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Technical Documentation

Diesel Engine 12 V 2000 G22/42/62/82 16 V 2000 G22/42/62/82 18 V 2000 G62/82 Operating Instructions M015402/00E

Printed in Germany E 2002 Copyright MTU Friedrichshafen GmbH Diese Veröffentlichung einschließlich aller seiner Teile ist urheberrechtlich geschützt. Jede Verwertung oder Nutzung bedarf der vorherigen schriftlichen Zustimmung der MTU Friedrichshafen GmbH. Das gilt insbesondere für Vervielfältigung, Verbreitung, Bearbeitung, Übersetzung, Mikroverfilmungen und die Einspeicherung und / oder Verarbeitung in elektronischen Systemen, einschließlich Datenbanken und Online-Diensten. Das Handbuch ist zur Vermeidung von Störungen oder Schäden beim Betrieb zu beachten und daher vom Betreiber dem jeweiligen Wartungs- und Bedienungspersonal zur Verfügung zu stellen. Änderungen bleiben vorbehalten. Printed in Germany E 2002 Copyright MTU Friedrichshafen GmbH This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, microfilming and storage or processing on electronic systems including data bases and online services. This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage during operation. Subject to alterations and amendments. Imprimé en Allemagne E 2002 Copyright MTU Friedrichshafen GmbH Tout droit réservé pour cet ouvrage dans son intégralité. Toute utilisation ou exploitation requiert au préalable l’accord écrit de MTU Friedrichshafen GmbH. Ceci s’applique notamment à la reproduction, la diffusion, la modification, la traduction, l’archivage sur microfiches, la mémorisation et / ou le traitement sur des systèmes électroniques, y compris les bases de données et les services en ligne. Le manuel devra être observé en vue d’éviter des incidents ou des endommagements pendant le service. Aussi recommandons-nous à l’exploitant de le mettre à la disposition du personnel chargé de l’entretien et de la conduite. Modifications réservées. Impreso en Alemania E 2002 Copyright MTU Friedrichshafen GmbH Esta publicación se encuentra protegida, en toda su extensión, por los derechos de autor. Cualquier utilización de la misma, así como su reproducción, difusión, transformación, traducción, microfilmación, grabación y/o procesamiento en sistemas electrónicos, entre los que se incluyen bancos de datos y servicios en línea, precisa de la autorización previa de MTU Friedrichshafen GmbH. El manual debe tenerse presente para evitar fallos o daños durante el servicio, y, por dicho motivo, el usario debe ponerlo a disposición del personal de mantenimiento y de servicio. Nos reservamos el derecho de introducir modificaciones. Stampato in Germania E 2002 Copyright MTU Friedrichshafen GmbH Questa pubblicazione è protetta dal diritto d’autore in tutte le sue parti. Ciascun impiego od utilizzo, con particolare riguardo alla riproduzione, alla diffusione, alla modifica, alla traduzione, all’archiviazione in microfilm ed alla memorizzazione od all’elaborazione in sistemi elettronici, comprese banche dati e servizi on line, deve essere espressamente autorizzato per iscritto dalla MTU Friedrichshafen GmbH. II manuale va consultato per evitare anomalie o guasti durante il servizio, per cui va messo a disposizione dall’ utente al personale addetto alla manutenzione e alla condotta. Con riserva di modifiche. Printed in Germany  2002 Copyright MTU Friedrichshafen GmbH A presente publicação, inclusive todas as suas partes, está protegida pelo direito autoral. Qualquer aproveitamento ou uso exige a autorização prévia e por escrito da MTU Friedrichshafen GmbH. Isto diz respeito em particular à reprodução, divulgação, tratamento, tradução, microfilmagem, e a memorização e/ou processamento em sistemas eletrônicos, inclusive bancos de dados e serviços on-line. Para evitar falhas ou danos durante a operação, os dizeres do manual devem ser respeitados. Quem explora o equipamento economicamente consequentemente deve colocá- à disposição do respetivo pessoal da conservação, e à dispositção dos operadores. -lo Salvo alterações.

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Safety Safety, accident prevention and environmental protection instructions

A

Product Summary Engine summary, technical data

C

Operating Instructions Task descriptions

D

Maintenance Schedule Time schedule and maintenance task chart

E

Troubleshooting Malfunctions, causes, remedies

G

Task Description Inspection and maintenance tasks

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). spare parts. Die Informationen der Inbetriebnahmemeldung sind Grundlage für den vertraglich vereinbarten LogistikSupport (Gewährleistung. etc. Rogamos separen la tarjeta „Aviso de puesta en servicio“ y la devuelvan rellenda a MTU Friedrichshafen.). Le informazioni ivi registrate sono la base per il supporto logistico contrattuale (garanzia. Ersatzteile etc. etc. Les informations concernant la signalisation de mise en service constituent la base pour l’assistance en exploitation contrctuelle (garantie. etc.). Staccare „Avviso di messa in servizio e rispedirlo debitamente compilato alla MTU Friedrichshafen. Las informaciones respecto al aviso de puesta en servicio constituyen la base para la asistencia de logístíca contractual (garantía. rechanges.).). Veuillez séparer la carte „Signalisation de mise en service“ et la renvoyer á la MTU Friedrichshafen. piezas de repuesto. Postkarte MTU-Friedrichshafen GmbH AbteilungSCSD 88040 Friedrichshafen GERMANY .Wichtig / Important Important / Importante / Importante Bitte die Karte „Inbetriebnahmemeldung“ abtrennen und ausgefüllt an MTU Friedrichshafen zurücksenden. ricambi. Please complete and return the „Commissioning Note Card“ below to MTU Friedrichshafen. ecc. The Commissioning Note information serves as a basis for the contractually agreed logistic support (warranty.

Messa in servizio il: Inbetriebnahmemeldung Commissioning Note Notice de mese en service Aviso de puesta en servicio Avviso di messa in servizio .: No.: Order No.: Motor No. de commande: No.: Engine No.: Motore N:: Motortyp: Engine model: Moteur type: Motor tipo: Motore tipo: Eingebaut in: Installation site: Monté: Montado: Installato: Endabnehmer/Anschrift: End user's address: Adresse du client final: Dirección clientes final: Indirizzo del cliente finale: Bemerkung: Remarks: Remarques: Nota: Commento: Auftragsnr.Please use block capitals! Please use block capitals! Prière de remplir en lettres capitales! ¡A rellenar en letras de imprenta! Scrivere in stampatello! Motornr. de pedido: N.: Moteur No. commessa: Inbetriebnahmedatum: Commissioning date: Mise en service le: Puesto en servicio el.

persons and property may be at risk in the event of: • Incorrect use • Operation. This engine is a state-of-the art product and conforms with all applicable specifications and regulations. The responsibility is borne by the user alone.g. chains etc. repair or transportation. maintenance and repair personnel must be specified. Responsibilities of the operating. It must be kept at hand near the engine and accessible at any time to all personnel involved in operation. the applicable country-specific legislation and other compulsory regulations regarding accident prevention must be observed. Work clothing must be tight fitting so that it does not catch on rotating or projecting components. Modifications or conversions Modifications made by the customer to the engine may affect safety. Nevertheless. maintenance. Do not wear jewelry (e. Personnel requirements Work on the engine must only be carried out by properly qualified and instructed personnel. and in particular the safety instructions must be explained. Depending on the kind of work. maintenance or transportation of the machinery plant. General In addition to the instructions in this publication. helmet. no liability nor warranty claims vis-à-vis the engine manufacturer will be accepted. gloves. use additional protective equipment. repair or transportation. This is especially important for personnel who work on the engine only on an occasional basis. Any other use is considered improper use. The personnel must be instructed on engine operation and repair by means of this publication. Accident Prevention and Environmental Protection Instructions These instructions must be read and followed by every person involved in operation. apron.g. The specified legal minimum age must be observed. Spare parts Only genuine MTU spare parts must be used to replace components or assemblies. 15402/0 E 01-12 ©MTU . maintenance. Such personnel must be given instructions repeatedly.). In the event of any damage caused by the use of other spare parts. Working clothes and protective equipment Wear proper work clothing for all work. e. protective goggles. The manufacturer will accept no liability for any resultant damage. Correct use also includes observation of and compliance with the maintenance specifications. maintenance and repair by unqualified personnel • Modifications or Conversions • Non-compliance with the Safety Instructions Correct use The engine is intended exclusively for the application specified in the contract or defined at the time of delivery. rings. MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or conversions.Page !1 Safety. Organizational measures This publication must be issued to all personnel involved in operation.

Never place an engine on the oil pan. qualified personnel. • Laser devices of class 3B. suspend the engine on the lifting eyes of the transport pallet or transport with equipment for heavy loads (forklift truck). Laser equipment must be fitted with the protective devices necessary for safe operation according to type and application. compressed-air or hydraulic lines. When the engine is running. Mop up any leaked or spilt fluids and lubricants immediately or soak up with a suitable bonding agent. Ensure that the engine room is well ventilated. The exhaust pipework must be free of leaks and discharge the gases to atmosphere. Use only proper. unless expressively authorized by MTU on a case-to-case basis to do so. it is imperative to install transportation locking devices for crankshaft and engine mounts. do not touch battery terminals. Inadequate protection of electrical components can lead to electric shocks and serious injuries. In the case of special packaging with aluminum foil. fuel. oil. Inhalation of poisonous exhaust gases is a health hazard. which have maximum output in the visible wavelength range (400 to 700 nm). Attach sign "Do not operate" in operating area or to control equipment. generator terminals or cables. The main danger is irreparable damage to the eyes. Ensure appropriate consistency and load-bearing capacity of the ground or support surface. Always support these components in accordance with regulations on suitable frames or stands before beginning any maintenance or repair work. Take note of the engine center of gravity. © MTU 15402/0 E 01-12 . Exhaust gases from combustion engines are poisonous. never release coolant. Laser equipment can generate extremely intensive. The photochemical. Engine operation When the engine is running. thermal and optomechanical effects of the laser can cause damage. concentrated radiation by the effect of stimulated emission in the range of visible light or in the infrared or ultraviolet spectral range. During engine operation. For conducting light-beam procedures and measurement work. and in which the beam axis and surface are designed to prevent any risk to the eyes. The engine must be secured against inadvertent starting and the battery disconnected. always wear ear protectors. Maintenance and repair work must only be carried out by authorized. Never attempt to rectify faults or carry out repairs if you do not have the necessary experience or special tools required. Setting the engine down after transportation Place the engine only on an even. Prior to transporting the engine. Use only the transport and lifting equipment approved by MTU. Do not work on engines or components which are only held by lifting equipment or crane. Unless expressly permitted.Page !2 Transportation Lift the engine only with the lifting eyes provided. Secure the engine against tilting during transportation. firm surface. The engine must be especially secured against slipping or tilting when going up or down inclines and ramps. no maintenance or repair work must be carried out with the engine running. Persons not involved must keep clear. Maintenance and repair Compliance with maintenance and repair specifications is an important safety factor. always wear special laser-protection goggles. only the following laser devices must be used: • Laser devices of classes 1. calibrated tools. Working with laser equipment When working with laser equipment. a maximum output of 5 mW. Transport the engine only in the installation position. 2 or 3A.

When subjected to fire or temperatures above 300 °C the material degenerates. use the correct tightening torque and ensure that all retainers and dampers are installed correctly. are tested and authorized. mop up any spilt fluids or wipe or soak them with a suitable bonding agent. In order to prevent back injuries when lifting heavy components adults. Make sure components are placed on stable surfaces. hold a cloth over the screw or plug. To tighten the connections when installing the lines. "Viton" sealing rings) are stable under normal operating conditions. which can lead to pitting or other material damage). Do not touch elastomeric seals if they have carbonized or resinous appearance. Never bend a fuel line and do not install bent lines. lines which are to be opened. In order to avoid discharge of highly pressurized liquids. Before starting work. The max. 15402/0 E 01-12 ©MTU . or crossing MTU plant wiring harnesses. they must be removed from the engine. take care not to damage the fuel lines. 10 kg and 30 kg. collect fluids in a suitable container. Keep fuel injection lines and connections clean. (This prevents the welding current passing through the engine and causing scoring or burning at bearings. When working high on the engine. are sufficiently strong and that hooks are correctly positioned. ⇒ Risk of injury! When draining.Page !3 Before barring the engine. slings. make sure that nobody is standing in the danger zone. Do not place fuel or oil lines near hot components. etc. • Ensure that all chains. Never position the welding power supply cable adjacent to.g. Hydraulic installation and removal Only the hydraulic installation and removal equipment specified in the work schedule and in the assembly instructions must be used. The resulting acid leads to serious burning if it contacts the skin. exhaust manifold) are to be welded. The H. It is not necessary to remove the connector and the connections when carrying out welding operation on MTU electronics if the master switch for power supply is switched from "ON" to "OFF" and the wire is disconnected from the negative and positive poles on the battery. except when necessary for design reasons during installation. as the liquids can still be hot. Ensure that all fuel injection lines and pressurized oil lines have sufficient distance to other components to avoid contact with them. sliding surfaces and tooth flanks. relieve pressure in systems and H. permissible push-on pressure specified for the equipment must not be exceeded. Wear protective gloves! Take care with hot fluids in lines. Fluids emerging under high pressure can penetrate clothing and skin and may cause serious injury. ensure that the engine room is adequately ventilated. During maintenance and repair work. After working on the engine. It is even more dangerous if the engine has recently been shut down. When changing the engine oil or working on the fuel system. Welding work Never carry out welding work on the engine or engine-mounted units. Never use the engine as a ground connection. hooks. depending on age and sex. Always seal connections with caps or covers if a line is removed or opened. should only lift weights between max.P. giving off hydrogen fluoride gas. The welding unit ground connection must not be more than 60 cm from the weld point. therefore: • Use lifting gear or seek assistance. pipes and chambers ⇒ Risk of injury! Note cooling period for components which are heated for installation or removal ⇒Risk of injury! Take special care when removing ventilation or plugs from engine. Lifting eyes must not be unevenly loaded. Take special care when draining hot fluids.g. (The welding current could be induced in the cable harnesses and could possibly damage the electrical plant). check that all guards have been reinstalled and that all tools and loose components have been removed from the engine. Elastomers (e. always use suitable ladders and work platforms. If components (e.P. lines for hydraulic installation and removal are tested with 3800 bar.

Do not place tools on the battery. Do not secure wiring to fluid-carrying lines. At all workplaces with a sound pressure level over 85 dB(A). Do not allow battery acids to come in contact with skin or clothing. Operation of electrical equipment When operating electrical equipment. Always keep suitable fire-fighting equipment (fire extinguishers) at hand and familiarize yourself with their use. Do not leave cloths soaked with fluids and lubricants lying around on the engine. During hydraulic installation and removal. • For hydraulic installation. check battery polarity. screw spindle into shaft end until correct sealing is achieved. To avoid sparks in the vicinity of the battery. pump until bubble-free air emerges.g. by rubbing against other component or by a hot surface. When starting the engine with a foreign power source. Fire prevention Rectify any fuel or oil leaks immediately. open vent plugs. Noise Noise can lead to an increased risk of accident if acoustic signals. Do not weld pipes and components carrying oil or fuel. always wear ear protectors (protective wadding. the tools must be checked at regular intervals (crack test). close vent plugs). there is the risk that the component to be installed/removed may be suddenly released from the pressure connection. ensure that nobody is standing in the immediate vicinity of the component to be installed/removed. Battery pole reversal may lead to injury through the sudden discharge of acid or bursting of the battery body. On completion of the maintenance and repair work. even splashes of oil or fuel on hot components can cause fires . pay attention to the following: • Vent the hydraulic installation/removal tool. the pumps and the lines at the relevant points for the system to be used (e. any cables which have become loose must be correctly connected and secured. For a hydraulic installation/removal tool with central expansion pressure supply. • For hydraulic removal. Before connecting the cable to the battery. connect the ground lead last and remove it first. Do not store combustible fluids near the engine. Working on electrical assemblies Switch off all live appliances before carrying out any work on electrical assemblies. no cable binders must be used as.therefore always keep the engine in a clean condition. during maintenance and / or repair work. Before welding. Wear protective goggles. certain components of this equipment are live. Before use. Noncompliance with the warning instructions given for this equipment may result in serious injury or damage to property. warning shouts or noises indicating danger are drowned. © MTU 15402/0 E 01-12 . the binders can be removed but not installed a second time. As long as the system is under pressure. screw on the tool with the piston extended. Do not damage wiring during removal work and when reinstalling wiring and ensure that during operation it is not damaged by contact with sharp objects. Always tighten connectors with connector pliers.Page !4 Do not attempt to bend or apply force to lines. use cable clamps to properly support the wires. connect the ground lead from the foreign power source to the ground lead of the engine or to the ground terminal of the starter. Gases released from the battery are explosive. plugs or capsules). Before starting work. For this purpose. clean with an inflammable fluid. If wires are installed beside mechanical components and there is a risk of chafing. Avoid sparks and naked flames. screw on the tool with the piston retracted.

When using fluids. ⇒ Painting When painting in other than spray booths equipped with extractors. lubricants and filters in accordance with local regulations. compliance with environmental regulations may no longer be guaranteed. follow the safety instructions applicable to the product. After coming into contact with lead or lead-containing materials. properly designated containers. No smoking. gloves and protective clothing. oils and greases) within 5 m of the working area! Under no circumstances should clothing be oily or greasy. wear protective goggles or face mask. ⇒ Lead When working with lead or lead-containing pastes.Page !5 Environmental protection Dispose of used fluids. fixtures or workpieces. as this causes frostbite and possibly the loss of tissue. ensure good ventilation. Adopt suitable measures to avoid the formation of lead dust! Switch on fume extraction system. Do not allow vapors to penetrate clothing! Oxygen enrichment in fabric can cause working clothes to ignite suddenly! After working with liquid oxygen. Auxiliary materials Use only fluids and lubricants that have been tested and approved by MTU. Only fuels of the specified quality required to achieve emission limits must be used. Manipulation of the injection control system can influence the engine performance and exhaust emissions. As a result. do not smoke until clothing is free of vapors! Avoid all knocks and jars to the containers. Liquid oxygen should only be stored in small quantities and in regulation containers (without fixed seals)! Do not bring liquid oxygen in contact with the body (hands). Do not store combustible substances (e.g. no naked flame (risk of explosion)! Excessive oxygen in the air leads to explosive combustion. wash hands! ⇒ Acids and alkaline solutions When working with acids and alkalis. It is absolutely necessary to wear masks providing protection against paint and solvent fumes. Observe fire prevention regulations! No smoking. Take care when handling hot. Fluids and lubricants must be kept in suitable. chilled or caustic materials. which means work must only be carried out by authorized specialist companies (MTU is such a company). Immediately remove clothing wetted by acids and alkalis! Rinse injuries with plenty of water! Rinse eyes immediately with eyedrops or clean tap water. the VAwS (= regulations governing the use of materials that may affect water quality) is applicable. 15402/0 E 01-12 ©MTU . avoid direct contact to the skin and do not inhale lead vapors. lubricants and other chemical substances. No naked flame! ⇒ Liquid oxygen Liquid oxygen is highly inflammable. avoid sparks and do not smoke. In Germany. When using inflammable materials. Make sure that adjacent work areas are not affected.

fixtures or workpieces. which prevents air-borne particles being reflected and thereby prevents injury to eyes. forcing flammable liquids (danger class AI.g. ⇒ Compressed air Compressed air is air compressed at excess pressure and is stored in tanks from which it can be extracted. Avoid all knocks and jars to the containers. Rub barrier cream into hands! Wash hands after contact with used oil. When working with compressed air. if the permitted pressure for the connecting elements is lower than the pressure required. e. containers made of tin. as this causes frostbite and numbing. The pressure at which the air is kept can be read off at pressure gauges which must be connected to the compressed air tanks and the compressed air lines. results in a risk of explosion! • Do not blow dirty clothing with compressed air when being worn on the body. Wear protective clothing(including gloves and closed shoes) and protective goggles! Ensure the room is well ventilated (88% contamination of breathing with nitrogen will result in suffocation).g. © MTU 15402/0 E 01-12 . Even compressed air at low pressure penetrates clothing and. a pressure reducing valve and safety valve (set to permitted pressure) must form an intermediate connection. safety precautions must be constantly observed: • Pay special attention to the pressure level in the compressed air network and pressure vessel! • Connecting devices and equipment must either be designed for this pressure or. hands). Hose coupling and connections must be securely attached! • Always wear protective goggles when blowing off tools or extracting chips! • The snout of the air nozzle is provided with a protective disc (e.Page !6 ⇒ Liquid nitrogen Store liquid nitrogen only in small quantities and always in regulation containers without fixed covers. results in a risk of explosion! • Forcing compressed air into thin-walled containers (e.g. Do not bring liquid nitrogen in contact with the body (eyes. rubber disc). AII and B) out of containers. the air can enter the anal cavity and fatally rupture the intestines! ⇒ Used oil Used oil may contain health-threatening combustion residues. • First shut off compressed air lines before compressed air equipment is disconnected from the supply line or before equipment or tool is to be replaced! • Unauthorized use of compressed air. if the jet is directed at the back. plastic and glass) for drying purposes or to check for leaks.

Consequences: Slight injury or material damage In these cases. Pass on all safety instructions to your operating.Page !7 Warning signs Before putting the engine into service and before working on the engine. take special care. Do not paint on warning signs. Consequences: Death or serious injury ! WARNING ! In event of dangerous situations. Consequences: Death or serious injury. Warning notices This Publication contains especially emphasized safety instructions in accordance with the American standard ANSI Z535. read and follow all warning signs. maintenance. repair and transport personnel! 15402/0 E 01-12 ©MTU . Replace illegible signs. which begin with one of the following signal words according to the degree of danger: ! DANGER ! In event of immediate danger. ! CAUTION ! In event of dangerous situations. Read and become acquainted with all cautions and symbols before operating or repairing this product.

Page !8 © MTU 15402/0 E 01-12 .

driving end and free end Pumps (with separate drive) Driving. air supply 140 170 180 200 210 220 230 250 290 340 500 Exhaust system Starting system Lube oil system Cooling system Power supply. general Crankcase and externally mounted components Gear train Running gear Cylinder head Valve gear Fuel system (high pressure) Fuel system (low pressure) Turbocharger Intercooler Air intake. engine side Cooling-air system Mounting / support PTO systems. 2) 15402/0 E 01-12 ©MTU .g.Page A-1 Engine layout Illustration is also valid for 12/16/18V 2000 M60-82 engines 000 010 020 030 040 050 070 080 100 110 120 Engine. power generation and safety system Monitoring. control and regulation system Engine model designation Key to the engine model designations 12/16/18V 2000 G2x to 8x 12/16/18 = number of cylinders V = Cylinder configuration: V = Vee engine 2000 = Engine series G = Application 2/4/6/8 = Application segment x = Design index (e.

1580 mm 1605 mm Engine weight Engine model 12V 2000 G22/42/62/82 16V 2000 G22/42/62/82 18V 2000 G62/82 Engine dry weight approx. 3100 kg approx.Page A-2 Engine side and cylinder designations Engine sides are always designated as viewed from the driving end (KS). starting with No. starting with No. 2365 mm approx. 1580 mm 1690 mm approx. 2400 mm Overall width Overall height (B) (C) approx. The cylinders of each bank are numbered consecutively. 3500 kg © MTU 15402/0 E 01-12 . 1. approx. 2020 mm approx. Illustration is also valid for 12/16/18V 2000 M6082 engines Applicable designations and abbreviations Driving end = KS Free end = KGS Left side Right side Main engine dimensions Illustration is also valid for 12/16/18V 2000 G22-82 engines Engine model 12V 2000 G22/42/62/82 16V 2000 G22/42/62/82 18V 2000 G62/82 Overall length (A) approx. 1580 mm 1925 mm approx. The numbering of engine components is also from the driving end. The cylinders of the left engine side are designated "A" and those of the right side "B" (as per DIN ISO 1204). approx. 1 at the driving end. approx. 2490 kg approx.

Publication No. max. Lift the engine only with the lifting eyes provided. Engine preservation For engine preservation procedures refer to MTU Fluids and Lubricants Specification.Page A-3 Engine transportation Driving end (KS) Free end (KGS) Use only the transport and lifting equipment approved by MTU. A001061/… 15402/0 E 01-12 ©MTU . The engine must only be transported in installation position. permissible diagonal pull 10°.

16V 2000 G22/42/62/82 . 2 exhaust valves per cylinder Triple-walled.Stationary Power Generation 12V 2000 G22/42/62/82 .8 lit.18V 2000 G62/82 Engine Power Rating Engine ratings according to DIN ISO 3046: ICFN = Fuel stop power (application group 3D) ICXN = 10% overload capability (application groups 3A.84 lit. 100 . w/o coolant preheating) © MTU 15402/0 E 01-12 . / 35.Page A-4 Basic Data . G82 Direction of rotation (facing driving end) 130 mm 150 mm 1.88 lit.99 lit.10 °C Firing order 12V Firing order 16V Firing order 18V Final compression pressure at 120 rpm Firing speed at 40°C engine coolant temperature Flywheel housing Cold start capability: air temperature (w/o start assistance. 3C) MTU application group 3A: Diesel engine for power generation in unrestricted continuous operation at 100% load MTU application group 3B: Diesel engine for power generation in unrestricted continuous operation at variable load MTU application group 3D: Diesel engine for emergency standby power at variable load Intake air temperature 25 °C Barometric pressure 1000 mbar Intake air depression 15 mbar Exhaust back pressure 30 mbar Application Reference Conditions n n n n no derating up to 40 °C intake air temperature and 400 m site elevation above sea level (fan power consumption not considered) Basic Design n n n n n n n n n n n n n n n n n n n n n n n n n n 12/16/18 cylinders 90° V cylinder arrangement Four-stroke diesel Liquid cooling Direct fuel injection Exhaust turbocharging and charge-air cooling Wet. replaceable cylinder liners Piston cooling 2 inlet.120 rpm SAE 0 . / 31. G62 Compression ratio 12/16/18V G42. 23. 16 : 1 14 : 1 CCW A1-B2-A5-B4-A3-B1A6-B5-A2-B3-A4-B6 A1-B5-A3-A5-B2-B8-A2-A8B3-A7-B4-B6-A4-A6-B1-B7 A1-B6-A3-B4-A5-B2-A7-B1A9-B3-A8-B5-A6-B7-A4-B9A2-B8 30 to 36 bar approx. liquid-cooled exhaust lines Electronically-controlled fuel injection system Electronic engine management Bore Stroke Cylinder displacement Total displacement 12/16/18V Compression ratio 12/16/18V G22. 3B.

Page A-5 Basic Engine Configuration Stationary power generation. with external air-to-air charge-air cooling Emergency standby power (ESP) 3D Emergency standby power generation at variable load < 85 % max. 500 Fuel stop power (ICFN) Prime power limited time (LTP) 3C Standby power generation at variable load < 75 % max. 1000 10 % overload capability (ICXN) Prime power (PRP) Continuous power (COP) Application group Operating mode Load factors Operating hours per year Power rating according to DIN ISO 3046 Engine model 1) Optimizations 12V 2000 G22 12V 2000 G62 16V 2000 G22 16V 2000 G62 18V 2000 G62 Engine model Optimizations 12V 2000 G42 12V 2000 G82 16V 2000 G42 16V 2000 G82 18V 2000 G82 1) 3B Continuous power generation at variable load < 75 % unrestricted 10 % overload capability (ICXN) 3A Continuous power generation at 100 % load ” 100 % unrestricted 10 % overload capability (ICXN) T 625 680 805 895 985 kW at 1500 rpm (50 Hz) or 565 625 720 805 895 kW at 1800 rpm (60 Hz) - T j T 515 655 720 T or ó 735 835 1000 1115 1250 Tó or 695 925 1040 T or ó 625 835 900 Engine model Optimizations1) 12V 2000 G22 12V 2000 G62 16V 2000 G22 16V 2000 G62 18V 2000 G62 Reference conditions T/ó 625 / 625 680 / 680 805 / 805 895 / 895 985 / 985 kW at 1500/1800 rpm (50/60 Hz) switchable or / ó 565 / 565 625 / 625 720 / 720 805 / 805 895 / 895 T j T/ó 515 / 515 655 / 655 720 / 720 Standard 25 °C 100 m Fan power consumption not considered Intake air temperature Site elevation above sea level Specified power ratings available up to 40 °C 400 m 1) Optimizations j Exhaust emission (TA-Luft) ó Exhaust emission (EPA) T Fuel consumption ©MTU 15402/0 E 01-12 .

Page A-6 Basic Engine Configuration Stationary power generation. with external charge-air cooling Emergency standby power (ESP) 3D Emergency standby power generation at variable load < 85 % max. 500 Fuel stop power (ICFN) Prime power limited time (LTP) 3C Standby power generation at variable load < 75 % max. 1000 Prime power (PRP) Continuous power (COP) 3A Continuous power generation at 100 % load ” 100 % unrestricted Application group Operating mode Load factors Operating hours per year Power rating according to DIN ISO 3046 Engine model 2) Optimizations 12V 2000 G22 12V 2000 G62 16V 2000 G22 16V 2000 G62 18V 2000 G62 Engine model Optimizations 12V 2000 G42 12V 2000 G82 16V 2000 G42 16V 2000 G82 18V 2000 G82 2) 3B Continuous power generation at variable load < 75 % unrestricted 10 % 10 % 10 % overload capability overload capability overload capability (ICXN) (ICXN) (ICXN) kW at 1500 rpm (50 Hz) - T 625 680 805 895 985 T or j / 565 625 720 805 895 T 515 655 720 T or ó 735 835 1000 1115 1250 kW at 1800 rpm (60 Hz) or ó 695 925 1040 T T or ó 625 835 900 Engine model Optimizations2) 12V 2000 G22 12V 2000 G62 16V 2000 G22 16V 2000 G62 18V 2000 G62 Reference conditions T/ó 625 / 625 680 / 680 805 / 805 895 / 895 985 / 985 kW at 1500/1800 rpm (50/60 Hz) switchable or ó 565 / 565 625 / 625 720 / 720 805 / 805 895 / 895 T j T/ó 515 / 515 655 / 655 720 / 720 Standard 25 °C 100 m 60 °C 55 °C Intake air temperature Site elevation above sea level Charge-air coolant temperature Charge-air coolant temperature with Luft standard compliance) j (TA- Specified power ratings available up to 40 °C 400 m 60 °C 55 °C Fan power consumption not considered 2) Optimizations j Exhaust emission (TA-Luft standard) ó Exhaust emission (EPA standard) T Fuel consumption 15402/0 E 01-12 © MTU .

121 noise dB(A) Exhaust noise. 128 approx. approx. 121 approx. --noise dB(A) Exhaust noise. 123 approx. 122 approx. 125 unsilenced dB(A) 16V2000G42 Engine surface approx. 119 approx. 127 approx. 127 approx. 120 approx. approx. 121 approx. 122 approx. 123 approx. 123 approx. 125 noise dB(A) Exhaust noise. approx. 121 noise dB(A) Exhaust noise. 121 noise dB(A) Exhaust noise. --approx. --approx. 124 approx. 119 approx. 127 3A optimized exhaust emission approx. approx. 128 unsilenced dB(A) 16V2000G62 Engine surface approx. 130 unsilenced dB(A) 18V2000G62 Engine surface approx. 118 approx. 123 noise dB(A) Exhaust noise. approx. 127 unsilenced dB(A) 16V2000G82 Engine surface approx. 120 noise dB(A) Exhaust noise. 123 noise dB(A) Exhaust noise. 128 unsilenced dB(A) 12V2000G62 Engine surface approx. 128 approx.Page A-7 Acoustics Sound pressure level according to ISO 8528-10: 3D 3D optimized Characteristics optimized exhaust fuel consumption emission 12V2000G22 Engine surface approx. 123 approx. approx. 122 approx. 119 approx. --unsilenced dB(A) Engine model 3B 3B 3A optimized optimized optimized fuel exhaust fuel consumption emission consumption approx. 124 approx. 125 15402/0 E 01-12 ©MTU . 121 approx. 125 unsilenced dB(A) 12V2000G42 Engine surface approx. 125 approx. 127 approx. 126 approx. 120 approx. 128 unsilenced dB(A) 18V2000G82 Engine surface approx. approx. 123 approx. 130 unsilenced dB(A) 16V2000G22 Engine surface approx. 123 noise dB(A) Exhaust noise. 125 approx. 125 approx. 121 approx. approx. approx. 127 approx. approx. 124 noise dB(A) Exhaust noise. 127 approx. 122 approx. 122 approx. 126 unsilenced dB(A) 12V2000G82 Engine surface approx. 128 approx.

0 4.0 7.5 5.0 4.7 – © MTU 15402/0 E 01-12 . All data refer to an engine running at operating temperature and rated power.0 4.5 6.5 6.0 5.0 6.0 4.0 7.0 4. min.5 7.5 6. max.0 4.0 7. specifying engine model and number. max.0 7.0 6.0 5.0 0.Page A-8 Operating parameters The operating parameters specified in the test-stand protocol of the relevant engine are binding.5 7.5 6.5 4.5 5. emergency standby power (ESP) 12V 2000 G22 12V 2000 G42 12V 2000 G62 12V 2000 G82 16V 2000 G22 16V 2000 G42 16V 2000 G62 16V 2000 G82 18V 2000 G62 18V 2000 G82 Application group 3B.0 4.0 5.5 bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar %* 7.0 4.0 6. permissible Coolant preheating temperature Lube Oil System Lube oil operating temperature (from / to) Lube oil operating pressure before engine Application group 3D.0 4. Cooling system (high temperature) Coolant temperature at engine outlet Pressure loss in off-engine cooling system. Fuel pressure at supply connection on engine.0 5.5 5. continuous power (COP) 12V 2000 G62 12V 2000 G82 16V 2000 G62 16V 2000 G82 18V 2000 G62 18V 2000 G82 Lube oil consumption after 100 hrs operation.0 5.0 5.0 7.0 4.5 5.0 5.0 5.5 7.0 7.0 5. 12V 2000 G62 12V 2000 G82 16V 2000 G22 16V 2000 G62 16V 2000 G82 18V 2000 G62 18V 2000 G82 Application Group 3A.0 7.3 + 0. In case of questions related to the technical operating data please attend to your responsible MTU contact person.5 7.0 5.0 4. average *of fuel consumption in continuous operation with a run-in engine Fuel System Fuel pressure at supply connection on engine.0 °C 98 103 Unit of measure °C bar °C Guide value 95 – > 40 Limit value 102 0. prime power (PRP) 12V 2000 G22.0 4.0 5. Boundary conditions for maximum power Intake air depression Exhaust back pressure mbar mbar 15 30 30 50 bar bar – – – 0.0 5.

9 -2.2 -3.2 3. 16V engines - Initial filling 16V Oil dipstick mark „min“ approx.8 -2.40 mm 0.9 3.Page A-9 Charge Air Charge-air pressure before cylinder Unit of Measure Guide value optimized fuel consumption optimized exhaust emission -3.6 2.0 -2.1 -3.6 2. 69 lit.8 -2.6 -- Valve clearances With cold 12/16/18V 2000 engine - Inlet valve Exhaust valve 0. emergency standby power (ESP) 12V 2000 G42 12V 2000 G62 12V 2000 G82 16V 2000 G22 16V 2000 G42 16V 2000 G62 16V 2000 G82 18V 2000 G62 18V 2000 G82 Application group 3B. 15402/0 E 01-12 ©MTU .1 3.8 -2. prime power (PRP) 12V 2000 G22 12V 2000 G62 12V 2000 G82 16V 2000 G22 16V 2000 G62 16V 2000 G82 18V 2000 G62 18V 2000 G82 Application group 3A continuous power (COP) 12V 2000 G62 12V 2000 G82 16V 2000 G62 16V 2000 G82 18V 2000 G62 18V 2000 G82 1 bar ABS bar ABS bar ABS bar ABS bar ABS bar ABS bar ABS bar ABS bar ABS bar ABS bar ABS bar ABS bar ABS bar ABS bar ABS bar ABS bar ABS bar ABS bar ABS bar ABS bar ABS bar ABS bar ABS bar ABS 2.3 2. 67 lit.2 -3.9 -2. approx.1 3. 110 lit.6 -2.9 3.6 -2. approx.7 -3.8 -3.4 -3.9 Application group 3D. 50 lit. 82 lit.1 -2.60 mm Nozzle opening pressure 12/16/18V 2000 with new spring - Initial pressure setting 320 to 330 bar Oil capacity. Oil capacity.0 -2. 12V engines - Initial filling 12V Oil dipstick mark „min“ Oil dipstick mark „max“ approx.1 2.1 3. approx.3 -3.

18V engines - Initial filling 18V Oil dipstick mark „min“ Oil dipstick mark „max approx. 18V engines approx. Coolant capacity - Engine coolant capacity. approx.Page A-10 - Oil dipstick mark „max" approx. approx. 110 lit. 110 lit. 87 lit. 90 lit. 120 lit. 16V engines Engine coolant capacity. 130 lit. approx. 12V engines Engine coolant capacity. 92 lit. © MTU 15402/0 E 01-12 . Oil capacity. approx.

. . . . . .000. . .01 C000. . . . . .Operating Instructions Page C Contents C000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Out-of-service period . . . . . . . . . . . .07 C000. . . . .13 C000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .000.03 C000. . . . . . . . . . . . . . . . . . . . . . Initial operation . . . . . . . . . .000. . . . . . . . . . . Emergency measures in event of engine malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operational Checks –maintenance echelon W1– . . . . . . .09 C000. .15 Operating instructions – preface . . . . . . . . . . . . . . . . . . . . Preparations for initial operation .000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .000. . . . . . . . . . .11 C000. . . . . . . . . . . . 1 1 2 2 2 2 2 3 15406/0 E 01–12  MTU .05 C000. . . . .000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . After shutdown . . . . . . . . .000. . . . . . Shutdown . . . . . . .

Page C Operating Instructions  MTU 15406/0 E 01–12 .

000.03 Fuel supply system G364.15 Engine/alternator mounting Task Description Check signal ring position Check level Check level Preheat Check level (only TB version) Open supply line Check supply Switch on Bar engine manually Ensure guards are installed Check See MTU Fluids and Lubricants Specification A001061 Check security Check security of hoses and hose connections Vent Check Check Fill system Fill system Switch on Check vent line for obstructions Add coolant (only TB version) Check vent line for obstruction (only TB version) Remove transportation locking device B 1 2 3 15402/0 E 01–12  MTU . In the event of an engine malfunction a decision must be made as to whether: – the engine is to be shut down.05 Running gear G307.400.551.03 Engine oil G202.01 Mechanical accessories G500. Our Product Support service is available at all times should assistance be needed.000. G123.01 Contamination indicator G180.27 Attachments G000.000. Accordingly the Before-Operation Services are sub-divided into: – B1.000.Before-Operation Services after a short. Prior to engine startup it must be determined whether startup is: – after a short.01 Preheater G202.01 Engine control system G000.03 Engine coolant G202. scheduled operational shutdown – an extended out-of-service period.29 Attachments G080.001.053.01 Operating instructions – preface Low operating and maintenance costs as well as operational reliability and availability depend on maintenance and servicing being carried out in compliance with our specifications and instructions.651.01 Charge air coolant G203.01 Engine coolant G202.07 Air supply pipework G140.000. using emergency measures.401. until the fault can be rectified.000.01 Fuel supply system G500. scheduled operational shutdown (B1) – B2. Note: The code numbers on the following pages refer to the group numbers in Section G.000.050. Correct engine installation and alignment according to MTU regulations are basic requirements for initial engine start-up.000.000.000.000.000.000.07 Exhaust system G180.051. for a short period.000.01 Fuel system G120.Before-Operation Services after an extended operational shutdown (exceeding 1 week) (B2) – Before-Operation Services before initial start-up of a new or preserved engine (B3). Prior to engine shutdown it must be determined whether shutdown is for: – a short. or – operation may be continued.09 Engine wiring Depreservation G000.01 Engine coolant G203.000. C000.01 Engine oil G202.03 Preparations for initial operation Code No.03 Charge air coolant G364.01 Charge air coolant system G231.Operating Instructions Page C1 C000.01 Engine coolant system G203.000.000. scheduled operational shutdown – an extended out-of-service period – initial startup of a new engine.

401.000. G202.000.07 Engine coolant G202.07 Operational Checks –maintenance echelon W1– Carry out tasks in accordance with Maintenance Schedule section D C000.000. G180.000.000.000.000.09 Shutdown Code No.000. seal the engine air and exhaust sides.19 Engine operation G000.000.000. – with an antifreeze concentration of 50% and engine chamber temperature below –40 °C if antifreeze corresponds to MTU Fluids and Lubricants Specification A001061.  MTU 15402/0 E 01–12 .000.13 Engine operation G000.09 Exhaust system Check exhaust backpressure C000. carry out the following tasks in addition to those described above G140.000. If the engine is to remain out of service for more than 1 month.21 Fuel system During initial engine start-up.17 Engine operation G000.21 Engine operation G080.000.13 Out-of-service period Code No.09 Engine G000. carry out preservation (see MTU Fluids and Lubrications Specification A001061).05 Preheater G203.000.05 Charge air coolant 1) Task Description Drain1 Switch off Drain1 (only TB version) Only when freezing temperatures are expected and the engine is to remain out of service for an extended period and – the engine coolant has no antifreeze additive.23 Engine Task Description Shut down engine C000. – the antifreeze concentration is insufficient for the engine room temperature.01 Engine oil Task Description Check level C000. If the engine is to remain out of service for more than 1 week.07 Engine Task Description Turn engine on starting system – only  after 1st startup  after engine oil change  after engine oil filter change  after extended out-of-service period (exceeding 1 month) Start engine Check speed Check pressures Check temperatures Check running noises Check engine and external pipework for leaks Vent G000. G000.Page C2 Operating Instructions C000.15 Engine operation G000.000.000.11 After shutdown Code No. – the coolant cannot be maintained at a suitable temperature.05 Initial operation Code No. G000. – the engine room cannot be heated.000.000.

011.01 Exhaust turbocharger Emergency Measure Engine operation without turbocharger 15402/0 E 01–12  MTU .000.Operating Instructions Page C3 C000. G101.15 Emergency measures in event of engine malfunction Code No.

Page C4 Operating Instructions  MTU 15402/0 E 01–12 .

. . . . . . . . . . . . .000. . . . . . . . . . . . . unrestricted. .05 D000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Application 3A Continuous operation. . . .07 D000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .000. . . . . . . . . .000. . . . . . . . . . . . . . . . . . . 1 1 2 2 2 4 4 5 5 5 7 7 15402/00 E 01–12  MTU . . . . .000. . . . . . . . . . . . . . . . variable . .01 D000. . . . . . . . . . . . . . . . . . . . . . .Maintenance Schedule Page D Contents D000. . . . . . . . . . . . . . . . . . . . . . . . .000.11 D000. . . and 3B Continuous operation. . . . .000. . . . . . . . . . . . . Maintenance frequency chart . . . . . . . . . . . . . . . . . . Maintenance system . . . . . . . . . . . . . . . . . .15 D000. . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance frequency chart . . . . . . . . . . . . . . . . . . .17 Maintenance schedule – preface . .03 D000. . . . . . . . . .000. . . . . . . . . . .17 D000. . . . . . . . . . . . . .15 D000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .000.07 D000. . Maintenance schedule . .11 D000. . . . . . . . . . . . . . . . . . . . . .000. . . . . . Application 3D Emergency power operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .05 D000. . . . . . . . . . . . . . . . . . . . . . . . . . .000. . Maintenance schedule . . Out-of-service periods . . . . . . . . . Maintenance echelon W6 . . . . .000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance echelon W6 . . . . . . . . . . . . . . . . . . . . . . Out-of-service periods . .000. . . . . . . . . . . . . . . . . . . . . . . . . .

Page D Maintenance Schedule  MTU 15402/00 E 01–12 .

Complete engine disassembly. The overall system. Main features of maintenance echelons W1: W2. This echelon requires partial engine disassembly. Wipe with a dry cloth only. The maintenance intervals have been determined so as to ensure correct engine operation until the next scheduled maintenance echelon. – Always replace all seals and gaskets. Particular operating conditions may require the Maintenance Schedule to be altered to compensate. always: – Ensure that sufficient fuel is available – Ensure that the combustion air is dry and clean – Use only clean. 15402/00 E 01–12  MTU . For this purpose. W3 and W4: W5 W6: Operational checks. never treat with organic detergents. D000. Note: The Maintenance Schedule for application 3A and 3B is shown on Pages 2 to 4. Periodic maintenance services to be carried out during out-of-service periods without the need for engine disassembly.000. – Protect rubber and synthetic parts from oil and fuel. The maintenance system comprises maintenance echelons W1 to W6. filtered raw water Maintenance notes: – Special care should be taken to keep the machinery plant in a clean and serviceable condition at all times to facilitate detection of possible leaks and prevent subsequent damage. Major overhaul.03 Maintenance system Preventive maintenance permits advance operational planning and increases availability.Maintenance Schedule Page D1 D000. for application 3D from Pages 5 to 7.000.01 Maintenance schedule – preface Low operating and maintenance costs as well as operational reliability and availability depend on maintenance and servicing being carried out in compliance with our specifications and instructions. must be maintained in such a way as to ensure troublefree engine operation at all times. of which the engine is an integral part.

000.15 Engine operation G000.000.000.000.01 Intercooler G121.01 Engine mounting Code No. One-time services after first 3 months.051.000.000.01 Valve gear G083.19 Engine operation G000.01 Engine oil G202.050.05 Exhaust system G180.01 Engine/charge air coolant pump G231.000.000.03 Exhaust system G202.101.000. unrestricted.07 Maintenance frequency chart 3A Maintenance echelon W1: W2: W3: W4: W5: W6: Operational checks daily Operating hours limit Every month Operating hours limit Every year Operating hours limit Every year Operating hours limit Every year See Page 4.21 Engine operation G111.03 Charge air coolant  MTU 15402/00 E 01–12 .05 Application 3A Continuous operation.000.Page D2 Maintenance Schedule D000. Maintenance Echelon W1 – Monthly test run / operational checks Do not carry out trial run with less than 1/3 load at least until steady-state temperature is reached Check speed Check pressures (where gauges are installed) Check temperatures (where gauges are installed) Check running noises Check engine and external pipework for leaks Check drain line for coolant discharge and obstruction (only TB version) Check contamination indicator Check exhaust gas colour Check level Check level Check level (only TB version) G000.17 Engine operation G000.13 Engine operation G000.000.051.000.10 Engine operation G000.052. D000.000.051.11 Maintenance schedule Note: The code numbers on the following pages refer to the group numbers in Section G.03 Engine coolant G203. variable D000. and 3B Continuous operation. replace element if necessary Check security Check relief bore Check security G055.000.01 Air filter G140.15 X 500 6 1000 1 4000 4 8000 8 3B X 500 6 1000 1 3000 4 6000 8 – D000.09 Fuel prefilter G140. Code No. or after W5 or W6 maintenance Check valve clearances Check. limit 50 operating hours – on a new engine.000.

03 G000.001.052.07 G205.052.000.07 G073.051.051.051.051.101.01 G205.01 G083.Maintenance Schedule Code No.051.15 G202. fluid viscosity and electrolyte level Check Remove and check rocker arms and valve bridges Check rocker arm bearings.000. drain coolant and flush coolant systems.05 Fuel filter Fuel filter Air supply pipework Engine oil Engine oil Page Task Description Replace filter Replace filter Check intake side for leaks or damage Used oil – take sample and analyse Change – after every 2 years – with oil category 2 no later than after 500 operating hours – with oil category 3 no later than after 1000 operating hours Replace – when changing oil Check drive belt condition and tension Check drive belt condition and tension Check valve clearances Clean Take sample and analyze – Change engine coolant – See MTU Fluids and Lubricants Specification Check relief bore Take sample and analyse (only TB version) – Change charge air coolant. 15402/00 E 01–12  MTU .011.050.051.01 G203.01 G055.000.101. see MTU Fluids and Lubricants Specification Check cooler elements for external contamination Check cooler elements for external contamination Perform endoscopic examination Replace filter Clean oil preseparator Replace Replace Check ease of movement Replace Check security Check charge state.051.05 G500. ball joints and push rods for wear Check compression pressures Overhaul or replace Overhaul or replace (only TB version) Clean.000.000.03 G083.03 G121.05 G202.03 G213. check for leaks Clean.051.05 G018.051.101.09 Engine oil filter Generator drive Fan drive Valve gear Fuel prefilter Engine coolant Engine/charge air coolant pump Charge air coolant Engine coolant cooler Charge air coolant cooler Cylinder chambers Crankcase breather Crankcase breather Fuel injection pumps Fuel injectors Exhaust turbocharger Air filter Engine mounting Battery Engine wiring Valve gear Cylinders Engine coolant pump Engine/charge air coolant pump Engine coolant cooler Charge air coolant cooler Engine coolant thermostat Before starting W5 maintenance services. check for leaks (only TB version) Replace thermal element (only TB version) D3 W 2 3 4 5 G183.01 G309.000.051.03 G180.33 G018.000.05 G101.01 G231.04 G180.01 G221. G083.03 G120.04 G075.

000.000. carry out preservation (see MTU Fluids and Lubrications Specification A001061). If the engine is to remain out of service for more than 3 months.15 Maintenance echelon W6 The W6 echelon requires complete disassembly of the engine.Page D4 Maintenance Schedule D000. Repair/overhaul of the relevant components is determined by the actual condition of the components and their dimensions.17 Out-of-service periods Turn running gear monthly by hand (Section G). which are referenced to the Tolerances and Wear Limits List.  MTU 15402/00 E 01–12 . Recommended major overhaul: Application Group Operating hours Years 3A 16 000 16 3B 10 000 16 D000.

D000.053.000.01 Intercooler G123.01 Valve gear G083.000.000.052.000.15 1 x 6 250 1 500 4 1500 8 3000 – D000.01 Contamination indicator G140.05 Application 3D Emergency power operation D000. limit 50 operating hours – on a new engine.051. replace element if necessary Check security Check relief bore Check security Check security G055.000.000.000. Check speed Check pressures (where gauges are installed) Check temperatures (where gauges are installed) Check running noises Check engine and external pipework for leaks Check drain line for coolant discharge and obstruction (only TB version) Check signal ring position Check exhaust gas colour Check level Check level Check level (only TB version) G000.101.000.09 Fuel prefilter G140.20 Engine/alternator mounting G231. Code No.000.07 Maintenance frequency chart Maintenance echelon W1: W2: W3: W4: W5: W6: Every month In extended operation daily Every month Operating hours limit Every year Operating hours limit Every year Operating hours limit Every year Operating hours limit See Page 7.000.050.10 Engine operation G000.01 Engine/charge air coolant pump G231.000.20 Engine/alternator mounting Code No. or after W5 or W6 maintenance Check valve clearances Check.19 Engine operation G000.051.000.05 Exhaust system G180.000.15 Engine operation G000.17 Engine operation G000.000.13 Engine operation G000.21 Engine operation G111.03 Engine coolant G203.03 Exhaust system G202.Maintenance Schedule Page D5 D000.01 Engine oil G202.051. One-time services after first 3 months.03 Charge air coolant 15402/00 E 01–12  MTU .000.11 Maintenance schedule Note: The code numbers on the following pages refer to the group numbers in Section G. Maintenance Echelon W1 – Monthly test run / operational checks Perform trial run at least until steady-state temperatures have been reached and not under 1/3 load.

03 G083.15 G180. G120.052. check for leaks Clean. see MTU Fluids and Lubricants Specification Check cooler elements for external contamination Check cooler elements for external contamination Perform endoscopic examination Replace filter Check ease of movement Replace Check security Check security Check condition of damping mount Check charge state.051. fluid viscosity and electrolyte level Check Check compression pressures Remove and check rocker arms and valve bridges Check rocker arm bearings.050.09 Engine oil filter Engine coolant Engine/charge air coolant pump Charge air coolant Engine coolant cooler Charge air coolant cooler Cylinder chambers Crankcase breather Exhaust turbocharger Air filter Engine/alternator mounting Engine/alternator mounting Engine/alternator mounting Battery Engine wiring Cylinders Valve gear Injection pumps Injectors Engine coolant pump Engine/charge air coolant pump Engine coolant cooler Charge air coolant cooler Engine coolant thermostat Elastomers Take sample and analyze – Change engine coolant – See MTU Fluids and Lubricants Specification Check relief bore Take sample and analyse (only TB version) – Change charge air coolant. check for leaks (only TB version) Replace thermal element Replace (external) (only TB version) Before starting W5 maintenance services.101.20 G231.05 G500.01 G221.000.000.05 G101.01 G083.20 G231.03 G083.011.001.03 G000.052.051.01 G203.03 G121.03 G213.052.000.30 G309.07 G205.01 G205.051.05 G202.052.101.000.04 G180.051.051.33 G018.051.051.03 G202.051.000.000. ball joints and push rods for wear Replace Replace Overhaul or replace Overhaul or replace (only TB version) Clean.000.05 D6 Task Description Air supply pipework Generator drive Fan drive Valve gear Fuel filter Fuel filter Fuel prefilter Engine oil Engine oil Check intake side for leaks or damage Check condition and tension of drive belt Check condition and tension of drive belt Check valve clearances Replace filter Replace filter Clean Used oil – take sample and analyse Change – after every 2 years – with oil category 2 no later than after 500 operating hours – with oil category 3 no later than after 1000 operating hours Replace – when changing oil Maintenance Schedule W 2 3 4 5 G183.Page Code No. drain coolant and flush coolant systems.  MTU 15402/00 E 01–12 .01 G055.01 G231.

Maintenance Schedule Page D7 D000. Recommended major overhaul: Years Operating hours 16 6 000 D000. 15402/00 E 01–12  MTU .15 Maintenance echelon W6 The W6 echelon requires complete disassembly of the engine. If the engine is to remain out of service for more than 3 months.000. Repair/overhaul of the relevant components is determined by the actual condition of the components and their dimensions. carry out preservation (see MTU Fluids and Lubrications Specification A001061).17 Out-of-service periods Turn running gear monthly by hand (Section G).000. which are referenced to the Tolerances and Wear Limits List.

Page D8 Maintenance Schedule  MTU 15402/00 E 01–12 .

Starting power supply faulty . . . . . . . .02 E140. . . . . . . . .03 E000. . . . . . . . . . . . . . . . . . . . . . .09 E202. Engine oil level abnormally high . . . . . . . . . . . . . . . . . . . . . . . .000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine coolant pressure too low . . . .02 E202. . . . . .000. . . . . . .000. . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine does not reach rated speed . . . . . . . . . . . . . . . . . .000. . . . . . .05 E202. . . . . . . . . . . . Exhaust gases blue . . Charge air coolant pressure too low . . . . . . . Charge air coolant loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .09 E202. . . . . . . . . . . . . . . . . . . . . . . .01 E110. . . . . . . . . . . . .03 E180. . .03 E114. . . . . . . . . . .000. . . . . . . . . . . . . . . . . . . . . . . . . . Compression pressure too low . .05 E000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01 E203. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .011. . . . . . . . . . . . .07 E180. . . . . . . . . . . . . . Exhaust gases white . . . . . . . . . . . . . . . . . . . . . .000. .000.051. . . . . . . . . . . . . . . . .000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .000. . . . . . . . . . . Coolant discharge at intercooler relief bore . . . . . . . . .07 E202. . . . . . .01 E180. . . . . . . . . . . . . . . . . . . . . .11 E080. . . . . . . . . . . . .000. . . . . . . . . . . Fan drive faulty . . .01 E101. .09 E000. . . . . . . . . . . . . . . . .000. . . Charge air coolant temperature too high . . . Engine speed not steady . . . . Engine coolant temperature too low . . . .01 E110. . . . . . . . . . . . . . . . . . . . . . . . . .000. . . . . . . . . . . . .000.000. . . . . . . . . . . . . . . . . . . . . . . . . . .000. . . . . . . . . . . . . . . . . . .02 E000. . . . . . . . . . . . . . .000. . . .03 E172. .01 E180. . . . . . . . . . . . . . . . . . .000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .051. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charge air coolant temperature too low . . . . . . . . . . . . . . . .000. . . . . . . . . . . . . .000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .05 E180. . . . . . . . . . . . . . . . . . . . . . . .000. . . . . . . . . . . . . . . . . .01 E202. . . . . . . . . . . . . . . .Troubleshooting Page E Contents E000. . . . . . . . . . . . . . . . . . . . .07 E221. . . . . . .000. . . . . . . . Charge air pressure too low . . . . . . . . . . . . . . . . . . . . . .000. . . . . . . . . . . . . . . . . . . . . . . . . . Engine coolant pump leaking at relief bore . . . . . . . . . . . . . . . . 1 1 1 2 2 2 2 3 3 3 3 3 4 4 4 4 5 5 5 5 6 6 6 7 7 7 7 8 8 8 8 8 15402/00 E 01–12  MTU . . . . . . . . . . .000. . . . . . . . . . . . . . . . .03 E203. . . . . . . . . . . . . Engine coolant level rising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine oil pressure too low . Engine oil consumption abnormally high . . . . . . .01 E140. . . . . . . . . . . . . . . . . . . . . . . . . . . .051. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine turns but does not fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01 E140. . . . . .000. .07 E000. . . . . . . . . . . . . . . . . . . .000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust gases black . . . . . . . . . . . . . . . . . . . . . . . . . . . .01 General . . . . . . . . . . . . . . . . . . . . . . .000. . . Engine oil pressure too high . . . . . . . . . . . . . . . . . . . . . . . . Engine oil temperature too high . . . . . . . . . . . . . Abnormal turbocharger running noises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine fires unevenly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01 E000. . . . . . .05 E203. . . . . . . . . . . . .01 E203. . . . . . . . . . . . . . . . . . . . . . . . . Engine coolant temperature too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine does not turn when starter is actuated . . . . . . . . . . . . . . . . . . . . . . . Coolant loss . . . . . . . . Fuel pressure too low . . . . . . . . . . . . . . . . . . . . . . . . Charge air temperature too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page E Troubleshooting  MTU 15402/00 E 01–12 .

Troubleshooting Page E1 E000. E000.000. After Work on Engine If running gear components. Engine Oil Diluted by Fuel It is essential to change the engine oil before restarting the engine after rectifying the fault. etc. kerosene or diesel fuel into the crankcase via the oil filler neck until the max.02 Engine does not turn when starter is actuated Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ Probable causes Battery Starter Check Remedial action Battery charge state Cable connections Charge battery. piston rings.000. Before restarting the repaired engine. level is reached – disconnect charge air/coolant manifolds – remove the fuel injectors – bar the engine manually and spray corrosion-inhibitor oil. kerosene or diesel fuel into the combustion chambers via the opening inlet valves NOTE: These corrosion-prevention measures are only effective for a few days. replace if necessary Connect.01 Remedial action – Battery Starter/engine wiring Starter Charge. therefore.01 General In Event of Internal Coolant Leakage Consequential damage caused by corrosion must be avoided. It is essential to change the engine oil after 50 operating hours as the new oil may be contaminated by coolant residues left in the crankcase. If the engine cannot be repaired immediately. be carried out as soon as possible. Repair of the engine and thorough cleaning of all components should. have been replaced. Remove the used oil from the oil pan with particular care.000. carry out the following operations: – drain coolant and engine oil – introduce corrosion-inhibitor oil. Replace the engine oil filter. e. pistons. carry out the engine running-in procedure. replace if necessary Replace Replace Starter/engine wiring Starter Ring gear Electronics Engine monitoring system Voltage supply See Electronics Documentation Repair E000. replace if necessary Connect. fill with new engine oil and engine coolant in compliance with the MTU Fluids and Lubricants Specification A001061. replace if necessary Connect.000.g. cylinder liners. replace if necessary Replace Engine monitoring system Voltage supply See Electronics Documentation Repair 15402/00 E 01–12  MTU .03 Engine turns but does not fire Probable causes Check Engine receiving insufficient fuel Engine does not reach firing speed Electronics See E080.

000.03 Check Engine monitoring system Wiring Injection pump solenoid valve Injection timing Injectors Injection pumps Replace Adjust (G055.07 Engine does not reach rated speed Piston rings worn Valves do not close Valve seats in cylinder head worn Cylinder head gasket leaking Probable causes Electronics Probable causes Electronics Overloading Compression pressure too low Charge air temperature too high Fuel injection equipment faulty Engine receiving insufficient fuel Engine receiving insufficient combustion air Probable causes Electronics Piston rings Valve clearances Valves Cylinder head Cylinder head gasket Check Engine governor Voltage supply Check Engine governor Injection pump solenoid valve Engine overloaded Compression pressure (G000.01 Check – Remedial action Troubleshooting  MTU 15402/00 E 01–12 .05) Replace (G073.09 Engine speed not steady E000.000.050.000.05) Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á E000.05 Engine fires unevenly Fuel injection equipment faulty Engine receiving insufficient fuel Probable causes Page E2 See E080.000.051. replace if necessary Repair Replace Remedial action See Electronics Documentation Repair Remedial action See Electronics Documentation Replace – See E000.000.01) (G073.000.01) (G073.11 Compression pressure too low E000.051.000.11 – See Electronics Documentation Replace (G075.ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á E000.05) Replace (G073.051.000.01 See E110.01 Injection timing Injectors Injection pumps See E080.000.01) Recondition.31) See E110.05) – – Remedial action See Electronics Documentation Tighten connections Replace See Electronics Documentation Replace (G075.051.051.051.000.

000.051.051.01 Coolant discharge at intercooler relief bore E110.101.01) Air filter Intercooler Check Engine monitoring system Temperature sensor.01 Abnormal turbocharger running noises E080.052.101.03 Charge air pressure too low E110. Rectify concentration as per specifications Clean (G221.052.000. wiring Exhaust turbocharger Air filter contamination indicator (G121.09) Replace filter (G083.098.098.01) Clean coolant system. Treat engine coolant in accordance with MTU Fluids and Lubricants Specification A001061.03) or (G083. replace if necessary Replenish Open Remedial action Page E3 15402/00 E 01–12  MTU .01 Fuel pressure too low Intercooler leaking Probable causes Electronics Exhaust turbocharger faulty Engine receiving insufficient combustion air Probable causes Electronics Incorrect corrosion inhibitor (deposits in intercooler) Antifreeze concentration too high Intercooler contaminated Fan drive Probable causes Exhaust turbocharger faulty Exhaust turbocharger contaminated Probable causes Fuel delivery pump faulty Fuel filter contaminated Fuel line Fuel level too low Fuel supply blocked Probable causes Troubleshooting Whether coolant discharges from drain line (not condensate) Check Engine monitoring system Pressure sensor.01) Repair – Replace (G121.01) Clean.03) Seal pump.01 Charge air temperature too high E101. replace intercooler if necessary. wiring Engine coolant.ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁ Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á E114. corrosion inhibitor Engine coolant Intercooler Drive belt condition and tension Check Turbocharger bearing Rotor assembly Exhaust turbocharger Check Fuel delivery pump Fuel filter Fuel prefilter Seals Fuel supply Shut-off valve(s) in fuel system Check Replace intercooler Remedial action See Electronics Documentation Check monitoring units (G507. replace (G083.000. replace if necessary Clean (G083. replace if necessary Remedial action See Electronics Documentation Check monitoring units (G507.051.15) or if necessary.051.01) Remedial action Replace Replace Clean Remedial action Repair.011.

051.000.31) Engine oil level (G180.01 Exhaust gases black Engine receiving insufficient combustion air Probable causes Page E4 Air filter contamination indicator (G121.03) Repair Replace Remedial action Repair Replace Replace Replace See E202.000.01) Air filter Intercooler Check – Replace (G121.03) Repair Replace filter (G018.01) Clean.000.000.02 Remedial action See E000.07 Exhaust backpressure See E000. replace if necessary (G221.000.000.052.101.01) Exhaust turbocharger Crankcase breather Valve stem seals Piston rings Valve guides Cylinder liners Check voltage (G221.000.ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á E172.000.000. drive belt.11 Correct oil level (G180.051.01).000.03 Exhaust gases white Battery not or insufficiently charged Probable causes Fuel injection equipment Coolant in combustion chambers Engine cold Probable causes Compression pressure too low Generator Battery Generator drive belt Check Injectors Exhaust turbocharger Intercooler Cylinder heads Cylinder liners Engine coolant temperature Check Compression pressure (G000.02 Exhaust gases blue Too much oil in combustion chambers Probable causes Overloading Exhaust system faulty Fuel injection equipment faulty Check See E000.051.000. replace if necessary Remedial action Troubleshooting  MTU 15402/00 E 01–12 .01 Starting power supply faulty E140.04) Replace Replace Replace Replace Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ E140.07 Remedial action – Clean exhaust silencer – Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á E140.

098.000. wiring See E202.01 Engine oil consumption abnormally high Electronics Engine coolant in engine oil Engine oil system Oil viscosity too high Probable causes Electronics Engine coolant temperature too high Engine oil heat exchanger dirty Probable causes Engine coolant in engine oil Fuel in engine oil Fuel or engine coolant in engine oil Probable causes Engine wear Exhaust turbocharger leaking Oil pipes to engine oil heat exchanger leaking Engine oil system leaking externally Probable causes Troubleshooting Engine monitoring system Pressure sensor.000.000.03 Engine oil level abnormally high E180.000.098. wiring Engine oil quality Engine oil pressure relief valve(s) Engine oil viscosity Check Engine monitoring system Temperature sensor.000.01 Engine oil heat exchanger Check Cylinder heads Cylinder liner seals Cylinder liners Crankcase Injectors Injection pumps Engine oil quality Check Valve stem seal Piston rings Valve guides Cylinder liners Exhaust turbocharger Oil in coolant system External subassemblies External pipework Engine oil drains Shaft seals Oil pan Crankcase Check See Electronics Documentation Check monitoring units (G507. tighten if necessary Seal pipework Replace Seal pipework Repair Remedial action Page E5 15402/00 E 01–12  MTU .Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁ Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á E180.000.01) See under E180.03 Replace Change engine oil Remedial action See Electronics Documentation Check monitoring units (G507.05 Engine oil temperature too high E180.01) – Clean.07 Engine oil pressure too high E180. replace if necessary Remedial action Replace Replace Replace Repair Replace seal to cylinder head Replace seal to crankcase Refer to “Fuel in engine oil” and “Engine coolant in engine oil” Remedial action Replace Replace Replace Replace Replace bearings Replace sealing rings Seal pipework Check connections.

000.02 Engine coolant temperature too low E202.01) Replace – Clean Clean Clean Top up engine coolant Remedial action Replace bearings See Electronics Documentation Check monitoring units (G507.098. replace if necessary Adjust. wiring Engine coolant thermostat Check Engine monitoring system Temperature sensor.051.05 Engine coolant thermostat See E221.01) Replace Remedial action See Electronics Documentation Check monitoring units (G507.01 Engine coolant temperature too high E180.000.09 Engine oil pressure too low Electronics Engine coolant thermostat defective Probable causes Electronics Engine coolant pressure too low Engine coolant thermostat defective Fan drive faulty Engine coolant system contaminated Engine coolant level too low Probable causes Pressure loss in running gear Electronics Engine oil pump Engine oil pressure relief valve(s) Engine oil filter dirty Fuel in engine oil Engine oil system leaking externally Engine oil level too low Probable causes Page E6 Engine monitoring system Temperature sensor.01 Engine oil level Check See Electronics Documentation Check monitoring units (G507.03 – Top up engine oil Remedial action Troubleshooting  MTU 15402/00 E 01–12 . or replace engine oil pressure relief valve(s) Replace filter See under E180.000.01 Engine coolant system Vent lines Engine coolant cooler Engine coolant level Check Running gear lubrication points Engine monitoring system Pressure sensor.098. wiring Engine oil pump Opening pressure – Engine oil quality See under E180.000.000.ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁ Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á E202.098.000.01) Repair. wiring See E202.

000.05 Engine coolant pressure too low Engine coolant pump leaking Probable causes Engine oil in engine coolant Probable causes Engine coolant level transmitter display error Engine coolant pump leaking Engine coolant system leaking internally Engine coolant system leaking externally Probable causes Engine coolant pump faulty Engine coolant system leaking internally Engine coolant level too low Engine coolant system leaking externally Coolant system not sealed Probable causes Troubleshooting For engine oil discharge (G202.07 Coolant loss E202.01) Repair – – Remedial action Replace Change engine oil (G180.000.01) For coolant discharge (G202. engine coolant pump Remedial action Repair Remedial action Check monitoring units (G507.000. engine coolant pump Replace slip ring and.098. if necessary. tighten if necessary Seal Repair Check for leaks.09 Engine coolant level rising E202. replace if necessary Close cover Replace cover Remedial action Page E7 15402/00 E 01–12  MTU .051.000. wiring Engine coolant pump See E202.01 Engine coolant pump leaking at relief bore E202. tighten if necessary Check connections.05) Replace Replace Replace Top up engine coolant Check connections.051.05 See E202.05 Check Engine coolant pump Oil quality Cylinder heads Injector protective sleeve gasket Cylinder liner gaskets Engine coolant level External pipework External subassemblies Coolant drain points Engine coolant cooler Crankcase Whether cover closed Breather valve Check Replace sealing ring and.000.01) Check Engine oil heat exchanger Check Probe.ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á Á ÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁ Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á E202. if necessary.051.000.

ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á Á Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁ Á Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Á E221.098. tighten if necessary Check connections.01 Fan drive faulty E203.07 Charge air coolant loss E203.03) Remedial action Check monitoring units (G507.098.01 internally Charge air coolant pump faulty Charge air coolant level too low Charge air coolant system leaking External pipework externally External subassemblies Charge air coolant drain points Charge air coolant system not sealed Probable causes Electronics Charge air coolant thermostat Probable causes Electronics Charge air coolant pressure too low Charge air coolant thermostat Fan drive faulty Charge air coolant system contaminated Charge air coolant level too low Probable causes Page E8 V-belt tension Check Probe.000.05 Charge air coolant thermostat See E221.098.051. replace if necessary (G221.051.05 Charge air coolant pressure too low E203. wiring Check Charge air coolant pump Charge air coolant level Intercooler Charge air coolant cooler Whether cover closed Breather valve Check Engine monitoring system Temperature sensor.03 Charge air coolant temperature too low E203. wiring Charge air coolant thermostat Check Engine monitoring system Temperature sensor.000. replace if necessary Top up charge air coolant Remedial action Troubleshooting  MTU 15402/00 E 01–12 .01 Charge air coolant temperature too high V-belt Probable causes Charge air coolant level transmitter display fault Charge air coolant system leaking See E203.01) – – Remedial action – Replace Top up charge air coolant Check connections.05 internally Charge air coolant system leaking See E203.000.000. renew sealing if necessary Check for leaks.01) Replace Remedial action See Electronics Documentation Check monitoring units (G507.000.051.000.05 externally Probable causes Charge air coolant system leaking See E114.01) – Replace – Clean Clean Clean. wiring See E203. replace if necessary Repair Close cover Replace cover Remedial action See Electronics Documentation Check monitoring units (G507.051. tighten if necessary Check for leaks.000.01 Charge air coolant system Vent lines Charge air coolant heat exchanger Charge air coolant level Check Tension.

. . . . . . . . . . . . . . . . . . . . . . Exhaust turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01 G055. . . . . . . . . . . .25 G000. . . . . . . . .09 G083. . . . . . . . . . . . . . . . intake side leak and damage check . . . . . . . . . . . . . . . . . . drain line water discharge and obstruction check . . . . . Fuel draining . . . . . . . . . . . . . . . . . . . . . . . . . .01 G030. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel system venting . . . . . . . . . . . Emergency shutdown . . . . . . . . . . . . . . . . . . . . . .05 G000. . . .03 G083. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder head cover removal .101. . .051. .01 G123. . . . . . . . . . .05 G083. .02 G083. . . . . . . . . . . . . . . . . . . exhaust backpressure check . .33 G000. . . . . . . . . . . . . . . . engine operation in event of turbocharger failure . . Crankcase ventilation – oil preseparator cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankcase ventilation filter replacement . . . . . . . . . . . . . . . . . . . . . . Injection pump installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .000. . . . . . . . .04 G073. . . . . . . . . . . . .000. . . . . . . . . Contamination indicator resetting . . . . ease-of-movement check . . .001. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel filter. .19 G000. . . . . . . . . . . . . .000. . .000. . . Cleaning engine externally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .000. . . . . . . . . . . . . . Engine barring tool removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .051. . . . . . . . . . . . . . . . . . .Task Description Page G Contents G000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .000. . . . . . . . . Fuel filter replacement . . . . . . .000. . . . . . . . . .000. . . . . . . . . . . . . Attachments. . . . . . . . . . . .051. Fuel prefilter. . . . . . . .001. . .000. . . .03 G000. . . . . Barring engine manually . . . . . . . . . . .03 G083. . . . . . . . . Engine oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injection pump replacement . . . . . . . . . . . . . . Intake air system check .39 G018. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .011. . . . . . . . . . . . . . . . . . . .17 G000. . . . . . .05 G075. .01 G055. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .07 G140. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01 G083. . . . .31 G000. . . . . . . . . . . . . . . . .011. . . . . . . . . . .000. . . . Injector installation . .101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . signal ring position check . . . . . . . . . . . . .051. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .000. . . . . . . . . . . . . . . . . . . . .000. . . . . . . . . . Injector removal . . . . . Injector removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine and external lines leak check . . . . . . . . . . . . . . . . . . . . .000. . . . . . . Cylinder chamber endoscopic examination . . Exhaust system. . . . . . . . . . . . . . . . . . .053. . . . . . . . . . . . . . . . . . . . . . . . Cylinder head cover installation . . . . . . .05 G140. . . . . . . . . . . . . . . . . . . . . Trial run . . .051. . . . . . . . . . . .01 G075. . . . . . .000. . . . . . . . . . . Fuel filter replacement . . . . . . . . . . . . . . . . . . . . . . . . .052. . . . . . . . . . . . . . . . . . . . . . . . .000. . . . . . . . . . .000. . . . . . . . . . . . . . . . . .01 G120. . .000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .000. . .15 G000. . . . . Contamination indicator.03 Engine start disabling . . . . . . . . Engine oil system filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .05 G075. . . . . . . . . . . . . . . . . . . . . . . . . . .000. . . . . . . . . . . . . . . . . . . .03 G111. . . . . . . . . . . . . . . . . . .051. . . . . . . .000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intake air system. . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure checks . . . . . . . . . . . . . . . . . .000. Engine shutdown . . . . .01 G080. . . . . . . . . . . . . . . . . hoses and hose connections check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01 G000. . . . . . . . .050. . . .000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01 G180. . . . . . . . . . . . . . Exhaust system check . . . . . . . .09 G180. . . . . . . . . .07 G121. . Injector replacement . . . Engine start release . Engine starting . . . . . . . . . . . . . . . Fuel prefilter cleaning . . . . .03 G073. . . . . . . . . . . .10 G000. . . . . . . . . . . . . . . . . . . . . . . . .27 G000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .053. . . . . . . . . . . . . . . . . . . . . . . .05 G018. . . . . . . . . . . . . . . . . .15 G101. . . . . . . . . . . . . . . . . .101. Air filter replacement . . .051. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .03 G055. . . . . . .07 G030. . . . . . . . . . . . . . . . . . . .051. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101. . . . . . . . . . . . . . . . . . . . . . . . . . Engine speed check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101. . . . . . . . . . . . .29 G000.03 G140. . . . . . . . . . . . . . . . . . Intercooler. . . . . . . . . . . . . . . . . . . . . . 1 1 1 1 2 2 2 2 2 2 3 3 4 4 4 4 6 8 9 9 10 10 11 13 14 14 15 15 17 18 19 21 22 23 24 26 27 28 28 28 28 29 29 29 30 30 30 31 31 31 31 32 32 15402/00 01–12  MTU . . .21 G000. . . . . . . . . . . . . . . . . . . . . Engine running noise check . . . . . . . . . . . . . . . .101. . . . . . . .09 G080. . Exhaust system. . . . . . . . . . . . . . . . . . . . . .01 G073. . . . . . . . . . . . . . . .23 G000. . . . . . . . . . . . . . . . . . . .000. . . . . . . . . . . . . . . . . . . . . . . . . .01 G101. . . . . .000. . . . . . . . .01 G123. . Attachments security check . .051. . . . . . . . . . . . . . . . Temperature checks . . . . . . . . . . . . . . . Exhaust turbocharger. . . . . . Exhaust system security check . . . . . . . . . . . . . . . . . operating position check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 G000. . . . . . . . . .03 G120. . . . . . . . . . . . . . . Valve clearance check and adjustment . . . . . . . . . . . . . Engine barring tool installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . element and gasket replacement .051. . . . . . . . Compression pressure check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .051. . . . . . . . . . . . .000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 G140. . . . . . . . . . . . . . . . . . . . . . Barring engine with starting system . . . . . . . . . . . . . . . . exhaust gas colour check . . . . . . . . . . . Fuel filter venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .07 G000. . . . . . . . . . . . . . . . . . . . . . .09 G000. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . Charge air coolant sample extraction and analysis . . . . . . . .000. . . . drive belt condition and tension check . . . . . . Engine coolant preheating unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 33 34 34 35 35 36 37 38 39 40 40 41 41 41 41 41 41 43 44 45 45 45 46 46 47 48 48 49 52 52 55 56 57 57 58 58 58 58 58 58 59 59 59 59 60 G180. . . .01 G221. . . . Charge air coolant changing . . . . . .01 G500. . .000. . . . . .000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .551.03 G500. . . . . . . . . . . . . . .09 G507.03 G202. . . . . . . . . . . . . . . .01 G364. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine coolant system filling . . . . . . . . . . . . . . . . . . . . . . . . .651. . . . . . . . . . . . . . . . . . . . . . . . . .01 G205. . . . . . . . . . . . . . . . . . . . . . . . .000. . . .051. . . . . . . . . . . . . . . . . . . . . . . . .098. . .01 G203. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .05 G180. . . . . . . . . . . .000. . . . . . . .051. . . . . . . . . . . . . . . . . . .01 G202. . . . . . . . . . . . . .051. .000. . . . . . . . . . .05 G364. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .03 G364. .000. . . . . . . . . . . .01 G205. . . . . . . . . . . . . . . . . . . . . . . . . . .01 G202. . . . . . . . . .000. . Breather valve opening . . . . . . . . . . . . . . . . . Corrosion inhibitor oil draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine coolant preheating unit. . . . . . . . . .03 G231. . . . . . .09 G202. . . . . . .000. . . . . . . . . . . . . . Engine/alternator mount security check . . . . . . . . . . . . . . . Engine coolant change . . . Charge air coolant cooler. . . . . . . . . . . . . . . . . . . . . . vent line obstruction check . . . Engine/alternator mounting. . . . . . . . . . Fuel supply system filling . . . . . . . . . . . . . . . . . . . . . .051. . . .01  MTU 15402/00 01–12 . . . . . . . . . . . . . . . . . .05 G221. . . . . . switching off . Charge air coolant system filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .051. . . . .051. . . . . . . Engine/alternator mount. . . . . . . . . . . . . . . . Breather valve closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .400. .000. . . . .01 G213. . external element contamination check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan drive belt replacement . . . . equipment function check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine coolant cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vent line obstruction check . . . . . . . Engine coolant preheating . . . . Charge air coolant level check . . . . . . . . . . . . . . . . . . . . . . . Engine coolant pump relief bore check . . . . . . . .001. .11 G183. . . . . . . . . . . . . . . . . . . . .03 G500. . . . . .01 G203. . . . . . . . Generator drive. . . . . . . . . . . . .01 G208. . . . .401.000. . . . Engine wiring check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .07 G180.05 G202. . . .050. . . . . . .101. . . . . . . . . . . . . . . . . . . . . . .30 G307. . . Engine/alternator mount security check . . . . . . Generator drive belt replacement . . . . . . . . . . .07 G203. . . . . . . . . transportation locking device removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .05 G203. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .03 G208. . . . . . . . . . . . . .000. . . . . . . . . . . . . . . . . .07 G202. . . .000.01 G309. . . . . . . . . . . . Engine control system switching on . . . . . . . . . . . . . external element contamination check . . . Engine control system switching on . . . . . . . . . . . . . . . . . . . . .20 G231. . . . . . . . . . . . . . . . . . . . drive belt condition and tension check .001. . . . . . . . . . . . . . . .05 G202. . . . . . . . . . . . Fuel supply closing . . . . . . . . . . . . . . . . . . . . . . . . .03 G202. .01 G202. . . . . . . . .000. Fuel system supply check . electrolyte condition and level check . . . . .01 G203. . . . . . . . . . . . . . .000. . . . . . . . . . . . .401. Engine coolant sample extraction and analysis . . . . . . . . . . . . . . . . . Engine oil draining . . . . . . . . . . . . . . . . Monitoring system. . . . . .050. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Protective device check . . . . . . . . . . . . . . . . .052. . switching on . . . . . Engine coolant preheating unit initial operation . . . . . . . . . . . . . . . . Corrosion inhibitor oil filling . . . . . . . . . . . . . . . . . . . . . . . . . . .20 G231. .15 G231. .01 G364. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .052. .04 G180. .051. . . Engine coolant draining . . . . . .000. . . . . . . . . . . . . . . . . .051. Fan drive. . . damping mount condition check . . . . . . .03 G213. . . .051. . . . .Page G Task Description Engine oil sample extraction and analysis . . Engine oil filter replacement . . . Fuel supply opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine coolant system. . . . . . . .09 G203. . . . . . . . . . . . . . Charge air coolant draining . . . . . . . . . . . . .01 G202. . . . . . . . . . . . . . . .03 G202. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401. . . . . . . . . Charge air coolant pump relief bore check . . . . . . . . . . . . . . . .000. . . . . . . . . . . . . . .052. . . . . . . .03 G203. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .000. Charge air coolant system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery charge state. . . . .000. . . . . . . . . . . . .000. . . . . . . . . . . . . . . . . . . . Engine oil change . . . . . . . . . . . . . . . . . . . . . . . . . . Engine coolant level check . . . . . . . .09 G180. . . . .051. . . . . . . . . . . . . . . . . . . . . . . .

01 Engine start disabling Switch off power supply for Engine Control System at control panel.001. Note: Apart from the normal compression resistance. Switch on power supply for Engine Control System at control panel. G000. Bar engine manually. 15402/00 E 01–12  MTU . 10 seconds.07 Barring engine with starting system ! DANGER ! Rotating and moving engine components. there should be no abnormal resistance. Disconnect battery. 5 seconds. Remove engine barring tool (G030. If necessary. Open fuel supply to engine (G364.000. Work in progress” to control panel.000. G000. Connect battery.000.03 Engine start release Remove warning notice “Do not start engine.000.000. Install engine barring tool (G030.05 Barring engine manually Disable engine start (G000.03). Note: Engine start is automatically interrupted after approx. repeat engine start after approx.000. Work in progress” from switch cabinet.000.01).000.03). Release engine start (G000. ensure that nobody is in the danger zone. Shut off fuel supply to engine (G364. Risk of bodily harm and fatal injury! Before barring or starting the engine. G000. Note: Control panel description – see Manufacturer’s Documentation.000.01).Task Description Page G1 G000.01). Bar engine without ignition – see control cabinet manufacturer’s documentation.03). Attach warning notice “Do not start engine.

Note: Always start the engine under no-load conditions. Risk of fume poisoning! Ensure that engine room is always well ventilated.000.19 Engine running noise check Operate engine at rated speed. Risk of bodily harm and fatal injury! After working on the engine.  MTU 15402/00 E 01–12 . Start engine – see control cabinet manufacturer’s documentation.000. When the preparatory work has been carried out in accordance with the Operating Instructions (Section C).21).21). G000. G000.17 Temperature checks Check engine coolant temperature (where gauges are installed).000.000. Repair leaking exhaust pipework immediately.15 Pressure checks Check all pressures (where gauges are installed). no abnormal sounds must be heard.09 Engine starting ! DANGER ! Rotating and moving engine components.000.23).000. Before barring or starting the engine.000. G000.10 Trial run WARNING! Exhaust gases are harmful to health. check that all protective devices have been reinstalled and all tools removed from the engine. ensure that nobody is in the danger zone.000. Perform trial run at least until steady-state temperatures have been reached and not under 1/3 load.000. Start engine (G000.000.13 Engine speed check Check rated speed. G000. the engine can be restarted. Specified values – see operational data (A000.09). Specified values – see operational data (A000. Shut down engine (G000. Apart from the usual running noises. G000.Page G2 Task Description G000.

Run engine under load. 15402/00 E 01–12  MTU . Repair leaking exhaust pipework immediately.000. Before shutting down. Risk of fume poisoning! Ensure that engine room is always well ventilated. If significant leaks are found.23 Engine shutdown Note: Never shut down the engine directly from the full-load operation as this may result in overheating and wear of the engine components. Check engine and all pipework for leaks. shut down engine. G000.Task Description Page G3 G000. Press shutdown button on control panel.21 Engine and external lines leak check WARNING! Exhaust gases are harmful to health.000. When the engine has cooled. rectify the cause. disengage the alternator and run the engine at rated speed until a falling then constant temperature is recorded. Note: Never tighten lines when under pressure.

29 Attachments. Immediately replace hoses showing signs of scuffing.000.000.  MTU 15402/00 E 01–12 . Bar engine with starting system (G000.000. G000.25 Emergency shutdown Press emergency shutdown button on control panel.03).000.052. Remove injectors (G075.000. hoses and hose connections check Check all hoses and hose connections on the engine for condition and leaks.31 Compression pressure check Special tool: Engine barring tool Compression pressure recorder 550 589 09 21 00 Connector Y4 343 698 Shut off fuel supply to engine (G364.01).000.20) or (G231.27 Attachments security check Exhaust system (G140. G000.Page G4 Task Description G000. aging or cracking.01).000.03) Engine/alternator mount (G231.000. Release engine start (G000.20).051.051. G000.07) to remove any loose carbon deposits from the combustion chambers.

Task Description

Page Install connector with sealing ring in the injection nozzle opening and tighten with clamping element. Connect compression pressure recorder to connector. Bar engine with starting system until no further pressure rise is indicated.

G5

Actuate vent valve. Tighten adjuster pin to move the diagram sheet to the next position. Remove compression pressure recorder and connector. Carry out check in same way on all other cylinders.

Determine mean value of compression pressures: The difference between the mean value and the individually measured compression pressures must not exceed 3 bar. Install injectors (G075.051.09). Open fuel supply to engine (G364.000.03).

15402/00 E 01–12

 MTU

Page

G6

Task Description

G000.000.33 Cylinder chamber endoscopic examination
Special tool: Endoscope Y2 0097 353 Ratchet with socket (A/F 36 mm).
Note: For engines in service, if possible carry out a combustion chamber endoscopic examination after operation under load. Use an endoscope with an adequate light rating and a prism (5) which pivots 95° (total viewing angle 140 °), see – No.I –. If an endoscope with pivoting prism is not available, individual endoscopes with prism settings of 0°, 45° and 90° are required, see – No.II –. Max. possible diameter (a): 7 mm.

Before the endoscopic examination: Remove injector (G075.051.01). Release engine start (G000.000.03). Bar engine with starting system (G000.000.07) to remove any loose carbon deposits from the combustion chambers. Disable engine start (G000.000.01). Use engine barring tool to turn engine (G000.000.05) until, for the respective cylinder, – the piston is at BDC for cylinder liner inspection. – the piston is at a position which permits unobstructed and exact inspection of components for inspecting piston crown and cylinder head lower side and valves. – all valves are open or closed for inspection of valves and valve seats Endoscopic examination: Connect endoscope to light source (4) and insert it through the cylinder head (fuel injector bore) to the combustion chamber. Use the focussing device (2) to focus the eyepiece (1) and adjuster ring (3) to align the prism (5) with the area under inspection. Visually assess the cylinder liners, piston crowns, underside of the cylinder heads and valves. To do this, rotate the endoscope through 360° in each case and set the prism accordingly.

 MTU

15402/00 E 01–12

Task Description Assessment:

Page

G7

Cylinder liners are OK when: – the honing pattern is clearly visible – no or only locally limited polished areas are evident in the honing structure – no or only minor scoring is evident (minor scoring can be caused during piston installation). – no or only minor corrosion is evident (film rust after extended out-of-service periods is possible). Piston crowns are OK when: – injector spray pattern is clearly visible – only minor carbon or oil deposits are evident – no or only minor corrosion is evident (film rust after extended out-of-service periods is possible). Cylinder heads and valves are OK when: – only minor carbon or oil deposits are evident – only minor pitting is evident on valves and valve seats. – the valves close fully – no or only minor corrosion is evident (film rust after extended out-of-service periods is possible).
Note: If extensive wear or damage due to mechanical, chemical or thermal action is found, or the inspection results are otherwise suspect: remove the affected cylinder heads and recheck, repair or replace the individual components as necessary.

After the endoscopic examination: Remove engine barring tool (G030.001.03). Install injectors (G075.051.09). Release engine start (G000.000.03).

15402/00 E 01–12

 MTU

Moisture penetrating electrical components (temperature sensor. Do not go any closer than 20 cm (8 inches) to the object that is being sprayed. The temperature of the cleaning agent must not exceed max. Wear protective clothing. read the respective operating instructions of the manufacturer. the high-pressure spray must not exceed a pressure of 100 bar. Exterior cleaning is carried out as follows: Disable engine start (G000. use a fan jet nozzle only. depending on the degree of contamination. pressure sensor. rubber gloves. For exterior cleaning with the high-pressure jet. Spray off the dirt that has been loosened with the high-pressure spraying jet.  MTU 15402/00 E 01–12 . Before using the H. For environmental reasons. clean the engine only at places with a suitable oil separator. nonferrous metal.000.000.03). 1 to 5 minutes. To remove dirt: Note: When cleaning the outside of the engine with a high-pressure cleaner or steam jet. speed sensor and ECU) may lead to malfunctions and engine failure.39 Cleaning engine externally WARNING! Hard water jet.Page G8 Task Description G000. To loosen dirt: Note: Use only cleaning agents which will not damage light metal. Release engine start (G000.000.01). cleaner or steam jet. Risk of injury and scalding! Never aim the water jet at persons or electrical or electronic equipment. protective goggles and safety mask. steel. for it to react.P. grey cast iron and elastomers. 80 _C. Spray on a thin coating of cleaning agent and allow approx.

Remove filter (1) from housing (4). treated engine coolant. Risk of burning and explosion. Coat new O-ring (3) with petroleum jelly and fit in groove in housing. Insert new filter in housing. Lubricant: Engine oil. oils. G018.Task Description Page G9 Disposal of Hazardous Materials Fluids and lubricants (e.101. Avoid open flames. G018. cleaning agents and numerous auxiliary materials are an environmental hazard and therefore constitute hazardous materials. fuels). general environmental protection regulations and local legal specifications is mandatory. Do not smoke WARNING! Compressed air Risk of injury! Never aim compressed air jet at persons. Wear protective goggles/safety mask and ear protection.05 Crankcase ventilation filter replacement Remove cover (2) and O-ring (3). When disposing of these hazardous materials. greases. Leaked hazardous materials must immediately be absorbed with suitable bonding agents and disposed of in accordance with regulations in appropriate vessels. 15402/00 E 01–12  MTU . Under no circumstances must even small amounts of hazardous materials be allowed to drain into water.101. compliance with manufacturer’s instructions.07 Crankcase ventilation – oil preseparator cleaning WARNING! Fuels are combustible. or be discarded or disposed of outdoors. The contents of these containers must be specified. Tightening torque: 6 Nm + 2 Nm.g. Tighten screws on cover. ensuring it is correctly positioned. and install cover with O-ring. electric sparks and sources of ignition.

03).03 Engine barring tool removal Remove engine barring tool.001.000. 18V: F6 558 557 Disable engine start (G000.Page G 10 Task Description Release clamps and remove hose from adapter. Wash out oil separator in fuel and blow out with compressed air.000. Remove cover from flywheel housing. oils. G030. When disposing of these hazardous materials. 16V: F6 558 557 Engine barring tool. Fit hose in position and tighten clamps. Install engine barring tool on flywheel housing. compliance with manufacturer’s instructions. Disposal of Hazardous Materials Fluids and lubricants (e.001.g. greases. The contents of these containers must be specified. Remove cover (1) from housing (4). general environmental protection regulations and local legal specifications is mandatory. G030. Screw cover to flywheel housing. 12V: F6 558 556 Engine barring tool. Fit oil separator with new gasket on housing and install cover. or be discarded or disposed of outdoors.01). fuels). Moisten oil separator with engine oil. Remove oil separator (2) and gasket (3). Under no circumstances must even small amounts of hazardous materials be allowed to drain into water.  MTU 15402/00 E 01–12 . Leaked hazardous materials must immediately be absorbed with suitable bonding agents and disposed of in accordance with regulations in appropriate vessels. Release engine start (G000. cleaning agents and numerous auxiliary materials are an environmental hazard and therefore constitute hazardous materials.01 Engine barring tool installation Special tool: Engine barring tool. treated engine coolant.

Task Description

Page

G 11

G055.050.01 Valve clearance check and adjustment
Special tool: Feeler gauge Y2 0010 128
Note: Check with the valve closed and when coolant temperature does not exceed 40 _C.

Disable engine start (G000.000.01). Remove cylinder head cover (G055.101.01). Bar crankshaft with engine barring tool in engine direction of rotation until marking TDC-A1 on flywheel (see arrow) and pointer on flywheel housing are aligned.

Diagram shows 12V 2000 If the rocker arms are unloaded on cylinder A1, the piston is in firing TDC. Check and adjust valve clearances as per adjacent valve clearance adjustment diagram (1). If the rocker arms are loaded on cylinder A1, the piston is in overlap TDC. Check and adjust valve clearances as per adjacent valve clearance adjustment diagram (2). Turn crankshaft a further 360_ (to next TDC position) and adjust remaining valve clearances as per adjacent valve clearance adjustment diagram. 1 = Firing TDC at cylinder A1 2 = Overlap TDC at cylinder A1 X = Exhaust valve I = Inlet valve

15402/00 E 03–02

 MTU

Page

G 12 Diagram shows 16V 2000

Task Description

Procedure – see diagram for 12V 2000

Diagram shows 18V 2000 Procedure – see diagram for 12V 2000

 MTU

15402/00 E 01–12

Task Description

Page

G 13

Use feeler gauge to check distance between valve bridge and rocker arm. Settings – see Section A (valve clearance).
Note: It must be possible to just pull the feeler gauge through the gap.

If the variation from the specified value exceeds 0.1 mm, adjust the valve clearance as follows: Release locknut (1) and back off adjusting screw (2). Insert feeler gauge between valve bridge and rocker arm. Set adjusting screw so that feeler gauge just passes through gap when locknut is tightened. Use torque wrench to tighten locknut, holding adjusting screw firmly in position with screwdriver. Tightening torque: 50 Nm Install cylinder head cover (G055.101.03). Release engine start (G000.000.03).

G055.101.01 Cylinder head cover removal
Disable engine start (G000.000.01). Remove screws. Remove cylinder head cover from cylinder head.

15402/00 E 01–12

 MTU

 MTU 15402/00 E 01–12 . Fit cylinder head cover. Avoid open flames. replace if necessary. Drain fuel (G080.000. Check that profile gasket in cylinder head cover is in perfect condition.000.03 Cylinder head cover installation Clean mating faces.Page G 14 Task Description G055. Tightening torque: 20 Nm Lubricant: Engine oil Release engine start (G000. G073.000. Remove engine control system.01 Injector removal WARNING! Fuels are combustible. Remove charge air pipes. Remove gaskets.03). Tighten screw with torque wrench. electric sparks and sources of ignition. Risk of burning and explosion.01).051.02).101. Do not smoke Disable engine start (G000.

Remove securing screws on injection pump.051. Disconnect H.P.051. electric sparks and sources of ignition. If necessary. G073. Remove injection pump. electric sparks and sources of ignition. carefully remove injection pump at the recess in the injection pump head. Risk of burning and explosion. Risk of burning and explosion. Cover installation bore.01).04 Injection pump replacement WARNING! Fuels are combustible. G 15 Note: The injection pump must not be levered out by force applied at the solenoid valve or the intermediate plate. Do not smoke 15402/00 E 01–12  MTU . Install new injection pump (G073.05).Task Description Page Disconnect wiring (1) from injection pump.05 Injection pump installation WARNING! Fuels are combustible. line (2). G073. Avoid open flames. Avoid open flames. Mark installation location on injection pump.051. Do not smoke Remove injection pump (G073. Remove O-rings (3) from injection pump.051.

remove all plugs and covers. If a new injection pump is being installed. Note: Before installation. Coat roller (arrow) with engine oil. Ensure that the installation position is correct. Tightening torque: 60 Nm + 12 Nm Lubricant: Engine oil Install injection line (2) and tighten union nuts with torque wrench. set the pump cam on the camshaft to base circle. Tighten union nut on injection pump: Tightening torque: 30 Nm + 5 Nm Tighten union nut on pressure pipe joint: Tightening torque: 20 Nm + 5 Nm Lubricant: Engine oil Install wiring (1) on injection pump and tighten the screws using a torque wrench. Coat new O-rings (1) and (2) with petroleum jelly and fit to injection pump. Using the engine barring tool. Tightening torque: 1. Install injection pump in accordance with markings for installation position and tighten screws with torque wrench. work according to the coding in the engine control system (request assistance from MTU Service).2 Nm Lubricant: Engine oil  MTU 15402/00 E 01–12 . Note: Sealing rings have different part numbers.Page G 16 Task Description Clean mating faces on the injection pump and roller. Pay attention to location – see Spare Parts Catalogue.0 Nm +/– 0. Note: The injection line must not be bent. Clean sealing surfaces at crankcase and installation bore.

Avoid open flames.000. Remove cylinder head cover (G055.000. Drain fuel (G080. electric sparks and sources of ignition. Install charge air pipework. Disconnect H. Vent fuel system (G080.P. which is now clear.03). Remove pressure pipe joint (3). line (1).02). Check gaskets for damage.03). Fit gasket on cylinder head. G075. Seal all connections with suitable plugs.051. 15402/00 E 01–12  MTU . Open fuel supply to engine (G364. Risk of burning and explosion.101.000. Using the fuel syphon. Remove O-ring from pressure pipe joint.000. Remove fuel return line (4).Task Description Page G 17 Clean mating faces on cylinder head and charge air pipe. Remove thrust screw (2). Do not smoke Special tool: Impact extractor F3 0377 999 Fuel suction lifter F3 0378 207 Disable engine start (G000. Release engine start (G000.01 Injector removal WARNING! Fuels are combustible. Install engine control system. Note: Fuel must not enter the cylinder chamber.01). drain the fuel from the bore.000.01).01). replace if necessary.

Screw removal tool into injector.051. Remove sealing ring from injector.051. Remove sealing ring (copper) with wire hook.  MTU 15402/00 E 01–12 . Install new injector (G075. G075.09).05 Injector replacement Remove injector (G075.051.Page G 18 Task Description Unscrew hex screw (1) and remove clamping element (2).01). Remove injector with removal tool.

The fork on the clamping element must engage in the cover. Check sealing surfaces on cylinder head and injector retainer.09 Injector installation WARNING! Fuels are combustible.051. The pin (1) must be positioned in the recess in the clamping element (2). Press injector into cylinder head by hand. The injector feed bore must face installation direction (arrow) of pressure pipe connection. and ensure that clamping element is perfectly seated on injector and end cover. Bar engine several times with starter to blow out the remaining fuel. electric sparks and sources of ignition. Tighten screw (3) with torque wrench.Task Description Page G 19 G075. remove all plugs and covers. Before installation. Tightening torque: 50 Nm Lubricant: Engine oil 15402/00 E 01–12  MTU . positioning correctly. Install clamping element (4) with hex screw. Risk of burning and explosion. Fit new copper sealing ring (1) with grease on injector. Avoid open flames. clean if necessary. ensuring that pin is positioned at 11 o’clock with regard to engine longitudinal axis in injector. Do not smoke Note: Make sure fuel-carrying components are perfectly clean. Coat new sealing ring (2) with petroleum jelly and fit on injector (3).

03). Note: The injection line must not be bent. Ensure that the installation position is correct.03). screw in thrust screw (2) a few turns into cylinder head. Release engine start (G000.000. Check fuel system for leaks during engine operation. Tighten thrust screw with torque wrench.  MTU 15402/00 E 01–12 . To guide pressure pipe connection when pressing into cylinder head.101.000.01). Tightening torque: 40 Nm + 5 Nm Lubricant: Engine oil Install injection line (1) and tighten union nut with torque wrench. Moisten sealing cone of pressure pipe connection with engine oil.Page G 20 Task Description Coat new O-ring (4) with petroleum jelly and fit on pressure pipe connection. Insert pressure pipe connection up to contact on sealing ring into cylinder head. but do not yet press in firmly. Vent fuel system (G080. Install cylinder head cover (G055. Tighten union nut on injection pump: Tightening torque: 30 Nm + 5 Nm Tighten union nut on pressure pipe joint: Tightening torque: 20 Nm + 5 Nm Lubricant: Engine oil Install fuel return line (6).

Risk of burning and explosion.Task Description Page G 21 G080.01 Fuel system venting WARNING! Fuels are combustible. Do not smoke Release vent plugs on fuel filter (G083. electric sparks and sources of ignition. Release plug and allow fuel to drain into the container.05). Avoid open flames.000. 15402/00 E 01–12  MTU . Provide a suitable container in which to collect and dispose of the coolant. Release fuel hand pump by unscrewing handle.051.

Close vent plugs on fuel filter (G083. Do not smoke Release vent plugs on fuel filter (G083.051. cleaning agents and numerous auxiliary materials are an environmental hazard and therefore constitute hazardous materials. Leaked hazardous materials must immediately be absorbed with suitable bonding agents and disposed of in accordance with regulations in appropriate vessels.  MTU 15402/00 E 01–12 . electric sparks and sources of ignition. greases.02 Fuel draining WARNING! Fuels are combustible. Secure fuel hand pump by screwing in handle.Page G 22 Task Description Actuate fuel hand pump until bubble-free fuel emerges at the vent plugs and the vent line. G080. treated engine coolant. fuels).05).g. When disposing of these hazardous materials. Risk of burning and explosion. or be discarded or disposed of outdoors.051. general environmental protection regulations and local legal specifications is mandatory. The contents of these containers must be specified. Disposal of Hazardous Materials Fluids and lubricants (e. Under no circumstances must even small amounts of hazardous materials be allowed to drain into water.05).000. oils. Avoid open flames. Tighten plug. compliance with manufacturer’s instructions.

051. Disposal of Hazardous Materials Fluids and lubricants (e. Release plug and drain fuel into container. Leaked hazardous materials must immediately be absorbed with suitable bonding agents and disposed of in accordance with regulations in appropriate vessels. compliance with manufacturer’s instructions. Close vent plugs on fuel filter (G083. cleaning agents and numerous auxiliary materials are an environmental hazard and therefore constitute hazardous materials. greases.g. operating position check Note: During engine operation the three-way cock must always be set to position A. the threeway cock can be set to position B or C. general environmental protection regulations and local legal specifications is mandatory. Right filter cut in. When disposing of these hazardous materials.05).051. Tighten plug when no more fuel emerges. Both filters cut in. Under no circumstances must even small amounts of hazardous materials be allowed to drain into water. Reset three-way cock at fuel filter. Position C: Right filter cut out. Left filter cut in.01 Fuel filter. G083. treated engine coolant. 15402/00 E 01–12  MTU .Task Description Page G 23 Provide a suitable container in which to collect and dispose of the coolant. oils. The contents of these containers must be specified. Position A: Operating position. fuels). or be discarded or disposed of outdoors. Position B: Left filter cut out. Only for filter replacement during engine operation.

Open respective vent plug and release pressure. – Fuel filter changing with engine stationary. electric sparks and sources of ignition.051. Close vent plug. A distinction is made between: – Fuel filter changing with engine running.Page G 24 Task Description G083.03 Fuel filter replacement WARNING! Fuels are combustible.  MTU 15402/00 E 01–12 . Fuel filter changing with engine running: Close filter to be changed – see G083.051. only one filter may be briefly cut out at any time for replacement. Do not smoke Special tool: Oil filter wrench F3 0379 104 Note: With the engine running. Risk of burning and explosion. Avoid open flames.01.

Vent fuel filter (G083.051. general environmental protection regulations and local legal specifications is mandatory. Disposal of Hazardous Materials Fluids and lubricants (e. Clean sealing surface at connector. cleaning agents and numerous auxiliary materials are an environmental hazard and therefore constitute hazardous materials. The contents of these containers must be specified. Replace second filter in same way. When disposing of these hazardous materials. greases. compliance with manufacturer’s instructions.051. Setting fuel filter to operating position – see G083.g. Fuel filter changing with engine stationary: Close fuel supply to filter to be changed – see G083. Check sealing ring of new filter and moisten with fuel.Task Description Page G 25 Use oil filter wrench to unscrew filter and dispose of filter in accordance with local regulations. Use oil filter wrench to unscrew filter and dispose of filter in accordance with local regulations. Setting fuel filter to operating position – see G083. fuels).051.051.01.05). Clean sealing surface at connector.01. Under no circumstances must even small amounts of hazardous materials be allowed to drain into water. Replace second filter in same way. Install filter and tighten by hand. 15402/00 E 01–12  MTU .01. Leaked hazardous materials must immediately be absorbed with suitable bonding agents and disposed of in accordance with regulations in appropriate vessels. Install filter and tighten by hand. treated engine coolant. Check sealing ring of new filter and moisten with fuel. Close vent plug. oils. or be discarded or disposed of outdoors.

Actuate fuel hand pump (G080. Do not smoke Setting fuel supply to operating position – see G083.01) until bubblefree fuel emerges at the vent plugs. Release both vent plugs.01. Risk of burning and explosion. Avoid open flames.  MTU 15402/00 E 01–12 .051.051.000.05 Fuel filter venting WARNING! Fuels are combustible. Close vent plugs. electric sparks and sources of ignition.Page G 26 Task Description G083.

Disposal of Hazardous Materials Fluids and lubricants (e. Install filter and tighten by hand. Check sealing ring of new filter and moisten with fuel. fuels). treated engine coolant. The contents of these containers must be specified.Task Description Page G 27 G083.000. cleaning agents and numerous auxiliary materials are an environmental hazard and therefore constitute hazardous materials. Risk of burning and explosion. 15402/00 E 01–12  MTU . Replace second filter in same way.03 Fuel filter replacement WARNING! Fuels are combustible.01). greases.000. Do not smoke Special tool: Oil filter wrench F3 0379 104 Disable engine start (G000. When disposing of these hazardous materials. Use oil filter wrench to unscrew filter and dispose of filter in accordance with local regulations. Leaked hazardous materials must immediately be absorbed with suitable bonding agents and disposed of in accordance with regulations in appropriate vessels. compliance with manufacturer’s instructions. general environmental protection regulations and local legal specifications is mandatory. oils. or be discarded or disposed of outdoors. Clean sealing surface at connector.g. Avoid open flames. Under no circumstances must even small amounts of hazardous materials be allowed to drain into water. electric sparks and sources of ignition.03). Release engine start (G000.052.

Remove intake housing from exhaust turbocharger.051. Install air filter on intake housing – see G121.101. Do not smoke Carry out tasks specified by manufacturer. Rotate rotor assembly by hand.101.). Note: Compressor and turbine wheels must not scrape against housing. G101.09 Fuel prefilter.011. Do not smoke Carry out tasks specified by manufacturer. determine the cause and assess whether the engine can continue in operation without risk. Avoid open flames.03).15 Fuel prefilter cleaning WARNING! Fuels are combustible.051. at same time pressing against compressor housing.Page G 28 Task Description G083. Risk of burning and explosion.000. Install intake housing on exhaust turbocharger.01). element and gasket replacement WARNING! Fuels are combustible. G101. electric sparks and sources of ignition. if rotor is seized).01.000.01.01 Exhaust turbocharger.  MTU 15402/00 E 01–12 . electric sparks and sources of ignition. Risk of burning and explosion. Avoid open flames. the engine must continue in operation. If. Remove air filter from air intake housing – see (G121. run the engine only under partial load. Release engine start (G000.03 Exhaust turbocharger. engine operation in event of turbocharger failure In the event of turbocharger failure. ease-of-movement check Disable engine start (G000. in the event of turbocharger failure (e.g. Run the engine in this condition only until it is possible to replace or repair the turbocharger.011. G083.

activate engine only in an emergency.000. Obstruction check: With the engine running.Task Description Page G 29 G111. Risk of damage to hearing! Wear ear protectors. If the intercooler is leaking. intake side leak and damage check ! DANGER ! Rotating and moving engine components. ensure that nobody is in the danger zone.051.000.03 Intake air system. it is condensate. Before barring or starting the engine.000.01). Risk of damage to hearing! Wear ear protectors. Check intake side of engine for condition and leaks with the engine running.051. CAUTION! Engine noise above 85 dB(A). If considerable coolant is discharged and the coolant level falling. 15402/00 E 01–12  MTU .07 Intake air system check Check that the cover from the air filters has been removed. If a leaking intercooler cannot be repaired immediately.07) and blow out combustion chambers. before starting the engine: – Remove injectors (G075. – Bar engine with starting system (G000. – Bar engine manually (G000. Risk of bodily harm and fatal injury! After working on the engine. Check engine coolant temperature: Note: If only a small amount of coolant is discharged. G120. check that all protective devices have been reinstalled and all tools removed from the engine. G120.05). drain line water discharge and obstruction check CAUTION! Engine noise above 85 dB(A).01 Intercooler. the intercooler is leaking. oil-containing air must emerge at the drain line.000.

10 Contamination indicator resetting Press reset button to return signal ring to normal position.01). G123. Remove air filter (1) and dispose of filter in accordance with local regulations. Install new air filter with clamp.051. G123. replace air filter (G121.01). If the signal ring is completely visible once the engine has been shut down. signal ring position check Check position of signal ring at observation window. Reset contamination indicator (G123.053.000.03).01 Contamination indicator. Release engine start (G000. and it remains in this position.Page G 30 Task Description G121.  MTU 15402/00 E 01–12 . Release clamp (2).000.10). Clean connection on intake housing (3).053.051.053.01 Air filter replacement Disable engine start (G000.

Exhaust gases blue: excessive engine oil in combustion chamber. For specified values. Exhaust gases white: unburnt fuel. G140. check tightness of securing screws by torque wrench application and retighten as necessary. G140. 15402/00 E 01–12  MTU . Exhaust gases black: incomplete combustion. exhaust gas colour check Exhaust gases light grey: good combustion.000.000.Task Description Page G 31 G140. G140.03 Exhaust system security check When the engine is cold. see Engine Acceptance Test Record. Remove U-pipe pressure gauge. Run engine at full load and read off measurement on U-pipe pressure gauge.000.07 Exhaust system check Check that the housing cover has been removed from the exhaust turbocharger outlet.000. exhaust backpressure check Connect U-pipe pressure gauge to exhaust manifold.09 Exhaust system.05 Exhaust system.

mark”.03). Start engine and run at idle for approx. 5 minutes withdraw dipstick from guide tube and wipe. Pour engine oil in at oil filler neck up to Max. Do not fill engine oil above the ”max.000. mark (G180.  MTU 15402/00 E 01–12 . Carry out oil level check. Engine oil must be between Min.000. marks. and Max. marks. Do not fill engine oil above the Max. If necessary. and Max. Insert dipstick in guide tube. see MTU Fluids and Lubricants Specification A001061. If necessary. top up oil to Max. Checking before starting engine: Withdraw dipstick from guide tube and wipe. Insert dipstick in guide tube. Checking after engine shutdown: Shut down engine and after approx. mark. 1 to 2 minutes. and Max. mark (G180. marks. 5 minutes withdraw dipstick from guide tube and wipe. Carry out oil level check.Page G 32 Task Description G180. Seal oil filler neck with cover and tighten handle. top up oil to Max. Shut down engine and after approx.000.03 Engine oil system filling Note: Always use only MTU-approved engine oil. see MTU Fluids and Lubricants Specification A001061. top up oil to Max. Engine oil must be between Min. Turn handle counterclockwise until the cover of the oil filler neck can be removed.03). G180. mark on oil dipstick.01 Engine oil level check Note: Always use only MTU-approved engine oil. Carry out oil level check.000. mark. If necessary. Engine oil must be between Min.

When disposing of these hazardous materials. Pour in new engine oil (G180.05 Engine oil change Disable engine start (G000.03).000. Note: After each engine oil change and filter replacement.000. fuels). 2 litres of engine oil into a container in order to flush out the oil sludge. inspect the engine oil for dispersion capability (spot test). Release engine start (G000. Replace engine oil filter (G183.07).07). or be discarded or disposed of outdoors.000.01).04 Engine oil sample extraction and analysis WARNING! Engine oil can contain combustion residues which are harmful to health.03).000. treated engine coolant. Drain engine oil (G180. Do not inhale oil vapour. protective goggles and safety mask. The contents of these containers must be specified. coolant content and fuel dilution – see Publication for MTU Test Kit. Avoid contact with skin. greases. general environmental protection regulations and local legal specifications is mandatory. Disable engine start (G000. cleaning agents and numerous auxiliary materials are an environmental hazard and therefore constitute hazardous materials.052. Risk of injury and scalding! Wear protective clothing. Disposal of Hazardous Materials Fluids and lubricants (e. Using equipment and chemicals from the MTU Test Kit. 1 litre of engine oil coolant into a clean container. 15402/00 E 01–12  MTU .Task Description Page G 33 G180. Remove drain plug and drain approx.000.g.000.000. Leaked hazardous materials must immediately be absorbed with suitable bonding agents and disposed of in accordance with regulations in appropriate vessels. rubber gloves. oils.000. Install drain plug with a new sealing ring. Under no circumstances must even small amounts of hazardous materials be allowed to drain into water. Drain approx. compliance with manufacturer’s instructions.03). Note: Drain engine oil with the engine at operating temperature. Release engine start (G000.000. bar the engine with the starting system (G000. G180.03).01).

cleaning agents and numerous auxiliary materials are an environmental hazard and therefore constitute hazardous materials. Do not inhale oil vapour. G180. oils. Fill engine with corrosion inhibitor oil in same way as engine oil (G180. Risk of injury and scalding! Wear protective clothing. or be discarded or disposed of outdoors.000. Leaked hazardous materials must immediately be absorbed with suitable bonding agents and disposed of in accordance with regulations in appropriate vessels. When disposing of these hazardous materials. rubber gloves.000.03). Under no circumstances must even small amounts of hazardous materials be allowed to drain into water.Page G 34 Task Description G180. Avoid contact with skin.g. greases. Open oil drain plug and drain the engine oil into the container. treated engine coolant. general environmental protection regulations and local legal specifications is mandatory. Disposal of Hazardous Materials Fluids and lubricants (e. fuels). Provide a suitable container in which to collect and dispose of the engine oil. The contents of these containers must be specified. compliance with manufacturer’s instructions.000. Install drain plug with a new sealing ring.  MTU 15402/00 E 01–12 .07 Engine oil draining WARNING! Engine oil can contain combustion residues which are harmful to health. protective goggles and safety mask.09 Corrosion inhibitor oil filling Note: Always use only new MTU-approved corrosion inhibitor oil – see current MTU Fluids and Lubricants Specification A001061. Note: Drain engine oil with the engine at operating temperature.

fuels).000.01).000. greases. Avoid contact with skin. protective goggles and safety mask.Task Description Page G 35 G180. Install new engine oil filter and tighten by hand. Release engine start (G000.11 Corrosion inhibitor oil draining Note: Drain the corrosion inhibitor oil with the engine at operating temperature.g. G183. Clean sealing surface at connector. Risk of injury and scalding! Wear protective clothing.03).000. Special tool: Oil filter wrench F3 0379104 Disable engine start (G000.000. Replace other engine oil filters in same way.07).01). Drain remaining oil out of engine oil filter into a container. general environmental protection regulations and local legal specifications is mandatory.052. Check engine oil level (G180. Drain corrosion inhibitor oil in same way as engine oil (G180. treated engine coolant. Under no circumstances must even small amounts of hazardous materials be allowed to drain into water. Note: After each engine oil change and filter replacement.03 Engine oil filter replacement WARNING! Engine oil can contain combustion residues which are harmful to health. Check sealing ring of new engine oil filter and coat with oil. 15402/00 E 01–12  MTU . bar the engine with the starting system (G000. Leaked hazardous materials must immediately be absorbed with suitable bonding agents and disposed of in accordance with regulations in appropriate vessels. Do not inhale oil vapour. rubber gloves. The contents of these containers must be specified.000. oils. Remove engine oil filter with oil filter wrench. When the engine is started again. Disposal of Hazardous Materials Fluids and lubricants (e.000. check the oil filters for leaks. or be discarded or disposed of outdoors. When disposing of these hazardous materials.07). compliance with manufacturer’s instructions. cleaning agents and numerous auxiliary materials are an environmental hazard and therefore constitute hazardous materials.

000.03). untreated water is used to top up the coolant system. Add treated engine coolant via the filler line or the filler neck.000. Check engine coolant level (G202.01). Note: Always use only treated coolant in accordance with MTU Fluids and Lubricants Specification A001061.000. Open breather valve (G208.101. Never pour cold coolant into a hot engine. Run engine a number of minutes at idling speed. Risk of injury and scalding! Allow engine to cool. Close breather valve (G208.03). protective goggles and safety mask.03).  MTU 15402/00 E 01–12 .101.01 Engine coolant system filling WARNING! Coolant is hot and under pressure. rubber gloves. If. the coolant concentration must be checked and rectified at the earliest opportunity. Check engine coolant level (G202.Page G 36 Task Description G202. in an emergency. Wear protective clothing.

rubber gloves. Wear protective clothing.Task Description Page G 37 G202.” coolant level is automatically monitored by the engine control system.03).01). The engine coolant must be visible at the lower edge of the filler neck. Via level sensor: Switch on engine control system (G500.000. the coolant concentration must be checked and rectified at the earliest opportunity. 15402/00 E 01–12  MTU . Risk of injury and scalding! Allow engine to cool.101.000. untreated water is used to top up the coolant system.000. Via filler neck: WARNING! Coolant is hot and under pressure. Open breather valve (G208. Top up only with treated engine coolant.03 Engine coolant level check Note: The ”Min. in an emergency. Never pour cold coolant into a hot engine. If.101. Note: Always use only treated coolant in accordance with MTU Fluids and Lubricants Specification A001061. protective goggles and safety mask.01). Close breather valve (G208. as required (G202.01) and check indicator.

– Corrosion-inhibitor – pH value Close breather valve (G208.000. Change engine coolant according to the coolant operating times in the MTU Fluids and Lubricants Specification A001061 (G202. Under no circumstances must even small amounts of hazardous materials be allowed to drain into water. treated engine coolant.01).  MTU 15402/00 E 01–12 . rubber gloves.101. check coolant for: – Antifreeze. cleaning agents and numerous auxiliary materials are an environmental hazard and therefore constitute hazardous materials. fuels). When disposing of these hazardous materials. greases. protective goggles and safety mask. compliance with manufacturer’s instructions. Disposal of Hazardous Materials Fluids and lubricants (e. oils.000. Using the equipment and chemicals provided in the MTU Test Kit. Leaked hazardous materials must immediately be absorbed with suitable bonding agents and disposed of in accordance with regulations in appropriate vessels.101.03). or be discarded or disposed of outdoors.05 Engine coolant sample extraction and analysis WARNING! Coolant is hot and under pressure. Wear protective clothing.09). The contents of these containers must be specified. general environmental protection regulations and local legal specifications is mandatory.g. 1 litre engine coolant into a clean container. draw off approx.Page G 38 Task Description G202. Open breather valve (G208. Risk of injury and scalding! Allow engine to cool. Via the filler neck. Draw off precipitated corrosion inhibitor oil from expansion tank via filler neck and dispose of oil in appropriate manner.

000.01). Risk of injury and scalding! Allow engine to cool. rubber gloves. protective goggles and safety mask. Open breather valve (G208. Wear protective clothing. Disable engine start (G000. Drain remaining coolant at following points: – crankcase. Drain the expansion tank via the filler neck.Task Description Page G 39 G202.101. right side – coolant line – engine coolant pump 15402/00 E 01–12  MTU .01).000. Note: Drain engine coolant when engine has cooled. Preheating unit (if fitted) must be switched off. Open drain plugs on engine coolant cooler and preheating unit and drain coolant.07 Engine coolant draining WARNING! Coolant is hot and under pressure. Start at lowest point of coolant system. Provide a suitable container in which to collect and dispose of the engine coolant. Draw off precipitated corrosion inhibitor oil from expansion tank via filler neck and dispose of oil in appropriate manner.

The contents of these containers must be specified. Dispose of engine coolant. Clean the bore if it is contaminated.03). compliance with manufacturer’s instructions. Disposal of Hazardous Materials Fluids and lubricants (e.07).01 Engine coolant pump relief bore check Check relief bore for oil and coolant discharge (visual inspection). Leaked hazardous materials must immediately be absorbed with suitable bonding agents and disposed of in accordance with regulations in appropriate vessels. treated engine coolant. cleaning agents and numerous auxiliary materials are an environmental hazard and therefore constitute hazardous materials. When disposing of these hazardous materials. G202.g. oils.01).09 Engine coolant change Drain engine coolant (G202.Page G 40 Task Description – crankcase.000. general environmental protection regulations and local legal specifications is mandatory.03). Permissible volume of discharge: Coolant up to 10 drops/hour Oil up to 5 drops/hour Note: Repair engine coolant pump only if number of drops exceeds the above. left side – oil heat exchanger Fit all plugs with new sealing rings.051. Fill engine coolant system (G202. greases. Release engine start (G000. fuels).000. or be discarded or disposed of outdoors.000.000. Close breather valve (G208.101. G202. Under no circumstances must even small amounts of hazardous materials be allowed to drain into water.  MTU 15402/00 E 01–12 .

Open breather valve (G208.21). G202. 15402/00 E 01–12  MTU .401.400.01 Engine coolant preheating unit initial operation Carry out tasks specified by manufacturer.401.01 Engine coolant system.401.01 Engine coolant preheating Switch on preheating unit (G202. If. Engine coolant preheat temperature (A000. switching off Carry out tasks specified by manufacturer. protective goggles and safety mask. vent line obstruction check WARNING! Compressed air Risk of injury! Never aim compressed air jet at persons. the charge air coolant concentration must be checked and rectified at the earliest opportunity. Wear protective goggles/safety mask and ear protection. untreated charge air coolant is used to top up the coolant system. Never pour cold charge air coolant into a hot engine.651. G202.101.000.000. Note: Always use only treated coolant in accordance with MTU Fluids and Lubricants Specification A001061.Task Description Page G 41 G202. Install vent lines. G202. G202. G203.03 Engine coolant preheating unit.01).401.01 Charge air coolant system filling WARNING! Coolant is hot and under pressure. Risk of injury and scalding! Allow engine to cool. Wear protective clothing. switching on Carry out tasks specified by manufacturer. rubber gloves. Remove vent lines and blow out with compressed air.05 Engine coolant preheating unit. in an emergency.03).

Check charge air coolant level (G203.03). Close breather valve (G208.03). Check charge air coolant level (G203.101.000.  MTU 15402/00 E 01–12 . Run engine a number of minutes at idling speed.Page G 42 Task Description Add treated charge air coolant via the filler line or the filler neck.03).000.

01). Via filler neck: WARNING! Coolant is hot and under pressure. Note: Always use only treated coolant in accordance with MTU Fluids and Lubricants Specification A001061. Charge air coolant must be visible at the lower edge of the filler neck.000. the charge air coolant concentration must be checked and rectified at the earliest opportunity. rubber gloves. in an emergency. 15402/00 E 01–12  MTU .03 Charge air coolant level check Note: The ”Min” charge air coolant level is automatically monitored by the engine control system.Task Description Page G 43 G203.01). untreated charge air coolant is used to top up the coolant system.101. Top up only with treated charge air coolant. protective goggles and safety mask.101. Wear protective clothing.000.03). Via level sensor: Switch on engine control system (G500.000. Never pour cold charge air coolant into a hot engine. Open breather valve (G208. If. as required (G202. Close breather valve (G208.01) and check indicator. Risk of injury and scalding! Allow engine to cool.

Disable engine start (G000.05 Charge air coolant draining WARNING! Coolant is hot and under pressure. Note: Drain charge air coolant when engine has cooled. Open breather valve (G208.000. greases. The contents of these containers must be specified. Leaked hazardous materials must immediately be absorbed with suitable bonding agents and disposed of in accordance with regulations in appropriate vessels.03). oils.Page G 44 Task Description G203. treated engine coolant. rubber gloves. When disposing of these hazardous materials. Close breather valve (G208.000. general environmental protection regulations and local legal specifications is mandatory. Risk of injury and scalding! Allow engine to cool. Provide a suitable container in which to collect and dispose of the charge air coolant. cleaning agents and numerous auxiliary materials are an environmental hazard and therefore constitute hazardous materials.  MTU 15402/00 E 01–12 .03). Wear protective clothing. Drain charge air coolant at drain plug into a clean container.101. Disposal of Hazardous Materials Fluids and lubricants (e. Draw off precipitated corrosion inhibitor oil from expansion tank via filler neck and dispose of oil in appropriate manner.g. compliance with manufacturer’s instructions.01). Install plug with a new sealing ring. fuels). protective goggles and safety mask.101. Under no circumstances must even small amounts of hazardous materials be allowed to drain into water. Release engine start (G000.000. or be discarded or disposed of outdoors.01).

Disposal of Hazardous Materials Fluids and lubricants (e.000.03). Fill system with charge air coolant (G203. Open breather valve (G208. general environmental protection regulations and local legal specifications is mandatory.01). Using the equipment and chemicals provided in the MTU Test Kit. G203.g. Wear protective clothing.000. Change charge air coolant according to the coolant operating times in the MTU Fluids and Lubricants Specification A001061 (G203. oils. greases.01). Draw off precipitated corrosion inhibitor oil from expansion tank via filler neck and dispose of oil in appropriate manner. or be discarded or disposed of outdoors.000. check charge air coolant for: – Antifreeze. cleaning agents and numerous auxiliary materials are an environmental hazard and therefore constitute hazardous materials. Leaked hazardous materials must immediately be absorbed with suitable bonding agents and disposed of in accordance with regulations in appropriate vessels.01. The contents of these containers must be specified. G203. compliance with manufacturer’s instructions.09 Charge air coolant changing Drain charge air coolant (G203.07 Charge air coolant sample extraction and analysis WARNING! Coolant is hot and under pressure.051.101. Via the filler neck. 15402/00 E 01–12  MTU .05). draw off approx.000.09).000. 1 litre charge air coolant into a clean container.01 Charge air coolant pump relief bore check See G202.101. Risk of injury and scalding! Allow engine to cool. rubber gloves. protective goggles and safety mask.Task Description Page G 45 G203. When disposing of these hazardous materials. fuels). treated engine coolant. Under no circumstances must even small amounts of hazardous materials be allowed to drain into water.051. – Corrosion-inhibitor – pH value Close breather valve (G208.

fuels). The contents of these containers must be specified.g. Check cooler elements for contamination (visual inspection). Blow out cooler elements against direction of cooling air with a compressed air jet or spray with a water jet.  MTU 15402/00 E 01–12 .Page G 46 Task Description G203. before cleaning treat elements with a hot. When disposing of these hazardous materials. Under no circumstances must even small amounts of hazardous materials be allowed to drain into water. general environmental protection regulations and local legal specifications is mandatory. In event of heavily contaminated cooler elements. Remove vent line and blow out with compressed air. Note: The direction of the jet must be parallel to the cooling fins in order to avoid deforming the blades. or be discarded or disposed of outdoors. G205.01 Engine coolant cooler. treated engine coolant.01 Charge air coolant system. Disposal of Hazardous Materials Fluids and lubricants (e. greases. greasedissolving alkali cleaning agent.051. Clean heavily contaminated cooler elements. Wear protective goggles/safety mask and ear protection. oils. vent line obstruction check WARNING! Compressed air Risk of injury! Never aim compressed air jet at persons. external element contamination check WARNING! Compressed air Risk of injury! Never aim compressed air jet at persons. Wear protective goggles/safety mask and ear protection. cleaning agents and numerous auxiliary materials are an environmental hazard and therefore constitute hazardous materials. Install vent line.551. compliance with manufacturer’s instructions. Leaked hazardous materials must immediately be absorbed with suitable bonding agents and disposed of in accordance with regulations in appropriate vessels.

Under no circumstances must even small amounts of hazardous materials be allowed to drain into water. Clean heavily contaminated cooler elements. general environmental protection regulations and local legal specifications is mandatory. When disposing of these hazardous materials. Leaked hazardous materials must immediately be absorbed with suitable bonding agents and disposed of in accordance with regulations in appropriate vessels. compliance with manufacturer’s instructions. The contents of these containers must be specified. or be discarded or disposed of outdoors. fuels). Disposal of Hazardous Materials Fluids and lubricants (e. Wear protective goggles/safety mask and ear protection. external element contamination check WARNING! Compressed air Risk of injury! Never aim compressed air jet at persons. before cleaning treat elements with a hot.03 Charge air coolant cooler. Check cooler elements for contamination (visual inspection).051. Blow out cooler elements against direction of cooling air with a compressed air jet or spray with a water jet.g. Note: The direction of the jet must be parallel to the cooling fins in order to avoid deforming the blades. greases. treated engine coolant. oils. cleaning agents and numerous auxiliary materials are an environmental hazard and therefore constitute hazardous materials. In event of heavily contaminated cooler elements.Task Description Page G 47 G205. 15402/00 E 01–12  MTU . greasedissolving alkali cleaning agent.

Disable engine start (G000.000. protective goggles and safety mask. Risk of injury and scalding! Allow engine to cool.03). Clean sealing surfaces. Continue to turn breather valve counterclockwise and remove.03 Breather valve closing Check that breather valve is in perfect condition. Release engine start (G000.01 Breather valve opening WARNING! Coolant is hot and under pressure.101.101. G208.000.01). Fit breather valve and turn clockwise as far as it will go. Turn breather valve counterclockwise to first stop.  MTU 15402/00 E 01–12 . Allow pressure to escape.Page G 48 Task Description G208. rubber gloves. Wear protective clothing.

Before barring or starting the engine. overheating and wear. Risk of bodily harm and fatal injury! After working on the engine.051. oil. Check ribs for cracks. Remove guard plate.01 Generator drive. Special tool: Pretension gauge Y2 0097 429 Condition check: Disable engine start (G000. ensure that nobody is in the danger zone. clean or replace as necessary. the V-ribbed belt can continue in service. F2130001 0a 15402/00 E 01–12  MTU . check that all protective devices have been reinstalled and all tools removed from the engine.Task Description Page G 49 G213. drive belt condition and tension check ! DANGER ! Rotating and moving engine components.000.01). Note: Never use solvents such as petroleum or benzol or sharpedged objects. Damage pattern of ribbed belt: Normal wear: One or two rib fractures over 25 mm can be considered normal after a long period of service.

F2130002 0a The V-ribbed belt must be replaced immediately as the ribbed material has broken through and the ribs are broken around the entire circumference.Page G 50 Task Description The V-ribbed belt must be replaced as the ribs are broken around the entire circumference.  MTU 15402/00 E 01–12 . F2130003 0a Tension check: Place measuring instrument in the centre between pulleys on the V-ribbed belt (arrow).

Release engine start (G000. Check V-ribbed belt tension. Tighten securing screw (2) with torque wrench. the V-ribbed belt tension must be readjusted. exert pressure only on the pressure pad and stop pressing when the spring is released. Read off the value from the scale. Worn drive belt: 350 N – 50 N. In order to avoid errors in measurement. If the measured value does not correspond to the specified setting. Tightening torque: 40 Nm + 4 Nm Lubricant: Engine oil Tighten securing screw (3). Page G 51 Press straight down with the pressure pad onto the belt upper surface until the spring is heard or felt to be released. 15402/00 E 01–12  MTU . Settings: New drive belt: 450 N – 50 N. Read off belt tension indicated where pointer crosses scale. Tension ribbed belt with clamping nut (1). Carefully lift V-belt tension gauge without altering the position of the pointer. Check V-ribbed belt tension.03).Task Description Note: The gauge pointer must be inside the gauge.000. Tension adjustment: Release securing screws (2+3).

Check V-ribbed belt for cracks. G221.051. Tightening torque: 40 Nm + 4 Nm Lubricant: Engine oil Tighten securing screw (2).000. clean or replace as necessary.01.000.051.Page G 52 Task Description G213. If. ensure that nobody is in the danger zone. for whatever reason. Special tool: Pretension gauge 550 589 01 19/0 00 Condition check: Disable engine start (G000. oil.051. Tighten securing screws (2) with torque wrench. Remove guard plate.051. Check that V-ribbed belt pulleys are clean.01 Fan drive. Risk of bodily harm and fatal injury! After working on the engine. Fit new ribbed belt. Release clamping nut (1) so that the ribbed belt can be removed. see G213.01). one or more of the V-belts becomes defective.03. overheating and wear.03. Install guard plate. clean if necessary.01).05 Generator drive belt replacement Disable engine start (G000.  MTU 15402/00 E 01–12 .03). Before barring or starting the engine. For V-ribbed belt tension setting. check that all protective devices have been reinstalled and all tools removed from the engine. Remove drive belt from fan drive – see G221.000.051. Release engine start (G000. Note: Never use solvents such as petroleum or benzol or sharpedged objects. a new V-belt set must be installed. Release securing screws (2+3). Install drive belt of fan drive – see G221. Tension ribbed belt with clamping nut (1). drive belt condition and tension check ! DANGER ! Rotating and moving engine components.

15402/00 E 01–12  MTU . Check voltage 18V: Place tension gauge in the centre between pulleys on the V-ribbed belt (arrow). exert pressure only on the pressure pad and stop pressing when the spring is released. Note: The stop (arrow) of the gauge must be positioned to the side of the drive belt and the pointer in the gauge. Press straight down with the pressure pad onto the belt upper surface until the spring is heard or felt to be released.Task Description Check voltage 12V/16V: Page G 53 Place tension gauge in the centre between pulleys on the V-ribbed belt (arrow). In order to avoid errors in measurement.

Task Description Carefully lift V-belt tension gauge without altering the position of the pointer. Note: NOTE: For multi V-belt drives. Screw in tensioning screw (1) and tighten V-belt.000. Tightening torque: 100 Nm Lubricant: Engine oil Release engine start (G000. Tighten securing screws (2+3) with torque wrench. Release locknut (2). Adjust voltage 12V/16V: Release securing screws (3).Page G 54 Read off the value from the scale. Release engine start (G000. Screw in tensioning screw (1) and tighten V-belt. Settings 12/16V: New V-belt: 660 N Used V-belt: 510 N Settings 18V: New V-belt: 670 N – 50 N Used V-belt: 570 N – 50 N If the measured value does not correspond to the specified setting. the V-ribbed belt tension must be readjusted.  MTU 15402/00 E 01–12 . check all V-belts. Tighten locknut (2). Tightening torque: 69 Nm Lubricant: Engine oil Check V-belt tension.03). Tighten securing screws (3) with torque wrench. Check V-belt tension.03).000. Read off belt tension indicated where pointer crosses scale. Adjust voltage 18V: Release securing screws (2+3).

01). Release engine start (G000.051. Install guard plates. clean if necessary. Tightening torque: 100 Nm Lubricant: Engine oil Check V-belt tension. check that all protective devices have been reinstalled and all tools removed from the engine. V-belts must be placed in the grooves without the use of force. Check belt pulley on the fan bearing pedestal and crankshaft for cleanness. Tighten securing screws (3) with torque wrench. Disable engine start (G000. Remove guards from cooler.000.03).03 Fan drive belt replacement ! DANGER ! Rotating and moving engine components. Tighten locknut (2). Pretension V-belt with clamping screw. Install fan. Fit new set of V-belts. Release locknut (2). Before barring or starting the engine. Release bearing cap stud (1) so that the V-belts can be removed. ensure that nobody is in the danger zone. Note: Always replace V-belts in sets. Set V-belt tension. Remove air filter.Task Description Page G 55 G221.01).051. 15402/00 E 01–12  MTU . see under (G221. The fan bearing pedestal must contact the gear case for V-belt tensioning. Risk of bodily harm and fatal injury! After working on the engine.000. 12V/16V: Release securing screws (3). Replace drive belts.

V-belts must be placed in the grooves without the use of force. Remove screws (1). Release bearing cap stud (1) so that the V-belts can be removed. 18V: Task Description Release securing screws (2+3). For V-belt tensioning. the fan bearing pedestal must be in contact with the gear case.15 Engine/alternator mounting. The engine/plant must not be operated with the engine mounts locked in place. remove transportation locking devices. Install guard plates. Secure V-belt with stress bolt (1). Fit new set of V-belts. Release engine start (G000.000. remove washers and spacer sleeve (2).051. G231. Tighten securing screws (2+3) with torque wrench.01).  MTU 15402/00 E 01–12 .Page G 56 Replace drive belts. transportation locking device removal Before initial operation or after engine/plant transportation. clean if necessary.051. Check belt pulley on the fan bearing pedestal and crankshaft for cleanness.03). see under (G221. Set V-belt tension. Tightening torque: 69 Nm Lubricant: Engine oil Install fan.

15402/00 E 01–12  MTU .20 Engine/alternator mount security check Check tightness of all engine/alternator mount securing screws by torque wrench application and retighten as necessary.20 Engine/alternator mount security check Check tightness of all engine/alternator mount securing screws by torque wrench application and retighten as necessary.051. G231.052.Task Description Page G 57 G231.

03 Fuel supply opening Open shut-off valve in the supply line. If dimension (a) = 55 mm is not reached. Risk of burning and explosion.000.000. G364.050.05 Battery charge state.001. Avoid open flames. Note: A full fuel tank reduces condensation and the growth of bacteria. G309. G364. replace damping mount. Positioning check: Measure distance (a).01 Fuel supply closing Close shut-off valve in the supply line. Replace cracked mounts. top up if necessary. G364.052.01 Fuel system supply check WARNING! Fuels are combustible.30 Engine/alternator mount.  MTU 15402/00 E 01–12 .Page G 58 Task Description G231. never clean with organic detergents. Check damping mounts for cracks and deformation (visual check). electric sparks and sources of ignition.01 Protective device check Check that all guards are correctly installed on generator and fan drive. G307. Do not smoke Check fuel supply in fuel tank. electrolyte condition and level check Carry out tasks specified by manufacturer. The engine must be filled with coolant and engine oil.001. damping mount condition check Note: Wipe rubber surfaces with dry cloth only.

01 Engine control system switching on Move power supply switch on control panel from “Off” to “On”.Task Description Page G 59 G364.03). Pliers must therefore be used to tighten the union nut. Check security of all plug connectors on temperature sensors.01). G500. Note: Control panel description – see Manufacturer’s Documentation. Do not smoke G500.09 Engine wiring check Special tool: Pipe wrench F3 0017 884 Disable engine start (G000. Avoid open flames. Release engine start (G000. and coolant level probes by hand. 15402/00 E 01–12  MTU . G500. pressure sensors. Note: It is not sufficient to tighten the bayonet union nut by hand. electric sparks and sources of ignition.03 Fuel supply system filling WARNING! Fuels are combustible. Check security of all plug connectors on ECU with a pipe wrench (pliers).050.000.000. Note: Control panel description – see Manufacturer’s Documentation.000. There is the risk that the lock does not properly engage and the connector may then come loose during engine operation. speed sensors.000. Risk of burning and explosion.000.03 Engine control system switching off Move power supply switch on control panel from “On” to “Off”.

Check plug-in contacts for scorching. replace the wiring harness. Check lines and connection terminals for damage. Check fixture components for damage. The temperature sensor. a warning is given. wrap insulating tape around the cable.000. install new clamps if necessary.000. Damaged parts must be replaced immediately. If a monitoring unit fails. replace respective component. If the outer insulation of the cable is damaged and individual cores are visible. G507. Switch off engine control system (G500.01).098. contacts and connector bushes thoroughly with isoprophyl alcohol.03).  MTU 15402/00 E 01–12 .01 Monitoring system. Check security of screw (2). wear and vibration damage. If individual cores are damaged. pressure sensor and speed sensor are continuously monitored with the Integrated Test System (ITS) in the Engine Control System. equipment function check Disable engine start (G000.Page G 60 Check security of cable guides: Task Description Check security of cable in plastic tube (1) secured to engine with a bracket (3). provided that none of the individual cores are damaged. In event of a fault signal. Check security of cable clamps. Check electrical lines: Clean connector housing.

Withdraw speed sensor from flywheel housing. replace sensor. Withdraw speed sensor from flywheel housing. 1 2 Disconnect electrical plug connector for speed sensor (2). Remove securing screw (1).Task Description Page Removing speed sensor (crankshaft) G 61 Note: The speed sensor is an electronic component. Check magnetic force as follows: Apply iron screwdriver to the front end of speed sensor. F507 0050a0 Removing speed sensor (camshaft) Note: The speed sensor is an electronic component. Required resistance = 136 ohms $ 20 ohms In event of deviation from specified value. otherwise replace speed sensor. Disconnect electrical plug connector for speed sensor (2). 15402/00 E 01–12  MTU . F507 0049a0 Checking speed sensor Use an ohmmeter to measure resistance between Pin 1 and Pin 2. 1 2 Remove end cover from flywheel housing. Appropriate care is required for removal. Appropriate care is required for removal. magnetic attraction should be clearly detectable. Remove securing screw (1).

Appropriate care is required for installation. Coat O-ring (arrow) with petroleum jelly.6 mm  MTU 15402/00 E 01–12 . Gap clearance “S” between graduated disc (1) and speed sensor (2): S = from 0. Insert speed sensor in appropriate fitted bore in flywheel housing and tighten mounting screw.Page G 62 Task Description Installing speed sensor (crankshaft) Note: The speed sensor is an electronic component.1 mm to 1.45 mm Measure fitting length “E” of speed sensor and compare with depth of location hole. clean if necessary.45 mm to 1. Installing speed sensor (camshaft) Installation sequence is the same as with –Installing speed sensor (crankshaft)–. Fitting length “E” must be smaller than insertion depth “T” by dimension “S”. Check gap clearance “S” between graduated disc (1) and speed sensor (2): S = from 0. Check seating surface in flywheel housing.

temperature sensor and coolant level probe: Note: Sensor and probe are electronic components. Checking temperature sensor Measure resistance between Pin 1 and Pin 2 with an ohmmeter at different bath temperatures. Specified resistance at 0 °C = 1000 ohms Specified resistance at 100 °C = 1385 ohms In event of deviation from specified values. 15402/00 E 01–12  MTU . Appropriate care is required for removal. replace sensor. Checking speed sensor Carry out DC voltage test on sensor. seal removal bores with suitable plugs. Pin 1 = Voltage input Pin 2 = Voltage output Pin 4 = Earth Input voltage at 25 °C= 5 VDC Specified output voltage (1) = 0. replace sensor.Task Description Page G 63 Remove pressure sensor. Remove sensor and probe with open-end wrench.5 VDC In event of deviation from specified value. If necessary. Store sensors so that they are protected from dirt and mechanical damage. Attach suitable dust caps to screw-in thread of pressure sensors.

remove sensor and replace gasket.000. Check sealing surface and sensor installation bore (thread) for particular cleanness. Make sure that lube oil sensor and charge air sensor are particularly clean. Insert sensor and coolant level probe and tighten with a torque wrench. Remove blanking plug. Check operation of probe with falling coolant level.03).Page G 64 Task Description Checking coolant level probe (minimum probe) Note: In the case of minus-switching probes. and clean if necessary. measure switching threshold between plug contacts 2 and 3 with a voltmeter.000.01). Tightening torque: – Temperature sensor: 15 Nm to 30 Nm – Charge air pressure sensor: 20 Nm to 70 Nm – Lube oil pressure sensor: 20 Nm to 45 Nm – Coolant level probe: max. 30 Nm Lubricant: Engine oil Note: After starting the engine. Switch on engine control system (G500. Release engine start (G000. there is a danger of destruction if the minus potential is connected to the signal connection and plus potential to the minus connection. If leaks are found.  MTU 15402/00 E 01–12 . Appropriate care is required for installation. If correct sealing cannot be achieved in this way. when doing so. Rated voltage: 24 VDC Contact designations: 1 = plus (+UB) 2 = minus (⊥) 3 = signal (Uout) Installing pressure sensor. temperature sensor and coolant level probe: Note: Sensor and probe are electronic components. lightly tighten connection. check the connection for leaks (visual inspection).