DT_MUE_00057_US_1

Use and maintenance manual

MTU Diesel Engine 12V 4000 G20 12V 4000 G60 12V 4000 G80

Réf. constructeur : M015340/20E Réf. GPAO : 33522014401 ind1

The handbook is provided for the use by maintenance and operating personnel in order to avoid malfunctions or damage during operation. Other than for this purpose, the handbook shall not be reproduced, used or disclosed to others without our prior consent.

Subject to alterations and amendments.

Notes for the user ! Safety Instructions

This Manual is divided intosections.

Summarysections.

These sections are listed onthis page. A Product Summarythis age.

Each section has its ownTable of Contents

Engine layout, technical dataTable of Contents.

C Operating Instructions

Task descriptions

D Maintenance Schedule

Time schedule and maintenancetask chart

Using the Table of Contentsto trace an entry

E Troubleshootingto trace an entry

� Table of Contents Causes, remedies

� Table of Contents (general)

� SectionG Task Description

� Section

� ContentsInspection and maintenance tasks

� Contents

� Heading K Preservation

Using the AlphabeticalIndex to trace an entry

Engine preservationIndex to trace an entry

� Search term T Transportation Locking Device� Search term

� Section Drawing, instructions

� Heading ? Keyword Index

Alphabetical index of key terms

Publication AmendmentService

Please complete and returnthe Confirmation of Receiptthe Confirmation of Recei tcard; you will then receiveamendments to your manual.

.

Amendment Service !Any changes in contents will be sent to you in the form of an amendment, provided you complete the reverse of this receipt card and return it to us.

Postcard

MTU Motoren- und Turbinen-UnionFriedrichshafen GmbHDepartment VLT

88040 Friedrichshafen

Germany

Please mark all filed amendments here.

Please use block capitals!

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Receipt Amendment No.

M015340/20EPublication number:

Section !Safety InstructionsPage 1

15340/20 E 00–01

Safety, Accident Prevention and Environmental Protection Instructions

These instructions must be read and followed by every person involved inoperation, maintenance or transportation of the machinery plant.

General

In addition to the instructions in this publication, the applicable country-specific legislation and other compulsoryregulations regarding accident prevention must be observed.

This engine is a state-of-the-art product and conforms with all applicable specifications and regulations. Neverthe-less, persons and property may be at risk in the event of

• Incorrect use• Operation, maintenance and repair by unqualified personnel• Modifications or conversions• Non-compliance with the Safety Instructions

Correct Use

The engine is intended exclusively for the application specified in the contract or upon delivery. Any other use isconsidered improper use. The manufacturer will accept no liability for any resultant damage. The responsibility isborne by the user alone.

Correct use also includes observation of and compliance with the maintenance specifications.

Personnel Requirements

Work on the engine must only be carried out by properly qualified personnel.

The specified legal minimum age must be respected.

Responsibilities of the operating, maintenance and repair personnel must be specified.

Modifications or Conversions

Modifications made by the customer to the engine may affect safety.

MTU will accept no liability or warranty claims for any damage caused by unauthorised modifications or conver-sions.

Organisational Measures

This publication must be issued to all personnel involved in operation, maintenance, repair or transportation.

It must be kept at hand near the engine and accessible to all personnel involved in operation, maintenance, repairor transportation.

The personnel must be instructed on engine operation and repair by means of this publication, and in particular thesafety instructions must be explained.

This is especially important for personnel who work on the engine only on an occasional basis. Such personnelmust be given instructions repeatedly.

Spare Parts

Only genuine MTU spare parts must be used to replace components or assemblies. In event of any damagedcaused by the use of other spare parts, no liability or warranty claims vis–à–vis the engine manufacturer will be ac-cepted.

Working Clothes and Protective Equipment

Wear proper work clothing for all work.

Section ! Safety InstructionsPage 2

15340/20 E 00–01

Depending on the kind of work, use additional protective equipment, e.g. protective goggles, protective gloves, pro-tective helmet, apron.

Work clothing must be tight-fitting so that it does not catch on rotating or projecting components.

Do not wear jewellery (e.g. rings, chains, etc.).

Transportation

Lift the engine only with the lifting eyes provided.

Use only the transport and lifting equipment approved by MTU.

Take note of the engine centre of gravity.

The engine must only be transported in installation position.

In the case of special packaging with aluminium foil, suspend the engine on the lifting eyes of the bearing pedestalor transport with equipment suitable for heavy loads (forklift truck).

Prior to transporting the engine, it is imperative to install transportation locking devices for crankshaft and enginemounts.

Secure the engine against tilting during transportation. The engine must be especially secured against slipping ortilting when going up inclines and ramps.

Setting the Engine Down after Transportation

Place the engine only on an even, firm surface.

Ensure appropriate consistency and load-bearing capacity of the ground or support surface.

Never place an engine on the oil pan unless expressly authorised by MTU on a case-by-case basis to do so.

Working with Laser Equipment

When working with laser equipment, always wear special laser-protection goggles.

Laser equipment can generate extremely intensive, concentrated radiation by the effect of stimulated emission inthe range of visible light or in the infrared or ultraviolet spectral range. The photochemical, thermal and optome-chanical effects of the laser can cause damage. The main danger is irreparable damage to the eyes.

Laser equipment must be fitted with the protective devices necessary for safe operation according to type and ap-plication.

For conducting ray 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 only in the visible wavelength range (400 to 700 nm), amaximum output of 5 mW, and in which the beam axis and surface are designed to prevent any risk to the eyes.

Engine Operation

When the engine is running, always wear ear protectors.

Ensure that the engine room is well ventilated.

Mop up any leaked or spilt fluids and lubricants immediately or soak up with a suitable bonding agent.

Exhaust gases from combustion engines are poisonous. Inhalation of poisonous exhaust gases is a health hazard.The exhaust pipework must be leak-free and must discharge the gases to atmosphere.

During engine operation, do not touch battery terminals, generator terminals or cables.

Inadequate protection of electrical components can lead to electric shocks and serious injuries.

When the engine is running, never release coolant, oil, fuel, compressed air or hydraulic lines.


15340/20 E 00–01

Maintenance and Repair

Compliance with maintenance and repair specifications is an important safety factor.

Unless expressly permitted, no maintenance or repair work must be carried out with the engine running. The en-gine must be secured against inadvertent starting and the battery disconnected. Attach sign “Do not operate” inoperating area or to control equipment. Persons not involved must keep clear.

Never attempt to rectify faults or carry out repairs if you do not have the necessary experience or special tools re-quired. Maintenance and repair work must only be carried out by authorised, qualified personnel.

Use only the proper, calibrated tools.

Do not work on engines or components which are only held by lifting equipment or crane. Always support thesecomponents in accordance with regulations on suitable frames or stands before beginning any maintenance or re-pair work.

Before barring the engine, make sure that nobody is standing in the danger zone. After working on the engine,check that all guards have been reinstalled and that all tools and loose components have been removed from theengine.

Fluids emerging under high pressure can penetrate clothing and skin and may cause serious injury. Before startingwork, relieve pressure in systems and H.P. lines which are to be opened.

Never bend a fuel line and do not install bent lines. Keep fuel injection lines and connections clean. Always sealconnections with caps or covers if a line is removed or opened.

During maintenance and repair work, take care not to damage the fuel lines. To tighten connections when installinglines, use the correct tightening torque and ensure that all retainers and dampers are installed correctly.

Ensure that all fuel injection lines and compressed oil lines have sufficient play to avoid contact with other compo-nents. Do not place fuel or oil lines near hot components, except when necessary for design reasons during in-stallation.

Take care with hot fluids in lines, pipes and chambers ⇒ Risk of injury!

Not cooling period for components which are heated for installation or removal ⇒ Risk of injury!

Take special care when removing ventilation or plugs from engine. In order to avoid the discharge of highly pressur-ised liquids, hold a cloth over the screw or plug. It is even more dangerous if the engine has recently been shutdown, as the liquids can still be hot.

Take special care when draining hot fluids ⇒ Risk of injury!

When draining, collect fluids in a suitable container, mop up any spilt fluids or wipe or soak them up with a suitablebonding agent.

When changing engine oil or working on the fuel system, ensure that the engine room is adequately ventilated.

When working high on the engine, always use suitable ladders and work platforms. Make sure components areplaced on stable surfaces.

In order to prevent back injuries when lifting heavy components, adults should not lift weights between max. 10 kgand 30 kg, depending on age and sex.

• Use lifting gear or seek assistance.

• Ensure that all chains, hooks, slings, etc. are tested and authorised, are sufficiently strong and that hooks arecorrectly positioned. Lifting eyes must not be unevenly loaded.

Welding Operations

Never carry out welding work on the engine or engine-mounted units.

Never use the engine as an earth connection. – (This prevents the welding current passing through the engine andcausing scorching or burning at bearings, sliding surfaces and tooth flanks, which can lead to pitting or other ma-terial damage).


15340/20 E 00–01

Never position the welding power supply cable adjacent to, or crossing MTU plant wiring harnesses. (The weldingcurrent can be induced in the wiring harnesses, which could damage the electrical unit.)

The welding unit earth connection must not be more than 60 cm from the weld point.

If components (e.g. exhaust manifold) are to be welded, they must first be removed from the engine.

When carrying out work on MTU electronics components, it is not necessary to remove connectors provided thatthe master switch for power supply has been moved from “ON” to “OFF” and the cable is disconnected from thebattery negative and positive terminals.

Hydraulic Installation and Removal

Only the hydraulic installation and removal equipment specified in the work schedule and in the assembly instruc-tions must be used.

The max. permissible push-on pressure specified for the equipment must not be exceeded.

The H.P. lines for hydraulic installation and removal are tested with 3800 bar.

Do not attempt to bend or apply force to lines.

Before starting work, pay attention to the following:

• Vent the hydraulic installation/removal tool, the pumps and the lines at the relevant points for the system to beused (e.g. open vent plugs, pump until bubble-free air emerges, close vent plugs).

• For hydraulic installation, screw on the tool with piston retracted.

• For hydraulic removal, screw on the tool with piston extended.

For a hydraulic installation/removal tool with central expansion pressure supply, screw spindle into shaft end untilcorrect sealing is achieved.

During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of the compo-nent to be installed/removed. As long as the system is under pressure, there is the risk that the component to beinstalled/removed may be suddenly released from the pressure connection.

Before use, the tools must be checked at regular intervals (crack test).

Working on Electrical Assemblies

Switch off all live appliances before carrying out any work on electrical assemblies.

Gases released from the battery are explosive. Avoid sparks and naked flames. Do not allow battery acids to comeinto contact with skin or clothing. Wear protective goggles. Do not place tools on the battery. Before connecting thecable to the battery, check battery polarity. Battery pole reversal may lead to injury through the sudden discharge ofacid or bursting of the battery body.

Do not damage wiring during removal work and when reinstalling wiring and ensure that during operation it is notdamaged by contact with sharp objects, by rubbing against another component or by a hot surface.

Do not secure wiring to fluid-carrying lines.

On completion of the maintenance and repair work, any cables which have become loose must be correctly con-nected and secured.

Always tighten connectors with a connector pliers.

If wires are installed beside mechanical components and there is a risk of chafing, use cable clamps to properlysupport the wires.

For this purpose, no cable straps must be used as, during maintenance and/or repair work, the straps can be re-moved but not installed a second time.


15340/20 E 00–01

Operation of Electrical Equipment

When operating electrical equipment, certain components of this equipment are live.

Noncompliance with the warning instructions given for this equipment may result in serious injury or damage toproperty.

Fire Prevention

Rectify any fuel or oil leaks immediately; even splashes of oil or fuel on hot components can cause fires – thereforealways keep the engine in a clean condition. Do not leave cloths soaked with fluids and lubricants lying around onthe engine. Do not store combustible fluids near the engine.

Do not weld pipes and components carrying oil or fuel. Before welding, clean with a nonflammable fluid.

When starting the engine with a foreign power source, connect the ground lead last and remove it first. To avoidsparks in the vicinity of the battery, connect the ground lead from the foreign power source to the ground lead of theengine or to the ground terminal of the starter.

Always keep suitable fire-fighting equipment (fire extinguishers) at hand and familiarise yourself with their use.

Noise

Noise can lead to an increased risk of accident if acoustic signals, warning shouts or noises indicating danger aredrowned.

At all workplaces with a sound pressure level over 85 dB(A), always wear ear protectors (protective wadding, plugsor capsules).

Environmental Protection

Dispose of used fluids and lubricants and filter in accordance with local regulations.

Manipulation of the injection or control system can influence the engine performance and exhaust emissions. As aresult, compliance with environmental regulations may no longer be guaranteed.

Only fuels of the specified quality required to achieve emission limits must be used.

In Germany, the VAwS (=regulations governing the use of materials that may affect water quality) is applicable,which means work must only be carried out by authorised specialist companies. (MTU is such a company.)

Auxiliary Materials

Use only fluids and lubricants that have been tested and approved by MTU.

Fluids and lubricants must be kept in suitable, properly designated containers. When using fluids, lubricants andother chemical substances, follow the safety instructions applicable to the product. Take care when handling hot,chilled or caustic materials. When using inflammable materials, avoid all sparks and do not smoke.

⇒ Lead

When working with lead or lead-containing pastes, avoid direct contact to the skin and do not inhale lead vapours.

Adopt suitable measures to avoid the formation of lead dust!

Switch on fume extraction system.

After coming into contact with lead or lead-containing materials, wash hands!

⇒ Acids and Alkaline Solutions

When working with acids and alkalis, wear protective goggles or face mask, gloves and protective clothing.

Immediately remove clothing wetted by acids and alkalis!

Rinse injuries with plenty of clean water!

Rinse eyes immediately with eyedrops or clean tap water.


15340/20 E 00–01

⇒ Painting

When painting in other than spray booths equipped with extractors, ensure good ventilation. Make sure that adjac-ent work areas are not affected.

It is absolutely essential to wear masks providing protection against paint and solvent fumes.

Observe fire prevention regulations!

No smoking.

No naked flame!

⇒ Liquid Oxygen

Liquid oxygen is highly inflammable.

Liquid oxygen should only be stored in small quantities and in regulation containers (without fixed seals)! Do notbring liquid oxygen into contact with the body (hands), as this causes frostbite and possibly the loss of tissue.

No smoking, no naked flame (risk of explosion)! Excessive oxygen in the air leads to explosive combustion.

Do not store combustible substances (e.g. oils and greases) within 5 m of the working area!

Under no circumstances should clothing be oily or greasy.

Do not allow vapours to penetrate clothing! Oxygen enrichment in fabric can cause working clothes to ignitesuddenly!

After working with liquid oxygen, do not smoke until clothing is free of vapours!

Take great care to avoid impact and shock when working with liquid oxygen!

⇒ Liquid Nitrogen

Store liquid nitrogen only in small quantities and always in regulation containers without fixed covers.

Do not bring liquid nitrogen into contact with the body (eyes, hands) as this causes frostbite and numbing.

Wear protective clothing (including gloves and closed shoes) and protective goggles!

– Ensure the room is well ventilated (88% contamination of breathing with nitrogen will result in suffocation).

Avoid all knocks and jars to the containers, fixtures or workpieces.

⇒ Compressed Air

Compressed air is air which has been compressed at excess pressure and is stored in tanks from which it can thenbe extracted.

The pressure at which the air is kept can be read off at pressure gauges which must be connected to the com-pressed air tanks and the compressed air lines.

When working with compressed air, safety precautions must be constantly observed:• Pay special attention to the pressure level in the compressed air network and pressure vessel!• Connecting devices and equipment must either be designed for this pressure or, if the permitted pressure for the

connecting elements is lower than the pressure required, a pressure reducing valve and safety valve (set to per-mitted pressure) must form an intermediate connection. Hose coupling and connections must be securely at-tached!

• Always wear protective goggles when blowing off tools or extracting chips!• The snout of the air nozzle is provided with a protective disc (e.g. rubber disc), which prevents air-borne par-

ticles being reflected and thereby prevents injury to eyes.• First shut off compressed air lines before compressed air equipment is disconnected from the supply line or be-

fore equipment or tool is to be replaced!• Unauthorised use of compressed air, e.g. forcing flammable liquids (danger class AI, AII and B) out of con-

tainers, results in a “Risk of explosion”!• Forcing compressed air into thin-walled containers (e.g. containers made of tin, plastic and glass) for drying pur-

poses or to check for leaks results in a “Risk of explosion”!


15340/20 E 00–01

• Do not blow dirty clothing with compressed air when being worn on the body.Even compressed air at low pressure penetrates clothing and, if the jet is directed at the back, the air can enterthe anal cavity and fatally rupture the intestines!

⇒ Used Oil

Used oil may contain health-threatening combustion residues.

Rub barrier cream into hands!

Wash hands after contact with used oil.

Warning Signs

Before putting the engine into service and before working on the engine, read and follow all warning signs. Do notpaint over warning signs. Replace illegible signs.

Warning Notices

Publication contains especially emphasised safety instructions in accordance with the American standard ANSIZ535, which begin with one of the following signal words according to the degree of danger:

In event of immediate danger.Consequences: Death or serious injury

DANGER

WARNING

In event of dangerous situations.Consequences: Serious injury

CAUTION

In event of dangerous situations.Consequences: Slight injury or material damage

Take extreme care in these situations!

Read and become acquainted with all warning notices and symbols before operating or repairing this product.

Pass on all safety instructions to your operating, maintenance, repair and transport personnel.


15340/20 E 00–01

Section AProduct Summary

15340/20 E 00–01

Contents

A000.000.01 Engine layout 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A000.000.03 Engine model designation 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A000.000.05 Engine side and cylinder designations 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A000.000.09 Main engine dimensions 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A000.000.13 Engine weight 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A000.000.17 Main engine specifications 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A000.000.19 Engine power 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A000.000.21 Operational data 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A000.000.25 Engine and exhaust noise 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A050.000.01 Timing data (valve clearance adjusted) 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A055.050.01 Valve clearances 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A170.000.01 Engine starting system 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A180.000.01 Oil capacity 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A202.000.01 Coolant capacity 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section A Product Summary

15340/20 E 00–01

Section A

Page 1

Product Summary

15340/20 E 00–01

A000.000.01 Engine LayoutIllustrations may show additional equipmentAlso applies to 8 V and 12 V engines

1 Coolant system vent connection 2 Engine oil heat exchanger 3 Centrifugal oil filter 4 Exhaust turbocharger 5 Exhaust outlet 6 Air filter 7 Governor / engine control system 8 Charge air line 9 Starter

10 Engine mount

11 Engine oil filter (easy-change filter) 12 Fuel duplex filter (easy-change filter) 13 H.P. fuel pump 14 Vibration damper 15 Charge air coolant pump 16 Charge air coolant thermostat 17 Charge air coolant inlet 18 Engine coolant outlet 19 Charge air coolant outlet 20 Crankcase ventilation

Section A

Page 2Product Summary

15340/20 E 00–01

1 Air filter 2 Crankcase ventilation 3 Charge air line 4 Exhaust turbocharger 5 Charge air coolant outlet 6 Cylinder head cover / cylinder head 7 Engine lifting eyes 8 Engine coolant pump 9 Oil filler neck

10 Oil pan

11 Oil dipstick 12 Oil drain plug 13 Starter 14 Flywheel 15 Flywheel housing 16 Charge air line 17 Governor / engine control system 18 Intercooler

A000.000.03 Engine Model DesignationKey to engine model designations 12V4000G20, 12V4000G60, 12V4000G80

12 = number of cylindersV = Vee configuration4000 = displacement per cylinder in cm3

G = application for stationary power generation2,–8 = external charge air cooling0 = design index

Section A

Page 3

Product Summary

15340/20 E 00–01

A000.000.05 Engine Side and Cylinder DesignationsEngine sides are always designated as viewed from the driving end.The cylinders on the left engine side are designated “A” and those of the right engine side “B” (as per DIN ISO 1204).The cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end.The numbering of other engine components is also from the driving end, starting with No. 1.

Applicable designations and abbreviationsDriving end KS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Free end KGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A000.000.09 Main Engine Dimensions

A = Overall length approx. 2410 mm. . . . . . . . . . . . . . B = Overall width approx. 1660 mm. . . . . . . . . . . . . . . C = Overall height approx. 2400 mm. . . . . . . . . . . . . . D = Engine length to flange surfaceapprox. 2140 mmE = Crankshaft centreline to oil pan 625 mm. . . . . . . F = Crankshaft centerline to engine mount 339 mm.

A000.000.13 Engine WeightEngine dry weight (12V4000G20) approx. 5250 kg. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine dry weight (12V4000G60, 12V4000G80) approx. 5350 kg. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A000.000.17 Main Engine Specifications

Operating method four-stroke cycle, single-acting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Combustion method direct injection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section A


15340/20 E 00–01

Injection method common rail (accumulator injection). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mode of supercharging exhaust turbocharging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling liquid-cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Construction 90° Vee. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bore 165 mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stroke 190 mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Displacement, cylinder 4.06 litres. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Number of cylinders 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Displacement, total 48.75 litres. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compression ratio 16.6 : 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compression ratio with 12V4000G80 14 : 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direction of rotation (viewed on driving end) c.c.w. (non-reversible). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Firing order A1 – B2 – A5 – B4 – A3 – B1 – A6 – B5 – A2 – B3 – A4 – B6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Final compression pressure at 120 rpm 22 to 24 bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Firing speed at 40 °C engine coolant temperature approx. 80 – 120 rpm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mean piston speed at 1500 rpm 9.5 m/s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mean piston speed at 1800 rpm 11.4 m/s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A000.000.19 Engine Power

Continuous power with 12V4000G20 1205 kW at 1500 rpm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Continuous power with 12V4000G60 1330 kW at 1500 rpm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Continuous power with 12V4000G80 1490 kW at 1800 rpm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reference conditions– Intake air temperature 25 °C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . – Charge air coolant temperature 55 °C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . – Altitude 100 m. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . – Exhaust backpressure 30 mbar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . – Intake air pressure loss 15 mbar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section A

Page 5

Product Summary

15340/20 E 00–01

A000.000.21 Operational DataThe Engine Acceptance Test Records operational data are binding.All figures relate to the engine at operating temperature.

Pressures Normal bar Limit bar

Engine oil pressure, measured before engine, at

– Rated speed 5.0 4.5

– Lower idling speed 3.0 2.5

Engine coolant, before engine coolant pump (Coolant system sealed with breather valve locked in position)

0.5 0.2

Fuel supply, before fuel delivery pump 0.5 –0.3

Charge air, measured after intercooler* Max. deviation from values recorded on Engine Acceptance Test Record and referenced to the

acceptance test peripheral conditions.

– –0.15*

Intake depression, at compressor inlet*Air filter new: max. 25 mbar; air filter contaminated: max. 35 mbar

25 mbar 35 mbar

Exhaust backpressure, measured at exhaust junction pipe 30 mbar 50 mbar

Temperatures Normal°C

Limit°C

Engine oil, before engine 95 105

Engine oil, before engine (warning) 110 115

Engine coolant, after engine 85 –

Engine coolant, after engine (warning) 95 98

Engine coolant preheat temperature, measured after engine 40

Exhaust temperature, after engine with 12V4000G20 460 –

Exhaust temperature, after engine for 12V4000G20 (optimised emission as perClear-Air Standard)

480 –

Exhaust temperature, after engine for 12V4000G60 465 –

Exhaust temperature, after engine for 12V4000G60 (optimised emission as perClear-Air Standard)

485 –

Exhaust temperature, after engine for 12V4000G80 443 –

Charge air, measured after intercooler 55 65

Consumptions Normal Limit

Fuel with 12V4000G20 196 g/kWh* 206 g/kWh*

Fuel (emission-optimised as per Clear-Air Standard) for 12V4000G20 210 g/kWh* 220 g/kWh*

Fuel with 12V4000G60 196 g/kWh* 206 g/kWh*

Fuel (emission-optimised as per Clear-Air Standard) for 12V4000G60 212 g/kWh* 223 g/kWh*

Section A


15340/20 E 00–01

Fuel with 12V4000G80* at continuous power and using a fuel which conforms to current MTU Fluids and

Lubricants Specification.

193 g/kWh* 203 g/kWh*

Engine oil

* of fuel consumption in continuous operation with run-in engine

0.5%* max. 1.0%*

The engine may be operated at full power up to the specified limit values.The normal values may approach the limit values as a result of different reference conditions or faults when theprescribed service life is reached.If the limit values are exceeded, determine and rectify the cause.

A000.000.25 Engine and Exhaust NoiseApplicable to engine model 12V4000G20

Engine surface noise (free-field level) at distance of 1 m approx. 106 dB (A). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Undamped exhaust noise free-field level) at distance of 1 m approx. 115dB (A). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Applicable to engine model 12V4000G60

Engine surface noise (free-field level) at distance of 1 m approx. 107dB (A). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Undamped exhaust noise (free-field level)at distance of 1 m approx. 116 dB (A). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Applicable to engine model 12V4000G80

Engine surface noise (free-field level) at distance of 1 m approx. 106 dB (A). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Undamped exhaust noise free-field level) at distance of 1 m approx. 115dB (A). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A050.000.01 Timing Data (Valve Clearance Adjusted)

Valve clearance adjusted ° Crank angle

1 Inlet valve opens 42.6° before TDC. . . . . . . . . . . . .

2 Inlet valve closes 66.6° after BDC. . . . . . . . . . . . . .

3 Exhaust valve opens 57.6° before BDC. . . . . . . . . .

4 Exhaust valve closes 30.4° after TDC. . . . . . . . . . . .

5 Overlap 73°. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Start of delivery Performance-map controlled. . . .

I Top dead center (TDC). . . . . . . . . . . . . . . . . . . . . . . . II Bottom dead center (BDC). . . . . . . . . . . . . . . . . . . .

A055.050.01 Valve ClearancesWith engine cold– Inlet valve 0.20 mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

– Exhaust valve 0.50 mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section A

Page 7

Product Summary

15340/20 E 00–01

A170.000.01 Engine Starting SystemElectric starting with starter motor– Rated power of starter motor (two starters) 2 x 9 kW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . – Rated voltage of starter motor 24 VDC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . – Max. power consumption 2600 A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . – Power consumption of starter motor, at firing speed 1000 A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A180.000.01 Oil CapacityOil capacity, oil pan– to lower mark on dipstick approx. 160 litres. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . – to upper mark on dipstick approx. 200 litres. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Total capacity– for initial filling approx. 260 litres. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

– for oil change approx. 220 litres. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A202.000.01 Coolant Capacity– Engine circuit (without cooler) approx. 160 litres. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . – Charge air circuit (without cooler) approx. 40 litres. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section A


15340/20 E 00–01

Section COperating Instructions

15340/20 E 00–01

Contents

C000.000.01 Operating instructions – preface 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C000.000.03 Preparations for initial operation 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C000.000.05 Initial operation 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C000.000.07 Operational checks –maintenance echelon W1– 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C000.000.09 Shutdown 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C000.000.11 After shutdown 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C000.000.13 Out-of-service period 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section C Operating Instructions

15340/20 E 00–01

Operating Instructions Section C

Page 1

15340/20 E 00–01

C000.000.01 Operating Instructions – PrefaceLow operating and maintenance costs as well as operational reliability and availability depend on maintenance andservicing being carried out in compliance with our specifications and instructions.It is essential that:– Trained personnel must be employed– Suitable tools be used– Original spare parts and fluids and lubricants as per MTU Fluids and Lubricants Specifications be used and– The maintenance tasks be carried out as per the MTU Maintenance Schedule.Our Product Support service is available at all times should assistance be needed.Prior to engine start-up it must be determined whether start-up is:

– after a short, scheduled operational shutdown,– after an extended out-of-service period,– initial start-up of a new engine.Accordingly, the Before-Operation Services are sub-divided into:– B1– Before-Operation Services after a short, scheduled operational shutdown– B2– Before-Operation Services after an extended operational shutdown (exceeding 1 week)– B3- Before-Operation Services before initial start-up of a new or preserved engine.Correct engine installation and alignment according to MTU regulations are basic requirements for initial enginestart-up.Prior to engine shutdown it must be determined whether:– a short, scheduled operational shutdown, or

– an extended out-of-service period is involved.In the event of an engine malfunction a decision must be made as to whether– the engine is to be shut down, or– operation may be continued, for a short period, using emergency measures, until rectification can be effected.

Note:

The code numbers on the following pages refer to the section numbers in Section G in which the checks and tasks are described.

These Operating Instructions may include components which are not installed on your engine; these may be disregarded.

Operating InstructionsSection C

Page 2

15340/20 E 00–01

C000.000.03 Preparations for Initial Operation

Code No. B 1 2 3

G124.051.01 Air system Check drain bore for water discharge

G180.000.01 Engine oil Check level

G202.000.03 Engine coolant Check level

G202.400.01 Engine coolant Preheat

G203.000.03 Charge air coolant Check level

G364.050.01 Fuel Check supply

G500.000.01 Engine control system Switch on

G000.000.05 Running gear Bar engine manually

G055.000.03 Valve gear Lubricate

G307.001.01 Accessories, mechanical Ensure guards are installed

G500.000.09 Engine control system Check wiring for security and condition

K000 Depreservation Carry out before-operation services

G080.000.03 Fuel system Fill system

G083.101.01 Fuel prefilter Prime

G120.000.07 Air system Ensure cover plates are removed

G140.000.07 Exhaust system Ensure cover plates are removed

G180.000.03 Engine oil Fill system

G202.000.01 Engine coolant Fill system

G202.401.01 Preheater Switch on

G202.651.01 Engine coolant system Check vent line for obstructions

G203.000.01 Charge air coolant Fill system

G203.551.01 Charge air coolant system Check vent line for obstructions

G213.051.05 Generator Check condition and tension of drive belt

G213.051.10 Generator Remove connection bridge

G309.001.03 Battery Fill with acid / alkaline solution

G364.200.01 Fuel supply system Open shut-off valve(s)

G364.200.05 Fuel supply system Fill fuel suction line to engine

G500.000.07 Engine control system Switch on

T Crankshaft Ensure transportation locking device is removed

T Engine mounting Ensure locking device is removed

C000.000.05 Initial Operation

Code No.

Carry out before-operation services

G000.000.07 Engine Turn engine on starter:– only on initial operation

after engine oil changeafter engine oil filter changeafter extended out-of-service period (exceeding 1 month)

G000.000.09 Engine Start engine

G000.000.11 Engine operation Carry out warm-up procedure

G000.000.13 Engine operation Check speed

G000.000.15 Engine operation Check pressures (where gauges are installed)

G000.000.17 Engine operation Check temperatures (where gauges are installed)

G000.000.19 Engine operation Check running noises

G000.000.21 Engine operation Check engine and external pipework for leaks

On initial start-up of a new or preserved engine or after a W6 overhaul, the following additional tasks must be performed:

G055.000.01 Valve gear Check oil supply

G080.000.05 Engine test run Fuel delivery pump supply pressure check

G120.000.05 Engine test run Check intake depression

G140.000.09 Engine test run Check exhaust backpressure

Operating Instructions Section C

Page 3

15340/20 E 00–01

C000.000.07 Operational Checks –Maintenance Echelon W1–

Carry out tasks in accordance with Maintenance Schedule Section D

C000.000.09 Shutdown

Code No.

G000.000.35 Engine Disengage load

G000.000.23 Engine Shut down engine

C000.000.11 After Shutdown

Code No.


G202.000.07 Engine coolant Drain1)

G203.000.05 Charge air coolant Drain1)

G500.000.03 Engine control system Switch off

C000.000.13 Out-of-Service PeriodIf the engine is to remain out of service for more than 2 weeks, seal the engine air and exhaust sides.If the engine is to be taken out of service for a period exceeding 3 months, it must be preserved according to the instruc-tions given in K.000.

Engine transportationPrior to transporting the engine, it is imperative to install transportation locking devices for crankshaft and enginemount (Section T).The engine must only be lifted using the lifting eyes provided.The engine must not be lowered onto the engine oil pan.

1) Only when freezing temperatures are expected and the engine is to remain out of service for an extended period and– no antifreeze has been added to the coolant– the engine room cannot be heated– the coolant cannot be maintained at a suitable temperature– the antifreeze concentration is insufficient for the engine room temperature– or with an antifreeze concentration of 50% and at an engine room temperature below -40 °C, if the antifreeze additive conforms

to the MTU Fluids and Lubricants Specification.

Operating InstructionsSection C

Page 4

15340/20 E 00–01

Section DMaintenance Schedule

15340/20 E 00–01

Contents

D000.000.01 Maintenance schedule – preface 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D000.000.03 Maintenance system 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D000.000.05 Application 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D000.000.07 Maintenance frequency chart 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D000.000.11 Maintenance schedule 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D000.000.15 Maintenance echelon W6 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D000.000.17 Out-of-service periods 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section D Maintenance Schedule

15340/20 E 00–01

Section D

Page 1Maintenance Schedule

15340/20 E 00–01

D000.000.01 Maintenance Schedule – PrefaceLow operating and maintenance costs as well as operational reliability and availability depend on maintenance andservicing being carried out in compliance with our specifications and instructions.The overall system, of which the engine is an integral part, must be maintained in such a way as to ensure trouble-free engine operation at all times.For this purpose, always:– Ensure that sufficient fuel is available– Ensure that the combustion air is dry and clean– Use only clean, filtered raw waterPreventive maintenance instructions– Special care should be taken to keep the machinery plant in a clean and serviceable condition at all times to facilitate

detection of possible leaks and prevent subsequent damage.– Protect rubber and synthetic parts from oil and fuel, never treat with organic detergents. Wipe with a dry cloth only.– Always replace all seals and gaskets.

D000.000.03 Maintenance SystemThe MTU maintenance concept is a preventive maintenance concept and features the W1 to W6 MaintenanceEchelons as outlined below.Preventive maintenance permits advance operational planning and increases availability.Main features of maintenance echelon

W1: Operational checks.

W2, W3 and W4: Periodic maintenance services to be carried out during out-of-service periods without the need for engine disassem-bly.

W5 –

W6: Major overhaul. This echelon requires complete engine disassembly.

The time intervals according to which W2 to W6 maintenance operations are to be performed and the relevant in-spection and maintenance tasks are based on operational experience. They have been determined so as to ensurecorrect engine operation until the next scheduled maintenance echelon. Particular operating conditions may requirethe Maintenance Schedule to be altered to compensate.NOTE:

The code numbers on the following pages refer to the group numbers in Section G.

This Maintenance Schedule may include components which are not installed on your engine; these may be disregarded.

Section D


15340/20 E 00–01

D000.000.05 Application3B : Continuous operation, variable3C : Continuous operation, with time limit

D000.000.07 Maintenance Frequency Chart

Maintenance echelon W1: Operational checks daily X

W2: Operating hoursLimit (months)

2506

W3: Operating hoursLimit (year)

5001

W4: Operating hoursLimit (years)

1 5003


4 5009


9 00018

D000.000.11 Maintenance Schedule

Code No. One-time services after the first 50 operating hours− on a new engine, or after W5 or W6 maintenance

G055.050.01 Valve gear Check valve clearances

G073.051.07 H.P. fuel pump Check relief bore for obstructions

G083.051.03 Fuel duplex filter Replace filter element

G083.101.03 Fuel prefilter Drain water and contaminants

G083.101.09 Fuel prefilter Replace filter element

G083.101.15 Fuel prefilter Clean

G140.000.03 Exhaust system Check security

G180.000.04 Engine oil Used oil – take sample and analyse

G202.051.01 Engine coolant pump Check relief bore for obstructions

G203.051.01 Charge air coolant pump Check relief bore for obstructions

Code No. Maintenance echelon W1− Operational checks

G000.000.13 Engine operation Check speed

G000.000.15 Engine operation Check pressures (where gauges are installed)

G000.000.17 Engine operation Check temperatures (where gauges are installed)

G000.000.19 Engine operation Check running noises

G000.000.21 Engine operation Check engine and external pipework for leaks

G083.101.03 Fuel prefilter Drain water and contaminants

G121.052.01 Air filter Check contamination indicator

G124.051.01 Air system Check drain bore for water discharge and obstruction

G140.000.05 Exhaust system Check exhaust gas colour

G140.000.11 Exhaust system Drain (if drain provided)


G202.000.03 Engine coolant Check level

G203.000.03 Charge air coolant Check level

G303.000.01 Compressed air system Drain condensate

G303.000.03 Compressed air system Check operating pressure

G510.070.01 Monitoring system Carry out lamp test

Section D


15340/20 E 00–01

Code No. Maintenance Echelons W 2 3 4 5

G120.000.03 Air system Check intake side for leaks or damage

G180.000.04 Engine oil Used oil – take sample and analyse

G180.000.05 Engine oil Change−For oil category 1 without additional cleaning

every 250 operating hours−For oil category 1 with additional cleaning

every 500 operating hours−For oil category 2 without additional cleaning

every 500 operating hours−For oil category 2 with additional cleaning

every 1 000 operating hours−at least every 2 years

G183.052.03 Engine oil filter Replace−when changing oil

G183.101.01 Centrifugal oil filter Check thickness of deposit layer, clean centrifugesReplace sleeve

G055.050.01 Valve gear Check valve clearances

G083.051.03 Fuel duplex filter Replace filter element

G083.101.09 Fuel prefilter Replace filter element

G083.101.15 Fuel prefilter Clean

G140.000.01 Exhaust system Leak testing

G202.000.05 Engine coolant Take sample and analyze(Change engine coolant – see MTU Fluids and Lubricants Specification)

G202.051.01 Engine coolant pump Check relief bore for obstructions

G203.000.07 Charge air coolant Take and analyse sample, change coolant if necessary(See MTU Fluids and Lubricants Specification)

G203.051.01 Charge air coolant pump Check relief bore for obstructions

G205.051.01 Engine coolant cooler Check cooler elements for external contamination

G205.051.03 Charge air coolant cooler Check cooler elements for external contamination

G252.051.01 Coupling (flywheel end) Check condition (visual inspection)

G309.001.05 Battery Check charge state, fluid viscosity and electrolyte level

G073.051.07 H.P. fuel pump Check relief bore for obstructions

G121.051.03 Air filter Replace

G172.051.09 Starter Check (visual inspection)

G213.051.01 Generator drive Check condition and tension of drive belt

G231.051.01 Engine mounting Check security

G231.051.03 Engine mounting Check condition of resilient mounts

G500.000.09 Engine wiring Check

G510.000.01 Monitoring system Check function of monitoring units

Before starting W5 maintenance services, drain coolant and flush coolant systems.

Valve gear Remove and check rocker arms and valve bridgesCheck rocker arms, rollers, pushrod seats and rocker arm bearings for wear

Cylinder chambers Carry out endoscopic examination of combustion chambers and valves, check wear pat-tern of cylinder liners

Vibration damper Remove and examine, replace if necessary

Fuel injectors Replace

Crankcase breather Replace filter element

Exhaust turbocharger Sight check, check bearing clearance

Intercooler Check for contamination, clean if necessary

Section D


15340/20 E 00–01

D000.000.15 Maintenance Echelon W6

The W6 echelon requires complete disassembly of the engine.Repair / overhaul of the relevant components is determined by the actual condition of the components and theirdimensions, which are referenced to the Tolerance and Wear Limits List.

D000.000.17 Out-of-Service Periods

If the engine is to remain out of service for several weeks, spray engine oil into the engine air intake.Operate the engine shutdown device and use the starting equipment to turn the engine over while performing thisprocedure.The maintenance schedule will then be governed by the time limits specified.In addition, the engine must be turned over by hand once a month.If the engine is to remain out of service for more than 1 month, carry out engine preservation in accordance withSection K.

Section ETroubleshooting

15340/20 E 00–01

Contents

E000.000.01 General 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E000.000.02 Engine does not turn when starter is actuated 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E000.000.03 Engine turns but does not fire 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E000.000.05 Engine fires unevenly 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E000.000.07 Engine does not reach full-load speed 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E000.000.09 Engine speed not steady 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E000.000.11 Compression pressure too low 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E070.000.01 Fuel pressure too low 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E070.000.03 Fuel pressure too high 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E073.051.01 H.P. fuel pump leaking at relief bore 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E080.000.01 Fuel pressure too low 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E101.011.01 Abnormal turbocharger running noises 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E110.000.01 Charge air temperature too high 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E110.000.03 Charge air pressure too low 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E114.051.01 Coolant discharge at intercooler relief bore 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E140.000.01 Exhaust gases black 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E140.000.02 Exhaust gases blue 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E140.000.03 Exhaust gases white 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E172.000.01 Power supply faulty 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E180.000.01 Engine oil consumption abnormally high 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E180.000.03 Engine oil level abnormally high 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E180.000.05 Engine oil temperature too high 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E180.000.07 Engine oil pressure too high 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E180.000.09 Engine oil pressure too low 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E202.000.01 Engine coolant temperature too high 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E202.000.02 Engine coolant temperature too low 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E202.000.05 Engine coolant pressure too low 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E202.000.07 Coolant loss 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E202.000.09 Engine coolant level rising 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E202.051.01 Engine coolant pump leaking at relief bore 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E202.400.01 Preheat temperature too low 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E203.000.01 charge air coolant temperature too high 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E203.000.03 Charge air coolant temperature too low 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E203.000.05 Charge air coolant pressure too low 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E203.000.07 Charge air coolant loss 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E203.000.09 Charge air coolant level 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E203.051.01 Charge air coolant pump leaking at relief bore 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section E Troubleshooting

15340/20 E 00–01

Section E

Page 1

Troubleshooting

15340/20 E 00–01

E000.000.01 General

In Event of Internal Coolant Leakage

Subsequent damage caused by corrosion must be avoided. If the engine cannot be repaired immediately, carry outthe following operations:– Drain coolant and engine oil– Introduce corrosion-inhibitor oil, kerosene or diesel fuel into the crankcase via the oil filler neck until the max. level

is reached– Remove the charge air/coolant manifolds– Remove the fuel injectors– Bar the engine manually and spray corrosion-inhibitor oil, kerosene or diesel fuel into the combustion chambers via

the opening inlet valvesIt is essential to change the engine oil after 50 operating hours as the new oil may be contaminated by coolant resi-dues left in the crankcase.NOTE:

These corrosion-prevention measures are only effective for a few days. Repair of the engine and thorough cleaning of all compon entsshould, therefore, be carried out as soon as possible.

Before restarting the repaired engine, fill with new oil and coolant in compliance with the MTU Fluids and LubricantsSpecification.

Engine Oil Diluted by Fuel

It is essential to change the engine oil before restarting the engine after rectifying the fault. Remove the old oil fromthe crankcase with particular care. Replace engine oil filter.

After Work on Engine

If running gear components, e.g. pistons, piston rings, cylinder liners, etc. have been replaced, carry out the enginerunning-in procedure.

E000.000.02 Engine does not turn when starter is actuated

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Probable causes ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Check ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Remedial Action

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Battery ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Battery charge stateCable connections

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Charge battery, replace if necessaryConnect, replace if necessary

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Starter ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Starter/engine wiringStart repeat relayStarterRing gear

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Connect, replace if necessaryReplaceReplaceReplace


Monitoring (electronics)ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Monitoring start releaseÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

See Operating Instructions of PlantManufacturer


Running gear blocked ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Whether engine can be turned byhand


Repair running gear

Section E

Page 2

Troubleshooting

15340/20 E 00–01

E000.000.03 Engine turns but does not fire



Check ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁRemedial Action


Engine coolant preheat tempera-ture too low


See E202.400.01

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ–


Fuel pressure too low, no start re-lease


See E070.000.01


ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Engine receiving insufficient com-bustion air

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Air filter contamination indicator(G121.051.01)Air filterIntercooler


––Replace (G121.051.01)Clean, replace if necessary


Compression pressure too lowÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Compression pressure(G000.000.31)


See E000.000.11


Engine does not reach firingspeed


BatteryStarter


Charge, replace if necessaryReplace


Engine wiring ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Engine wiring ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁCheck – see G500.000.09

E000.000.05 Engine fires unevenly




Remedial Action




See E202.400.01ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ–


Fuel system is not yet vented ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Whether engine fires steadily aftershort period

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ–


Fuel injection equipment faultyÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

InjectorsPressure maintaining valvesInjection pump solenoid valve


Replace (G075.051.05)Replace


Engine wiringÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Engine wiringÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁCheck – see G500.000.09

E000.000.07 Engine does not reach full-load speed







See E110.000.03



Engine receiving insufficient fuelÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

See under E080.000.01 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ–


Fuel injection equipment faulty ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

InjectorsPressure maintaining valves




H.P. fuel pump generating insuffi-cient pressure




Charge air temperature too highÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

See E110.000.01 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ–


Power take-off too high ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Auxiliary PTO (power consumptiontoo high) dialogue unit/data recorder(speed-sensitive fuel limiter actual/specified injection)


Contact MTU-Service

Section E

Page 3

Troubleshooting

15340/20 E 00–01

E000.000.09 Engine speed not steady





Fuel injection equipment faultyÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

InjectorsPressure maintaining valves




H. P. fuel pump

Suction valve sluggish


Fuel pressure with dialogue unit/data recorder

Check suction valve for ease ofmovement


Contact MTU-Service

Repair, replace if necessary


Speed sensorÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Speed sensor with dialogue unit /data recorder


Replace speed sensor

E000.000.11 Compression pressure too low




Remedial Action


Cylinder head gasket leaking ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Cylinder head gasket ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁReplace


Valve seats in cylinder head wornÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Cylinder head (G000.000.33) ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁRepair if necessary


Valves do not close ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Valve clearances (G055.050.01)Valves


Adjust (G055.050.03)Recondition, replace if necessary


Piston rings worn ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Piston rings ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁReplace


Combustion chamber ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Cylinder liner (G000.000.33)Piston (G000.000.33)


Replace if necessaryReplace if necessary

E070.000.01 Fuel pressure too low





H.P. fuel sensor faultyÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

H.P. fuel with dialogue unit/data re-corder or fault display in monitoringmodule


Replace H.P. fuel sensor


H.P. fuel pump of fuel quantityregulator/pressure regulator(actuating solenoid)


Suction valve

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁRepair, replace if necessary


Pressure relief valve leaking ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Fuel return from pressure reliefvalve


Replace pressure relief valve


Fuel pressure less than 4 barÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ



H.P. fuel pump generating insuffi-cient pressure



ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁReplace H. P. fuel pump


Fuel injector faultyÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ



Replace injector(G075.051.05)

Section E

Page 4

Troubleshooting

15340/20 E 00–01

E070.000.03 Fuel pressure too high





H.P. fuel pump of fuel quantityregulator/pressure regulator(actuating solenoid)


Harsh engine running noise at idling,connector and wiringSuction valve




H.P. fuel sensor not workingÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ


ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁReplace H.P. fuel sensor if necessary

E073.051.01 H.P. fuel pump leaking at relief bore





H.P. fuel pump seals leakingÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

For engine oil or fuel dischargeÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁReplace H. P. fuel pump

E080.000.01 Fuel pressure too low




Remedial Action


Fuel supply blocked ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Shut-off valve in fuel system ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁOpen (G364.000.01)


Fuel level too low ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Fuel supply ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁTop up fuel


Fuel lineÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

SealsÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁRenew seals, replace if necessary


Fuel filter contaminatedÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Fuel prefilter

Fuel duplex filter


Clean filter (G083.101.15), replace ifnecessary (G083.101.09)Replace filter (G083.051.03)


Fuel delivery pump faulty ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Fuel delivery pump, fuel deliverypump drive

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁRepair, replace if necessary


El. fuel delivery pump does notoperate before engine start


Operation and direction of rotation(wiring )Pressure relief valve


Replace safety device, if necessary re-place pump and repair wiringClean, replace if necessary

E101.011.01 Abnormal turbocharger running noisesÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Probable causesÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

CheckÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Remedial Action


Exhaust turbocharger dirty ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Exhaust turbocharger ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁClean


Exhaust turbocharger faulty ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Turbocharger bearing Rotor assembly


ReplaceReplace

E110.000.01 Charge air temperature too high





Intercooler dirtyÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

IntercoolerÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁClean


Charge air coolant temperaturetoo high

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁSee under E203.000.01

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ–

Section E

Page 5

Troubleshooting

15340/20 E 00–01


Remedial ActionÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

CheckÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Probable causes


Antifreeze concentration too highÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Charge air coolant ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁRectify concentration as per specifica-tionsÁÁÁÁÁÁÁÁÁÁÁ


Incorrect corrosion inhibitor (deposits in intercooler)

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Charge air coolant Corrosion inhibitor


Clean coolant system. Treat enginecoolant in accordance with the currentMTU Fluids and Lubricants Specifica-tion, replace intercooler if necessary

E110.000.03 Charge air pressure too low




ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ


ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Air filter-contamination indicator(G121.052.01)Charge air pressure (A000.000.21)Air filterIntercoolerCharge pressure control valveAir flow control flap controlExhaust turbocharger control


–

–Replace (G121.051.01)Clean, replace if necessaryReplaceReplaceReplaceÁÁÁÁÁÁÁÁÁÁÁ


Air flow control flap does not closeif only one exhaust turbochargeris operating


Function of air flow control flap

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁRepair


Pressure sensor faultyÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Pressure sensor with dialogue unit /fault recorder, fault display in moni-toring module




Exhaust turbocharger faulty ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Exhaust turbocharger ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁRepair

E114.051.01 Coolant discharge at intercooler relief boreÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ



Remedial Action


Intercooler leaking ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Whether coolant discharges fromcondensate drain line (not conden-sate)

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁReplace intercooler

E140.000.01 Exhaust gases black







See E110.000.03



Fuel injection equipment faultyÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

See E000.000.07ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁResistance in exhaust systemÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁExhaust backpressure

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁClean exhaust silencerÁÁÁÁÁÁÁÁÁÁÁ


Power take-off too high, engineoverload


Auxiliary PTO (power consumptiontoo high) dialogue unit/data recorder(speed-sensitive fuel limiter actual/specified injection)


Contact MTU-Service

Section E

Page 6

Troubleshooting

15340/20 E 00–01

E140.000.02 Exhaust gases blue




ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Too much oil in combustionchambers


Engine oil level (G180.000.01)Exhaust turbochargerCrankcase breatherValve stem sealsPiston ringsValve guidesCylinder liners


Correct oil level (G180.000.01)RepairReplace (G018.101.03)ReplaceReplaceReplaceReplace


Compression pressure too low ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Compression pressure(G000.000.31)


See E000.000.11

E140.000.03 Exhaust gases white







See E202.400.01


ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁEngine cold

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁEngine coolant temperature

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁSee E202.000.02ÁÁÁÁÁÁÁÁÁÁÁ


Coolant in combustion chambersÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Exhaust turbochargerIntercoolerCylinder head gasketsCylinder heads (G000.000.33)Cylinder liners (G000.000.33)


RepairReplaceReplaceReplace if necessaryReplace if necessary

E172.000.01 Power supply faulty




ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Battery not or insufficientlycharged


Generator drive belt

GeneratorBattery


Adjust tension (G213.051.01), replacedrive belt if necessary (G213.051.05)RepairReplace


Charge indicator lamp does notlight up when engine is inoperat-ive and propulsion control lever isswitched on


Connection cableCharge indicator lampBatteryGenerator voltage regulatorGenerator


SecureReplaceReplaceReplaceRepair

Section E

Page 7

Troubleshooting

15340/20 E 00–01




Probable causes


With engine inoperative, chargeindicator lamp burns brightly butbecomes dark when engine run-ning


Connection cableGenerator


SecureRepair


Charge indicator lamp still lightsup brightly at higher speed


Connection cable from generator tostarter/batteryGenerator driveGenerator


SecureReplaceRepair


Charge indicator lamp flickersÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

GeneratorGenerator drive belt


Tighten cable fixturesAdjust tension (G213.051.01)Replace drive belt if necessary(G213.051.05)ÁÁÁÁÁÁÁÁÁÁÁ


Wiring faultyÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

WiringÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁCheck G500.000.09

E180.000.01 Engine oil consumption abnormally high




ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁCrankcase ventilation faulty

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁCrankcase breather

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁReplaceÁÁÁÁÁÁÁÁÁÁÁ


Engine oil system leaking exter-nally

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

External subassembliesExternal pipeworkEngine oil drainsShaft sealsOil panCrankcase

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Seal pipeworkCheck connections, tighten if necessarySeal (G180.000.05)ReplaceSeal pipeworkRepair


Intake air depression too high ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Air filter-contamination indicator(G121.052.01)


Replace air filter (G121.051.01)


Oil pipes to engine oil heat ex-changer leaking

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁOil in coolant system

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁReplace sealing ringsÁÁÁÁÁÁÁÁÁÁÁ


Exhaust turbocharger leakingÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Exhaust turbochargerÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁReplace bearings


Engine wear ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Valve stem sealPiston ringsValve guidesCylinder liners


ReplaceReplaceReplaceReplace


Combustion chamber ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Combustion chamber (G000.000.33) ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ–

Section E

Page 8

Troubleshooting

15340/20 E 00–01

E180.000.03 Engine oil level abnormally high





Fuel or engine coolant in engineoil


Engine oil quality


See – “Fuel in engine oil”– “Coolant in engine oil”


Fuel in engine oil ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

InjectorsH.P. pumpRelief bore


Replace seal to cylinder headIn event of fluid discharge, replace H.P.pumpÁÁÁÁÁÁÁÁÁÁÁ


Coolant in engine oilÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Cylinder headsCylinder liner sealsCylinder linersCrankcaseCoolant distribution housing


Replace if necessaryReplaceReplaceRepairReplace

E180.000.05 Engine oil temperature too high




ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁEngine oil heat exchanger dirty

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁEngine oil heat exchanger

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁClean, replace if necessaryÁÁÁÁÁÁÁÁÁÁÁ


Engine coolant temperature toohigh


See E202.000.01

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁSee E202.000.01


Temperature sensor faultyÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Temperature sensorÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Check temperature sensor – see RepairManual


Combustion chamberÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Combustion chamber (G000.000.33)ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ–

E180.000.07 Engine oil pressure too high




Remedial Action


Oil viscosity too high ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Engine oil viscosity ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁChange engine oil


Engine oil system ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Engine oil pressure relief valve ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁReplace


Coolant in engine oilÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Engine oil qualityÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁSee under E180.000.03


Pressure sensor faultyÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Pressure sensorÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Check pressure sensor – see RepairManual

E180.000.09 Engine oil pressure too low




Remedial Action


After oil filter change, the pure oilor contaminated oil drain plugs onequipment carrier are still open

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁDrain plugs on equipment carrier

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁClose drain plugsÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁEngine oil level too lowÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁEngine oil level

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁTop up engine oilÁÁÁÁÁÁÁÁÁÁÁ


Engine oil system leaking exter-nally

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁSee under E180.000.01

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁSee under E180.000.01ÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁFuel in engine oilÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁEngine oil quality

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁSee under E180.000.03ÁÁÁÁÁÁÁÁÁÁÁ


Engine oil filter dirtyÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

–ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁReplace filter (G183.052.03)ÁÁÁÁÁÁÁÁÁÁÁ


Engine oil pressure relief valveÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Opening pressureÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁAdjust or replace


Engine oil pump ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Engine oil pump ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁRepair, replace if necessary

Section E

Page 9

Troubleshooting

15340/20 E 00–01




Probable causes


Pressure loss in running gear ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Running gear lubrication points ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁReplace bearings


Pressure sensor faulty ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Pressure sensor ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Check pressure transmitter – see Re-pair Manual

E202.000.01 Engine coolant temperature too high




ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁEngine coolant level too low

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁEngine coolant level

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁTop up engine coolantÁÁÁÁÁÁÁÁÁÁÁ


Engine coolant system contami-nated


Engine coolant systemVent linesEngine coolant heat exchanger


CleanCleanClean, replace if necessary


Engine coolant pressure too lowÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

See E202.000.05 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁSee E202.000.05


Engine coolant thermostatÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Engine coolant thermostatÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁReplace


Temperature sensor faultyÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Temperature sensorÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Check temperature sensor – see Re-pair Manual

E202.000.02 Engine coolant temperature too low




Remedial Action


Engine coolant thermostat ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Engine coolant thermostat ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁReplace


Temperature sensor faulty ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Temperature sensor ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ


E202.000.05 Engine coolant pressure too low





Coolant system not sealedÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Cover closedBreather valve

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁClose coverReplace coverÁÁÁÁÁÁÁÁÁÁÁ


Engine coolant system leakingexternally


External pipeworkExternal subassembliesCoolant drain pointsEngine coolant heat exchanger,crankcase


Check connections, tighten if necessaryCheck connections, tighten if necessarySealRepairCheck for leaks, replace if necessaryÁÁÁÁÁÁÁÁÁÁÁ


Engine coolant level too lowÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Engine coolant levelÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁTop up engine coolant


Engine coolant pump faulty ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Engine coolant pump ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁReplace


Engine coolant system leaking in-ternally


Engine oil qualityCylinder headsInjector protective sleeve gasketCylinder liner gaskets


Change engine oil (G180.000.05)ReplaceReplaceReplace


Pressure sensor faulty ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Pressure sensor ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ


Section E

Page 10

Troubleshooting

15340/20 E 00–01

E202.000.07 Coolant loss





Engine coolant system leaking ex-ternally


See under E202.000.05



Engine coolant system leaking in-ternally


See under E202.000.05



Engine coolant pump leakingÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Engine coolant pumpÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁRepair

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁLevel monitor display error

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁLevel monitor, wiring

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁRepair, replace if necessary

E202.000.09 Engine coolant level rising




Remedial Action


Engine oil in engine coolant ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Engine coolant qualityEngine oil heat exchanger


(G202.000.05)Repair, replace if necessary


Air in engine coolant ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Vent linesIncorrect cylinder compression pres-sures


CleanReplace cylinder head gaskets

E202.051.01 Engine coolant pump leaking at relief bore


Probable causesÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

CheckÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁRemedial Action


Engine coolant pump leakingÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

For oil dischargeFor water discharge


Replace sealing ring.Replace engine coolant pump ifnecessaryReplace rotary sealReplace engine coolant pump ifnecessary

E202.400.01 Preheat temperature too low




Remedial Action


Power supply for preheater ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Power supply available ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁProvide power supply


Preheater not working ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Preheater switched on ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

See Operating Instructions of Manufac-turer

E203.000.01 Charge air coolant temperature too high





Charge air coolant level too lowÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Charge air coolant level ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁTop up charge air coolant


Charge air coolant system con-taminated


Charge air coolant systemVent linesCharge air coolant heat exchanger


CleanCleanClean, replace if necessary


Engine wiring ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Engine wiring ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁCheck (G500.000.09)


Charge air coolant thermostat ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Charge air coolant thermostat ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁReplace


Charge air coolant pressure toolow


See E203.000.05



Temperature sensor faulty ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Temperature sensor ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Repair, replace if necessaryCheck temperature sensor – see RepairManual

Section E

Page 11

Troubleshooting

15340/20 E 00–01

E203.000.03 Charge air coolant temperature too low




ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁCharge air coolant thermostat

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁCharge air coolant thermostat



Temperature sensor faultyÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Temperature sensorÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Repair, replace if necessaryCheck temperature sensor – see RepairManual

E203.000.05 Charge air coolant pressure too low





Charge air coolant system notsealed


Cover closedBreather valve


Close coverReplace cover


Charge air coolant system leakingexternally


External pipeworkExternal subassembliesCharge air coolant drain pointsIntercoolerCharge air coolant heat exchanger


Check connections, tighten if necessaryCheck connections, tighten if necessaryCheck for leaks, replace if necessaryCheck for leaks, replace if necessaryRepair

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁCharge air coolant level too low

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁCharge air coolant level

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁTop up charge air coolantÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁCharge air coolant pump faultyÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁCharge air coolant pump



Charge air coolant system leakinginternally



E203.000.07 Charge air coolant lossÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ



Remedial Action


Charge air coolant system leakingexternally

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

See E203.000.05 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ–


Charge air coolant system leakinginternally



ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁCharge air coolant pump leaking

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁCharge air coolant pump

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁRepairÁÁÁÁÁÁÁÁÁÁÁ


Charge air coolant level trans-mitter display error


Charge air coolant level transmitterÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ


E203.000.09 Charge air coolant level




ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁAir in charge air coolant

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁVent lines

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁClean

E203.051.01 Charge air coolant pump leaking at relief bore




Remedial Action


Charge air coolant pump leakingÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

For oil dischargeEngine coolant discharge


Replace sealing ringReplace rotary sealReplace coolant pump if necessary

Section E

Page 12

Troubleshooting

15340/20 E 00–01

Section GTask Description

15340/20 E 00–01

Contents

G000.000.01 Engine start disabling 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G000.000.03 Engine start release 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G000.000.05 Barring engine manually 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G000.000.07 Barring engine with starting system 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G000.000.09 Engine starting 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G000.000.11 Engine warm-up procedure 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G000.000.13 Engine speed check 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G000.000.15 Engine pressure checks 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G000.000.17 Engine temperature checks 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G000.000.19 Engine running noise check 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G000.000.21 Engine and external lines leak check 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G000.000.23 Engine shutdown 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G000.000.25 Emergency shutdown 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G000.000.27 Attachments security check 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G000.000.29 Attachments, hoses and hose connections check 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G000.000.31 Compression pressure check 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G000.000.33 Cylinder chamber endoscopic examination 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G000.000.39 Cleaning engine externally 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G018.101.01 Crankcase ventilation, oil separator check 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G030.001.01 Engine barring tool installation 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G030.001.03 Engine barring tool removal 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G055.000.01 Valve gear oil supply check 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G055.000.03 Valve gear lubrication 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G055.050.01 Valve clearance check 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G055.050.03 Valve clearance adjustment (valve bridge with adjusting screw M16 (locknut 24 AF)) 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G055.050.03 Valve clearance adjustment (valve bridge with adjusting screw M16 (locknut 24 AF)) 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G055.101.01 Cylinder head cover removal 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G055.101.03 Cylinder head cover installation 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G073.051.07 High-pressure pump, relief bore obstruction check 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G075.051.01 Injector removal 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G075.051.05 Injector replacement 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G075.051.09 Injector installation 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G080.000.03 Fuel system filling 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G080.000.05 Fuel system, fuel delivery pump supply check 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G083.051.03 Fuel duplex filter replacement 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G083.101.01 Fuel prefilter priming 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G083.101.03 Fuel prefilter, water and contaminants draining 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G083.101.09 Fuel prefilter, element and gasket replacement 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G083.101.15 Fuel prefilter cleaning 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section G Task Description

15340/20 E 00–01

G101.011.01 Exhaust turbocharger, engine operation in event of turbocharger failure 37. . . . . . . . . . . . . . . . . .

G101.011.05 Exhaust turbocharger connections check 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G120.000.03 Intake air system, intake side leak and damage check 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G120.000.05 Intake air system, intake depression check 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G120.000.07 Intake air system check 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G121.051.01 Air filter replacement 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G121.052.01 Air filter, contamination indicator position check 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G124.051.01 Charge air line, drain water discharge and obstruction check 40. . . . . . . . . . . . . . . . . . . . . . . . . . .

G124.051.03 Charge air line drain cleaning 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G140.000.01 Exhaust system leak check 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G140.000.03 Exhaust system security check 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G140.000.05 Exhaust system, exhaust gas colour check 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G140.000.07 Exhaust system cleanness check 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G140.000.09 Exhaust system, exhaust backpressure check 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G140.000.11 Exhaust system drain obstruction check 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G146.000.01 Exhaust system, security and exhaust manifold insulation checks 42. . . . . . . . . . . . . . . . . . . . . . .

G172.051.09 Starter condition check (visual inspection) 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G180.000.01 Engine oil level check 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G180.000.03 Engine oil system filling 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G180.000.04 Engine oil – used oil sample extraction and analysis 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G180.000.05 Engine oil change 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G180.000.07 Engine oil draining 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G180.000.09 Corrosion inhibitor oil filling 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G180.000.11 Corrosion inhibitor oil draining 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G183.052.03 Engine oil filter replacement 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G183.101.01 Centrifugal oil filter cleaning 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G202.000.01 Engine coolant system filling 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G202.000.03 Engine coolant level check 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G202.000.05 Engine coolant sample extraction and analysis 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G202.000.07 Engine coolant 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G202.000.09 Engine coolant change 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G202.051.01 Engine coolant pump relief bore check 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G202.400.01 Engine coolant preheating 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G202.401.01 Engine coolant preheating unit initial operation 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G202.651.01 Engine coolant system, vent line obstruction check 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G203.000.01 Charge air coolant system filling 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G203.000.03 Charge air coolant level check 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G203.000.05 Charge air coolant draining 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G203.000.07 Charge air coolant sample extraction and analysis 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G203.051.01 Charge air coolant pump relief bore check 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G203.551.01 Charge air coolant system, vent line obstruction check 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G205.051.01 Engine coolant cooler, external element contamination check 59. . . . . . . . . . . . . . . . . . . . . . . . . . .

G205.051.03 Charge air coolant cooler, external element contamination check 59. . . . . . . . . . . . . . . . . . . . . . . .

G208.101.01 Open breather valve 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section GTask Description

15340/20 E 00–01

G208.101.03 Close breather valve 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G213.051.01 Generator drive, drive belt condition and tension check 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G213.051.05 Generator drive belt installation / replacement 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G213.051.10 Generator connecting bridge removal 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G231.051.01 Engine mount security check 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G231.051.03 Engine mount resilient element check 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G250.000.01 Drive system (driving end) security check 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G252.051.01 Coupling condition check 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G303.000.01 Compressed air system condensate draining 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G303.000.03 Compressed air system, operating pressure check 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G307.001.01 Protective device check 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G309.001.01 Battery check 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G309.001.05 Battery charge state check 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G364.050.01 Fuel supply check 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G364.200.01 Fuel supply opening 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G364.200.03 Fuel supply closing 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G364.200.05 Fuel supply system filling 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G365.000.03 Exhaust system drain obstruction check 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G500.000.01 Engine control system switching on 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G500.000.03 Engine control system switching off 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G500.000.07 Engine control system initial operation 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G500.000.09 Engine wiring check 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G510.000.01 Monitoring system, equipment function check 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section G Task Description

15340/20 E 00–01

Section G

Page 1

Task Description

15340/20 E 00–01

G000.000.01 Engine Start DisablingSwitch off power supply for Engine Control System atcontrol panel / master switch.Disconnect battery.Shut off fuel supply to engine (G364.000.01).Attach “Danger” sign to control panel / master switch.

G000.000.03 Engine Start ReleaseRemove “Danger” sign from control panel / masterswitch.Connect battery.Open fuel supply to engine (G364.000.03).Switch on power supply for Engine Control Systemat control panel / master switch.

G000.000.05 Barring Engine ManuallySpecial tools:Engine barring tool No. F6 555 766

Disable engine start (G000.000.01).Install engine barring tool (G030.001.001).Attach ratchet to engine barring tool.Bar engine manually.

Note:Apart from the normal compression resistance, there shouldbe no abnormal resistance.

Remove ratchet.Remove engine barring tool (G030.001.03).Release engine start (G000.000.03).

G000.000.07 Barring Engine with Starting System

Unguarded rotating and moving engine compo-nents can cause injury.Risk of fatal injury!After working on the engine, check that all protec-tive devices have been reinstalled and all toolsremoved from the engine.Before barring or starting the engine, ensure thatnobody is in the danger zone.

DANGER

Section G

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Task Description

15340/20 E 00–01

Do not actuate starter for longer than max. 10 sec-onds. Before repeating a start attempt, wait at least20 seconds so that the starter cools down.Bar engine without firing.

G000.000.09 Engine Starting


DANGER

When the preparatory work has been carried out inaccordance with the Operating Instructions(Section C), the engine can be restarted.Note: Always start the engine under no-load conditions.

Carry out engine starting procedure – see MTU Elek-tronik Documentation / control panel manufacturer’sdocumentation.Do not actuate starter for longer than max. 10 sec-onds. Before repeating a start attempt, wait at least20 seconds so that the starter cools down.Do not increase engine speed until oil pressure isdisplayed.Note: If the engine oil pressure is not built up within the timespecified in Engine Monitoring, the engine is shut down bythe Engine Control System.

Determine cause and rectify.

G000.000.11 Engine Warm-Up ProcedureIncrease engine load as slowly as possible until cool-ant temperature of 40 °C is reached.NOTE: Do not operate the engine at full speed until enginecoolant temperature reaches 40 �C.

G000.000.13 Engine Speed checkCheck idle and full-load speeds.

G000.000.15 Engine Pressure ChecksCheck engine oil pressure.Specified values (A000.000.21)

Section G

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Task Description

15340/20 E 00–01

G000.000.17 Engine Temperature ChecksCheck engine coolant temperature.Specified values (A000.000.21)

G000.000.19 Engine Running Noise CheckRun engine at idling speed.Apart from the usual running noises, no abnormalsounds must be heard.

G000.000.21 Engine and External Lines Leak Check

DANGERExhaust gases in closed areas are harmful tohealth.Risk of poisoning!Ensure that engine room is well ventilated.Repair leaking exhaust pipework immediately.

Run engine under load.Check engine and all pipework for leaks.If leaks are found, shut down engine.When the engine has cooled, rectify the cause.Note: Never tighten lines when under pressure.

G000.000.23 Engine Shutdown

NOTE: Never shut down engine directly from full-load oper-ation, as this may result in overheating and wear of the en-gine components.

Before shutting down the engine, run the engine atidling speed until falling and then constant tempera-tures are indicated.Press shutdown button on control panel.

Section G

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Task Description

15340/20 E 00–01

G000.000.25 Emergency Shutdown

Press emergency shutdown button on control panel.

G000.000.27 Attachments Security CheckExhaust system (G146.000.01)PTO system, driving end (G250.000.01)Engine (G231.051.01)

G000.000.29 Attachments, Hoses and Hose Connections CheckCheck all hoses and hose connections on the enginefor condition and leaks.Immediately replace hoses showing signs of scuf-fing, aging or cracking.

Section G

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Task Description

15340/20 E 00–01

G000.000.31 Compression Pressure CheckSpecial tools:Compression measuring unitConnector: Y4343683Threaded union: Y4343684Connector: Y4343685

Adapter for compression measuring unit.Shut off fuel supply to engine (G364.000.01).Remove cylinder head cover (G055.101.01).Remove injector (G075.051.01).Bar engine with starting system to remove any loosecarbon deposits from the combustion chambers(G000.000.07).

Install adapter with sealing ring in the injectionnozzle bore and tighten with clamping element.Connect the compression pressure recorder to theadapter.Bar engine with starting system until no further pres-sure rise is indicated.Read off and note down the values.

Actuate vent valve.Carry out check in same way on all other cylinders.Determine mean value of compression pressures:The difference between the mean value and the indi-vidually measured compression pressures must notexceed 3 bar (300 kPa).Install injector (G075.051.09).

Install cylinder head cover (G055.101.03).Open fuel supply to engine (G364.000.03).

Section G

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Task Description

15340/20 E 00–01

G000.000.33 Cylinder Chamber Endoscopic Examination

NOTE: For engines in service, if possible carry out a combus-tion chamber endoscopic examination after operation underload.

Use an endoscope with an adequate light rating and a prism(5) which pivots 95 � (total viewing angle 140 �), see –No. I–.

If an endoscope with pivoting prism is not available, individ-ual endoscopes with prism settings of 0 �, 45� and 90� arerequired, see –No. II–.

Max. possible diameter (a): 16 mm.

Before the endoscopic examination:

Remove injector (G075.051.01).Bar engine with starting system (G000.000.07).Disable engine start (G000.000.01).Install engine barring tool (G030.001.01).Use engine barring tool to turn engine until, for therespective cylinder,– the piston is at BDC for cylinder liner inspection.– the piston is in a position which allows unrestricted

examination of the piston crown, lower side of thecylinder head and valves.

– all valves are open or closed for inspection of valvesand valve seats.

Endoscopic examination:

Connect endoscope to light source (4) and insert itthrough the cylinder head (injector bore) to the com-bustion chamber.Use the focussing device (2) to focus the eyepiece(1) and adjuster ring (3) to align the prism (5) withthe area under inspection.Visually assess the cylinder liners, piston crowns,underside of the cylinder heads and valves.

To do this, rotate the endoscope through 360° ineach case and set the prism accordingly.

Section G

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Task Description

15340/20 E 00–01

Assessment

Cylinder liners are OK when:– the honing pattern is clearly visible.– no or only locally limited polished areas are evident

in the honing structure.– no or only minor scoring is evident (minor scoring

can be caused during piston installation).– no or only minor corrosion is evident (film rust after

extended out-of-service periods is possible).Piston crowns are OK when:– fuel injector spray pattern is clearly visible.– only minor carbon or oil deposits are evident.– no or only minor corrosion is evident.Cylinder heads and valves are OK when:– only minor carbon or oil deposits are evident.– no or only minor corrosion is evident.– only minor pitting is evident on valves and valve

seats.

– the valves close fully.

Note:If extensive wear or damage due to mechanical, chemical orthermal action is found, or the inspection results are other-wise suspect: remove the affected cylinder heads and re-check, repair or replace the individual components asnecessary.

After the endoscopic examination

Remove engine barring tool (G030.001.03).Install injector (G075.051.09).

Release engine start (G000.000.03).

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G000.000.39 Cleaning Engine Externally

WARNINGWhen working with high-pressure and steam jets,never aim at persons, animals, electrical or elec-tronic equipment.Risk of injury and scalding!Wear protective clothing, protective gloves and pro-tective goggles / safety mask.

To remove deposits and for cleaning, use only clean-ing agents containing no chemicals which may dam-age light metal, nonferrous metal, steel, grey castiron and elastomers.Clean the engine only at places where there is anappropriate oil separator (environmental protection).Before using the H.P. cleaner or steam jet, read therespective operating instructions, paying particularattention to safety instructions.

For cleaning externally with the H.P. jet, use only aflat-jet nozzle.

Carry out external cleaning as follows:

Disable engine start (G000.000.01).

To loosen dirt:

Spray on a thin coating of cleaning agent and allow 1 to 5 minutes, depending on the degree of conta-mination, for it to react.

To remove dirt:

Use the H.P. jet to spray off the loosened dirt.NOTE: During exterior engine cleaning with a high-pressurecleaner or steam jet, the jet pressure must not exceed 100 bar(1450 PSI).

Do not go any closer than 20 cm (8 inches) to theobject that is being sprayed.The temperature of the cleaning agent must not riseabove a max. of 80 °C (176 °F).NOTE: Moisture penetrating electrical components (tempera-ture transmitter, pressure transmitter, terminal) may lead tomalfunctions and engine failure.


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Safety measures when carrying out welding operations on machine plants with MTU engines.

Never use the engine as an earth connection. (This prevents the welding current passing throughthe engine and causing fires or melting at bearings,which may lead to pitting or other material damage).Never carry out welding work on the engine or en-gine-mounted units.

Never position the welding power supply cable ad-jacent to, or crossing MTU plant wiring harnesses.(The welding current can be induced in the wiringharnesses, which could damage the electrical unit).The ground connection for the welding unit must notbe attached more than 60 cm from the welding point.If components (e.g. exhaust manifold) are to bewelded, they must first be removed from the engine.When carrying out work on MTU electronics compo-nents, it is not necessary to remove connectors pro-vided that the master switch for power supply hasbeen moved from “ON” to “OFF” and the cable isdisconnected from the battery negative and positiveterminals.

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G018.101.01 Crankcase Ventilation, Oil Separator Check

Check oil separator (visual inspection) for externaldamage and oil discharge from breather (arrow).If external damage is detected, or if oil emergesthrough defective rubber diaphragms, always replacethe oil separator.NOTE: A slight film of oil at the breather is normal.

G030.001.01 Engine Barring Tool InstallationSpecial tools:Engine barring tool No. F6 555 766

Disable engine start (G000.000.01).Remove cover from flywheel housing.Engage engine barring tool (1) with ring gear (2) andattach to flywheel housing.

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G030.001.03 Engine Barring Tool Removal

Remove engine barring tool from flywheel housing.Screw cover to flywheel housing.Release engine start (G000.000.03).

G055.000.01 Valve Gear Oil Supply Check

CAUTIONWith the engine running, hot oil emerges at therocker arm bearings under high pressure.Risk of eye injury and burning!Run engine only when cylinder head covers areinstalled.

Shut down engine (G000.000.23).Disable engine start (G000.000.01).Remove cylinder head cover (G055.101.01).Check that the rocker arms and the cylinder headcover (inside) are coated with oil.Install cylinder head cover (G055.101.03).Release engine start (G000.000.03).

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G055.000.03 Valve Gear LubricationNote: The oil chambers must be filled with oil during initialoperation, extended out-of-service periods and after cleaningvalve gear.

Disable engine start (G000.000.01).Remove cylinder head cover (G055.101.01).

Fill oil chambers of the valve bridges with oil.Fill oil chambers of the rocker arms and adjustingscrews with oil.Install cylinder head cover (G055.101.03).Release engine start (G000.000.03).

G055.050.01 Valve Clearance CheckSpecial tools:Valve clearance adjusting gauge: Y2 0010 128Engine barring tool: F6 555 766

NOTE: Check with the valve closed and when coolant tem-perature does not exceed 40 �C.

Disable engine start (G000.000.01).

Remove cylinder head cover (G055.101.01).Install engine barring tool (G030.001.01).

Checking valve clearance in two crankshaft posi-tions

Rotate crankshaft with barring tool in engine direc-tion of rotation until marking TDC-A1 at starting ringgear and arrow on flywheel housing are aligned.

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Adjust all valve clearances at two crankshaft posi-tions (firing TDC and overlap TDC, cylinder A1) asper the diagram shown. The crankshaft must beturned in the engine direction of rotation.If the rocker arms are unloaded on cylinder A1, thepiston is in firing TDC.1 = Firing TDC for cylinder A1If the rocker arms are loaded on cylinder A1, the pis-ton is in overlap TDC.2 = Overlap TDC for cylinder A1X = Exhaust valveO = Inlet valve

Inlet valves: long rocker arm.Exhaust valves: short rocker arm.Valve clearance (A055.050.01).Use feeler gauge to check distance between valvebridge and rocker arm.If deviation from specified value is more than 0.05 mm, adjust valve clearance (G055.050.03).NOTE: It must be possible to just pull the feeler gaugethrough the gap.

Remove engine barring tool (G030.001.03).Install cylinder head cover (G055.101.03).Release engine start (G000.000.03).

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G055.050.03 Valve Clearance Adjustment (Valve Bridge with Adjusting Screw M16 (Locknut 24 AF))

NOTE: Before starting adjustment, it is essential to check whether the valve bridges are provided with adjusting screw M16(locknut 24 AF) or adjusting screws M12 (locknut 19 AF). Then select the appropriate Task Description.

Special tools:Valve clearance adjusting gauge: Y2 0010 128Retaining device: F6 557 950Engine barring tool: F6 555 766

Adjust with the valve closed and when coolant temperaturedoes not exceed 40 �C.

NOTE: Before valve clearance is adjusted, it is essential thatthe valve bridge be checked.

Disable engine start (G000.000.01).Remove cylinder head cover (G055.101.01).Install engine barring tool (G030.001.01).

Adjusting valve clearance in two crankshaft posi-tions



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Checking valve bridge adjustment

Use feeler gauge to determine distance betweenvalve bridge and rocker arm.NOTE: It must be possible to just pull the feeler gaugethrough the gap.

Place feeler gauge with determined value betweenvalve bridge and valve stem (B).Using a second feeler gauge, measure distance be-tween opposite valve stem and valve bridge (A).A feeler gauge thicker / thinner by more than�0.05 mm must not fit.Do not adjust valve bridge if deviation from deter-mined value (B) to (A) valve stem end to valve bridgeis less than �0.05 mm.Valve bridge must be adjusted if deviation from de-termined value is greater than �0.05 mm.

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Adjusting valve bridge

CAUTION

To release the locknut, the valve bridge must beheld firmly with the retaining device, otherwisethe valves will be deformed.

Install retaining device.Insert locating pin of retaining device into oil bore ofvalve bridge.NOTE: The locating pin can be inserted into the valve bridgeoil bore only when the valves are closed / unloaded.

Release locknut.

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Withdraw locating pin of retaining device from oilbore of valve bridge.

Place a feeler gauge of determined distance be-tween valve bridge and valve stem (A) and (B), e.g. 0.20 mm.The valve bridge must be adjusted so that bothfeeler gauges can just be pulled through.Hold adjusting screw securely in position with Allenkey and fit locknut by hand on valve bridge.Insert locating pin of retaining device into oil bore ofvalve bridge.NOTE: The locknut and adjusting screw must move easily.

Use torque wrench to tighten locknut, holding adjust-ing screw firmly with Allen key.The adjusting screw must not turn.Tightening torque = 90 Nm + 9 NmLubricant = Engine oilWithdraw locating pin of retaining device from oilbore of valve bridge.

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Again check valve bridge adjustment.Remove retaining device.

CAUTION

Before barring the engine, the retaining devicemust be removed, otherwise with a securedvalve bridge the valve gear or retaining devicewill be damaged.

Valve clearance adjustment

Inlet valves: long rocker arm.Exhaust valves: short rocker arm.Valve clearance, see (A055.050.01).Release locknut (1) and adjusting screw (2) withAllen key.Insert feeler gauge between valve bridge and rockerarm.Set adjusting screw so that feeler gauge just passesthrough gap when locknut is tightened.Tighten locknut with torque wrench, holding adjustingscrew firm.NOTE: The locknut and adjusting screw must move easily.

Tightening torque = 90 Nm + 9 Nm.Lubricant = Engine oilAgain check valve clearance.

Remove engine barring tool (G030.001.03).Install cylinder head cover (G055.101.03).Release engine start (G000.000.03).

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G055.050.03 Valve Clearance Adjustment (Valve Bridge with Adjusting Screw M16 (Locknut 24 AF))

NOTE: Before starting adjustment, it is essential to check whether the valve bridges are provided with adjusting screw M16 (locknut 24 AF) or adjusting screws M12 (locknut 19 AF). Then select the appropriate Task Description.

Special tools:Valve clearance adjusting gauge: Y2 0010 128Engine barring tool: F6 555 766

Adjust with the valve closed and when coolant temperaturedoes not exceed 40 �C:

Note:Before valve clearance is adjusted, it is essential that thevalve bridge be checked.

Disable engine start (G000.000.01).Remove cylinder head cover (G055.101.01).

Install engine barring tool (G030.001.01).

Adjusting valve clearance in two crankshaft posi-tions



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Checking valve bridge adjustment

Use feeler gauge to determine distance betweenvalve bridge and rocker arm.

Note:It must be possible to just pull the feeler gauge through thegap.

Place feeler gauge with determined value betweenvalve bridge and valve stem (B).Using a second feeler gauge, measure distance be-tween opposite valve stem and valve bridge (A).A feeler gauge thicker / thinner by more than �0.05 mm must not fit.The valve bridge must be adjusted if deviation fromdetermined value (B) to (A) valve stem end to valvebridge is greater than �0.05 mm.

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Adjusting valve bridge

CAUTION

When releasing the locknut, the valve bridge mustbe held firmly, as otherwise the valves will be bent.

Hold valve bridge (1) firmly in position with open-endwrench and release locknut (2).

Place a feeler gauge of determined distance be-tween valve bridge and valve stem (A) and (B), e.g. 0.20 mm.The valve bridge must be adjusted so that bothfeeler gauges can just be pulled through.Hold adjusting screw securely in position with Allenkey and fit locknut by hand on valve bridge.

Note:The locknut and adjusting screw must be free to move.

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Using torque wrench, tighten locknut (2); for this pur-pose hold valve bridge (1) in position with open-endwrench.Tightening torque = 35 Nm + 5 NmLubricant = Engine oil

Again check valve bridge adjustment.

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Valve clearance adjustment

Inlet valves: long rocker arm.Exhaust valves: short rocker arm.Valve clearance, see (A055.050.01).Release locknut (1) and adjusting screw (2) withAllen key.Insert feeler gauge between valve bridge and rockerarm.Set adjusting screw so that feeler gauge just passesthrough gap when locknut is tightened.Tighten locknut with torque wrench, holding adjustingscrew firm.

Note:The locknut and adjusting screw must move easily.

Tightening torque = 90 Nm + 9 Nm.Lubricant = Engine oilAgain check valve clearance.Remove engine barring tool (G030.001.03).Install cylinder head cover (G055.101.03).Release engine start (G000.000.03).

G055.101.01 Cylinder Head Cover Removal

WARNINGWith the engine running, hot oil emerges at therocker arm bearings under high pressure.Risk of eye injury and burning!Run engine only when cylinder head covers areinstalled.

Disable engine start (G000.000.01).Remove screws.Remove cylinder head cover from cylinder head.

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G055.101.03 Cylinder Head Cover Installation

Clean mating faces.Check that profile gasket in cylinder head cover is inperfect condition, replace if necessary.Place cylinder head cover on cylinder head.Insert screws with washers and tighten with torquewrench.Tightening torque = 45 Nm

Lubricant = Engine oilRelease engine start (G000.000.03).

G073.051.07 High-Pressure Pump, Relief Bore Obstruction Check

Check relief bore for oil and fuel discharge (visualinspection).Clean the bore if it is contaminated.NOTE: Replace H.P. fuel pump if oil and / or fuel emergesfrom the relief bore.

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G075.051.01 Injector Removal

WARNINGFuels are combustible.Fire hazard!When working on the fuel system:no naked flameno electrical sparksdo not smokedo not spill fuel.

Note:The fuel injectors can only be replaced completely, as theinjection nozzle can only be replaced at MTU.

Special tools:Extractor sleeve for injector: F3 0377 769Extractor: F6557991

Disable engine start (G000.000.01).Shut off fuel supply to engine (G364.000.01).Remove cylinder head cover (G055.101.01).

Remove fuel return line on cylinder head and on fuelcollecting line.

Note:Fuel must not penetrate the cylinder chamber.

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Release the cable terminal threaded connection onthe injector and remove cable terminals.

Remove screw (1) together with hold-down clamp(2).

Unscrew H.P. fuel line (2) from injector (1) and con-nector (limiting valve) (3) and remove H.P. line.

Note:The H.P. line must not be bent.

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Place extractor sleeve (section 1) (4) on injector (1).Fit section 2 (2) over section 1 and turn to correctposition – see next illustration.Secure section 2 with hex nut (3).

Starting point for section 2 (2) is position “a” (2 o’clock)End point is position “b” (12 o’clock).

Screw threaded rod (3) into extractor sleeve (5) andsecure with hex nut (4).Place extractor (2) on cylinder head.Turn nut (1) clockwise to withdraw injector.Remove special tool.Remove injector manually.

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Remove CE support ring (1) from injector or use wirehook to remove from cylinder head.Remove O-rings (2) from injector.Cover all connections and bores, or seal with suit-able plugs.

Note:Fuel must not penetrate the cylinder.

G075.051.05 Injector Replacement


Remove injectors (G075.051.01).Install injectors (G075.051.09).

Note:The fuel injectors for replacement can be ordered from MTU.

G075.051.09 Injector Installation


Special tools:Press-fitting lever for injector: F6 557 952Press-fitting sleeve for injector: F3 0378 403Lever: F6 555 197

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Coat new O-rings with petroleum jelly and fit on in-jector.

Check sealing surface on cylinder head (heat protec-tion sleeve) for contamination, clean if necessary.Fit new CE Ring (2) with grease on injector (1).

Ensure that CE ring is correctly positioned.

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Note:Before installation, remove all plugs and covers.

Insert fuel injector (1) into cylinder head, ensuringthe H.P. line connection is correctly aligned.Fit press-fitting sleeve (2).

Lock press-fitting tool (1) between pushrods.Release palm grip (3) and move pressure element(2) to correct position for press-fitting sleeve.Secure palm grip and press injector (4) with press-fit-ting tool into cylinder head.Remove press-fitting tool.

Install hold-down clamp (2), positioning correctly, andfit hex screw (1) by hand.

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Tighten screw of hold-down clamp with torquewrench.Tightening torque: 5 Nm to 10 NmLubricant = Engine oil

Coat new O-ring (2) with petroleum jelly and fit onH.P. line (3).Install H.P. line (3) at injector (1) and connector (limit-ing valve) (4).

Note:The H.P. line must not be bent. Ensure that the installationposition is correct.

Using torque wrench, tighten H.P. line (2) at injector(1) and connector (limiting valve) (3).Tightening torque: 5 Nm to 10 NmLubricant = Engine oil


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Tighten hex screw of hold-down clamp with torquewrench.Tightening torque: 100 Nm + 10 NmLubricant = Engine oil

Using torque wrench, tighten threaded connection ofH.P. line at injector (1) and connector (limiting valve)(2).Tightening torque: 100 Nm + 10 NmLubricant = Engine oil


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Fit cable terminals below the screws on injector andtighten.Tightening torque: 1.0 Nm +/– 0.2 NmInstall cylinder head cover (G055.101.03).

Attach fuel return line between cylinder head andmanifold and tighten.Open fuel supply to engine (G364.000.03).Release engine start (G000.000.03).

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G080.000.03 Fuel System Filling

WARNING

Fuels are combustible.Fire hazard!When working on the fuel system:no naked flameno electrical sparksdo not smokedo not spill fuel.

Special tools:Filling device: B8 014 485 22

On initial operation/restart or after a fuel filterchange, the L.P. fuel system must be refilled.

Disable engine start (G000.000.01).Fill L.P. fuel system.Remove flushing line (1) from the H.P. pump (3) andrelease from filter block (2).Connect the fuel return hose of the filling device tothe H.P. pump (3).Connect the filling device fuel supply to connection(P) of the filter block.NOTE: When filling, a fuel pressure of between 0.5 and 1.5 barmust be achieved.

The fuel system is filled by the hand pump untilbubble-free fuel is seen to emerge in the hose.

Filling deviceFuel system (1)Fuel return (2)

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Remove fuel return hose from the H.P. pump (3).Screw flushing line (1) onto the H.P. pump (3) andfilter block (2) and tighten.Remove the filling device fuel supply from connec-tion (P) of the filter block.Seal filling connection (P) with blanking plug andtighten.Release engine start (G000.000.03).

The H.P. system is filled when the engine is started.

Disposal of Hazardous MaterialsFluids and lubricants (e.g. oils, greases, treated enginecoolant, fuels), cleaning agents and numerous auxiliarymaterials are an environmental hazard and therefore consti-tute hazardous materials.When disposing of these hazardous materials, always follow themanufacturer’s instructions, general environmental protectionregulations and local legal specifications.Under no circumstances must even small amounts of hazardousmaterials be allowed to drain into water, or be discarded or dis-posed of outdoors.Leaked hazardous materials must immediately be absorbed withsuitable bonding agents and disposed of in accordance withregulations in appropriate vessels. The contents of these con-tainers must be specified.

G080.000.05 Fuel System, Fuel Delivery Pump Supply CheckConnect pressure gauge before fuel delivery pump.Run engine at full load and read off pressure gauge.Specified value, see (A000.000.21).Remove pressure gauge.

G083.051.03 Fuel Duplex Filter Replacement

WARNING


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Special tools:Strap wrench F3 0006 199

Remove filter and dispose of in accordance withlocal regulations.Clean sealing surface at connector.Check sealing ring of new filter and moisten withfuel.Install filter and tighten by hand.Replace second filter in same way.


G083.101.01 Fuel Prefilter Priming

WARNING


Fuel prefilter not supplied by MTU.See Operating Instructions of Plant Manufacturer.

G083.101.03 Fuel Prefilter, Water and Contaminants DrainingFuel prefilter not supplied by MTU.See Operating Instructions of Plant Manufacturer.

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G083.101.09 Fuel Prefilter, Element and Gasket Replacement

WARNING



G083.101.15 Fuel Prefilter Cleaning

WARNING



G101.011.01 Exhaust Turbocharger, Engine Operation in Event of Turbocharger FailureIn the event of turbocharger failure, determine thecause and assess whether the engine can continuein operation without risk.If, in the event of turbocharger failure (e.g. if rotor isseized), the engine must continue in operation, runthe engine only under partial load.Run the engine in this condition only until it is poss-ible to replace or repair the turbocharger.

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G101.011.05 Exhaust Turbocharger Connections Check

Check exhaust connections for leaks.

Check oil supply and return lines for leaks.

G120.000.03 Intake Air System, Intake Side Leak and Damage CheckCheck intake side of engine for condition and leakswith the engine running.

G120.000.05 Intake Air System, Intake Depression CheckConnect U-pipe pressure gauges to turbocharger airintake housings.Run engine at full load and read off indicated pres-sures. Specified value, see (A000.000.21).Remove U-pipe pressure gauges.

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G120.000.07 Intake Air System CheckCheck that cover is removed.Check for cleanliness.

G121.051.01 Air Filter Replacement

Disable engine start (G000.000.01).Remove guard and loose material on intake housingor air filter.Remove contamination indicator (4).Release clamp (2).Remove air filter (3), clean or dispose of in accord-ance with local regulations.

Clean connection on air flow-control flap housing (1).Install new air filter with clamp.Install contamination indicator with reset signal ring(G121.052.01).Release engine start (G000.000.03).

G121.052.01 Air Filter, Contamination Indicator Position Check

Check

Check position of signal ring (1) (visual check).If signal ring is fully visible, replace air filter(G121.051.01).

Reset

Press reset button (2) to return signal ring to normalposition.

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G124.051.01 Charge Air Line, Drain Water Discharge and Obstruction Check

WARNING

Engine coolant is hot and under pressure.Risk of injury!Wear protective gloves.

Engine noise above 85 dB(A).Risk of damage to hearing!Wear ear protectors.

ËËËË

Coolant discharge check

If the coolant is continuously discharged and thecoolant level falling, the intercooler is leaking.If a leaking intercooler cannot be repaired immedi-ately, before starting the engine:– Remove injector (G075.051.01).– Bar engine manually (G000.000.05).

– Bar engine with starting system (G000.000.07) andblow out combustion chambers.

NOTE: If the intercooler is leaking, activate engine only in anemergency.

Obstruction check

NOTE: Check drain bore on engine A and B sides.

With the engine running, oil-containing air mustemerge at the drain bore.

G124.051.03 Charge Air Line Drain Cleaning

Compressed air is air compressed under pressure.Risk of injury!If compressed air is used for blowing out or blow-drying compo-nents, always wear protective goggles or safety mask.Compressed air must not be aimed at parts of the body.The pressure must not exceed 3.0 bar.Compressed air is air compressed under pressure. Risk of injury!

CAUTION

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Disable engine start (G000.000.01).Clean drain bore, blow out with compressed air andcheck for obstructions.NOTE: Clean and check drain bore on engine A and B sides.


G140.000.01 Exhaust System Leak CheckCheck engine exhaust system (visual inspection) forleaks and damage.

G140.000.03 Exhaust System Security CheckWhen the engine is cold, check tightness of securingscrews by torque wrench application.

G140.000.05 Exhaust System, Exhaust Gas Colour CheckExhaust gases light grey: good combustion.Exhaust gases black: incomplete combustion.Exhaust gases blue: excessive engine oil in combus-tion chamber.Exhaust gases white: unburnt fuel.

G140.000.07 Exhaust System Cleanness CheckCheck that cover is removed.Check for cleanliness.

G140.000.09 Exhaust System, Exhaust Backpressure CheckConnect U-pipe pressure gauge to exhaust manifold.Run engine at full load and read off indicated pres-sures.Specified value, see (A000.000.21).Remove U-pipe pressure gauges.

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G140.000.11 Exhaust System Drain Obstruction CheckCheck drain for obstruction (if applicable).Drain exhaust system (if drain provided).See Operating Instructions of Plant Manufacturer.

G146.000.01 Exhaust System, Security and Exhaust Manifold Insulation ChecksCheck tightness of the exhaust system securingscrews (after engine) by torque wrench applicationand the insulation for damage by visual inspection.

G172.051.09 Starter Condition Check (Visual Inspection)Disable engine start (G000.000.01).Check starter for mechanical damage.Check security of starter securing screws.Check security and condition of all cable connec-tions.Check all electric cables for damage.Release engine start (G000.000.03).

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G180.000.01 Engine Oil Level Check

Checking before starting engine

Withdraw dipstick from guide tube and wipe.Carry out oil level check.Engine oil must be between Min. and Max. marks.If necessary, top up oil to Max. mark.Insert dipstick in guide tube.

Checking after engine shutdown

Remove the oil dipstick from the guide tube 5 min-utes after engine shutdown.Engine oil must be between Min. and Max. marks.If necessary, top up oil to Max. mark.Insert dipstick in guide tube.

G180.000.03 Engine Oil System Filling

Note: Always use MTU-approved engine oil, see MTU Fluidsand Lubricants Specification.

Turn cover counterclockwise until the cover of the oilfiller neck can be removed.Pour engine oil in at oil filler neck up to Max. mark onoil filler neck.Start engine and run at idle for approx. 1 to 2 min-utes.Shut down engine and after approx. 5 minutes with-draw dipstick from guide tube and wipe.Carry out oil level check.Engine oil must be between Min. and Max. marks.If necessary, top up oil to Max. mark.NOTE: Do not fill engine oil above the Max. mark.

Insert dipstick in guide tube.Reinstall oil filler neck cover.

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G180.000.04 Engine Oil – Used Oil Sample Extraction and Analysis

DANGER

Engine oil is hot and can contain combustion resi-dues which are harmful to health.Risk of injury!Wear protective gloves.Avoid extended and intensive contact with skin.Do not inhale oil vapour.

ËËËË

Open shut-off cock with engine running and engineat operating temperature.Drain approx. 2 litres engine oil to flush out the oilsludge in the shut-off cock.Drain approx. 1 litre of engine oil coolant into a cleancontainer.Using equipment and chemicals from the MTU TestKit, inspect the engine oil for dispersion capability(spot test), coolant content and fuel dilution – seePublication for MTU Test Kit.


G180.000.05 Engine Oil ChangeDisable engine start (G000.000.01).Drain engine oil (G180.000.07).Replace engine oil filter (G183.052.03).Pour in new engine oil (G180.000.03).Release engine start (G000.000.03).Note: After each engine oil change and filter replacement, barthe engine with the starting system (G000.000.07).

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G180.000.07 Engine Oil Draining

DANGER


ËËËË

NOTE: Drain engine oil with the engine at operating tempera-ture.

Provide a suitable container to collect and dispose ofthe engine oil.Drain engine oil from oil pan at oil drain plug.Install oil drain plug with a new sealing ring.

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Drain remaining oil from equipment carrier.Install oil drain plug with a new sealing ring.


G180.000.09 Corrosion Inhibitor Oil FillingNOTE: Always use only approved corrosion inhibitor oil – seeMTU Fluids and Lubricants Specifications.

Fill engine with corrosion inhibitor oil in same way asengine oil (G180.000.03).

G180.000.11 Corrosion Inhibitor Oil DrainingDrain corrosion inhibitor oil in same way as engineoil (G180.000.07).NOTE: Drain the corrosion inhibitor oil with the engine atoperating temperature.

Section G

Page 47

Task Description

15340/20 E 00–01

G183.052.03 Engine Oil Filter Replacement

DANGER


ËËËË

Special tools:Chain wrench F3 0006 199

Remove with chain wrench.Drain remaining oil out of the filters into a container.Clean sealing surface at connector.Check sealing ring of new engine oil filter and coatwith oil.Install new engine oil filter and tighten by hand.Replace other engine oil filters in same way.


Section G

Page 48

Task Description

15340/20 E 00–01

G183.101.01 Centrifugal Oil Filter Cleaning

DANGER


ËËËË

Disable engine start (G000.000.01).Release Tommy nut.Release band clamp.

Release band clamp.Remove housing cover.Remove sealing ring.

Section G

Page 49

Task Description

15340/20 E 00–01

Carefully remove complete rotor from housing.Drain oil.

Note: The rotor must not be clamped in a vice.

Release knurled nut on rotor cap.Press out rotor lower section downwards.

Carefully remove rotor cap from standpipe.Remove sealing ring.

Section G

Page 50

Task Description

15340/20 E 00–01

Compressed air is air compressed under pressure.Risk of injury!If compressed air is used for blowing out or blow-drying compo-nents, always wear protective goggles or safety mask.Compressed air must not be aimed at parts of the body.The pressure must not exceed 3.0 bar.Compressed air is air compressed under pressure. Risk of injury!

CAUTION

Remove insertion sleeve.Assess the layer thickness and weight of the oil resi-dues on the sleeve and compare to the values notedduring the previous check.Note: Layer thickness max 20 mm (approx. 1800 gr.)

If the two values deviate greatly, the oil must bechanged.Perform the next oil change earlier than scheduled.Clean rotor cap, standpipe and rotor base.Wash components, blow out with compressed air.Insert new insertion sleeve.

Insert new sealing ring and fit on rotor lower section.

Section G

Page 51

Task Description

15340/20 E 00–01

Assemble rotor cap and standpipe.Tighten knurled nut on rotor cap.

Insert rotor in housing lower section.

Fit new sealing ring.Mount housing cover.Tighten Tommy nut.Tighten band clamp.Release engine start (G000.000.03).When the engine is again started, check the centrifu-gal oil filters for leaks.

Section G

Page 52

Task Description

15340/20 E 00–01


G202.000.01 Engine Coolant System Filling

WARNING

Engine coolant is hot and under pressure.Risk of injury!Wear protective gloves.

ËË

Open breather valve (G208.101.01), so that the aircan escape from the engine when the coolant sys-tem is filled.

Section G

Page 53

Task Description

15340/20 E 00–01

Note:Always use only treated coolant in accordance with MTUFluids and Lubricant Specifications.

Never pour cold coolant into a hot engine.

If, in an emergency, untreated water is used to top up thecoolant system, the coolant concentration must be checkedand rectified at the earliest opportunity.

Connect suitable hose to the drain valve (arrow).Open drain valve and pour in engine coolant via thehose.Close drain valve.Check engine coolant level (G202.000.03).Close breather valve (G208.101.03).Run engine a number of minutes at idling speed.

Check engine coolant level (G202.000.03).

G202.000.03 Engine Coolant Level CheckNote:The Min. coolant level is automatically monitored by the En-gine Control System.

Via level sensor

Switch on engine control system (G500.000.01) andcheck indicator.

WARNING

Engine coolant is hot and under pressure.Risk of injury!Wear protective gloves.ËË

ËË

Note:Always use only treated coolant in accordance with MTUFluids and Lubricant Specifications.

Never pour cold coolant into a hot engine.


Open breather valve of coolant expansion tank(G208.101.01).If fluid is too low, add only treated coolant – see(G202.000.01).Close breather valve (G208.101.03).

Section G

Page 54

Task Description

15340/20 E 00–01

G202.000.05 Engine Coolant Sample Extraction and Analysis

WARNING


ËË

Disable engine start (G000.000.01).Open drain valve.Drain a small quantity of coolant to flush the drainpoint.Drain approx. 1 litre of engine coolant into a cleancontainer.Close drain valve.

Check engine coolant level (G202.000.03).Using the equipment and chemicals in the MTU TestKit, examine the coolant for:– antifreeze– corrosion inhibitor– pH valueSee MTU Test Kit instructions.Change engine coolant according to the coolant op-erating times in the Fluids and Lubricants Specifica-tion A001061.Release engine start (G000.000.03).

Section G

Page 55

Task Description

15340/20 E 00–01

G202.000.07 Engine Coolant

WARNING


ËËDisable engine start (G000.000.01).

Note:Drain engine coolant when engine has cooled.

Open breather valve (G208.101.01).

Provide a suitable container to collect and dispose ofthe coolant.Open lower drain valve on coolant inlet elbow anddrain coolant.Drain residual coolant from engine via the upperdrain point on crankcase (A and B sides).Seal all drain points.Close breather valve (G208.101.03).

Dispose of engine coolant.


G202.000.09 Engine Coolant ChangeDrain engine coolant (G202.000.07).Fill engine coolant system (G202.000.01).

Section G

Page 56

Task Description

15340/20 E 00–01

G202.051.01 Engine Coolant Pump Relief Bore Check

Check relief bore for oil and coolant discharge (visualinspection).Clean the relief bore if it is dirty.NOTE: If oil and / or coolant emerge from the relief bore, re-pair the engine coolant pump.

G202.400.01 Engine Coolant PreheatingSwitch on preheating unit.Check function of coolant circulating pump.Preheat engine coolant to preheat temperature (A000.000.21).Switch off the preheating unit.

G202.401.01 Engine Coolant Preheating Unit Initial OperationEngine coolant preheating unit not supplied by MTU.Carry out tasks as specified by Manufacturer.

G202.651.01 Engine Coolant System, Vent Line Obstruction CheckRemove vent lines and blow out with compressedair.Install vent lines.

Section G

Page 57

Task Description

15340/20 E 00–01

G203.000.01 Charge Air Coolant System Filling

NOTE: Always use treated coolant in accordance with MTUFluids and Lubricants Specifications.

Open breather valve (G208.101.01).

Pour in treated engine coolant via filler neck.Check charge air coolant level (G202.000.03).Close breather valve (G208.101.03).Run engine a number of minutes at idling speed.Check charge air coolant level (G202.000.03).

G203.000.03 Charge Air Coolant Level CheckNOTE: The Min. coolant level is automatically monitored bythe Engine Control System.

Via level sensor

Switch on Engine Control System (ECS) and checkdisplay – see MTU Elektronik Documentation.

WARNING


ËË

Open breather valve of coolant expansion tank(G208.101.01).Coolant expansion tank is not supplied by MTU.In event of drop in coolant level only fill with treatedengine coolant.NOTE: Never pour cold coolant into a hot engine.


Close breather valve (G208.101.03).

Section G

Page 58

Task Description

15340/20 E 00–01

G203.000.05 Charge Air Coolant Draining

WARNING



Note:Drain engine coolant when engine has cooled.

Open breather valve (G208.101.01).Provide a suitable container to collect and dispose ofthe coolant.Drain the coolant expansion tank via the filler neck.Drain engine coolant from cooling system via thedrain points.Seal all drain points.Dispose of coolant.


G203.000.07 Charge Air Coolant Sample Extraction and AnalysisDisable engine start (G000.000.01).Open blanking plug.By means of the blanking union, drain approx. 1 litrecoolant into a clean container.Close blanking plug.Check charge air coolant level (G203.000.03).Using MTU Test Kit, check coolant for:

– Antifreeze– Corrosion-inhibitor oil– Check pH value.Release engine start (G000.000.03).

Section G

Page 59

Task Description

15340/20 E 00–01

G203.051.01 Charge Air Coolant Pump Relief Bore Check

Check relief bore for oil and coolant discharge (visualinspection).Clean the relief bore if it is dirty.NOTE: If oil and / or coolant emerge from the relief bore, re-pair the charge air coolant pump.

G203.551.01 Charge Air Coolant System, Vent Line Obstruction CheckVent lines not supplied by MTU.Carry out tasks as specified by Manufacturer.

G205.051.01 Engine Coolant Cooler, External Element Contamination CheckCoolant cooler not delivered by MTU.Carry out tasks as specified by Manufacturer.

G205.051.03 Charge Air Coolant Cooler, External Element Contamination CheckCoolant cooler not delivered by MTU.Carry out tasks as specified by Manufacturer.

Section G

Page 60

Task Description

15340/20 E 00–01

G208.101.01 Open Breather Valve

WARNING



Turn breather valve counterclockwise to first stop.Allow pressure to escape.Continue to turn breather valve counterclockwiseand remove.

G208.101.03 Close Breather Valve

Check that breather valve is in perfect condition.Clean sealing surfaces.Fit breather valve and turn clockwise as far as it willgo.Release engine start (G000.000.03).

Section G

Page 61

Task Description

15340/20 E 00–01

G213.051.01 Generator Drive, Drive Belt Condition and Tension Check


DANGER

Special tools:V-ribbed belt tension tester

Condition check

Disable engine start (G000.000.01).Remove guard plate.Check V-ribbed belts for cracks, oil, overheating andwear; clean or replace as necessary.NOTE: Solvents such as petroleum or benzol must not beused. Sharp-edged objects are not cleaning agents.

F2130001 0a

Damage pattern of V-ribbed belts.

Normal wear.One or two cracks in the rib, measuring approx. 25 mm (1 inch), usually appear after long-term use;the V-ribbed belts can continue to be used.

Section G

Page 62

Task Description

15340/20 E 00–01

F2130002 0a

The V-ribbed belts must be replaced if the ribs arebroken around the entire circumference.

F2130003 0a

The V-ribbed belt must be replaced immediately ifthe ribbed material has broken through and the ribsare broken around the entire circumference.

Tension check

Position the V-ribbed belt tension tester on the V-ribbed belt midway between the belt pulleys.Read off the value from the scale.

Settings

New V-ribbed belts: 57–70 kg (125–155 lbs)

Used V-ribbed belts: 57–70 kg (125–155 lbs)

Section G

Page 63

Task Description

15340/20 E 00–01

If the measured value does not correspond to thespecified set value, V-ribbed belt tension must becorrected.Release locknut (2) and securing screws (1).Secure V-ribbed belt with clamping nut (3).Check V-ribbed belt tension.Tighten locknut (2).

Tighten securing screws (1).Install guard plate.Release engine start (G000.000.03).

G213.051.05 Generator Drive Belt Installation / Replacement

Disable engine start (G000.000.01).Remove guard plate.Release securing screws (1).Release locknut (2) and clamping nut (3) so that bothV-ribbed belts can be removed.Check that V-ribbed belt pulleys are clean; clean ifnecessary.

Fit new V-ribbed belts.Secure V-ribbed belt with clamping nut (3).Set V-ribbed belt tension, see under (G213.051.01).Tighten locknut (2).Tighten securing screws (1).Install guard plate.Release engine start (G000.000.03).NOTE: After the engine has run for 30 minutes, again checkV-ribbed belt tension; readjust if necessary. After the enginehas run for 8 hours, again check V-ribbed belt tension; read-just if necessary.

Section G

Page 64

Task Description

15340/20 E 00–01

G213.051.10 Generator Connecting Bridge Removal

Remove bridge between cable connections 61 andB–.

G231.051.01 Engine Mount Security CheckCheck tightness of all securing screws by torquewrench application.

G231.051.03 Engine Mount Resilient Element CheckCheck resilient mounts for cracks and deformation(visual inspection).Replace cracked rubber elements.NOTE: Wipe rubber surfaces with dry cloth only, never cleanwith organic detergents.

G250.000.01 Drive System (Driving End) Security CheckDisable engine start (G000.000.01).Remove guard plates from driving end.Check tightness of drive system, driving end secur-ing screws by torque wrench application.Install guard plate (driving end).Release engine start (G000.000.03).

G252.051.01 Coupling Condition CheckDisable engine start (G000.000.01).Coupling is not supplied by MTU. Carry out tasksspecified by Manufacturer.


Section G

Page 65

Task Description

15340/20 E 00–01

G303.000.01 Compressed Air System Condensate DrainingOpen drain valves on compressed air system andallow condensate to drain.NOTE: The pressure drop on the pressure gauge must not bemore than approx. 1 bar.

Close drain valves.Drain condensate from compressed air tank in ac-cordance with manufacturer’s specifications.

G303.000.03 Compressed Air System, Operating Pressure CheckOpen shut-off valve before pressure gauge.Check compressed air at pressure gauge.Always fill compressed air tank to maximum pres-sure.NOTE: Examine compressed air systems regularly; clean andsubject them to a pressure test.Observe the local safety regulations.

G307.001.01 Protective Device CheckCheck that all guards are correctly installed on thegenerator and PTO systems, driving end and freeend.Guard plates on PTO system, driving end.

G309.001.01 Battery Check

WARNINGBattery acid is highly caustic and may splash intoeyes.During filling or charging, explosive gases maydevelop.Metal objects between battery terminals causeshort-circuiting.Risk of explosion, burning and short-circuit-ing!No naked flames.No electrical sparks.Do not smoke.Wear rubber gloves, protective goggles and pro-tective clothing.Before starting work, provide clean water for wash-ing.If battery filling gets into eyes, rinse immediatelywith water and seek medical attention.Do not place metal objects on battery.

The battery is not supplied by MTU. Carry out tasksspecified by manufacturer.

G309.001.05 Battery Charge State CheckCheck fluid viscosity and electrolyte level. Carry outtasks specified by manufacturer.

Section G

Page 66

Task Description

15340/20 E 00–01

G364.050.01 Fuel Supply Check

WARNING


Check fuel supply in fuel tank, top up if necessary.NOTE: A full fuel tank reduces condensation and the growthof bacteria.

G364.200.01 Fuel Supply OpeningClose shut-off valve in supply line before fuel pre-filter.

G364.200.03 Fuel Supply ClosingOpen shut-off valve in supply line before fuel pre-filter.

G364.200.05 Fuel Supply System FillingFill fuel intake line to engine with fuel.

G365.000.03 Exhaust System Drain Obstruction CheckExhaust system not supplied by MTU.

G500.000.01 Engine Control System Switching OnMove power supply master switch from “Off” to “On”.

G500.000.03 Engine Control System Switching OffMove power supply master switch from “On” to “Off”.

G500.000.07 Engine Control System Initial OperationSee MTU Elektronik Documentation.

Section G

Page 67

Task Description

15340/20 E 00–01

G500.000.09 Engine Wiring Check

WARNINGBattery acid is highly caustic and may splash intoeyes.During filling or charging, explosive gases maydevelop.Metal objects between battery terminals causeshort-circuiting.Risk of explosion, burning and short-circuit-ing!No naked flames.No electrical sparks.Do not smoke.Wear rubber gloves, protective goggles and pro-tective clothing.Before starting work, provide clean water for wash-ing.If battery filling gets into eyes, rinse immediatelywith water and seek medical attention.Do not place metal objects on battery.

Disable engine start (G000.000.01).Disconnect battery.

Check security of all plug-in connections as follows:Try to turn the bayonet union nuts of the connectorsby hand using little force.If this is possible, tighten the respective bayonetunion nut clockwise with pliers.Note: It is not sufficient to tighten the bayonet unionnuts by hand. There is the risk that the lock does notproperly engage and the connector may then comeloose during engine operation. Pliers must thereforebe used to turn the union nut.Check all plug-in connections for security and dam-age at:– Governor– Speed, pressure and temperature transmitters– Level sensor– Actuating solenoid on H.P. fuel pump– Solenoid 3-way valvesFor other plug-in connections, see Manufacturer’sElectronics Manual.

Check that all wiring is installed free of kinks and ten-sion. Check that cable clamps are secure and clean.Check all mechanical fixtures and electrical connec-tions.– Starter– Generator– BatteryConnect battery.Release engine start (G000.000.03).

Section G

Page 68

Task Description

15340/20 E 00–01

G510.000.01 Monitoring System, Equipment Function CheckCheck operation of level sensor on engine coolantexpansion tank – see Electronics Documentation.The temperature transmitter, speed transmitter andpressure transmitter are continuously monitored withthe Integrated Test System (ITS) in the Engine Con-trol System. If a monitoring unit fails, a warning isgiven – see Electronics Documentation.

Section KPreservation

15340/20 E 00–01

Contents

K000.000.01 Preservation – Preface 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

K000.000.03 Preservation 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

K000.000.05 Represervation 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

K000.000.07 Depreservation 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

K000.000.09 Description of services 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section K Preservation

15340/20 E 00–01

Section KPreservationPage 1

15340/20 E 00–01

K000.000.01 Preservation – PrefaceLow operating and maintenance costs as well as operational reliability and availability depend on maintenance andservicing being carried out in compliance with our specifications and instructions.These instructions differentiate between preservation, represervation and depreservation.Preservation must be carried out on– New or overhauled engines, following the test run preservation is carried out by DDC/MTU, but may be omitted if

the engine is to be put into immediate operation.– Engines being withdrawn from operation for a period exceeding three months, as soon after the final operating

period as possible.Preservation is adequate for storage for a period up to– 12 months under favourable storage conditions.

– 6 months under unfavourable storage conditions, e.g. high humidity, salt-laden atmosphere, pronounced tempera-ture fluctuations, etc.

On conclusion of the preservation period, carry out represervation at the required intervals.Represervation is adequate for a storage period of up to– 6 months under favourable storage conditions.– 3 months under unfavourable storage conditions, e.g. high humidity, salt-laden atmosphere, pronounced tempera-

ture fluctuations, etc.Engines in special packing do not need to be represerved as long as the permissible relative humidity is not ex-ceeded in the packaging enclosure room.– See inspection specification for Special Packing.Only preservation agents approved by the manufacturer may be used for preservation and represervation.

– See Fluids and Lubricants Specification.These services may be omitted if– they cannot be completed due to operationally required special equipment (e.g. test stand).– the specified component is not fitted on the diesel engine.Before- and after-operation services on the engine must be carried out in accordance with the Operating Instruc-tions (Section C).NOTE:

The operations and tasks required for preservation, represervation and depreservation must be carried out in the recommended se -quence.

They are specified by 3-digit and 8-digit codes.

Task descriptions:

3-digit codes in Section K

8-digit codes in Section G

Section K PreservationPage 2

15340/20 E 00–01

K000.000.03 Preservation

Code No. Task DescriptionG000.000.23 Shut down engine

G000.000.01 Disable engine start

G180.000.07 Drain engine oil

K001 Clean engine

G180.000.09 Fill corrosion inhibitor oil into engine

K002 Preserve fuel system

G000.000.03 Release engine start

G000.000.09 Start engine

K003 Preserve engine coolant system

K004 Perform preservation run

G000.000.23 Shut down engine

G000.000.07 Bar engine with starting system and

K005 spray corrosion inhibitor oil into air manifolds

G000.000.01 Disable engine start

K006 Spray corrosion inhibitor oil onto turbocharger compressor wheels

– Connect fuel suction line to fuel system

G180.000.11 Draw off corrosion inhibitor oil from engine

K007 Seal engine exhaust system

K008 Seal engine air system

K009 Preserve engine externally

K000.000.05 Represervation

Code No. Task DescriptionK001 Clean engine

G000.000.05 Bar engine manually, and

K005 spray corrosion inhibitor oil into air manifolds



K000.000.07 Depreservation

Code No. Task DescriptionK001 Clean engine

G055.101.01 Remove cylinder head covers

G000.000.07 Turn engine on starter, and

K011 check valve gear

G055.101.03 Install cylinder head covers

G180.000.11 Draw off corrosion inhibitor oil (residue) from engine

K012 Remove seals from engine air system

K013 Remove seals from engine exhaust system

– For other services see Operating Instructions

Section KPreservationPage 3

15340/20 E 00–01

K000.000.09 Description of Services

K001 Clean engine

Clean engine externally and check for corrosion. If necessary, remove rust spots and renew paint.NOTE:

Do not use organic detergents to clean rubber or synthetic components. Wipe with a dry cloth only.

K002 Preserve fuel system

Connect the fuel delivery pump suction line to a separate tank,which should be filled with– injection pump testing oil, to DIN ISO 4113 or– Diesel fuel with 10% corrosion inhibitor oil, for internal preservation.If possible, preserve the fuel system when the engine is hot. (Preservation is carried out during the preservationrun, 004)

K003 Preserve engine coolant system

NOTE:

Engine coolant systems are usually filled with prepared engine coolant and, therefore, protected from corrosion.

Fill engine coolant system with coolant containing 2% corrosion inhibitor oil or 50% antifreeze. The coolant pre-serves the engine during the preservation run.The coolant should be allowed to remain in the engine to provide protection against corrosion.Only drain the coolant at ambient temperatures

– below 0 °C for coolant / corrosion inhibitor oil emulsions– Below –40 °C for coolant / antifreeze emulsions

K004 Perform preservation run

Run the engine approximately 20 minutes at idling speed.

K005 Spray corrosion inhibitor oil into air manifolds

Remove plugs from air manifolds.Turn engine on starter.Spray corrosion inhibitor oil into air manifolds.Insert plugs into air manifolds.

– Use only sealing rings which are in perfect condition.


Disconnect air pipework from turbochargers.Spray compressor wheels and compressor housing with corrosion inhibitor oil while rotating the compressorwheels.Reconnect air pipework.

K007 Seal engine exhaust system

Cover the exhaust outlets at the turbocharger with blanking plates so that they are sealed against air and moisturepenetration.NOTE:

In order to ensure that these plates are not overlooked when the engine is returned to service, they must be shaped in such a w ay asto project beyond the flanges at a certain point. Paint the projections bright red and fold them back.

K008 Seal engine air system

Cover the air filter with plastic sheet.

Section K PreservationPage 4

15340/20 E 00–01


Spray or brush preservation agent on all exposed metalwork.NOTE:

Do not apply grease to the sealing lips of radial-lip oil seals. Seal all openings in pipework, housings and turbochargers, wit h suitable,plugs or plates.

K010 Spray V-belt pulleys with corrosion inhibitor oil

Spray corrosion inhibitor oil onto belt running surfaces on generator, crankshaft PTO, fan wheel PTO and tensionroller.

K011 Check and preserve valve gear

Check valve gear and fuel injection components for moisture, corrosion or other evidence of damage.Spray corrosion inhibitor oil into housing and onto valve gear and fuel injection system components.

K012 Remove seals from engine air system

Remove plastic sheet from air filters.

K013 Remove seals from engine exhaust system

Remove blanking plates from exhaust outlets.

Note:When removing the plates, ensure that no foreign particles fall into the engine.

Reconnect bellows.

Section TTransportation Locking Device

15340/20 E 00–01

Contents

T036.051.01 Crankshaft transportation locking device 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section T Transportation Locking Device

15340/20 E 00–01

Section TTransportation Locking DevicePage 1

15340/20 E 00–01

T036.051.01 Crankshaft Transportation Locking Device

Version 1

Applicable to: 062.546/02; 870 041/08; 870 042/03, /04, /05, /06, /07, /08; 870 043/03

GeneralThe transportation locking devices protect the crankshaft mounts against damage caused by impacts and vibra-tions during engine transportation.

Transportation Locking Device– must be left in place until just before engine installation.– must, in the meantime, be removed only for engine barring (e.g. during preservation work) and immediately rein-

stalled.– must always be installed before the engine is transported.

Transportation Locking Device RemovalCompletely remove transportation locking devices at the driving end (–Page 2–) and free end (–Page 3–) of theengine.Store the transportation locking devices (including fixtures) together with this documentation for possible reinstalla-tion at a later date.

Transportation Locking Device InstallationTransportation locking device at driving end:Install device, as shown in the drawing (Page 2), on flywheel housing (1) and flywheel (2).

Transportation locking device at free end:Install locking device as shown in illustration (Page 3) on equipment carrier (1) and crankshaft.Fit nuts (3) on both sides of carrier (2) and then tighten.

Attach this documentation to the engine where it can clearly be seen.

Section T Transportation Locking DevicePage 2

15340/20 E 00–01

Section TTransportation Locking DevicePage 3

15340/20 E 00–01

Section T Transportation Locking DevicePage 4

15340/20 E 00–01

Section ?Keyword Index

Page 1

15340/20 E 00–01

AAbnormal turbocharger running noises, Troubleshooting, Section E, 4

After shutdown, C000.000.11, Section C, 3

Air filter replacement, G121.051.01, Section G, 39

Air filter, contamination indicator position check, G121.052.01, Section G, 39

Application, D000.000.05, Section D, 2

Attachments security check, G000.000.27, Section G, 4

Attachments, hoses and hose connections check, G000.000.29, Section G, 4

BBarring engine manually, G000.000.05, Section G, 1

Barring engine with starting system, G000.000.07, Section G, 1

Battery charge state check, G309.001.05, Section G, 65

Battery check, G309.001.01, Section G, 65

CCentrifugal oil filter cleaning, G183.101.01, Section G, 48

Charge air coolant cooler, external element contamination check, G205.051.01, Section G, 59

Charge air coolant draining, G203.000.05, Section G, 58

Charge air coolant level check, G203.000.03, Section G, 57

Charge air coolant level rising, Troubleshooting, Section E, 11

Charge air coolant loss, Troubleshooting, Section E, 11

Charge air coolant pressure too low, Troubleshooting, Section E, 11

Charge air coolant pump leaking at relief bore, Troubleshooting, Section E, 11

Charge air coolant pump relief bore check, Troubleshooting, Section E, 59

Charge air coolant sample extraction and analysis, G180.000.04, Section G, 58

Charge air coolant system filling, G203.000.01, Section G, 57

Charge air coolant system, vent line obstruction check, G202.651.01, Section G, 59

Charge air coolant temperature too high, Troubleshooting, Section E, 10

Charge air coolant temperature too low, Troubleshooting, Section E, 11

Charge air line drain cleaning, G124.051.03, Section G, 40

Charge air line, drain water discharge and obstruction check, G124.051.01, Section G, 40

Charge air pressure too low, Troubleshooting, Section E, 5

Charge air temperature too high, Troubleshooting, Section E, 4

Cleaning engine externally, G000.000.39, Section G, 8

Close breather valve, G208.101.03, Section G, 60

Compressed air system condensate draining, G303.000.01, Section G, 65

Compressed air system, operating pressure check, G303.000.03, Section G, 65

Compression pressure check, G000.000.31, Section G, 5

Compression pressure too low, Troubleshooting, Section E, 3

Section ? Keyword IndexPage 2

15340/20 E 00–01

Coolant capacity, A202.000.01, Section A, 7

Coolant discharge at intercooler relief bore, Troubleshooting, Section E, 5

Coolant loss, Troubleshooting, Section E, 10

Corrosion inhibitor oil draining, G180.000.11, Section G, 46

Corrosion inhibitor oil filling, G180.000.09, Section G, 46

Coupling condition check, G252.051.01, Section G, 64

Crankcase ventilation, oil separator check, G018.101.01, Section G, 10

Crankshaft transportation locking device, T000.000.01, Section T, 1

Cylinder chamber endoscopic examination, G000.000.33, Section G, 6

Cylinder head cover installation, G055.101.03, Section G, 24

Cylinder head cover removal, G055.101.01, Section G, 23

DDepreservation, K000.000.07, Section K, 2

Description of services, K000.000.09, Section K, 3

Drain engine coolant, G202.000.07, Section G, 55

Drive system (driving end) security check, G250.000.01, Section G, 64

EEmergency shutdown, G000.000.25, Section G, 4

Engine and exhaust noise, A000.000.25, Section A, 6

Engine and external lines leak check, G000.000.21, Section G, 3

Engine barring tool installation , G030.001.01, Section G, 10

Engine barring tool removal , G030.001.03, Section G, 11

Engine control system initial operation, G500.000.07, Section G, 66

Engine control system switching off, G500.000.01, Section G, 66

Engine control system switching on, G500.000.01, Section G, 66

Engine coolant change, G202.000.09, Section G, 55

Engine coolant cooler, external element contamination check, G205.051.01, Section G, 59

Engine coolant level check, G202.000.03, Section G, 53

Engine coolant level rising, Troubleshooting, Section E, 10

Engine coolant preheating, G202.400.01, Section G, 56

Engine coolant preheating unit initial operation, G202.401.01, Section G, 56

Engine coolant pressure too low, Troubleshooting, Section E, 9

Engine coolant pump leaking at relief bore , Troubleshooting, Section E, 10

Engine coolant pump relief bore check, Troubleshooting, Section E, 56

Engine coolant sample extraction and analysis, G180.000.04, Section G, 54

Engine coolant system filling, G202.000.01, Section G, 52

Engine coolant system, vent line obstruction check, G202.651.01, Section G, 56

Engine coolant temperature too high, Troubleshooting, Section E, 9

Engine coolant temperature too low, Troubleshooting, Section E, 9


Page 3

15340/20 E 00–01

Engine does not reach full-load speed, Troubleshooting, Section E, 2

Engine does not turn when starter is actuated, Troubleshooting, Section E, 1

Engine fires unevenly, Troubleshooting, Section E, 2

Engine layout, A000.000.01, Section A, 1

Engine model designation, A000.000.03, Section A, 2

Engine mount resilient element check, G231.051.03, Section G, 64

Engine mount security check, G231.051.01, Section G, 64

Engine oil – used oil sample extraction and analysis, G180.000.04, Section G, 44

Engine oil change, G180.000.05, Section G, 44

Engine oil consumption abnormally high, Troubleshooting, Section E, 7

Engine oil draining, G180.000.07, Section G, 45

Engine oil filter replacement, G183.052.03, Section G, 47

Engine oil level abnormally high, Troubleshooting, Section E, 8

Engine oil level check, G180.000.01, Section G, 43

Engine oil pressure too high, Troubleshooting, Section E, 8

Engine oil pressure too low, Troubleshooting, Section E, 8

Engine oil system filling, G180.000.03, Section G, 43

Engine oil temperature too high, Troubleshooting, Section E, 8

Engine power, A000.000.19, Section A, 4

Engine pressure checks, G000.000.15, Section G, 2

Engine running noise check, G000.000.19, Section G, 3

Engine shutdown, G000.000.23, Section G, 3

Engine side and cylinder designations, A000.000.05, Section A, 3

Engine speed check, G000.000.13, Section G, 2

Engine speed not steady, Troubleshooting, Section E, 3

Engine start disabling, G000.000.01, Section G, 1

Engine start release, G000.000.03, Section G, 1

Engine starting, G000.000.09, Section G, 2

Engine starting system, A170.000.01, Section A, 7

Engine temperature checks, G000.000.17, Section G, 3

Engine turns but does not fire, Troubleshooting, Section E, 2

Engine warm-up procedure, G000.000.11, Section G, 2

Engine weight, A000.000.13, Section A, 3

Engine wiring check, G500.000.09, Section G, 67

Exhaust gases black, Troubleshooting, Section E, 5

Exhaust gases blue, Troubleshooting, Section E, 6

Exhaust gases white, Troubleshooting, Section E, 6

Exhaust system cleanness check, G140.000.07, Section G, 41

Exhaust system drain obstruction check, G140.000.11, G365.000.03, Section G, 42, 66

Exhaust system leak check, G140.000.01, Section G, 41

Exhaust system security check, G140.000.03, Section G, 41

Exhaust system, exhaust backpressure check, G140.000.09, Section G, 41


15340/20 E 00–01

Exhaust system, exhaust gas colour check, G140.000.05, Section G, 41

Exhaust system, security and exhaust manifold insulation checks, G146.000.01, Section G, 42

Exhaust turbocharger connections check, G101.011.05, Section G, 38

Exhaust turbocharger, engine operation in event of turbocharger failure, G101.011.01, Section G, 37

FFuel duplex filter replacement, G083.051.03, Section G, 35

Fuel prefilter cleaning, G083.101.15, Section G, 37

Fuel prefilter priming, G083.101.01, Section G, 36

Fuel prefilter, element and gasket replacement, G083.101.09, Section G, 37

Fuel prefilter, water and contaminants draining, G083.101.03, Section G, 36

Fuel pressure too high, Troubleshooting, Section E, 4

Fuel pressure too low, Troubleshooting, Section E, 3, 4

Fuel supply check, G364.050.01, Section G, 66

Fuel supply closing, G364.200.03, Section G, 66

Fuel supply opening, G364.200.01, Section G, 66

Fuel supply system filling, G364.200.05, Section G, 66

Fuel system filling, G080.000.03, Section G, 34

Fuel system, fuel delivery pump supply check, G080.000.05, Section G, 35

GGeneral, Troubleshooting, Section E, 1

Generator connecting bridge removal, G213.051.10, Section G, 64

Generator drive belt installation / replacement, G213.051.05, Section G, 63

Generator drive, drive belt condition and tension check, G213.051.01, Section G, 61

HH.P. fuel pump leaking at relief bore, Troubleshooting, Section E, 4

High-pressure pump, relief bore obstruction check, G073.051.07, Section G, 24

IInitial operation, C000.000.05, Section C, 2

Injector installation, G075.051.09, Section G, 28

Injector removal, G075.051.01, Section G, 25

Injector replacement, G075.051.05, Section G, 28

Intake air system check, G120.000.07, Section G, 39

Intake air system, intake depression check, G120.000.05, Section G, 38

Intake air system, intake side leak and damage check, G120.000.03, Section G, 38


Page 5

15340/20 E 00–01

MMain engine dimensions, A000.000.09, Section A, 3

Main engine specifications, A000.000.17, Section A, 3

Maintenance echelon W6, D000.000.15, Section D, 4

Maintenance frequency chart, D000.000.07, Section D, 2

Maintenance schedule, D000.000.11, Section D, 2

Maintenance schedule – preface, D000.000.01, Section D, 1

Maintenance system, D000.000.03, Section D, 1

Monitoring system, equipment function check, G510.000.01, Section G, 68

OOil capacity, A180.000.01, Section A, 7

Open breather valve, G208.101.01, Section G, 60

Operating instructions – preface, C000.000.01, Section C, 1

Operational checks –maintenance echelon W1–, C000.000.07, Section C, 3

Operational data, A000.000.21, Section A, 5

Out-of-service period, C000.000.13, Section C, 3

Out-of-service periods, D000.000.17, Section D, 4

PPower supply faulty, Troubleshooting, Section E, 6

Preheat temperature too low , Troubleshooting, Section E, 10

Preparations for initial operation, C000.000.03, Section C, 2

Preservation, K000.000.03, Section K, 2

Preservation – Preface, K000.000.01, Section K, 1

Protective device check, G307.001.01, Section G, 65

RRepreservation, K000.000.05, Section K, 2

SShutdown, C000.000.09, Section C, 3

Starter condition check (visual inspection), G172.051.09, Section G, 42

TTiming data (valve clearance adjusted), A050.000.01, Section A, 6


15340/20 E 00–01

VValve clearance adjustment (valve bridge with adjusting screw M16 (locknut 24 AF)), G055.050.03, Section G,

14, 19

Valve clearance check, G055.050.01, Section G, 12

Valve clearances, A055.050.01, Section A, 6

Valve gear lubrication, G055.000.03, Section G, 12

Valve gear oil supply check, G055.000.01, Section G, 11

Documents

DT_MUE_00057_US_1