message
MPU Microprocessor Unit, Microprocessing
Unit
OT Oberer Totpunkt Top dead center (TDC)
PAN Panel Control panel
PCU/PMU Propeller Control Unit Propeller controller
PIM Peripheral Interface Module
PPC Priming Pump Control
RCS Remote Control System
RL Redundancy Lost Alarm: Redundant CAN bus failure
SAT Sea Acceptance Test
SD Sensor Defect Alarm: Sensor failure
SDAF Shut Down Air Flap(s) Emergency air-shutoff flap(s)
SS Safety System Safety system alarm
SSK Schnellschlussklappen Emergency air-shutoff flap(s)
TD Transmitter Deviation Alarm: Sensor comparison fault
UT Unterer Totpunkt Bottom dead center (BDC)
TIM-ID: 0000026477 - 004
MS15054/00E 2015-09 | Appendix A | 165

8.2 MTU contact persons/service partners
Our worldwide sales network with its subsidiaries, sales offices, representatives and customer service cen-
ters 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 oper-
ating conditions, or for spare parts supply.
Your contact person in our Customer Assistance Center:
E-mail: info@mtu-online.com
Tel.: +49 7541 9077777
Fax: +49 7541 9077778
Asia/Pacific: +65 6100 2688
North and Latin America: +1 248 560 8000
Spare parts service

Fast, simple and correct identification of spare parts for your drive system or vehicle fleet. The right spare
part at the right time at the right place.
With this aim in mind, we can call on a globally networked spares logistics system, a central warehouse at
headquarters and on-site stores at our subsidiary companies, agencies and service workshops.
Your contact at Headquarters:
E-mail: spare.parts@mtu-online.com
Tel.: +49 7541 908555
Fax: +49 7541 908121
TIM-ID: 0000000873 - 015
166 | Appendix A | MS15054/00E 2015-09

9 Appendix B
9.1 Special Tools
Angular screw driver
Part No.: F30453001
Qty.: 1
Used in: 7.3.1 Valve clearance – Check and adjustment
(→ Page 105)
Barring device
Part No.: F6792910
Qty.: 1
(→ Page 105)
Barring tool
Part No.: F6792910
Qty.: 1
Used in: 7.1.1 Engine – Cranking manually (→ Page 102)
DCL-ID: 0000037216 - 002
MS15054/00E 2015-09 | Appendix B | 167

Belt tension tester, 150–600 N
Part No.: Y20097429
Qty.: 1
Used in: 7.14.2 Drive belt – Tension check (→ Page 150)
Qty.: 1
Used in: 7.15.1 Battery-charger drive – Drive belt replacement
(→ Page 154)
Crowfoot wrench, 19 mm
Part No.: F30027424
Qty.: 1
Used in: 7.4.2 Injector – Removal and installation (→ Page 110)
Double-head box wrench

Part No.: F30002800
Qty.: 1
(→ Page 105)
Double-head box wrench

Part No.: F30011450
Qty.: 1
DCL-ID: 0000037216 - 002
168 | Appendix B | MS15054/00E 2015-09

Filter wrench
Part No.: F30379104
Qty.: 1
Used in: 7.6.1 Fuel filter – Replacement (→ Page 119)
Qty.: 1
Used in: 7.11.1 Engine oil filter – Replacement (→ Page 132)
Fuel suction device

Part No.: F30378207
Qty.: 1
High-pressure cleaning unit

Part No.: -
Qty.: 1
Used in: 4.9 Plant – Cleaning (→ Page 69)
Measuring instrument
Part No.: Y4348409
Qty.: 1
(→ Page 105)
DCL-ID: 0000037216 - 002
MS15054/00E 2015-09 | Appendix B | 169

MTU test kit
Part No.: 5605892099/00
Qty.: 1
Used in: 7.12.6 Engine coolant – Sample extraction and analysis
(→ Page 141)
Plug-in open-end wrench, 19 mm

Part No.: F30453236
Qty.: 1
Press-fitting tool
Part No.: F6790085
Qty.: 1
Puller
Part No.: F6790636
Qty.: 1
DCL-ID: 0000037216 - 002
170 | Appendix B | MS15054/00E 2015-09

Ratchet
Part No.: F30006212
Qty.: 1
Used in: 7.1.1 Engine – Cranking manually (→ Page 102)
Qty.: 1
(→ Page 105)
Ratchet
Part No.: F30027340
Qty.: 1
Used in: 7.11.2 Centrifugal oil filter – Cleaning and filter-sleeve re-
placement (→ Page 133)
Ratchet adapter
Part No.: F30027340
Qty.: 1
Used in: 7.3.2 Cylinder head cover – Removal and installation
(→ Page 108)
Qty.: 1
Qty.: 1
Used in: 7.6.3 Fuel prefilter – Filter element replacement
(→ Page 121)
Qty.: 1
Used in: 7.14.3 Drive belt ‒ Tension adjustment (→ Page 152)
Ring socket, 22 mm
Part No.: F30038494
Qty.: 1
DCL-ID: 0000037216 - 002
Qty.: 1
Used in: 7.5.1 Fuel system – Venting (→ Page 117)
MS15054/00E 2015-09 | Appendix B | 171

Ring socket, 24 mm
Part No.: F30501562
Qty.: 1
Qty.: 1
Used in: 7.14.4 Drive belt – Replacement (→ Page 153)
Socket wrench
Part No.: F30030450
Qty.: 1
(→ Page 105)
Socket wrench, 24 mm
Part No.: F30453238
Qty.: 1
Tester
Part No.: Y4345711
Qty.: 1
Used in: 7.14.2 Drive belt – Tension check (→ Page 150)
Qty.: 1
Used in: 7.15.1 Battery-charger drive – Drive belt replacement
DCL-ID: 0000037216 - 002
(→ Page 154)
172 | Appendix B | MS15054/00E 2015-09

Torque wrench, 20-100 Nm
Part No.: F30026582
Qty.: 1
(→ Page 105)
Qty.: 1
Torque wrench, 20–100 Nm

Part No.: F30026582
Qty.: 1

Part No.: F30027337
Qty.: 1
Torque wrench, 6-50 Nm

Part No.: F30027336
Qty.: 1
Used in: 7.5.1 Fuel system – Venting (→ Page 117)
Qty.: 1
Used in: 7.6.3 Fuel prefilter – Filter element replacement
DCL-ID: 0000037216 - 002
(→ Page 121)
MS15054/00E 2015-09 | Appendix B | 173

Part No.: F30043446
Qty.: 1
(→ Page 108)
Qty.: 1
Used in: 7.11.2 Centrifugal oil filter – Cleaning and filter-sleeve re-
placement (→ Page 133)
Torque wrench, 0.5–5 Nm

Part No.: 0015384230
Qty.: 1
(→ Page 108)
Qty.: 1
Valve clearance gauge

Part No.: Y4345893
Qty.: 1
(→ Page 105)
DCL-ID: 0000037216 - 002
174 | Appendix B | MS15054/00E 2015-09

9.2 Index
A Crankcase breather
Actuators – Oil mist fine separator
– Overview 18 – Replacement 104
After stopping the engine 68 Cylinder
Air filter – Designation 16
– Installation 125 Cylinder head cover
– Removal 125 – Installation 108
– Replacement 124 – Removal 108
B D
Battery-charger drive Differential pressure
– Replacement – Check
– Drive belt 154 – Gage 156
Belt Drift correction parameters
– Replacement – Reset 116
– Drive 153 Drive belt
Belt drive – Adjustment
– Adjustment – Tension 152
– Tension 152 – Check
– Check – Tension 150
– Tension 150 – Condition
– Check 149
C – Replacement 153
Cabling – Battery-charger drive 154
– Check
E
– On engine 162
CDC Electric
– Reset 116 – Starter
Centrifugal oil filter – Overview 127
– Cleaning 133 Emergency stop
Charge-air coolant – Engine 67
– Change 145 Emission label
– Check – Check 65
– Level at filler neck 146 Engine
– Level via level sensor 146 – After stopping 68
– Draining 144 – Barring
– Filling 142 – Manually 102
Charge-air coolant pump – Barring with starting system 103
– Relief bore check 147 – Emergency stop 67
Connector – Main dimensions 60
– Cleaning 163 – Overview 17
Contact persons 166 – Shutdown 66
Coolant – Starting 63
– Change 136, 145 Engine cabling
– Check 162
DCL-ID: 0000037216 - 002
– Charge air
– Filling 142 Engine control system
– Filling 138 – Overview 159
– Intercooler Engine Control Unit
– Draining 144 – Fault messages 74
– Sample Engine coolant
– Extraction and analysis 141 – Change 136
Coolant level – Draining 137
– Check 135 – Filling 138
Coolant level sensor – Sample
– Check 157 – Extraction and analysis 141
MS15054/00E 2015-09 | Appendix B | 175

Engine coolant level Engine sides
– Check 135 – Designation 16
Engine coolant pump – Relief bore check 140
Engine data 12V2000Gx6S F
– EPA Nonroad T2 (40CFR89) Fault messages
– 3B, continuous operation, variable load, ICXN 40 – Engine Control Unit 74
– EPA Nonroad T2 (40CFR89) Filter sleeve
– 3D, standby current, fuel stop power (IFN) 44 – Replacement 133
– 3F, standby operation mode, unlimited, ICXN 48 Firing order 59
– 3G, continuous operation, time-limited, ICXN 52, Fuel
55 – Draining 118
– Optimized fuel consumption, Fuel filter
– 3B, continuous operation, variable load, ICXN 22 – Replacement 119
– 3D, standby current, fuel stop power (IFN) 26 Fuel prefilter
– 3F, standby operation mode, unlimited, ICXN 30 – Filter element replacement 121
– 3G, continuous operation, time-limited, ICXN 33 – Venting 123
– 3H, standby operation mode, special qualifications Fuel prefilter
36 – Drain condensate 120
Engine data 16V2000Gx6S Fuel system
– EPA Nonroad T2 (40CFR89) – Installation
– 3B, continuous operation, variable load, ICXN 40 – Injector 110
– EPA Nonroad T2 (40CFR89) – Removal
– 3D, standby current, fuel stop power (IFN) 44 – Injector 110
– 3F, standby operation mode, unlimited, ICXN 48 – Venting 117
– EPA Stationary EMERG T2 (40CFR60)
– 3F, standby operation mode, unlimited, ICXN 48 G
– 3G, continuous operation, time-limited, ICXN 55 Gage
– Optimized fuel consumption, – Check
– 3B, continuous operation, variable load, ICXN 22 – Differential pressure 156
– 3D, standby current, fuel stop power (IFN) 26
H
– 3F, standby operation mode, unlimited, ICXN 30
– 3G, continuous operation, time-limited, ICXN 33 Hotline 166
– 3H, standby operation mode, special qualifications
I
36
Engine data 16V2000Gx6S IIG
– EPA Nonroad T2 (40CFR89) – Input 116
– 3G, continuous operation, time-limited, ICXN 52, Injector
55 – Installation 110
Engine driving end – Removal 110
– Definition 16 – Replacement 109
Engine free end Injector coding
– Definition 16 – Input 116
Engine governor Injector functions 116
– Cleaning 163 Intercooler
– Installation 160 – Condensate drain for coolant discharge
– Plug connections – Check 148
– Check 161 – Condensate drain for obstructions
– Check 148
DCL-ID: 0000037216 - 002
– Removal 160
Engine oil
L
– Centrifugal oil filter
– Cleaning 133 List of abbreviations 164
– Change 131
M
– Filter sleeve
– Replacement 133 Main dimensions
Engine oil filter – Engine 60
– Replacement 132 Maintenance schedule
Engine oil level – Maintenance task reference table [QL1] 70
– Check 130 MTU contact persons 166
176 | Appendix B | MS15054/00E 2015-09

O T
Operational checks 64 Transport 8
Overview Troubleshooting 71
– Actuators 18
– Electric V
– Starter 127 Valve clearance
– Engine 17 – Adjustment 105
– Engine governor 159 – Check 105
– Sensors 18
P
Plant
– Cleaning 69
Pump
– Charge-air coolant
– Relief bore check 147
– Engine coolant
– Relief bore check 140
Pump capacity
– Check 158
Putting into operation
– After extended out-of-service periods
– Preparation 61
– After scheduled out-of-service period
– Preparation 62
Putting the engine into operation after extended out-of-
service periods (>3 months) 61
Putting the engine into operation after scheduled out-of-
service-period 62
S
Safety notices, standards 15
Safety regulations
– Auxiliary materials 13
– Environmental protection 13
– Fire prevention 13
– Fluids and lubricants 13
– Important provisions 5
– Maintenance work 10
– Operation 9
– Organizational requirements 7
– Personnel requirements 7
– Repair work 10
– Startup 9
Safety requirements
– Safety notices, standards 15
Sensors
DCL-ID: 0000037216 - 002
– Overview 18
Service indicator
– Signal ring position check 126
Service partners 166
Spare parts service 166
Starter
– Electric
– Installation 129
– Removal 128
MS15054/00E 2015-09 | Appendix B | 177

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Operating Instructions

© 2015 Copyright MTU Friedrichshafen GmbH

7.3.2 Cylinder head cover – Removal and

MS15054/00E 2015-09 | Table of Contents | 3

7.13 Low-Temperature Circuit 142 9 Appendix B

4 | Table of Contents | MS15054/00E 2015-09

MS15054/00E 2015-09 | Safety | 5

Replacing components with emission labels

TIM-ID: 0000040530 - 007

6 | Safety | MS15054/00E 2015-09

Working clothes and personal protective equipment

MS15054/00E 2015-09 | Safety | 7

Setting down the engine following transportation

TIM-ID: 0000056873 - 002

8 | Safety | MS15054/00E 2015-09

Safety regulations during operation

Malfunctions and emergency stop

Do not inhale the exhaust gases of the product.

Operation of electrical equipment

MS15054/00E 2015-09 | Safety | 9

Safety regulations during maintenance and repair work

Never use the product as a climbing aid.

10 | Safety | MS15054/00E 2015-09

Safety regulations following maintenance and repair work

Hydraulic installation and removal

MS15054/00E 2015-09 | Safety | 11

Working with batteries

Working on electrical and electronic assemblies

Work with laser devices

Measuring deviations on components

12 | Safety | MS15054/00E 2015-09

Environmental protection and disposal

Fluids and lubricants, auxiliary materials

Used oil contains combustion residues that are harmful to health.

MS15054/00E 2015-09 | Safety | 13

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

14 | Safety | MS15054/00E 2015-09

MS15054/00E 2015-09 | Safety | 15

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

16 | General Information | MS15054/00E 2015-09

1 Air intake/air supply 6 Engine coolant pump 11 Exhaust turbocharger

Explanation of engine model designation

6 Design index (0, 1, 2,...,9)

Table 2: Explanation of engine model designation

MS15054/00E 2015-09 | General Information | 17

Item Name Monitoring of

Table 3: Sensors and actuators – Driving end

Sensors and actuators – A-side

18 | General Information | MS15054/00E 2015-09

Table 4: Sensors and actuators – A-side

MS15054/00E 2015-09 | General Information | 19

Item Name Monitoring of

Table 5: Sensors and actuators – Free end

TIM-ID: 0000060374 - 001

20 | General Information | MS15054/00E 2015-09

Item Name Monitoring of

Table 6: Sensors and actuators – B-side

MS15054/00E 2015-09 | General Information | 21

ID Product type Application Engine speed Listed per-