Operating Instructions

Operating Instructions
Diesel engine
12 V 2000 Gx6 F
16 V 2000 Gx6 F
18 V 2000 Gx6 F
12 V 2000 Bx6 F
16 V 2000 Bx6 F
18 V 2000 Bx6 F
12 V 2000 B76 switchable
MS150118/00E
Downloaded from www.Manualslib.com manuals search engine

Engine model kW/cyl. rpm Application group
12V2000B26F 55 kW/cyl. 1500 3A, continuous operation, without restric-
tions
12V2000B76 switchable 59/60 kW/cyl. 1500/1800 3B, continuous operation, variable load,
ICXN
tions
ICXN
tions
ICXN
12V2000G16F 55 kW/cyl. 1500 3B, continuous operation, variable load,
ICXN
ICXN
ICXN
ICXN
ICXN
ICXN
Table 1: Overview of validity
© 2014 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 consent of MTU Friedrichshafen GmbH. This particularly applies to its reproduction, distribution, editing, transla-
tion, microfilming and storage or processing in electronic systems including databases and online services.
All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen
GmbH reserves the right to change, delete or supplement the information provided as and when required.

Table of Contents
1 Safety 6 Troubleshooting
1.1 Important requirements for all products 5 6.1 Troubleshooting 65
1.2 Personnel and organizational requirements 6
1.3 Transport 7 7 Task Description
1.4 Safety requirements for maintenance and
repair work 8 7.1 Engine 68
7.1.1 Engine – Cranking manually 68
1.5 Fire prevention and environmental
7.1.2 Engine – Barring with starting system 69
protection, fluids and lubricants, auxiliary
materials 11 7.2 Crankcase Breather 70
1.6 Standards for safety notices in the text 13 7.2.1 Crankcase breather – Oil mist fine separator
replacement 70
2 General Information 7.3 Valve Drive 71
7.3.1 Valve clearance – Check and adjustment 71
2.1 Engine side and cylinder designations 14 7.3.2 Cylinder head cover – Removal and
2.2 Engine overview 15 installation 74
7.4 Injection Valve / Injector 75

3 Technical Data
7.4.1 Injector ‒ Replacement 75
3.1 Engine data 12, 16, 18 V 2000 B26 F 18 7.4.2 Injector – Removal and installation 76
3.2 Engine data 12, 16, 18 V 2000 B76 7.4.3 Injector functions 81
switchable 1500 rpm 24 7.5 Fuel System 82
3.3 Engine data 12, 16, 18 V 2000 B76 7.5.1 HP fuel line and pressure pipe connection ‒
switchable 1800 rpm 30 Replacement 82
3.4 Engine data 12, 16 V 2000 G16 F 36 7.5.2 Fuel system – Venting 85
3.5 Engine data 12, 16, 18 V 2000 G26 F 40 7.5.3 Fuel – Draining 86
3.6 Engine data 12, 16, 18 V 2000 G76 F 45 7.6 Fuel Filter 87
3.7 Engine data 16 V 2000 G36 F 50 7.6.1 Fuel filter – Replacement 87
3.8 Firing order 54 7.6.2 Fuel prefilter – Differential pressure gage
3.9 Engine – Main dimensions 55 check and adjustment of gage 88
7.6.3 Fuel prefilter – Draining 89
7.6.4 Fuel prefilter – Flushing 90
4 Operation
7.6.5 Fuel prefilter – Filter element replacement 92
4.1 Preparing startup after long out-of-service 7.7 Air Filter 93
periods (>3 months) 56 7.7.1 Air filter – Replacement 93
4.2 Preparations for startup after scheduled out- 7.7.2 Air filter – Removal and installation 94
of-service-period 57
7.8 Air Intake 95
4.3 Starting the engine 58
7.8.1 Service indicator – Signal ring position check 95
4.4 Operation monitoring 59
4.5 Engine ‒ Stopping 60 7.9 Starting Equipment 96
4.6 Emergency stop 61 7.9.1 Electric starter – Overview 96
4.7 After stopping the engine 62 7.9.2 Starter – Removal 97
DCL-ID: 0000033223 - 001
7.9.3 Starter ‒ Installation 98

4.8 Plant – Cleaning 63
7.10 Lube Oil System, Lube Oil Circuit 99
5 Maintenance 7.10.1 Engine oil – Level check 99
7.10.2 Engine oil – Change 100
5.1 Maintenance schedule ‒ Task reference
table [QL1] 64 7.11 Oil Filtration / Cooling 101
7.11.1 Engine oil filter – Replacement 101
7.11.2 Centrifugal oil filter – Cleaning and filter
sleeve replacement 102
MS150118/00E 2014-07 | Table of Contents | 3

7.12 Coolant Circuit, General, High-Temperature 7.15.5 Coalescer filter element – Replacement 126
Circuit 104 7.16 Engine Governor 128
7.12.1 Drain and vent points 104 7.16.1 Engine control system – Overview 128
7.12.2 Engine coolant – Level check 108 7.16.2 Engine control system – Removal and
7.12.3 Engine coolant – Change 109 installation 129
7.12.4 Engine coolant ‒ Draining 110 7.16.3 Engine governor plug connections – Check 130
7.12.5 Engine coolant – Filling 111
7.12.6 Engine coolant pump – Relief bore check 113 7.17 Wiring (General) for Engine/Gearbox/Unit 131
7.12.7 Engine coolant – Sample extraction and 7.17.1 Еngine wiring ‒ Check 131
analysis 114
7.18 Accessories for (Electronic) Engine
7.13 Belt Drive 115 Governor / Control System 132
7.13.1 Drive belt – Condition check 115 7.18.1 Engine governor and connectors – Cleaning 132
7.13.2 Drive belt – Tension check 116 7.18.2 Engine governor plug connections – Check 133
7.13.3 Drive belt ‒ Tension adjustment 118
7.13.4 Drive belt – Replacement 119
8 Appendix A
7.14 Battery-Charging Generator 120
7.14.1 Battery-charger drive – Drive belt replacement 120 8.1 List of abbreviations 134
7.15 Fuel Supply System 122 8.2 MTU contact persons/service partners 136
7.15.1 Water drain valve – Check 122
7.15.2 Differential pressure gauge – Check 123 9 Appendix B
7.15.3 Water level probe (3-in-1 rod electrode) –
Check 124 9.1 Special Tools 137
7.15.4 Pump capacity – Check 125 9.2 Index 145
DCL-ID: 0000033223 - 001
4 | Table of Contents | MS150118/00E 2014-07

1 Safety
1.1 Important requirements for all products
Nameplate
The product is identified by a nameplate, model designation or serial number which must match the
information on the title page of this manual.
Nameplate, model designation or serial number can be found on the product.
General information
This product may pose a risk of injury or damage in the following cases:
• Improper use
• Operation, maintenance and repair by unqualified personnel
• Changes or modifications
• Noncompliance with the safety instructions and warning notices
Intended use
The product is intended for use in accordance with its contractually-defined purpose as described in the
relevant technical documents only.
Intended use entails operation:
• Within the permissible operating parameters in accordance with the (→ Technical data)
• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubri-
cants Specifications of the manufacturer)
• With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU
contact/Service partner)
• In the original as-delivered configuration or in a configuration approved by the manufacturer in writ-
ing (including engine management/parameters)
• In compliance with all safety regulations and in accordance with all warning notices in this manual
• With maintenance work performed in accordance with the (→ Maintenance Schedule) throughout the
useful life of the product
• In compliance with the maintenance and repair instructions contained in this manual, in particular
with regard to the specified tightening torques
• With the exclusive use of technical personnel trained in commissioning, operation, maintenance and
repair
• By contracting only workshops authorized by the manufacturer to carry out repair and overhaul
Any other use shall be considered non-intended. Such improper use increases the risk of injury and
damage when working with the product. The manufacturer shall not be held liable for any damage re-
sulting from improper, non-intended use.
Changes or modifications
Unauthorized changes to the product represent a contravention of its intended use and compromise
TIM-ID: 0000040530 - 004
safety.
Changes or modifications shall only be considered to comply with the intended use when expressly au-
thorized by the manufacturer. The manufacturer shall not be held liable for any damage resulting from
unauthorized changes or modifications.
MS150118/00E 2014-07 | Safety | 5

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

Wear proper protective clothing for all work.
When working, always wear the necessary personal protective equipment (e.g. ear protectors, protec-
tive gloves, goggles, breathing protection). Observe the information on personal protective equipment
in the respective activity description.
TIM-ID: 0000040531 - 002
6 | Safety | MS150118/00E 2014-07

1.3 Transport
Transport
Use only the lifting eyes provided to lift the engine.
Only use transport and lifting devices approved by MTU.
Take the engine's center of gravity into account.
Transport the engine in the installation position only, max. permissible diagonal pull 10°.
In the case of special packaging with aluminum foil, suspend the engine by the lifting eyes of the trans-
port pallet or transport with equipment suitable for heavy loads (forklift truck).
Install the crankshaft locking device and the locking screws for the engine mounts prior to engine trans-
portation.
Secure the engine against tilting during transportation. The engine must be additionally secured against
slipping or tilting when going up or down inclines and ramps.
Setting down the engine following transportation

Set the engine down on a firm, level surface only.
Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate.
Never set an engine down on the oil pan unless expressively authorized to do so by MTU on a case-to-
case basis .
TIM-ID: 0000002622 - 006
MS150118/00E 2014-07 | Safety | 7

1.4 Safety requirements for maintenance and repair work
Safety requirements before commencing maintenance and repair work
Have maintenance or repair work carried out by qualified and authorized personnel only.
Allow the product to cool down to less than 50°C (risk of explosion for oil vapors, fluids and lubricants,
risk of burning).
Relieve pressure in fluid and lubricant systems and compressed-air lines which are to be opened. Use
suitable collection vessels with a sufficient filling volume.
Ensure that the operating room is adequately ventilated when changing the oil or working on the fuel
system.
Do not perform maintenance or repair work when the product is running unless:
• expressly instructed to do so.
• the product is running in the low load range and only for as long as necessary to complete the task.
Lock-out the product to preclude undesired starting, e.g. start interlock.
Tag-out the product with a “Do Not Start” sign in the operation room or on the control facility.
Disconnect the battery. Lock the contactor.
Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic
starters are fitted.
Disconnect the control facility from the product.
For starters with pinions made of copper-beryllium alloy:
• Wear a respirator mask (filter class P3). Do not blow out the interior of the flywheel housing or the
starter with compressed air. Clean the interior of the flywheel housing with a class H dust extractor.
• Observe the safety data sheet.
Safety requirements during maintenance and repair work

Take special care when removing vent plugs or plug screws from the product. Hold a cloth over the
screw or plug to prevent discharge of highly pressurized liquids.
Take care when draining hot fluids and lubricants (risk of burning).
Use suitable and calibrated tools only. Observe the specified tightening torques during assembly or dis-
assembly.
Carry out work only on assembles and/or installations which are properly secured.
Never climb up on the lines.
Keep fuel injection lines and connections clean.
Always seal connections with caps or covers if a line is removed or opened.
Fit new seals when re-installing lines.
Avoid damaging lines, particularly the fuel lines.
TIM-ID: 0000040535 - 005
Ensure that all retainers and dampers are installed correctly.

Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent
contact with other components. Never route fuel or oil lines in the vicinity of hot components.
Do not touch elastomeric seals (e.g. Viton sealing rings) with your bare hands if they have a carbonized
or resinous appearance.
Observe the cooling time for components which have been heated for installation or removal (risk of
burning!).
Always use suitable ladders and work platforms when working above head-height. Ensure that compo-
nents or assemblies are placed on stable surfaces.
8 | Safety | MS150118/00E 2014-07

Pay particular attention to cleanliness at all times.
Safety requirements after completing maintenance and repair work

Ensure that all personnel is clear of danger zones before cranking.
Check that all access ports/apertures which have been opened to facilitate working are closed again.
Check that all safety equipment has been installed and that all tools and loose parts have been re-
moved (especially the barring gear).
Ensure that no unattached parts have been left in/on the product (e.g. including rags and cable straps).
Welding work
Do not perform welding on the product or its attachments. Cover the product when performing welding
work in the vicinity.
Before commencing welding work:
• Switch off the master power supply switch.
• Disconnect the battery.
• Disconnect electronic and genset grounds.
Do not perform maintenance or repair work on the product when welding is in progress in its vicinity.
Risk of explosion or fire due to oil vapors and highly flammable process materials.
Do not use the product as a grounding terminal.
Do not route the welding cable over or near the wiring harnesses of the product. The welding current
may otherwise induce an interference voltage in the wiring harnesses which could conceivably damage
the electrical system.
Remove components (e.g. exhaust pipe) from the product before performing necessary welding work .
Hydraulic installation and removal

Check function and satisfactory condition of the jigs and fixtures to be used. Use only the specified jigs
and fixtures for hydraulic removal/installation.
Observe the max. permissible force-on pressure specified for the installation/removal jig.
Do not attempt to bend or exert force on HP lines.
Before starting work, pay attention to the following:
• Vent the installation/removal jig, the pumps and the pipework at the relevant designated points.
• For hydraulic installation, screw on the jig with the piston retracted.
• For hydraulic removal, screw on the jig with the piston extended.
For hydraulic installation/removal jigs with central expansion pressure supply, screw the spindle into
the shaft end until correct sealing has been established.
During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of
the component to be installed/removed.
Working with batteries

TIM-ID: 0000040535 - 005
Observe the safety requirements of the battery manufacturer when working with batteries.
Gases released from the battery are explosive. Avoid sparks and naked flames.
Do not allow electrolyte (battery acid) to come into contact with skin or clothing.
Wear goggles and protective gloves.
Do not place tools on the battery.
Check polarity before connecting the cable to the battery. Battery polarity reversal may lead to injury by
the sudden discharge of acid or bursting of the battery unit.
MS150118/00E 2014-07 | Safety | 9

Working on electrical/electronic assemblies
Always obtain the permission of the duty supervisor before commencing maintenance or repair work or
switching off any part of the electronic system required to do so.
De-energize the appropriate areas prior to working on assemblies.
Avoid damaging cabling during removal. When reconnecting, ensure that cabling cannot be damaged
during operation by:
• Contact with sharp edges
• Chafing on components
• Contact with hot surfaces.
Do not secure cabling to lines bearing fluids.
Do not use cable ties to secure cabling.
Always use connector pliers to tighten union nuts on connectors.
Subject the device and also the product to appropriate function testing whenever repair work has been
completed. In particular, check the function of the emergency stop feature.
Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Pack-
age faulty electronic components or assemblies properly before dispatching for repair:
• Moisture-proof
• Shock-proof
• Wrapped in antistatic foil if necessary.
Working with laser equipment

Always wear special laser-protection goggles when working with laser equipment (danger due to in-
tensely focused radiation).
Laser equipment must be fitted with the protective devices necessary for safe operation according to
type and application.
For conducting light-beam procedures and measurement work, only the following laser devices must be
used:
• Laser devices of classes 1, 2 or 3A.
• Laser devices of class 3B, which have maximum output in the visible wavelength range (400 nm to
700 nm), a maximum output of 5 mW, and in which the beam axis and surface are designed to pre-
vent any risk to the eyes.
Measuring component deviations

Workpieces, components and measuring instruments are within specified tolerances at a reference
temperature of 20°C. TIM-ID: 0000040535 - 005
10 | Safety | MS150118/00E 2014-07

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

Modification or removal of any mechanical/electronic components or the installation of additional com-
ponents including the execution of calibration processes that might affect the emission characteristics
of the product are prohibited by emission regulations. Emission control units/systems may only be
maintained, exchanged or repaired if the components used for this purpose are approved by the manu-
facturer. Noncompliance with these guidelines will invalidate the design type approval issued by the
emissions regulation authorities. The manufacturer does not accept any liability for violations of the
emission regulations. The maintenance schedules of the manufacturer must be observed over the entire
life cycle of the product.
Dispose of used fluids, lubricants and filters in accordance with local regulations.
Within the EU, batteries can be returned free of charge to the manufacturer where they will be properly
recycled.
Fluids and lubricants and auxiliary materials

The Fluids and Lubricants Specifications will be amended or supplemented as necessary. Prior to opera-
tion, make sure that the latest version is used. The latest version can be found on the website on the
"Technical Info" or "Spare Parts and Service" tabs at http://www.mtu-online.com.
Consumable fluids and materials may also be hazardous or toxic. When using fluids, lubricants, consum-
ables and other chemical substances, follow the safety regulations that apply to the product. Take spe-
cial care when using hot, chilled or caustic substances. When using flammable materials, prevent them
TIM-ID: 0000040536 - 005
coming into contact with ignition sources and do not smoke.
Used oil
Used oil contains combustion residues that are harmful to health.
Rub barrier cream into hands.
Wash hands after contact with used oil.
MS150118/00E 2014-07 | Safety | 11

Lead
• Adopt suitable measures to avoid the formation of lead dust.
• Switch on extraction system.
• When working with lead or pastes that contain lead, avoid direct contact with the skin. Do not inhale
lead vapors.
• Wash hands after contact with lead or lead-containing substances.
Compressed air
Observe special safety precautions when working with compressed air:
• Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII and B) out of
containers, risks causing an explosion.
• Wear goggles when blowing dirt off workpieces or blowing away swarf.
• Blowing compressed air into thin-walled containers (e.g. containers made of sheet metal, plastic or
glass) for drying purposes or to check for leaks risks bursting them.
• Pay special attention to the pressure in the compressed air system or pressure vessel.
• Assemblies or products to be connected must either be designed for that pressure, or, if the permis-
sible pressure is lower than the system pressure, a pressure reducing valve and safety valve (set to
the permissible pressure) must be connected between the assemblies/products and the system.
• Hose couplings and connections must be securely attached.
• Provide the snout of the air nozzle with a protective disk (e.g. rubber disk).
• First shut off compressed air lines before compressed air device is disconnected from the supply
line, or before device or tool is to be replaced.
• Carry out leak test in accordance with the specifications.
Paints and varnishes

• Observe the relevant safety data sheet for all materials.
• When painting in areas other than spray booths equipped with extractors, ensure good ventilation.
Make sure that neighboring work areas are not adversely affected.
• There must be no naked flames in the vicinity.
• No smoking.
• Observe fire prevention regulations.
• Always wear a mask providing protection against paint and solvent vapors.
Liquid nitrogen
• Work with liquid nitrogen may be carried out only by qualified personnel.
• Store liquid nitrogen only in small quantities and always in regulation containers (without gas-tight
caps).
• Avoid body contact (eyes, hands).
• Wear protective clothing, protective gloves, closed shoes and safety goggles.
• Make sure that working area is well ventilated.
• Avoid knocking or jolting the containers, valves and fittings or workpieces in any way.
Acids/alkaline solutions/urea (AdBlue®, DEF)

TIM-ID: 0000040536 - 005

• When working with acids and alkaline solutions, wear goggles or face mask, gloves and protective
clothing.
• Do not inhale vapors.
• If urea solution is swallowed, rinse out mouth and drink plenty of water.
• If spilled onto clothing, remove the affected clothing immediately.
• After contact with skin, rinse affected parts of the body with plenty of water.
• Rinse eyes immediately with eye drops or clean tap water. Seek medical attention as soon as possi-
ble.
12 | Safety | MS150118/00E 2014-07

1.6 Standards for safety notices in the text
DANGER
In the event of immediate danger.
Consequences: Death, serious or permanent injury!
• Remedial action.
WARNING
In the event of a situation involving potential danger.
Consequences: Death, serious or permanent injury!
CAUTION
In the event of a situation involving potential danger.
Consequences: Minor or moderate injuries!
NOTICE
In the event of a situation involving potentially adverse effects on the product.
Consequences: Material damage!
• Additional product information.
Safety notices
1. This manual with all safety instructions and safety notices must be issued to all personnel involved in
operation, maintenance, repair or transportation.
2. The higher level warning notice is used if several hazards apply at the same time. Warnings related to
personal injury shall be considered to include a warning of potential damage.
TIM-ID: 0000040578 - 003
MS150118/00E 2014-07 | Safety | 13

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

2 Engine free end in accord- 4 Engine driving end in ac-
ance with DIN ISO 1204 cordance with
(KGS = Kupplungsgegen- DIN ISO 1204 (KS = Kup-
seite) plungsseite)
Engine sides are always designated (in accordance with DIN ISO 1204) as viewed from driving end (4).
For cylinder designation (in accordance with DIN ISO 1204), the letter "Ax" refers to the cylinders on
the left-hand side of the engine (1) and letter "Bx" refers to the cylinders on the right-hand side (3). The
cylinders of each bank are numbered consecutively, starting with x=1 at driving end (4).
The numbering of other engine components also starts with 1 at driving end (4).
TIM-ID: 0000002185 - 013
14 | General Information | MS150118/00E 2014-07

2.2 Engine overview
12 V 2000 Gx6F / Bx6F / B76 switchable
1 Air intake/air supply 6 Engine coolant pump 11 Charge-air line

2 charge-air pipe 7 Fuel system (low pressure) 12 Starting equipment
3 Monitoring, control and 8 Fuel filter 13 PTO system, driving end
regulation system 9 Exhaust turbocharger KS Driving end
4 Charge-air line 10 Fuel system (high pres-
5 Belt drive sure)
TIM-ID: 0000053439 - 001
MS150118/00E 2014-07 | General Information | 15

16 V 2000 Bx6F / Gx6F / B76 switchable

2 Charge-air manifold 7 Fuel system (low pressure) 12 PTO system, driving end
3 Monitoring, control and 8 Fuel filter KS Driving end
regulation system 9 Exhaust turbocharger
5 Belt drive sure)
TIM-ID: 0000053439 - 001
16 | General Information | MS150118/00E 2014-07

18 V 2000 Bx6F / Gx6F / B76 switchable

2 Charge-air manifold 7 Fuel system (low pressure) 12 Starting equipment
3 Monitoring, control and 8 Fuel filter 13 PTO system, driving end
regulation system 9 Exhaust turbocharger KS Driving end
5 Belt drive sure)
Explanation of engine model designation
12, 16, 18 Number of cylinders
V Cylinder arrangement (Vee engine)
2000 Series
B, G Application (G for peripheral energy systems engineering,
B for base load)
x Application segment (0, 1, 2,...,9)
6 Design index (0, 1, 2,...,9)
F Additional characteristic (F = 60 Hz)
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Table 2: Explanation of engine model designation
MS150118/00E 2014-07 | General Information | 17

3 Technical Data
3.1 Engine data 12, 16, 18 V 2000 B26 F
Explanation:
DL Ref. value: Continuous power
BL Ref. value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value up to which the engine can be operated without changes (e.g. to power settings).
N Value not yet defined
- Not applicable
X Applicable
Reference conditions
Engine model 12V2000B26F 16V2000B26F 18V2000B26F
Application group 3A 3A 3A
Intake air temperature °C 25 25 25
Charge air coolant temperature °C - - -
Barometric pressure mbar 1000 1000 1000
Site altitude above sea level m 100 100 100
Table 3: Reference conditions
Power-related data (power ratings are net brake power as per ISO 3046)
Number of cylinders 12 16 18
Rated engine speed A rpm 1500 1500 1500
Continuous power ISO 3046 (10% A kW 665 709 887
overload capability)
Net brake power (without fan) (fuel A kW 732 780 976
stop power ISO 3046)
Mean effective pressure (pme) bar 19.9 15.9 17.7
(continuous power ISO 3046)
(fuel stop power ISO 3046)
Table 4: Power-related data (power ratings are net brake power as per ISO 3046)
Boundary conditions (for maximum power)

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Intake depression (new filter) A mbar 15 15 15
Intake depression, max. L mbar 40 40 40
Exhaust overpressure A mbar 30 30 30
Exhaust overpressure, max. L mbar 50 50 50
18 | Technical Data | MS150118/00E 2014-07

Fuel temperature at engine supply R °C 25 25 25
connection
Fuel temperature at engine supply L °C 65 65 65
connection, max.
Table 5: Boundary conditions (for maximum power)
Consumption
Lube oil consumption after L % of B 0.8 0.8 0.8
100 hrs runtime (B = hourly fuel
consumption)
Table 6: Consumption
Model-related data (basic design)

Operating method: four-stroke cy- X X X
cle, diesel, single-action
Combustion method: direct fuel in- X X X
jection
Cylinder arrangement: Vee angle Degrees (°) 90 90 90
Bore mm 135 135 135
Stroke mm 156 156 156
Displacement of a cylinder Liters 2.233 2.233 2.233
Total displacement Liters 26.8 35.7 40.2
Compression ratio 17.50 17.5 17.5
Standard housing connecting SAE 0 0 0
flange (engine main PTO side)
Table 7: Model-related data (basic design)
Air / exhaust gas

Charge-air pressure before cylin- R bar abs 2.7 2.3 2.65
der - DL
der - BL
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Table 8: Air / exhaust gas
MS150118/00E 2014-07 | Technical Data | 19

Coolant system (HT circuit)
Coolant temperature (at engine A °C 100 100 100
connection: outlet to cooling sys-
tem)
Coolant temperature after engine, L °C 102 102 102
warning
shutdown
Coolant antifreeze content, max. L % 50 50 50
Cooling system: coolant flow rate A m³/h 31.6 41.6 46.3
Coolant pump: inlet pressure, min. L bar 0.4 0.4 0.4
Coolant pump: inlet pressure, L bar 1.5 1.5 1.5
max.
Pressure loss in external cooling L bar 1.0 1.0 1.0
system outside engine
Breather valve (expansion tank) R bar 1.0 1.0 1.0
opening pressure at gauge pres-
sure
Cooling system: height above en- L m 20 20 20
gine, max.
Table 9: Coolant system (HT circuit)
Coolant system (LT circuit)

Coolant temperature before inter- A °C - - -
cooler (at engine connection: cool-
ing system inlet)
Coolant antifreeze content, max. L % - - -
Coolant pump: Inlet pressure, L bar - - -
max.
Charge-air temperature after inter- L °C - - -
cooler, max.
Breather valve (expansion tank) R bar - - -
sure
Cooling system: height above en- L m - - -
gine, max.
TIM-ID: 0000053440 - 001
Table 10: Coolant system (LT circuit)
Lube oil system

Lube-oil operating temperature be- R °C 75 75 75
fore engine, from
Lube oil operating temperature be- R °C 100 100 100
fore engine, to

Lube-oil temperature before en- L °C 103 103 103
gine, warning
gine, shutdown
Lube oil operating pressure before R bar 5.8 6.2 6.0
engine, from
Lube-oil operating pressure before R bar 8.5 8.8 8.0
engine, to
Lube oil operating pressure before L bar 4.5 4.5 4.5
engine, warning
engine, shutdown
Lube oil fine filter (main circuit): 2 3 3
number of cartridges per unit
Table 11: Lube oil system
Fuel system
Fuel pressure at engine supply L bar -0.5 -0.5 -0.5
connection, min. (during engine
start)
Fuel pressure at engine supply bar 0.5 0.5 0.5
connection, max. (during engine
start)
Fuel supply flow rate, max. A Liters/min 30 30 30
Fuel return flow rate, max. A Liters/min 30 30 30
Table 12: Fuel system
General operating data

Coolant preheating: preheating L °C 32 32 32
temperature (min.)
Starting is blocked if the engine °C -20 -20 -20
coolant temperature is below
Firing speed, from R rpm 100 100 100
Firing speed. to R rpm 120 120 120
Table 13: General operating data

TIM-ID: 0000053440 - 001

Inclined positions, standard oil system (reference: waterline)
Longitudinal inclination, continu- L Degrees (°) 5 5 5
ous max. driving end bottom (op-
tion: max. operating inclination po-
sitions)
ous max. driving end top (option:
max. operating inclination posi-
tions)
Transverse inclination continuous L Degrees (°) 10 10 10
max. (design: max. operating incli-
nation positions)
Table 14: Inclined positions, standard oil system (reference: waterline)
Capacities
Engine coolant capacity, engine R Liters 63 70 73
side (without cooling system)
Charge-air coolant, engine side R Liters - - -
Fuel, engine side R Liters 6 6 7
Engine oil capacity, initial filling R Liters 92 114 122
(standard oil system) (design: max.
operating inclination positions)
Oil change quantity max. (standard R Liters 80 102 110
oil system) (design: max. operating
inclination positions)
Table 15: Capacities
Fan / fan cooler

Fan, push-type X X X
Fan drive: mechanical via V-belt X X X
Table 16: Fan / fan cooler
Sound
Exhaust noise, not attenuated - DL R dB(A) 111 - -
TIM-ID: 0000053440 - 001
(free-field sound pressure level Lp,

1 m distance, ISO 6798, +3 dB(A)
tolerance)
(sound power level LW, ISO 6798,
+3 dB(A) tolerance)

Engine surface noise with attenu- R dB(A) 100 - 101
ated intake noise (filter) - DL (free-
field sound power level Lp, 1 m
distance, ISO 6798, +2 dB(A) tol-
erance)
ated intake noise (filter) - DL
(sound power level LW, ISO
6798+2 db(A) tolerance)
Table 17: Sound

TIM-ID: 0000053440 - 001

3.2 Engine data 12, 16, 18 V 2000 B76 switchable 1500 rpm
Explanation:
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable
Engine model 12V2000B76 16V2000B76 18V2000B76
switchable switchable switchable
Application group 3B 3B 3B

TIM-ID: 0000054516 - 001


connection
connection, max.
Consumption
consumption)

jection
Bore mm 135 135 135
Stroke mm 156 156 156
Air / exhaust gas

der - DL
der - BL
TIM-ID: 0000054516 - 001

connection: outlet to cooling
equipment)
warning
shutdown
max.
sure
gine, max.

ing system inlet)
Coolant pump: inlet pressure, L bar - - -
max.
cooler, max.
sure
gine, max.
TIM-ID: 0000054516 - 001
Lube oil system

fore engine, from
fore engine, to

gine, warning
gine, shutdown
engine, from
engine, to
engine, warning
engine, shutdown
Fuel system
start)
start)

temperature (min.)

TIM-ID: 0000054516 - 001

sitions)
tions)
nation positions)
Capacities
Fan / fan cooler

Fan, pusher type X X X
Sound
Exhaust noise, not attenuated - DL R dB(A) 112 - 115
TIM-ID: 0000054516 - 001

tolerance)
Exhaust noise, not attenuated - DL R dB(A) 125 - 127
+3 dB(A) tolerance)

erance)
Engine surface noise with attenu- R dB(A) 118 - -
Table 32: Sound

TIM-ID: 0000054516 - 001

3.3 Engine data 12, 16, 18 V 2000 B76 switchable 1800 rpm
Explanation:
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable
Engine model 12V2000B76 16V2000B76 18V2000B76
switchable switchable switchable

TIM-ID: 0000054519 - 001


connection
connection, max.
Consumption
consumption)

jection
Bore mm 135 135 135
Stroke mm 156 156 156
Air / exhaust gas

der - DL
der - BL
TIM-ID: 0000054519 - 001

tem)
warning
shutdown
max.
sure
gine, max.

ing system inlet)
max.
cooler, max.
sure
gine, max.
TIM-ID: 0000054519 - 001
Lube oil system

fore engine, from
fore engine, to

gine, warning
gine, shutdown
engine, from
engine, to
engine, warning
engine, shutdown
Fuel system
start)
start)

temperature (min.)

TIM-ID: 0000054519 - 001

sitions)
tions)
nation positions)
Capacities
Fan / fan cooler

Sound
Exhaust noise, not attenuated - DL R dB(A) 111 115 115
TIM-ID: 0000054519 - 001

tolerance)
Exhaust noise, not attenuated - DL R dB(A) 124 127 128
+3 dB(A) tolerance)

Engine surface noise with attenu- R dB(A) 101 101 103
erance)
Engine surface noise with attenu- R dB(A) 119 118 121
Table 47: Sound

TIM-ID: 0000054519 - 001

3.4 Engine data 12, 16 V 2000 G16 F
Explanation:
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable
Engine model 12V2000 16V2000
G16F G16F
Application group 3A 3A
Intake air temperature °C 25 25
Charge air coolant temperature °C - -
Barometric pressure mbar 1000 1000
Site altitude above sea level m 100 100
Number of cylinders 12 16
Rated engine speed A rpm 1500 1500
Continuous power ISO 3046 (10% overload capability) A kW 665 806
Net brake power (without fan) (fuel stop power ISO 3046) A kW 732 887
Mean effective pressure (pme) (continuous power ISO 3046) bar 19.9 18.1
Mean effective pressure (pme) (fuel stop power ISO 3046) bar 21.8 19.9

Intake depression (new filter) A mbar 15 15
Intake depression, max. L mbar 40 40
Exhaust overpressure A mbar 30 30
TIM-ID: 0000053441 - 001
Exhaust overpressure, max. L mbar 50 50

Fuel temperature at engine supply connection R °C 25 25
Fuel temperature at engine supply connection, max. L °C 65 65

Consumption
Lube oil consumption after 100 hrs runtime (B = hourly fuel con- % of B 0.8 0.8
sumption)

Operating method: four-stroke cycle, diesel, single-action X X
Combustion method: direct fuel injection X X
Cylinder arrangement: Vee angle Degrees 90 90
(°)
Bore mm 135 135
Stroke mm 156 156
Displacement of a cylinder Liters 2.233 2.233
Total displacement Liters 26.8 35.7
Compression ratio 17.5 17.5
Standard housing connecting flange (engine main PTO side) SAE 0 0
Air / exhaust gas

Charge-air pressure before cylinder - DL R bar abs 2.9 2.6
Charge-air pressure before cylinder - BL R bar abs 3.2 2.8

Coolant temperature (at engine connection: outlet to cooling sys- A °C 100 100
tem)
Coolant temperature after engine, warning L °C 102 102
Coolant temperature after engine, shutdown L °C 105 105
Coolant antifreeze content, max. L % 50 50
Cooling system: coolant flow rate A m³/h 31.6 41.6
TIM-ID: 0000053441 - 001
Coolant pump: inlet pressure, min. L bar 0.4 0.4

Coolant pump: inlet pressure, max. L bar 1.5 1.5
Pressure loss in external cooling system outside engine L bar 1.0 1.0
Breather valve (expansion tank) opening pressure at gauge pres- R bar 1.0 1.0
sure
Cooling system: height above engine, max. L m 20 20

Coolant temperature before intercooler (at engine connection: A °C - -
cooling system inlet)
Coolant antifreeze content, max. L % - -
Coolant pump: inlet pressure, max. L bar - -
Charge-air temperature after intercooler, max. L °C - -
Breather valve (expansion tank) opening pressure at gauge pres- R bar - -
sure
Cooling system: height above engine, max. L m - -
Lube oil system

Lube-oil operating temperature before engine, from R °C 75 75
Lube-oil operating temperature before engine, to R °C 100 100
Lube-oil temperature before engine, warning L °C 103 103
Lube-oil temperature before engine, shutdown L °C 105 105
Lube oil operating pressure before engine, from R bar 5.8 6.2
Lube-oil operating pressure before engine, to R bar 8.5 8.8
Lube oil operating pressure before engine, warning L bar 4.5 4.5
Lube oil operating pressure before engine, shutdown L bar 4.0 4.0
Lube oil fine filter (main circuit): number of cartridges per unit 2 3
Fuel system
Fuel pressure at engine supply connection, min. (during engine L bar -0.5 -0.5
start)
Fuel pressure at engine supply connection, max. (during engine L bar 0.5 0.5
start)
Fuel supply flow rate, max. L Liters/ 30 30
min
Fuel return flow rate, max. L Liters/ 30 30
min
TIM-ID: 0000053441 - 001

Coolant preheating: preheating temperature (min.) L °C 32 32
Starting is blocked if the engine coolant temperature is below °C -20 -20

Firing speed, from R rpm 100 100
Firing speed. to R rpm 120 120

Longitudinal inclination, continuous max. driving end bottom (op- L Degrees 5 5
tion: max. operating inclination positions) (°)
Longitudinal inclination, continuous max. driving end top (option: L Degrees 5 5
max. operating inclination positions) (°)
Transverse inclination continuous max. (design: max. operating in- L Degrees 10 10
clination positions) (°)
Capacities
Engine coolant capacity, engine side (without cooling system) R Liters 63 70
Charge-air coolant, engine side R Liters - -
Fuel, engine side R Liters 6 6
Engine oil capacity, initial filling (standard oil system) (design: R Liters 92 114
max. operating inclination positions)
Oil change quantity max. (standard oil system) (design: max. oper- R Liters 80 102
ating inclination positions)
Fan / fan cooler

Fan, pusher type X X
Fan drive: mechanical via V-belt X X
Sound
Exhaust noise, not attenuated - DL (free-field sound pressure level R dB(A) 112 119
Lp, 1 m distance, ISO 6798, +3 dB(A) tolerance)
TIM-ID: 0000053441 - 001
Exhaust noise, not attenuated - DL (sound power level LW, ISO R dB(A) 125 117
6798, +3 dB(A) tolerance)
Engine surface noise with attenuated intake noise (filter) - DL R dB(A) 100 -
(free-field sound power level Lp, 1 m distance, ISO 6798, +2 dB(A)
tolerance)
Engine surface noise with attenuated intake noise (filter) - DL R dB(A) 117 -
(sound power level LW, ISO 6798+2 db(A) tolerance)
Table 62: Sound

3.5 Engine data 12, 16, 18 V 2000 G26 F
Explanation:
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable
Engine model 12V2000G26F 16V2000G26F 18V2000G26F

TIM-ID: 0000053442 - 001

connection
connection, max.

Consumption
consumption)

jection
Bore mm 135 135 135
Stroke mm 156 156 156
Air / exhaust gas

der - DL
der - BL

tem)
TIM-ID: 0000053442 - 001

warning
shutdown

max.
sure
gine, max.

ing system inlet)
max.
cooler, max.
sure
gine, max.
Lube oil system

fore engine, from
fore engine, to
gine, warning
gine, shutdown
TIM-ID: 0000053442 - 001

engine, from
engine, to
engine, warning

engine, shutdown
Fuel system
start)
Fuel pressure at engine supply L bar 0.5 0.5 0.5
start)

temperature (min.)

sitions)
TIM-ID: 0000053442 - 001
tions)
nation positions)

Capacities
Fan / fan cooler

Sound
tolerance)
+3 dB(A) tolerance)
erance)
Table 77: Sound

TIM-ID: 0000053442 - 001

3.6 Engine data 12, 16, 18 V 2000 G76 F
Explanation:
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable
Engine model 12V2000G76F 16V2000G76F 18V2000G76F
Application group 3D 3D 3D
Continuous power ISO 3046 (10% A kW - - -
Mean effective pressure (pme) bar - - -

TIM-ID: 0000053443 - 001

connection
connection, max.

Consumption
consumption)

jection
Bore mm 135 135 135
Stroke mm 156 156 156
Air / exhaust gas

Charge-air pressure before cylin- R bar abs - - -
der - DL
der - BL

tem)
TIM-ID: 0000053443 - 001

warning
shutdown

max.
sure
gine, max.

ing system inlet)
max.
cooler, max.
sure
gine, max.
Lube oil system

fore engine, from
fore engine, to
gine, warning
gine, shutdown
TIM-ID: 0000053443 - 001

engine, from
engine, to
engine, warning

engine, shutdown
Fuel system
start)
Fuel pressure at engine supply L bar 0.5 0.5 0.5
start)

temperature (min.)

sitions)
TIM-ID: 0000053443 - 001
tions)
nation positions)

Capacities
Fan / fan cooler

Sound
tolerance)
+3 dB(A) tolerance)
erance)
Table 92: Sound

TIM-ID: 0000053443 - 001

3.7 Engine data 16 V 2000 G36 F
Explanation:
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable
Engine model 16V2000G
36F
Application group 3B
Intake air temperature °C 25
Charge air coolant temperature °C -
Barometric pressure mbar 1000
Site altitude above sea level m 100
Number of cylinders 16
Rated engine speed A rpm 1500
Continuous power ISO 3046 (10% overload capability) A kW 1000
Net brake power (without fan) (fuel stop power ISO 3046) A kW 1100
Mean effective pressure (pme) (continuous power ISO 3046) bar 22.4
Mean effective pressure (pme) (fuel stop power ISO 3046) bar 24.6

Intake depression (new filter) A mbar 15
Intake depression, max. L mbar 40
Exhaust overpressure A mbar 30
TIM-ID: 0000053444 - 001
Exhaust overpressure, max. L mbar 50

Fuel temperature at engine supply connection R °C 25
Fuel temperature at engine supply connection, max. L °C 65

Consumption
Lube oil consumption after 100 hrs runtime (B = hourly fuel consumption) % of B 0.8

Operating method: four-stroke cycle, diesel, single-action X
Combustion method: direct fuel injection X
Cylinder arrangement: Vee angle Degrees (°) 90
Bore mm 135
Stroke mm 156
Displacement of a cylinder Liters 2.233
Total displacement Liters 35.7
Compression ratio 17.5
Standard housing connecting flange (engine main PTO side) SAE 0
Air / exhaust gas

Charge-air pressure before cylinder - DL R bar abs 3.4
Charge-air pressure before cylinder - BL R bar abs 3.5

Coolant temperature (at engine connection: outlet to cooling system) A °C 100
Coolant temperature after engine, warning L °C 102
Coolant temperature after engine, shutdown L °C 105
Coolant antifreeze content, max. L % 50
Cooling system: coolant flow rate A m³/h 41.6
Coolant pump: inlet pressure, min. L bar 0.4
Coolant pump: inlet pressure, max. L bar 1.5
TIM-ID: 0000053444 - 001
Pressure loss in external cooling system outside engine L bar 1.0

Breather valve (expansion tank) opening pressure at gauge pressure R bar 1.0
Cooling system: height above engine, max. L m 20

Coolant temperature before intercooler (at engine connection: cooling sys- A °C -
tem inlet)
Coolant antifreeze content, max. L % -
Coolant pump: inlet pressure, max. L bar -
Charge-air temperature after intercooler, max. L °C -
Breather valve (expansion tank) opening pressure at gauge pressure R bar -
Cooling system: height above engine, max. L m -
Lube oil system

Lube-oil operating temperature before engine, from R °C 75
Lube oil operating temperature before engine, to R °C 100
Lube-oil temperature before engine, warning L °C 103
Lube-oil temperature before engine, shutdown L °C 105
Lube oil operating pressure before engine, from R bar 6.2
Lube-oil operating pressure before engine, to R bar 8.8
Lube oil operating pressure before engine, warning L bar 4.5
Lube oil operating pressure before engine, shutdown L bar 4.0
Lube oil fine filter (main circuit): number of cartridges per unit 3
Fuel system
Fuel pressure at engine supply connection, min. (during engine start) L bar -0.5
Fuel pressure at engine supply connection, max. (during engine start) L bar 0.5
Fuel supply flow rate, max. L Liters/min 30
Fuel return flow rate, max. L Liters/min 30

TIM-ID: 0000053444 - 001
Coolant preheating: preheating temperature (min.) L °C 32

Starting is blocked if the engine coolant temperature is below °C -20
Firing speed, from R rpm 100
Firing speed. to R rpm 120

Longitudinal inclination, continuous max. driving end bottom (option: max. L Degrees (°) 5
Longitudinal inclination, continuous max. driving end top (option: max. op- L Degrees (°) 5
erating inclination positions)
Transverse inclination continuous max. (design: max. operating inclination L Degrees (°) 10
positions)
Capacities
Engine coolant capacity, engine side (without cooling system) R Liters 70
Charge-air coolant, engine side R Liters -
Fuel, engine side R Liters 6
Engine oil capacity, initial filling (standard oil system) (design: max. operat- R Liters 114
ing inclination positions)
Oil change quantity max. (standard oil system) (design: max. operating in- R Liters 102
clination positions)
Fan / fan cooler

Fan, pusher type X
Fan drive: mechanical via V-belt X
Sound
Exhaust noise, not attenuated - DL (free-field sound pressure level Lp, 1 m R dB(A) -
distance, ISO 6798, +3 dB(A) tolerance)
Exhaust noise, not attenuated - DL (sound power level LW, ISO 6798, R dB(A) -
+3 dB(A) tolerance)
Engine surface noise with attenuated intake noise (filter) - DL (free-field R dB(A) -
sound power level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance)
Engine surface noise with attenuated intake noise (filter) - DL (sound pow- R dB(A) -
er level LW, ISO 6798+2 db(A) tolerance)
TIM-ID: 0000053444 - 001
Table 107: Sound

3.8 Firing order
Firing order
Number of cylinders Firing order
12 V A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1
16 V A1-B5-A3-A5-B2-B8-A2-A8-B3-A7-B4-B6-A4-A6-B1-B7
18 V A1-B6-A3-B4-A5-B2-A7-B1-A9-B3-A8-B5-A6-B7-A4-B9-A2-B8
TIM-ID: 0000053446 - 001

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

12 V 2000 B26F approx. 2044 mm approx. 1522 mm approx. 1470 mm
12 V 2000 G16F approx. 2044 mm approx. 1522 mm approx. 1470 mm
12 V 2000 B76 switcha- approx. 2044 mm approx. 1522 mm approx. 1470 mm
ble
TIM-ID: 0000053447 - 001
ble
ble
Table 108: Engine model / deviations

4 Operation
4.1 Preparing startup after long out-of-service periods (>3 months)
Preconditions
☑Engine is stopped and starting disabled.
☑MTU Fluids and Lubricants Specifications (A001061/..) are available.
Startup after long out-of-service periods (>3 months)

Item Action
Engine Remove preservative (→ Preservation and Represervation Specifications
(A001070/…)).
Lube oil system Check engine oil level (→ Page 99).
Fuel system Use appropriate equipment to fill system via fuel supply line.
Fuel system Vent (→ Page 85).
Coolant circuit If engine is out of service for more than one year, change engine coolant
(→ Page 109).
Coolant circuit Check engine coolant level (→ Page 108).
Coolant circuit Preheat engine coolant with coolant preheating unit (if fitted).
Engine control system Check plug connections (→ Page 130).
Engine control system Switch on.
Table 109: Startup after long out-of-service periods (>3 months)
TIM-ID: 0000054737 - 001
56 | Operation | MS150118/00E 2014-07

4.2 Preparations for startup after scheduled out-of-service-period
Preconditions
Startup
Item Action
Lube oil system Check engine oil level (→ Page 99).
Coolant circuit Check engine coolant level (→ Page 108).
Coolant circuit Preheat engine coolant with coolant preheating unit, if fitted.
Fuel prefilter (if fitted) Drain water, see manufacturer's documentation.
Engine control system Switch on.
Table 110: Startup

TIM-ID: 0000054738 - 001
MS150118/00E 2014-07 | Operation | 57

4.3 Starting the engine
Preconditions
☑Engine is not connected to load.
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Before cranking the engine with starter system, make sure that there are no persons in the en-
gine's danger zone.
WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.
Start engine (for required operations, refer to the documentation of the vehi-
cle/plant manufacturer).
TIM-ID: 0000010107 - 005
58 | Operation | MS150118/00E 2014-07

4.4 Operation monitoring
DANGER
• Only run the engine at low power. Keep away from the engine's danger zone.
WARNING
Operation monitoring
Item Action
Control and display panels Check readings of operational data (speed, temperature, pressures).
Engine oil Check engine oil level (→ Page 99).
Engine operation Check engine visually for leaks and general condition;
Check engine for abnormal running noises, exhaust color and vibrations.
Air filter Check service indicator at air filter (if fitted), see manufacturer's docu-
mentation.
Exhaust system Check exhaust color (→ Page 65).
Fuel prefilter (if fitted) Check reading at differential pressure gauge of fuel prefilter, see manufac-
turer's documentation.
Engine coolant pump Check relief bore (→ Page 113).
TIM-ID: 0000054739 - 001
MS150118/00E 2014-07 | Operation | 59

4.5 Engine ‒ Stopping
Preconditions
☑Engine is not connected to load.
NOTICE
Stopping the engine when it is running at full load subjects it to extreme thermal and mechanical
stresses.
Overheating of and, therefore, damage to components is possible!
• Before shutting down the engine, allow it to idle until the engine temperatures decrease and
constant levels are indicated.
Preparation
Item Action
Engine Allow the engine to cool down by running it at idle speed for approx. 5 mi-
nutes.
Stopping the engine

Item Action
Engine Stopping (→ Documentation of the vehicle/plant manufacturer).
TIM-ID: 0000010138 - 006
60 | Operation | MS150118/00E 2014-07

4.6 Emergency stop
NOTICE
An emergency stop causes extreme stress to the engine plant.
Risk of overheating, damage to components!
• Initiate emergency stop only in emergency situations.
Emergency stop
Item Action
Emergency stop pushbutton Press EMERGENCY STOP pushbutton.
• Engine is stopped by disconnecting the power supply to the ECU;
• Emergency air shutoff flaps close (if provided);
• Signalization (e.g. by horn, beacon) is activated.
After emergency stop

Item Action
Switchgear cabinet, control Press pushbutton for alarm acknowledgment.
panel etc. (depending on • Audible and visual signalization stops.
manufacturer)
Engine Manually open emergency air shutoff flaps (if provided).
• Engine is ready for starting.
TIM-ID: 0000002307 - 003
MS150118/00E 2014-07 | Operation | 61

4.7 After stopping the engine
Preconditions
☑MTU Preservation and Represervation Instructions (A001070/..) are available.
NOTICE
Coolant sensors may freeze if there is a risk of frost.
Risk of sensor damage!
• Protect sensors from frost.
After stopping the engine

Item Action
Coolant circuit Drain engine coolant (→ Page 110) if
• freezing temperatures are expected, the engine is to remain out of
service for an extended period, but engine coolant has no antifreeze
additive.
• the engine room is not heated.
• the coolant is not kept at a suitable temperature.
• the antifreeze concentration is insufficient for the engine-room tem-
perature.
• the antifreeze concentration is 50 % and the engine-room temperature
is below -40°C.
Engine control system Switch off (see manufacturer's documentation).
Air intake and exhaust sys- If the engine is to remain out of service for more than one week, seal the en-
tem gine's air and exhaust sides.
If the engine is to remain out of service for more than one month, carry out
preservation (→ MTU Preservation and Represervation Instructions
A001070/..).
TIM-ID: 0000054740 - 001
62 | Operation | MS150118/00E 2014-07

4.8 Plant – Cleaning
Preconditions
☑Operating voltage is not applied.
Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Steam jet cleaner - 1
Cleaner (Hakupur 312) 30390 1
WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.
WARNING
Steam jet cleaner ejects jet of pressurized water.
Risk of injury to eyes and scalding!
• Never direct water jet at people.
• Wear protective clothing, protective gloves and safety goggles/face mask.
NOTICE
Cleaning agents should not be left to take effect for too long.
Damage to components is possible!
• Observe manufacturer's instructions.
NOTICE
Blowing down product with compressed air.
Entry of dirt and damage to components is possible!
• Do not aim compressed air gun directly at seals or electronic components such as connectors
or ECUs.
Plant – Cleaning
1. Carry out plant cleaning only in areas where an appropriate oil separator is provided (environmental
protection).
2. Prior to putting the cleaning unit into operation, read the operating instructions of the water/steam jet
unit carefully and observe the safety precautions.
3. For external cleaning of the plant with water or steam-jet cleaners:
• The pressure of the high-pressure jet (cleaning jet) must not exceed 50 bar.
• A minimum distance between spray nozzle and plant of 1 m must be observed.
TIM-ID: 0000010171 - 029
• The temperature of the cleaning medium must not exceed 80°C.

4. For external cleaning with high-pressure jet, use a flat-mouth nozzle only.
Note: Never aim compressed air directly at electronic components.
5. Carry out external cleaning as follows:
a) Seal all openings in a suitable way.
b) Remove coarse dirt.
c) Spray on cleaner sparingly and leave it for 1 to 5 minutes.
d) Use the high-pressure jet to remove the loosened dirt.
e) Dry engine with compressed air.
MS150118/00E 2014-07 | Operation | 63

5 Maintenance
5.1 Maintenance schedule ‒ Task reference table [QL1]
The maintenance tasks and intervals for this product are defined in the maintenance schedule. The
maintenance schedule is an independent publication.
The task numbers in this table provide reference to the maintenance tasks specified in the maintenance
schedule.
Option
Task Measures
W0500 Check engine oil level. (→ Page 99)

W0501 Visually inspect engine for leaks and general condition. (→ Page 59)
W0502 X Check intercooler drain(s). (→ Page 59)
W0503 Check service indicator of air filter. (→ Page 59)
W0505 Check relief bores of coolant pump(s) (→ Page 59)
W0506 Check for abnormal running noises, exhaust color and vibra- (→ Page 59)
tions.
W0507 X Drain water and contaminants from fuel prefilter. (→ Page 59)
W0508 X Check reading on differential pressure gauge of fuel prefilter (→ Page 59)
W1001 Replace fuel filter or fuel filter element (→ Page 87)
W1003 Check drive belt condition and tension, replace if necessary (→ Page 115)
W1005 Replace air filter. (→ Page 93)
W1006 Replace fuel injectors/injectors. (→ Page 75)
W1008 Replace engine oil filter when changing engine oil, or when (→ Page 101)
the limit value (years) is reached, at the latest
W1009 X Check layer thickness of the oil residue, clean and replace (→ Page 102)
filter sleeve, no later than with every engine oil change.
W1055 Replace oil separator. (→ Page 70)
W1178 Replace pressure pipe connection in cylinder head (→ Page 82)
W1207 Check valve clearance, adjust if necessary. ATTENTION! Ini- (→ Page 71)
tial adjustment after 1,000 operating hours and after every
overhaul of the cylinder heads after 1,000 operating hours.
W1244 X Check function of rod electrode . (→ Page 124)
W1245 X Check alarm function of differential-pressure gauge . (→ Page 123)
W1246 X Check pump capacity. (→ Page 125)
TIM-ID: 0000053809 - 001
W1481 X Replace intermediate fuel filter or intermediate fuel filter ele- -

ment.
W1636 Reset drift correction parameters (CDC) and enter code for (→ Page 81)
injectors (IIG).
W1675 X Replace fuel prefilter or fuel prefilter element. (→ Page 92)
Table 111: Maintenance schedule task reference table [QL1]
64 | Maintenance | MS150118/00E 2014-07

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

Component Probable Cause Action
Battery Low or faulty Charge or replace (see manufacturer's
documentation).
Cable connections faulty Check if cable connections are properly
secured (see manufacturer's documen-
tation).
Starter Engine cabling or starter faulty Check if cable connections are properly
secured, contact Service.
Engine cabling Faulty Check (→ Page 131).
Engine/generator Assemblies or connectors possibly loose Perform visual inspection (see manufac-
control system turer's documentation).
Engine governor Plug-in connections possibly loose Check plug-in connections (→ Page 130).
Engine Running gear blocked (engine cannot be Contact Service.
barred manually)
Engine turns but does not fire

Starter Poor rotation by starter Battery low or Charge or replace battery (see manufac-
faulty turer's documentation).
Fuel system Air in fuel system Vent fuel system (→ Page 85).
Engine governor Faulty Contact Service.
Engine fires unevenly

Fuel injection equip- Injector faulty Replace (→ Page 75).
ment Injection pump faulty Contact Service.
TIM-ID: 0000051898 - 001
Engine does not reach rated speed

Fuel supply Fuel prefilter clogged Replace (→ Page 92).
Fuel filter clogged Replace (→ Page 87).
Air supply Air filter clogged Check signal ring position of service in-
dicator (→ Page 95).
MS150118/00E 2014-07 | Troubleshooting | 65

Engine Overloaded Contact Service.
Engine speed not steady

Speed sensor Faulty Contact Service.
Charge air temperature too high

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

Intercooler Contaminated Contact Service.
Exhaust turbocharger Faulty Contact Service.
Coolant leaks at intercooler

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

Engine Overloaded Contact Service.
TIM-ID: 0000051898 - 001
66 | Troubleshooting | MS150118/00E 2014-07

Blue exhaust gas
Engine oil Engine oil level too high Drain engine oil (→ Page 100).
Oil separator of crankcase breather con- Replace (→ Page 70).
taminated
Exhaust turbocharger, Faulty Contact Service.
cylinder head, piston
rings, cylinder liner
White exhaust gas

Engine Not at operating temperature Run engine to reach operating tempera-
ture.
Fuel system Water in fuel Check fuel system at fuel prefilter
Drain fuel prefilter (→ Page 89).
Intercooler Leaking Contact Service.
TIM-ID: 0000051898 - 001
MS150118/00E 2014-07 | Troubleshooting | 67

7 Task Description
7.1 Engine
7.1.1 Engine – Cranking manually
Preconditions

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

al installation)
1. Remove starting equipment from flywheel
housing (→ Page 97).
2. Engage barring tool (2) with ring gear and
install on flywheel housing.
3. Apply ratchet (1) to barring tool (2).
4. Rotate crankshaft in engine direction of ro-
tation. Apart from the normal compression
resistance, there should be no other resist-
ance.
Result: If the resistance exceeds the normal com-
pression resistance, contact Service.
5. For removal, carry out reverse sequence.
6. Install starting equipment on flywheel
housing (→ Page 98).
TIM-ID: 0000053448 - 001
68 | Task Description | MS150118/00E 2014-07

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

1. Press pushbutton “Bar engine without starting” and hold it.
2. Let the crankshaft rotate until oil pressure is indicated, but not longer than 10 seconds.
3. Repeat this procedure after approx. 20 seconds if required.
TIM-ID: 0000000013 - 005
MS150118/00E 2014-07 | Task Description | 69

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

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

1. Unscrew screws (1) and remove together
with washers (2) and retainer (3).
2. Replace oil mist fine separator (4).
3. Replace O-ring (5) if necessary.
4. Replace further oil mist fine separators in
the same way.
TIM-ID: 0000053449 - 001

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

Valve clearance gauge Y4345893 1
Barring tool F6792910 1
Ratchet F30006212 1
Double-end box wrench F30002800 1
Offset screwdriver F30453001 1
Socket wrench F30030450 1
Torque wrench, 10-60 Nm F30510423 1
Measuring device Y4348409 1
Preparatory steps
1. Install barring tool (→ Page 68).
2. Remove cylinder head cover (→ Page 74).
Positioning A1 cylinder piston at

TDC
Note: With cylinder head and valve gear installed.
1. Insert preloaded dial gauge (2) into meas-
uring device (4) and clamp using screw (1).
2. Install measuring device (4) in cylinder
head and secure using knurled screw (3).
3. Zero dial gauge (2).
4. Turn engine using barring tool until piston
A1 reaches firing TDC.
Result: The piston is at firing TDC when both rock-
er arms are unloaded, i.e. have clearance.
TIM-ID: 0000053450 - 001

Checking valve clearance at two crankshaft positions
1. Check TDC position of piston in cylinder 1 bank A:
• If the rocker arms are unloaded at cylinder 1 bank A, the piston is in firing TDC.
• If the rocker arms are loaded at cylinder 1 bank A, the piston is in overlap TDC.
2. Check valve clearance with cold engine:
• Inlet (I) = 0.3 mm;
• exhaust (X) = 0.4 mm.
3. Check all valve clearance values at two crankshaft positions (firing TDC and overlap TDC) according to
the table below.
Position Cylinder 1 2 3 4 5 6 7 8 9 10
12 V
Firing TDC in cylinder A1 Bank A IX I– –X I– –X ––
Bank B I– –– –X I– IX –X
Overlap TDC in cylinder A1 Bank A –– –X I– –X I– IX
Bank B –X IX I– –X –– I–
16 V
Firing TDC in cylinder A1 Bank A IX –X –X I– –X I– –– ––
Bank B I– –X –– I– IX I– IX –X
Overlap TDC in cylinder A1 Bank A –– I– I– –X I– –X IX IX
Bank B –X I– IX –X –– –X –– I–
18 V
Firing TDC in cylinder A1 Bank A IX I– –X I– –X –– –X –– ––
Bank B –X –X –– IX –– IX I– IX I–
Overlap TDC in cylinder A1 Bank A –– –X I– –X I– IX I– IX IX
Bank B I– I– IX –– IX –– –X –– –X
I Inlet: Inlet valve adjustment permitted
X exhaust: Exhaust valve adjustment permitted
– Valve adjustment not permitted
Table 112: Valve clearance adjustments
4. Use feeler gauge to check the distance between valve bridge and rocker arm.
5. If the deviation from the set value exceeds 0.1 mm, adjust valve clearance.
Adjusting valve clearance

1. Undo locknut (1) and unscrew adjusting
screw (2) a few turns.
2. Insert feeler gauge between valve bridge
and rocker arm (3).
3. Readjust adjusting screw (2) so that the
TIM-ID: 0000053450 - 001
feeler gauge just passes through the gap.

4. Tighten locknut (1) with torque wrench to
the prescribed tightening torque of 50 Nm
while holding the adjusting screw (2) in
place with an offset screwdriver.
5. Insert feeler gauge between valve bridge
and rocker arm to verify that the gauge just
passes through the gap.
Result: If not, adjust valve clearance.

Final steps
1. Remove barring tool.
2. Install cylinder head cover (→ Page 74).
TIM-ID: 0000053450 - 001

7.3.2 Cylinder head cover – Removal and installation
Preconditions

Torque wrench, 0.5-5 Nm 0015384230 1
Ratchet F30027340 1
Engine oil
Gasket (→ Spare Parts Catalog)
Preparatory steps
u Disconnect wiring harness.
Cylinder head cover – Removal

and installation
Note: Before removing the gasket, release injec-
tor clamps and remove spade lugs.
1. Remove cylinder head cover (2) with gas-
ket (1) from cylinder head.
2. Clean mating face.
3. Check condition of gasket (1) in cylinder
head cover (2).
4. Replace gasket (1) if damaged.
5. Place gasket (1) in correct position on cyl-
inder head.
6. Push spade lugs under the terminals on the injector and tighten with torque wrench to the specified
tightening torque.
Name Size Type Lubricant Value/Standard
Nut M4 Tightening torque (Engine oil) 1.5 Nm ±0.25 Nm
7. Install cylinder head cover (2) with screws (4) and washers (3).
TIM-ID: 0000053452 - 001
Final steps
u Connect wiring harness.

7.4 Injection Valve / Injector
7.4.1 Injector ‒ Replacement
Injector (→ Spare Parts Catalog)
Screw for hold-down clamp (→ Spare Parts Catalog)
Replacing injector
u Remove injector and install new one (→ Page 76).
TIM-ID: 0000053453 - 001

7.4.2 Injector – Removal and installation
Preconditions

Press-in tool F6790085 1
Puller F6790636 1
Fuel suction device F30378207 1
Torque wrench, 0.5-5 Nm 0015384230 1
Ratchet F30027340 1
Plug-in open-end wrench, 19 mm F30453236 1
Crowfoot wrench, 19 mm F30027424 1
Ring socket, 22 mm F30038494 1
Open-end socket wrench, 24 mm F30453238 1
Assembly compound (Kluthe Hakuform 30-15) X00067260 1
Engine oil
Sealing ring (→ Spare Parts Catalog)
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
WARNING
Preparatory steps
1. Shut off fuel supply line.
2. Drain fuel (→ Page 86).
3. Remove cylinder head cover (→ Page 74).
TIM-ID: 0000050909 - 002

Removing injector
1. Remove HP fuel line (1).
2. Unscrew union nut (2).
3. Pull out pressure pipe connection (3).
4. Extract fuel from the exposed bores using
the fuel suction device.
5. Disconnect terminals (arrow) on injector

and pull out spade lugs.
6. Remove gasket.
7. Remove screw (3).

Note: Screw (3) may be used only once.
8. Take off hold-down clamp (2).
9. Use the puller to carefully pull out injec-
tor (1).
10. After removal, seal all openings with suita-
ble covers.
TIM-ID: 0000050909 - 002

Installing injector
1. Remove all covers before installation.
2. Clean sealing face on cylinder head and
protective sleeve.
3. Coat sealing ring on injector (1) with as-
sembly compound.
Note: Use either the press-in tool or the hold-
down clamp (2) to press injector (1) into
the cylinder head.
4. Align faces on injector (1) for mounting in
the hold-down clamp (2) and insert injector
by hand in a straight line into the cylinder
head.
5. Fit hold-down clamp (2) in correct position
by hand.
Installation without press-in tool

1. Insert new screw (3) and press injector (1) carefully into the cylinder head by tightening screw (3).
Screw M8 Preload torque (Engine oil) 5 Nm
2. Release screw (3) again and relieve hold-down clamp (2).
Installation with press-in tool

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

tion
1. Blow out HP fuel line (1) and pressure pipe
connection (3) with compressed air.
2. Coat sealing ring with assembly compound.
3. Coat sealing cone of pressure pipe connec-
tion (3) with engine oil.
4. Slide pressure pipe connection (3) up to
contact point on sealing ring in cylinder
head.
5. Press pressure pipe connection (3) in com-
pletely by hand.
6. Align HP connection of injector with pres-
sure pipe connection (3).
TIM-ID: 0000050909 - 002
7. Coat thread and shoulder of union nut (2) with engine oil and tighten with torque wrench to the speci-
fied tightening torque.
Retaining screw M25 Preload torque (Engine oil) 15 Nm +5 Nm

8. Use torque wrench to tighten screw (3) for hold-down clamp (2) to the specified tightening torque.
Screw M8 Tightening torque (Engine oil) 40 Nm +4 Nm
9. Tighten union nut (2) on pressure pipe connection (3) with torque wrench to the specified tightening
torque.
Retaining screw M25 Tightening torque 50 Nm +5 Nm
TIM-ID: 0000050909 - 002
Installing fuel line

1. Coat thread and shoulder of union nuts on HP fuel line (1) with engine oil.
Note: Position fuel line, ensuring it is free of tension.
2. Position fuel line (1) so that the union nut with the torque specification (2) faces the rail and the end
without torque specification faces the pressure pipe connection (3), and tighten hand-tight.

3. Tighten union nut of HP fuel line (1) on rail to specified tightening torque using a torque wrench.
a) For single-wall high-pressure fuel system
Union nut M20 Tightening torque (Engine oil) 37 Nm +3 Nm
b) For double-wall high-pressure fuel system
4. Tighten union nut of HP fuel line (1) on pressure pipe connection (3) to the specified tightening torque
using a torque wrench.
Fitting gasket and connecting in-

jector cable
1. Place gasket on cylinder head, ensuring
correct position.
2. Push spade lugs under the terminals (arrow) on the injector and tighten with torque wrench to the
specified tightening torque.
Nut M4 Tightening torque (Engine oil) 1.5 Nm ±0.25 Nm
Final steps
1. Install cylinder head cover (→ Page 74).
2. Open fuel supply line.
3. Vent fuel system (→ Page 85).
TIM-ID: 0000050909 - 002

7.4.3 Injector functions
Preconditions
Note: Failure to reset drift compensation parameters (CDC) will void the emissions certification for the en-
gine.
Resetting drift correction parameters (CDC) with DiaSys®

1. (→ Dialog system DiaSys® E531920/..).
2. If no DiaSys® is available, contact Service.
Entering injector coding (IIG)

1. (→ Dialog system DiaSys® E531920/..).
2. If no DiaSys® is available, contact Service.
TIM-ID: 0000045425 - 001

7.5 Fuel System
7.5.1 HP fuel line and pressure pipe connection ‒ Replacement
Preconditions

Ratchet F30027340 1
Plug-in open-end wrench, 19 mm F30025897 1
Crowfoot wrench, 19 mm F30027424 1
Assembly compound (Kluthe Hakuform 30-15) X00067260 1
Engine oil
Pressure pipe connection (→ Spare Parts Catalog)
HP fuel line (→ Spare Parts Catalog)
WARNING
• Do not smoke.
Preparatory steps
1. Shut off fuel supply line.
2. Drain fuel (→ Page 86).
3. Remove engine control system (→ Page 129).
4. Remove charge-air pipes and take off seals (only on engines with air-to-charge-air cooling).
5. Remove fuel return line.
TIM-ID: 0000050910 - 002

Replacing HP fuel line and pres-
sure pipe connection
1. Remove union nuts (1, 3) on HP fuel
line (2).
2. Remove HP fuel line (2).
3. Remove union nut (4).
4. Pull out pressure pipe connection (5).
5. Coat sealing ring of new pressure pipe con-

nection (5) with assembly compound.
6. Coat cone of pressure pipe connection (5)
with engine oil.
7. Insert pressure pipe connection (5) into cyl-
inder head until it has contact with the
sealing ring in the cylinder head.
8. Fully press in pressure pipe connection (5)
by hand.
9. Insert union nut (4).
10. Tighten union nut (4) with torque wrench to the specified tightening torque.
Union nut M24 Preload torque (Engine oil) 15 Nm +5 Nm
Union nut M24 Tightening torque 50 Nm +5 Nm
11. Coat mating face with engine oil between union nut and HP fuel line, end of line and thread on both
sides of the new HP fuel line (1).
12. Install new HP fuel line (2).
13. Tighten union nut (1) on HP fuel line (2) with torque wrench to the specified tightening torque.
TIM-ID: 0000050910 - 002
a) For single-wall high-pressure fuel system

b) For double-wall high-pressure fuel system

14. Tighten union nut (3) on HP fuel line (2) with torque wrench to the specified tightening torque.
Final steps
1. Clean mating faces on cylinder head and charge-air pipe.
2. Check gaskets for damage and replace them, if required.
3. Coat gaskets with assembly compound and place on cylinder head.
4. Install leak-off-fuel lines.
5. Install charge-air pipes.
6. Install engine control system (→ Page 129).
7. Open fuel supply line.
8. Vent fuel system (→ Page 85).
TIM-ID: 0000050910 - 002

7.5.2 Fuel system – Venting
Preconditions
☑Engine is stopped.

WARNING
• Do not smoke.
Fuel system – Venting

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

Threaded vent plug M16 Tightening torque 6 Nm +2 Nm
5. Lock hand pump (1).
TIM-ID: 0000043672 - 002

7.5.3 Fuel – Draining
Preconditions
WARNING
• Do not smoke.
Fuel – Draining
1. Provide a suitable container in which to collect the fuel.
2. Remove fuel filter (→ Page 87).
3. Catch fuel as it runs out.
4. Install fuel filter (→ Page 87).
TIM-ID: 0000004702 - 002

7.6 Fuel Filter
7.6.1 Fuel filter – Replacement
Preconditions

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

1. Remove easy-change filter (3) with filter
wrench.
2. Clean the sealing face on the retainer (1).
3. Slightly lubricate gasket (2) on the easy-
change filter.
4. Screw on easy-change filter and tighten by
hand.
5. Replace further easy-change filters in the
same way.
6. Vent fuel system (→ Page 85)
TIM-ID: 0000053454 - 001

7.6.2 Fuel prefilter – Differential pressure gage check and adjustment of gage
DANGER
WARNING
Setting adjustable pointer of dif-

ferential pressure gage
1. After installation of a new filter element:
Align adjustable pointer (2) with pressure-
indicating pointer (3) of pressure gage (1).
2. Verify that differential pressure is within
the limit.
Fuel prefilter – Checking differential pressure

1. With the engine running at full load or rated power, read off pressure at gage (1).
2. If differential pressure as indicated between position of adjustable pointer (2) and pressure-indicating
pointer (3) of pressure gage is ≥ 0.3 bar, flush filter element of the cut-in filter (→ Page 90).
TIM-ID: 0000004925 - 009

7.6.3 Fuel prefilter – Draining
Preconditions

Diesel fuel
Sealing (→ Spare Parts Catalog) 1
WARNING
• Do not smoke.
Fuel prefilter – Draining

1. Open vent plug (1) of the filter.
2. Unlock drain cock (2) by pressing toggle
and open it.
3. Drain water and contaminants from the fil-
ter until pure fuel emerges.
4. Close drain cock (2).
5. Remove screws (4) securing the cover (1)

and take off cover.
6. Fill filter housing with clean fuel.
7. Insert new seal (3) in cover (1).
8. Fit cover (1) with seal (3) and tighten
screws (4).
9. When fuel emerges from system, close
vent plug (2).
TIM-ID: 0000004928 - 006

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

1. Cut out the contaminated filter.
1 Left filter cut in
2 Right filter cut in
TIM-ID: 0000004937 - 018

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

1. Stop engine (→ Page 60) and disable engine start.
2. Remove screws securing the cover and take off cover (2).
4. Place new seal in cover (2).
5. Fit cover with gasket and secure it with screws.
6. Check differential pressure (→ Page 88).
Result: If flushing did not lead to an improvement of the differential pressure, replace filter element of fuel pre-
filter (→ Page 92).
TIM-ID: 0000004937 - 018

7.6.5 Fuel prefilter – Filter element replacement
Preconditions

Diesel fuel
Filter element (→ Spare Parts Catalog)
WARNING
• Do not smoke.
Replacing filter element

1. Close shut-off valve in fuel supply line.
2. Open vent plug (1) of the filter.
3. Unlock drain cock (2) by pressing toggle
and open it.
4. Drain water and dirt from filter.
5. Close drain cock (2).
6. Remove screws (6) securing the cover (1)

and take off cover.
7. Remove spring (2) and filter element (3).
8. Insert new filter element (3) and spring
housing (2).
10. Insert new seal (5) in cover (1).
11. Fit cover (1) with seal (5) and tighten
TIM-ID: 0000004943 - 006
screws (6).
12. Close vent plug (4) when fuel emerges.

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

1. Remove air filter(s) and install new one(s) (→ Page 94).
2. Reset signal ring of service indicator (→ Page 95).
TIM-ID: 0000013385 - 002

7.7.2 Air filter – Removal and installation
Preconditions
Air filter – Removal and installa-

tion
1. Release clamp (2).
2. Remove air filter (1) and clamp (2) from
connecting flange of intake housing (3).
3. Clean the connecting flange of the intake
housing (3) and check it for free passage.
4. Fit air filter (1) and clamp (2) on connecting
flange of intake housing (3).
5. Tighten clamp (2).
TIM-ID: 0000053455 - 001

7.8 Air Intake
7.8.1 Service indicator – Signal ring position check
Preconditions
Checking signal ring position

1. If the signal ring is completely visible in the
control window (2), replace air filter
(→ Page 93).
2. After installation of new filter, press reset
button (1).
Result: Engaged piston with signal ring moves
back to initial position.
TIM-ID: 0000005484 - 009

7.9 Starting Equipment
7.9.1 Electric starter – Overview
1 Starter 4 Gasket 7 Nut

2 Gasket 5 Stud screw
3 Flange 6 Washer
TIM-ID: 0000029152 - 002

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

1. Prior to disconnection, mark all cables.
2. Disconnect all cables from starter.
3. Protect all cables from damage.
4. Remove starter nuts as shown in overview drawing (→ Page 96).
5. Remove starter.
6. Protect starter from damage.
TIM-ID: 0000006063 - 004

7.9.3 Starter ‒ Installation
DANGER
Electric voltage supply for operation.
Danger of burns and fatal electric shock!
• Make certain that the power supply to the product is switched off before starting work. Secure
against unintentional switching on!
WARNING
The component is very heavy and may fall or tip over if unstable.
Risk of crushing injuries to persons or limbs!
• Use appropriate lifting gear and equipment.
• Wear safety footwear.
Installing starter
1. Coat starter pinion with lubricating grease.
2. Install starter as shown in overview drawing (→ Page 96).
Starter, electrical connection

1. Connect cables in accordance with the marking.
2. Screw on nuts of connections and use torque wrench to tighten to specified tightening torque.
a) Terminal 30 (battery connection)
Nut M18 Tightening torque 24.7 - 27.5 Nm
b) Terminal 50 (switching connection)
Nut M6 Tightening torque 5 - 7 Nm
c) Terminal 31 (negative terminal)
Nut M6 Tightening torque 13.5 - 15.8 Nm
3. Check starter for correct operation.
TIM-ID: 0000054682 - 001

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

start
1. Withdraw oil dipstick from guide tube and
wipe it.
2. Insert oil dipstick into guide tube up to the
stop, withdraw after approx. 10 seconds
and check oil level.
3. Oil level must be between "min." (2) and
"max." (1) marks.
4. Top up with oil up to the "max" (1) mark
(→ Page 100) if required.
5. Insert oil dipstick into guide tube up to the
stop.
Oil level check after the engine is stopped

1. 5 minutes after stopping the engine, remove oil dipstick from the guide tube and wipe it.
2. Insert oil dipstick into guide tube up to the stop, withdraw after approx. 10 seconds and check oil level.
3. Oil level must be between "min." and "max." marks.
4. Top up to "max." if required (→ Page 100).
5. Insert oil dipstick into guide tube up to the stop.
TIM-ID: 0000000032 - 003

7.10.2 Engine oil – Change
Preconditions
☑Engine is at operating temperature.

Engine oil
WARNING
Hot oil.
Oil change without semirotary hand pump: Draining oil at drain plug on oil
pan
1. Provide a suitable container to collect the oil.
2. Remove drain plug and drain oil.
3. Install drain plug with new sealing ring.
4. Replace engine oil filter (→ Page 101).
Oil change with semirotary hand pump: Oil extraction

1. Provide a suitable container to collect the oil.
2. Extract all oil from oil pan using the semirotary hand pump.
3. Replace engine oil filter (→ Page 101).
Filling with new oil

1. Open cover on filler neck.
2. Pour oil in at filler neck up to "max." mark
at oil dipstick.
3. Close cover on filler neck.
4. Check engine oil level (→ Page 99).
5. After oil change and filter replacement, bar
engine with starting system (→ Page 69).
TIM-ID: 0000000031 - 006

7.11 Oil Filtration / Cooling
7.11.1 Engine oil filter – Replacement
Preconditions

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

1. Remove oil filter (2) with filter wrench.
2. Clean sealing face on connecting piece (1).
3. Check sealing ring (arrow) of new oil filter
and moisten with oil.
4. Screw on and tighten oil filter by hand.
5. Replace other oil filters in the same way.
6. After each oil change and filter replace-
ment, crank engine with starting equip-
ment (→ Page 69).
7. Check oil level (→ Page 99).
TIM-ID: 0000053456 - 001

7.11.2 Centrifugal oil filter – Cleaning and filter sleeve replacement
Preconditions

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

and filter sleeve replacement
1. Undo nuts (4) crosswise.
2. Remove housing cover (1).
3. Carefully remove rotor (3) from lower part
of housing (5).
4. Remove nut (2).
5. Carefully remove rotor cap.
6. Remove filter sleeve from rotor cap.
7. Measure thickness of oil residues on filter
sleeve.
Result: If the oil residues exceed a maximum layer
thickness of 25 mm, shorten the mainte-
nance interval.
8. Disassemble rotor tube, filter cone and ro-
tor bottom.
9. Wash out rotor cover, rotor tube, filter cone
TIM-ID: 0000051622 - 002
and rotor bottom with cold cleaner.

10. Blow out with compressed air.
11. Check sealing ring, replace if necessary.
12. Insert new filter sleeve into rotor cap with
the smooth paper surface facing the outer
wall.
13. Assemble rotor tube, filter cone and rotor
bottom with sealing ring.
14. Carefully insert rotor in lower part of hous-
ing.

15. Use torque wrench to tighten nut (2) to specified tightening torque.
Nut Tightening torque 8 Nm + 1 Nm
16. Fit housing cover (1).
17. Screw on nuts (4).
18. Use torque wrench to tighten nuts (4) to specified tightening torque.
Nut Tightening torque 12 Nm + 2 Nm
TIM-ID: 0000051622 - 002

7.12 Coolant Circuit, General, High-Temperature Circuit
7.12.1 Drain and vent points
Plan view
1 HT circuit coolant ventila- 2 HT circuit coolant ventila- 3 HT circuit coolant ventila-

tion tion tion
Also applies to 12 V and 16 V engines.
TIM-ID: 0000053457 - 001

Left side
1 Coolant drain plug, crank- 2 Coolant drain plug, crank-

case driving end case free end
TIM-ID: 0000053457 - 001

Right side
1 Coolant drain plug, engine 2 Coolant drain plug, crank- 3 Coolant drain plug, crank-
coolant case free end case driving end
TIM-ID: 0000053457 - 001

Free end (KGS)
1 Coolant drain plug, lube-oil

heat exchanger
TIM-ID: 0000053457 - 001

7.12.2 Engine coolant – Level check
Preconditions
WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
Checking coolant level at filler

neck:
1. Turn breather valve on coolant expansion
tank counterclockwise to the first stop and
allow pressure to escape.
2. Continue to turn breather valve counter-
clockwise and remove.
3. Check coolant level (coolant must be visi-
ble at the lower edge of the cast-in eye or
at the marking plate).
4. Top up with treated coolant as necessary
(→ Page 111).
5. Check and clean breather valve.
6. Place breather valve on filler neck and
close.
Coolant-level check by means of level sensor:

1. Switch on engine control system and check readings on the display.
2. Top up with treated coolant as necessary (→ Page 111).
TIM-ID: 0000000037 - 004

7.12.3 Engine coolant – Change
Coolant
Engine coolant change

1. Drain engine coolant (→ Page 110).
2. Fill with engine coolant (→ Page 111).
TIM-ID: 0000000036 - 031

7.12.4 Engine coolant ‒ Draining
Preconditions
WARNING
Preparatory steps
1. Provide a suitable container to catch the coolant.
2. Switch off preheating unit.
Engine coolant ‒ Draining

1. Turn valve cover on coolant expansion tank
counterclockwise to the first stop and re-
lease pressure.
2. Continue to turn valve cover counterclock-
wise and remove.
3. Draw off precipitated corrosion inhibitor oil
from the coolant expansion tank through
filler neck.
4. Open drain valves and/or drain plugs and
drain coolant at the following points:
• At the preheating unit;
• At the HT coolant pump (1);
• At the crankcase (1) and (2), right side.
5. Draining of residual coolant:

• At the crankcase (1) and (2), left side.
• At the oil heat exchanger.
6. Close all open drain points.
7. Position valve cover on filler neck and
close. TIM-ID: 0000053458 - 001

7.12.5 Engine coolant – Filling
Preconditions

Coolant
WARNING
WARNING
NOTICE
Cold coolant in hot engine can cause thermal stress.
Possible formation of cracks in the engine!
• Fill / top up coolant only into cold engine.
Preparatory steps
1. Turn breather valve (1) on coolant expan-
sion tank counterclockwise to the first stop
and allow pressure to escape.
2. Continue to turn breather valve (1) counter-
clockwise and remove.
TIM-ID: 0000000034 - 008
Engine coolant – Filling

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

Final steps
1. Start the engine and operate it at idle speed for some minutes.
2. Check coolant level (→ Page 108), top up with coolant if required.
TIM-ID: 0000000034 - 008

7.12.6 Engine coolant pump – Relief bore check
DANGER
WARNING
Engine coolant pump – Relief

bore check
1. Check relief bore for oil and coolant dis-
charge.
• Permissible coolant discharge: up to 10
drops per hour;
• Permissible oil discharge: up to 5 drops
per hour.
Result: If discharge exceeds the specified limits,
contact Service.
2. If relief bore is dirty:
• Stop engine (→ Page 60) and disable en-
gine start.
• Clean relief bore with a wire.
TIM-ID: 0000025150 - 002

7.12.7 Engine coolant – Sample extraction and analysis
Preconditions

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

1. Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to
escape.
2. Continue to turn breather valve counterclockwise and remove.
3. Draw off precipitated corrosion inhibitor oil from expansion tank and dispose of oil.
4. Draw off approx. 1 liter coolant and drain into a clean container.
5. Using the equipment and chemicals from the MTU test kit, examine coolant for:
• antifreeze concentration;
• corrosion inhibitor concentration;
• pH value.
6. Fit breather valve and close it.
7. Engine coolant change intervals (→ MTU Fluids and Lubricants Specifications A001061/..).
TIM-ID: 0000014607 - 002

7.13 Belt Drive
7.13.1 Drive belt – Condition check
Preconditions
☑Guard is removed.
Drive belt – Condition check
Item Findings Action

Drive belt A Singular cracks None
Drive belt B Cracks on entire circumference Replace (→ Page 120)
Drive belt C Chunking
Drive belt Belt is oily, shows signs of over-
heating
TIM-ID: 0000000920 - 011

7.13.2 Drive belt – Tension check
Preconditions

Tester Y4345711 1
Preload measuring device, 150-600 N Y20097429 1
Belt tension check – Fan drive
Measuring depression depth with preload measuring device

Note: The frequency measurement procedure is the preferred one because it provides more exact measure-
ment results.
1. Remove protective cover.
2. Set preload measuring device onto the drive belt in the middle between the belt pulleys (arrow).
3. Using pushbutton, press vertically on top of drive belt exerting even pressure until spring can be heard
or felt to engage.
4. Do not exert any more pressure as displayed value will otherwise be falsified.
5. Remove preload measuring device without changing the position of the display arm.
6. Read off measured value at the intersection of display arm and “KG” scale. Refer to table below for set-
point value.
7. If the measured values deviate from the specified values, adjust drive belt tension (→ Page 118).
8. Install protective cover.
TIM-ID: 0000053489 - 001
Belt length ‒ Application Measured value Measured value

Initial installation (new belt, (used belt, runtime 500 h)
runtime 0.5-2 h)
Drive belt 1800 mm – Fan Depression depth: 7 mm Depression depth: 8 mm
Test force: 188 N Test force: 188 N
Drive belt 1520 mm – Fan Depression depth: 6 mm Depression depth: 7 mm
Test force: 188 N Test force: 188 N
Table 113: Set-point values ‒ Measurement with preload measuring device

Measuring belt tension with frequency meter
2. Tap against the belt with the handle of a hammer or with a wrench to initiate belt vibration.
3. Hold measuring tip of the frequency meter over belt drive.
4. The measured frequency value appears on the display of the frequency meter.
5. Compare measured value with value in the table.
6. If the measured values deviate from the specified values, adjust drive belt tension (→ Page 118).
Belt length ‒ Application Measured value Measured value
Initial installation (new belt) Operating tension (used belt)
Drive belt 1800 mm – Fan Frequency: 88 ±1 Hz Frequency: 77 ±1 Hz
Drive belt 1520 mm – Fan Frequency: 104 ±1 Hz Frequency: 92 ±1 Hz
Table 114: Set-point values ‒ Measurement with frequency meter

TIM-ID: 0000053489 - 001

7.13.3 Drive belt ‒ Tension adjustment
Preconditions

Ratchet F30027340 1
Engine oil
Drive belt ‒ Tension adjustment

1. Remove protective cover from cooler.
2. Remove protective grill from fan.
3. Loosen screws (1) slightly.
4. Adjust belt tension acc. to specifications
with screw (2) (→ Page 116).
5. Use torque wrench (1) to tighten screws to specified tightening torque.

Screw M16 x 50 Tightening torque (Engine oil) 180 Nm +18 Nm
6. Tighten screw (2) to specified torque using a torque wrench.
Screw M16 x Tightening torque (Engine oil) 50 Nm +5 Nm
200
7. Install protective grill on fan.
8. Install protective cover on cooler.
TIM-ID: 0000053490 - 001

7.13.4 Drive belt – Replacement
Preconditions

Drive belt (→ Spare Parts Catalog)
Fan drive – Drive belt replace-

ment
1. Remove protective cover from cooler.
2. Remove protective grill from fan.
3. Remove fan.
4. Undo securing screws (1).
5. Unscrew screw (2) as far as necessary to
allow drive belt removal.
6. Check belt pulley on fan bearing mount and
crankshaft for contamination and clean if
necessary.
Note: When placing the drive belt in the grooves,
no force must be applied.
7. Fit new drive belt.
8. Adjust and check drive belt tension
(→ Page 118).
9. Install fan.
10. Install protective grill on fan.
11. Install protective cover on cooler.
TIM-ID: 0000054754 - 001

7.14 Battery-Charging Generator
7.14.1 Battery-charger drive – Drive belt replacement
Preconditions

Tester Y4345711 1
Preload measuring device, 150-600 N Y20097429 1
Engine oil
Drive belt (→ Spare Parts Catalog) 1
Preparatory steps
1. Remove safety equipment (if fitted).
2. Remove screws of protective cover (free end).
Drive belt – Replacement

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

Screw M10 Preload torque 10 Nm
TIM-ID: 0000054572 - 001
7. Insert and tighten clamping bolt (4) to torque and tension drive belt to specified set value.
Clamping bolt - Preload torque 8 Nm
Belt ‒ Application Measured value Measured value

Drive belt – Battery-charging gen- Frequency: 95.9 +2 Hz Frequency: 84.1 +2 Hz
erator
Table 115: Set-point values ‒ Measurement with frequency meter

Belt ‒ Application Measured value Measured value
Drive belt – Battery-charging gen- Depression depth: 7.8 mm Depression depth: 8.9 mm
erator Test force: 60 N Test force: 60 N
Table 116: Set-point values ‒ Measurement with preload measuring device

8. Tighten screws (1).
9. Use nut (5) to fasten the clamping bolt (4).
Final steps
2. Install screws of protective cover.
3. Install safety equipment (if fitted).
4. Check function of safety equipment (if fitted).
TIM-ID: 0000054572 - 001

7.15 Fuel Supply System
7.15.1 Water drain valve – Check
Water drain valve – Check

1. Open water drain valve.
2. Check water outlet for obstructions.
3. Close water drain valve.
TIM-ID: 0000007733 - 007

7.15.2 Differential pressure gauge – Check
WARNING
• Do not smoke.
Differential pressure gauge – Check

1. Switch on fuel treatment system (optional).
2. Set the alarm points at the differential pressure gauge to zero.
Result: Alarm is issued after preset delay.
3. Reset the alarm points at the differential pressure gauge to the specified values.
TIM-ID: 0000054749 - 001

7.15.3 Water level probe (3-in-1 rod electrode) – Check
Preconditions
☑System is put out of service and emptied.
WARNING
• Do not smoke.
Water level probe (3-in-1 rod electrode) – Check

1. Disconnect plug from water level probe.
2. Unscrew water level probe.
4. Immerse water level probe into a tank filled with water until water level reaches the thread.
Result: Water drain valve opens.
5. Leave water level probe in tank.
Result: Alarm must be triggered with the preset delay.
7. Remove water level probe from tank.
8. Screw in water level probe.
9. Connect plug for water level probe.
10. Put the fuel treatment system into operation.
TIM-ID: 0000023558 - 001

7.15.4 Pump capacity – Check
WARNING
• Do not smoke.
Pump capacity – Check

1. Install suitable pressure gauge in the intake connection of the pump.
2. Check pump pressure.
a) Switch on fuel treatment system (optional).
Note: The pressure limiting valve at the pump might respond and open. Audible noise is caused by overflow-
ing fuel and can be disregarded.
b) Close ball valve at the outlet of the fuel treatment system.
c) Check pressure at the pressure gauge in the inlet to the fuel treatment system and note down.
3. Checking pump pressure in throttled condition
a) Reduce suction pressure of pump to -0.8 bar with the shut-off valve at the pump intake side.
b) Check pressure at the pressure gauge in the inlet to the fuel treatment system and note down.
c) Open ball valve at inlet and outlet of fuel treatment system.
4. Calculate wear limit.
Example:
Measured value (normal condition). 3 bar
Measured value (throttled). 2.6 bar
If the measured pressure (throttled) is 10% lower than the measured pressure (normal condition), the wear
limit is reached. Recondition pump (contact Service).
TIM-ID: 0000054750 - 001

7.15.5 Coalescer filter element – Replacement
Preconditions
☑System is stopped and starting disabled.

Ratchet F30027339 1
Diesel fuel
Engine oil
Coalescer filter element (→ Spare Parts Catalog)
WARNING
• Do not smoke.
NOTICE
Contamination of components.
Damage to component!
• Observe manufacturer's instructions.
• Check components for special cleanliness.
NOTICE
Incorrect installation of components and lines.
Damage to component!
• Ensure that components/lines are installed so that they are never under tension or strain.
• Ensure correct installation position of components.
Coalescer filter element – Re-

placement
1. Close ball valve at the inlet and outlet of
the fuel treatment system.
2. Open drain valve.
3. Drain fuel.
4. Close drain valve.
5. Remove nuts (9) and washers (2).
6. Remove screws (1).
7. Remove cover with gasket (10).
TIM-ID: 0000007735 - 009
8. Remove nut (3), washer (8) and end

plate (4).
9. Remove coalescer filter element (5).
10. Catch fuel as it runs out.
11. Clean housing with a non-linting cloth,
rinse with fuel if required.
12. Check housing for corrosion.
13. Clean housing sealing surfaces.
14. Install coalescer filter element (5).
15. Install end plate (4), washer (8) and nut (3).

16. Tighten nut (3) to specified tightening torque using a torque wrench.
Nut M16 Tightening torque (Engine oil) 30 Nm +3 Nm
17. Fit gasket (10).
18. Install cover.
19. Install screws (1), washers (2) and nuts (9).
20. Tighten nuts (9).
21. Open ball valve at the inlet and outlet of the fuel treatment system.
Result: The fuel treatment system is ready for operation.
TIM-ID: 0000007735 - 009

7.16 Engine Governor
7.16.1 Engine control system – Overview
1 Connector X2 3 Connector X3 5 Screw

2 Engine control system 4 Washer 6 Damper
TIM-ID: 0000053491 - 001

7.16.2 Engine control system – Removal and installation
Preconditions

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

from engine
1. Note or mark assignment of cables and
connectors.
2. Release latches on connectors (1) and (3).
3. Disconnect all connectors.
4. Remove all screws (5).
5. Remove engine control system (2).
Installing engine control system on engine

1. Install in reverse order. Ensure correct assignment of connectors and sockets in so doing.
2. Check resilient mount before installation.
Result: Replace resilient mount if porous or defective.
TIM-ID: 0000053492 - 001

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

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

7.17 Wiring (General) for Engine/Gearbox/Unit
7.17.1 Еngine wiring ‒ Check
Preconditions

Isopropyl alcohol X00058037 1
Еngine wiring ‒ Check

1. Check securing screws of cable clamps on engine and tighten loose threaded connections.
2. Ensure that cables are fixed in their clamps and cannot swing freely.
3. Check if all cable clips are closed and intact.
4. Replace faulty cable clips.
5. Check that cable clamps are firm, tighten loose cable clamps.
6. Replace faulty cable clamps.
7. Visually inspect the following electrical line components for damage:
• Connector housing
• Contacts
• Sockets
• Cables and terminals
• Plug-in contacts
Result: Contact Service if cable conductors are damaged.
Note: Close male connectors that are not plugged in with the protective cap supplied.
8. Clean dirty connector housings, sockets and contacts using isopropyl alcohol.
9. Ensure that all sensor connectors are securely engaged.
TIM-ID: 0000000029 - 021

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

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

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

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

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

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

8 Appendix A
8.1 List of abbreviations
Abbrevia- Meaning Explanation
tion
AL Alarm -
ANSI American National Standards Institute Association of American standardization organiza-
tions
ATL Abgasturbolader Exhaust turbocharger (ETC)
BDM Backup Data Module -
BR Baureihe Series
BV Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU Publication
No. A01061/..
CAN Controller Area Network Data bus system, bus standard
CPP Controllable Pitch Propeller
DIN Deutsches Institut für Normung e. V. At the same time identifier of German standards (DIN
= “Deutsche Industrie-Norm”)
DIS Display Unit Display panel
DL Default Lost Alarm: CAN bus missing
ECS Engine Control System Engine management system
ECU Engine Control Unit Engine governor
EDM Engine Data Module Memory module for engine data
EMU Engine Monitoring Unit
ETC Exhaust turbocharger
GCU Gear Control Unit
GMU Gear Monitoring Unit
HAT Harbor Acceptance Test
HI High Range violation alarm (1st upper limit value)
HIHI High High Range violation alarm (2nd upper limit value)
IDM Interface Data Module Memory module for interface data
ISO International Organization for Stand- International umbrella organization of all standards
ardization institutes
KGS Kupplungsgegenseite Engine free end in accordance with DIN ISO 1204
KS Kupplungsseite Engine driving end in accordance with DIN ISO 1204
LCD Liquid Crystal Display, Liquid Crystal
TIM-ID: 0000026477 - 004
Device
LCU Local Control Unit LOP subassembly
LED Light Emitting Diode
LO Low Range violation alarm (1st lower limit value)
LOLO Low Low Range violation alarm (2nd lower limit value)
LOP Local Operating Panel
LOS Local Operating Station Local control unit
LPU Oil refill pump
134 | Appendix A | MS150118/00E 2014-07

Abbrevia- Meaning Explanation
tion
MCS Monitoring and Control System
MG Message
MPU Microprocessor Unit, Microprocessing
Unit
OT Oberer Totpunkt Top dead center (TDC)
PAN Panel Control panel
PCU/PMU Propeller Control Unit Propeller controller
PIM Peripheral Interface Module
PPC Priming Pump Control
RCS Remote Control System
RL Redundancy Lost Alarm: Redundant CAN bus failure
SAT Sea Acceptance Test
SD Sensor Defect Alarm: Sensor failure
SDAF Shut Down Air Flap(s) Emergency air-shutoff flap(s)
SS Safety System Safety system alarm
SSK Schnellschlussklappen Emergency air-shutoff flap(s)
TD Transmitter Deviation Alarm: Sensor comparison fault
UT Unterer Totpunkt Bottom dead center (BDC)
TIM-ID: 0000026477 - 004
MS150118/00E 2014-07 | Appendix A | 135

8.2 MTU contact persons/service partners
Our worldwide sales network with its subsidiaries, sales offices, representatives and customer service
centers ensures fast and direct support on site and the high availability of our products.
Local support
Experienced and qualified specialists place their knowledge and expertise at your disposal.
For locally available support, go to the MTU Internet site: http://www.mtu-online.com
24h hotline
With our 24h hotline and the outstanding flexibility of our service staff, we are always ready to assist
you – either during operation, for preventive maintenance, corrective work in case of malfunction or
changed operating conditions, or for spare parts supply.
Your contact person in our Customer Assistance Center:
E-mail: info@mtu-online.com
Tel.: +49 7541 9077777
Fax: +49 7541 9077778
Asia/Pacific: +65 6100 2688
North and Latin America: +1 248 560 8000
Spare parts service

Fast, simple and correct identification of spare parts for your drive system or vehicle fleet. The right
spare part at the right time at the right place.
With this aim in mind, we can call on a globally networked spares logistics system, a central warehouse
at headquarters and on-site stores at our subsidiary companies, agencies and service workshops.
Your contact at Headquarters:
E-mail: spare.parts@mtu-online.com
Tel.: +49 7541 908555
Fax: +49 7541 908121
TIM-ID: 0000000873 - 015
136 | Appendix A | MS150118/00E 2014-07

9 Appendix B
9.1 Special Tools
Barring tool
Part No.: F6792910
Qty.: 1
Used in: 7.1.1 Engine – Cranking manually (→ Page 68)
Qty.: 1
Used in: 7.3.1 Valve clearance – Check and adjustment
(→ Page 71)
Crowfoot wrench, 19 mm
Part No.: F30027424
Qty.: 1
Used in: 7.4.2 Injector – Removal and installation (→ Page 76)
Qty.: 1
Used in: 7.5.1 HP fuel line and pressure pipe connection ‒ Re-
placement (→ Page 82)
Double-end box wrench

Part No.: F30002800
Qty.: 1
(→ Page 71)
DCL-ID: 0000033223 - 001
MS150118/00E 2014-07 | Appendix B | 137

Double-end box wrench
Part No.: F30011450
Qty.: 1
Qty.: 1
Filter wrench
Part No.: F30379104
Qty.: 1
Used in: 7.6.1 Fuel filter – Replacement (→ Page 87)
Qty.: 1
Used in: 7.11.1 Engine oil filter – Replacement (→ Page 101)
Fuel suction device

Part No.: F30378207
Qty.: 1
Measuring device
Part No.: Y4348409
Qty.: 1
(→ Page 71)
DCL-ID: 0000033223 - 001
138 | Appendix B | MS150118/00E 2014-07

MTU test kit
Part No.: 5605892099/00
Qty.: 1
Used in: 7.12.7 Engine coolant – Sample extraction and analysis
(→ Page 114)
Offset screwdriver
Part No.: F30453001
Qty.: 1
(→ Page 71)
Open-end socket wrench, 24 mm

Part No.: F30453238
Qty.: 1
Plug-in open-end wrench, 19 mm

Part No.: F30453236
Qty.: 1
DCL-ID: 0000033223 - 001
MS150118/00E 2014-07 | Appendix B | 139

Plug-in open-end wrench, 19 mm
Part No.: F30025897
Qty.: 1
Preload measuring device, 150-600 N

Part No.: Y20097429
Qty.: 1
Used in: 7.13.2 Drive belt – Tension check (→ Page 116)
Qty.: 1
Used in: 7.14.1 Battery-charger drive – Drive belt replacement
(→ Page 120)
Press-in tool
Part No.: F6790085
Qty.: 1
Puller
Part No.: F6790636
Qty.: 1
DCL-ID: 0000033223 - 001
140 | Appendix B | MS150118/00E 2014-07

Ratchet
Part No.: F30006212
Qty.: 1
Used in: 7.1.1 Engine – Cranking manually (→ Page 68)
Qty.: 1
(→ Page 71)
Ratchet
Part No.: F30027340
Qty.: 1
Used in: 7.3.2 Cylinder head cover – Removal and installation
(→ Page 74)
Qty.: 1
Qty.: 1
Qty.: 1
Used in: 7.13.3 Drive belt ‒ Tension adjustment (→ Page 118)
Ratchet
Part No.: F30027339
Qty.: 1
Used in: 7.15.5 Coalescer filter element – Replacement
(→ Page 126)
Ring socket, 22 mm
Part No.: F30038494
Qty.: 1
DCL-ID: 0000033223 - 001
Qty.: 1
Used in: 7.5.2 Fuel system – Venting (→ Page 85)
MS150118/00E 2014-07 | Appendix B | 141

Ring socket, 24 mm
Part No.: F30501562
Qty.: 1
Socket wrench
Part No.: F30030450
Qty.: 1
(→ Page 71)
Steam jet cleaner

Part No.: -
Qty.: 1
Used in: 4.8 Plant – Cleaning (→ Page 63)
Tester
Part No.: Y4345711
Qty.: 1
Used in: 7.13.2 Drive belt – Tension check (→ Page 116)
Qty.: 1
Used in: 7.14.1 Battery-charger drive – Drive belt replacement
(→ Page 120) DCL-ID: 0000033223 - 001
142 | Appendix B | MS150118/00E 2014-07

Torque wrench, 10-60 Nm
Part No.: F30510423
Qty.: 1
(→ Page 71)

Part No.: F30026582
Qty.: 1
Qty.: 1
Qty.: 1

Part No.: F30027337
Qty.: 1

Part No.: F30027336
Qty.: 1
Used in: 7.5.2 Fuel system – Venting (→ Page 85)
Qty.: 1
Used in: 7.15.5 Coalescer filter element – Replacement
DCL-ID: 0000033223 - 001
(→ Page 126)
MS150118/00E 2014-07 | Appendix B | 143

Part No.: F30043446
Qty.: 1
(→ Page 74)
Qty.: 1
Used in: 7.11.2 Centrifugal oil filter – Cleaning and filter sleeve
replacement (→ Page 102)
Torque wrench, 0.5-5 Nm

Part No.: 0015384230
Qty.: 1
(→ Page 74)
Qty.: 1
Valve clearance gauge

Part No.: Y4345893
Qty.: 1
(→ Page 71)
DCL-ID: 0000033223 - 001
144 | Appendix B | MS150118/00E 2014-07

9.2 Index
A Drive
After stopping the engine 62 – Replacement
Air filter – Drive 119
– Installation 94 Drive belt
– Removal 94 – Adjustment
– Replacement 93 – Tension 118
– Check
B – Tension 116
Battery-charger drive – Condition check 115
– Replacement – Replacement 119
– Drive belt 120 – Battery-charger drive 120
Belt drive
E
– Adjustment
– Tension 118 Electric starter
– Check – Overview 96
– Tension 116 Emergency stop
– Engine 61
C Engine
CDC – Barring
– Reset 81 – Manually 68
Centrifugal oil filter – Barring with starting system 69
– Cleaning 102 – Emergency stop 61
Coalescer filter element – Main dimensions 55
– Replacement 126 – Overview 15
Connectors – Starting 58
– Cleaning 132 – Stopping 60
Contact persons 136 Engine control system
Coolant – Installation 129
– Change 109 – Overview 128
– Filling 111 – Removal 129
– Sample Engine coolant
– Extraction and analysis 114 – Change 109
Coolant level – Draining 110
– Check 108 – Filling 111
Crankcase breather – Sample
– Oil mist fine separator – Extraction and analysis 114
– Replacement 70 Engine coolant level
Cylinder – Check 108
– Designation 14 Engine coolant pump – Relief bore check 113
Cylinder head cover
– Installation 74
– Removal 74
D
DCL-ID: 0000033223 - 001
Differential pressure
– Pressure gauge
– Check 123
Differential pressure gage
– Adjustment
– Fuel prefilter 88
– Check
– Fuel prefilter 88
Drain and vent points 104
Drift correction parameters
– Reset 81
MS150118/00E 2014-07 | Appendix B | 145

Engine data Fuel prefilter
– 12 V 2000 B26 F 18 – Adjustment
– 12 V 2000 B76 switchable – Differential pressure gage 88
– 1500 rpm 24 – Check
– 1800 rpm 30 – Differential pressure gage 88
– 12 V 2000 G16 F 36 – Draining 89
– 12 V 2000 G26 F 40 – Filter element replacement 92
– 12 V 2000 G76 F 45 – Flushing 90
– 16 V 2000 B26 F 18 Fuel system
– 16 V 2000 B76 switchable – Installation
– 1500 rpm 24 – Injector 76
– 1800 rpm 30 – Removal
– 16 V 2000 G16 F 36 – Injector 76
– 16 V 2000 G26 F 40 – Venting 85
– 16 V 2000 G36 F 50
– 16 V 2000 G76 F 45 H
– 18 V 2000 B26 F 18 Hotline 136
– 18 V 2000 B76 switchable HP fuel line
– 1500 rpm 24 – Replacement 82
– 1800 rpm 30
– 18 V 2000 G26 F 40 I
– 18 V 2000 G76 F 45 IIG
Engine driving end – Input 81
– Definition 14 Injector
Engine free end – Installation 76
– Definition 14 – Removal 76
Engine governor – Replacement 75
– Cleaning 132 Injector coding
– Plug connections – Input 81
– Check 130, 133 Injector functions 81
Engine oil
L
– Centrifugal oil filter
– Cleaning 102 List of abbreviations 134
– Change 100
M
– Filter sleeve
– Replacement 102 Main dimensions
Engine oil filter – Engine 55
– Replacement 101 Maintenance schedule
Engine oil level – Task reference table [QL1] 64
– Check 99 MTU contact persons 136
Engine sides
O
– Designation 14
Engine wiring Operation monitoring 59
– Check 131 Overview
– Engine 15
F – Engine governor 128
Filter
P
DCL-ID: 0000033223 - 001
– Coalescer element
– Replacement 126 Plant
Filter sleeve – Cleaning 63
– Replacement 102 Pressure guage
Firing order 54 – Differential pressure
Fuel – Check 123
– Draining 86 Pressure pipe connection
Fuel filter – Replacement 82
– Replacement 87 Pump
– Engine coolant
– Relief bore check 113
146 | Appendix B | MS150118/00E 2014-07

Pump capacity
– Check 125
S
Safety notices, standards 13
Safety regulations
– Auxiliary materials 11
– Environmental protection 11
– Fire prevention 11
– Fluids and lubricants 11
– Organizational requirements 6
– Personnel requirements 6
Safety requirements
– Important requirements 5
– Maintenance work 8
– Repair work 8
– Safety notices, standards 13
Service indicator
– Signal ring position check 95
Service partners 136
Spare parts service 136
Starter
– Electric
– Installation 98
– Removal 97
Startup
– after long out-of-service periods (>3 months)
– Preparations 56
– after scheduled out-of-service period
– Preparations 57
T
Transport 7
Troubleshooting 65
V
Valve clearance
– Adjustment 71
– Check 71
Vent and drain points 104
W
Water drain valve
– Check 122
Water level probe
– Check 124
Wiring
– Check
DCL-ID: 0000033223 - 001
– On engine 131
MS150118/00E 2014-07 | Appendix B | 147


Operating Instructions

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Operating Instructions

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Table 1: Overview of validity

© 2014 Copyright MTU Friedrichshafen GmbH

Downloaded from www.Manualslib.com manuals search engine

7.4 Injection Valve / Injector 75

7.9.3 Starter ‒ Installation 98

MS150118/00E 2014-07 | Table of Contents | 3

DCL-ID: 0000033223 - 001

4 | Table of Contents | MS150118/00E 2014-07

MS150118/00E 2014-07 | Safety | 5

Working clothes and personal protective equipment

TIM-ID: 0000040531 - 002

6 | Safety | MS150118/00E 2014-07

Setting down the engine following transportation

MS150118/00E 2014-07 | Safety | 7

Safety requirements during maintenance and repair work

Ensure that all retainers and dampers are installed correctly.

8 | Safety | MS150118/00E 2014-07

Safety requirements after completing maintenance and repair work

Hydraulic installation and removal

Working with batteries

MS150118/00E 2014-07 | Safety | 9

Working with laser equipment

Measuring component deviations

10 | Safety | MS150118/00E 2014-07

Environmental protection and disposal

Fluids and lubricants and auxiliary materials

coming into contact with ignition sources and do not smoke.

MS150118/00E 2014-07 | Safety | 11

Paints and varnishes

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

• Observe the relevant safety data sheet for all materials.

12 | Safety | MS150118/00E 2014-07

MS150118/00E 2014-07 | Safety | 13

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

14 | General Information | MS150118/00E 2014-07

1 Air intake/air supply 6 Engine coolant pump 11 Charge-air line

MS150118/00E 2014-07 | General Information | 15

1 Air intake/air supply 6 Engine coolant pump 11 Charge-air line

TIM-ID: 0000053439 - 001

16 | General Information | MS150118/00E 2014-07

1 Air intake/air supply 6 Engine coolant pump 11 Charge-air line

Table 2: Explanation of engine model designation

MS150118/00E 2014-07 | General Information | 17

Table 3: Reference conditions

Boundary conditions (for maximum power)

18 | Technical Data | MS150118/00E 2014-07

Table 5: Boundary conditions (for maximum power)

Model-related data (basic design)

Table 7: Model-related data (basic design)

Air / exhaust gas

Table 8: Air / exhaust gas

MS150118/00E 2014-07 | Technical Data | 19

Table 9: Coolant system (HT circuit)

Coolant system (LT circuit)

Table 10: Coolant system (LT circuit)

Lube oil system

20 | Technical Data | MS150118/00E 2014-07

Table 11: Lube oil system

Table 12: Fuel system

General operating data

Table 13: General operating data