MTU Diesel Engine Use and Maintenance Manual

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 into Summary
sections.
These sections are listed on Product Summary
this page.
age. A
Each section has its own Engine layout, technical data
Table of Contents
Contents.
C Operating Instructions
Task descriptions
D Maintenance Schedule
Time schedule and maintenance

task chart
Using the Table of Contents E Troubleshooting

to trace an entry
Causes, remedies
Table of Contents
(general)
G Task Description
Section
Inspection and maintenance tasks
Contents
K Preservation
Heading
Using the Alphabetical Engine preservation
Index to trace an entry
T Transportation Locking Device
Search term
Drawing, instructions
Section
Heading ? Keyword Index
Alphabetical index of key terms
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provided you complete the reverse of this receipt card and return it to us.
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Friedrichshafen GmbH
Department VLT
88040 Friedrichshafen
Germany
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Safety Instructions Section !
Page 1
Safety, Accident Prevention and Environmental Protection Instructions
These instructions must be read and followed by every person involved in

operation, maintenance or transportation of the machinery plant.
General
In addition to the instructions in this publication, the applicable country-specific legislation and other compulsory
regulations 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 is
considered improper use. The manufacturer will accept no liability for any resultant damage. The responsibility is
borne 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, repair
or transportation.
The personnel must be instructed on engine operation and repair by means of this publication, and in particular the
safety instructions must be explained.
This is especially important for personnel who work on the engine only on an occasional basis. Such personnel
must be given instructions repeatedly.
Spare Parts
Only genuine MTU spare parts must be used to replace components or assemblies. In event of any damaged
caused 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.
15340/20 E 00–01
Section ! Safety Instructions
Page 2
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 pedestal
or 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 engine
mounts.
Secure the engine against tilting during transportation. The engine must be especially secured against slipping or
tilting 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 in
the 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), a
maximum 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.
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Page 3
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” in
operating 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 these
components 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 the
engine.
Fluids emerging under high pressure can penetrate clothing and skin and may cause serious injury. Before starting
work, 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 seal
connections 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 installing
lines, 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 shut
down, 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 suitable
bonding 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 are
placed on stable surfaces.
In order to prevent back injuries when lifting heavy components, adults should not lift weights between max. 10 kg
and 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 are
correctly 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 and
causing 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
Page 4
Never position the welding power supply cable adjacent to, or crossing MTU plant wiring harnesses. (The welding
current 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 that
the master switch for power supply has been moved from “ON” to “OFF” and the cable is disconnected from the
battery 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 be
used (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 until
correct 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 be
installed/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 come
into contact with skin or clothing. Wear protective goggles. Do not place tools on the battery. Before connecting the
cable to the battery, check battery polarity. Battery pole reversal may lead to injury through the sudden discharge of
acid or bursting of the battery body.
Do not damage wiring during removal work and when reinstalling wiring and ensure that during operation it is not
damaged by contact with sharp objects, 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 properly
support 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
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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 to
property.
Fire Prevention
Rectify any fuel or oil leaks immediately; even splashes of oil or fuel on hot components can cause fires – therefore
always keep the engine in a clean condition. Do not leave cloths soaked with fluids and lubricants lying around on
the 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 avoid
sparks in the vicinity of the battery, connect the ground lead from the foreign power source to the ground lead of the
engine 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 are
drowned.
At all workplaces with a sound pressure level over 85 dB(A), always wear ear protectors (protective wadding, plugs
or 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 a
result, 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 and
other 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
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⇒ 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 not
bring 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 ignite
suddenly!
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 then
be 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
Page 7
• 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 enter
the 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 not
paint over warning signs. Replace illegible signs.
Warning Notices
Publication contains especially emphasised safety instructions in accordance with the American standard ANSI
Z535, which begin with one of the following signal words according to the degree of danger:
DANGER
In event of immediate danger.
Consequences: Death or serious injury
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
Page 8
15340/20 E 00–01
Product Summary Section A
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
15340/20 E 00–01
Section A Product Summary
15340/20 E 00–01
Page 1
A000.000.01 Engine Layout

Illustrations may show additional equipment
Also applies to 8 V and 12 V engines
1 Coolant system vent connection 11 Engine oil filter (easy-change filter)

2 Engine oil heat exchanger 12 Fuel duplex filter (easy-change filter)
3 Centrifugal oil filter 13 H.P. fuel pump
4 Exhaust turbocharger 14 Vibration damper
5 Exhaust outlet 15 Charge air coolant pump
6 Air filter 16 Charge air coolant thermostat
7 Governor / engine control system 17 Charge air coolant inlet
8 Charge air line 18 Engine coolant outlet
9 Starter 19 Charge air coolant outlet
10 Engine mount 20 Crankcase ventilation
15340/20 E 00–01
Page 2
1 Air filter 11 Oil dipstick

2 Crankcase ventilation 12 Oil drain plug
3 Charge air line 13 Starter
4 Exhaust turbocharger 14 Flywheel
5 Charge air coolant outlet 15 Flywheel housing
6 Cylinder head cover / cylinder head 16 Charge air line
7 Engine lifting eyes 17 Governor / engine control system
8 Engine coolant pump 18 Intercooler
9 Oil filler neck
10 Oil pan
A000.000.03 Engine Model Designation

Key to engine model designations 12V4000G20, 12V4000G60, 12V4000G80
12 = number of cylinders
V = Vee configuration
4000 = displacement per cylinder in cm3
G = application for stationary power generation
2,–8 = external charge air cooling
0 = design index
15340/20 E 00–01
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A000.000.05 Engine Side and Cylinder Designations

Engine 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 abbreviations

Driving 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 surface approx. 2140 mm
E = Crankshaft centreline to oil pan . . . . . . . 625 mm
F = Crankshaft centerline to engine mount . 339 mm
A000.000.13 Engine Weight

Engine 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
15340/20 E 00–01
Page 4
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
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
15340/20 E 00–01
Page 5
A000.000.21 Operational Data

The 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 0.5 0.2
(Coolant system sealed with breather valve locked in position)
Fuel supply, before fuel delivery pump 0.5 –0.3
Charge air, measured after intercooler – –0.15*
* Max. deviation from values recorded on Engine Acceptance Test Record and referenced to the
acceptance test peripheral conditions.
Intake depression, at compressor inlet 25 mbar 35 mbar

*Air filter new: max. 25 mbar; air filter contaminated: max. 35 mbar
Exhaust backpressure, measured at exhaust junction pipe 30 mbar 50 mbar
Temperatures Normal Limit

°C °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 per 480 –
Clear-Air Standard)
Exhaust temperature, after engine for 12V4000G60 465 –
Exhaust temperature, after engine for 12V4000G60 (optimised emission as per 485 –
Clear-Air Standard)
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 (emission-optimised as per Clear-Air Standard) for 12V4000G60 212 g/kWh* 223 g/kWh*
15340/20 E 00–01
Page 6

* at continuous power and using a fuel which conforms to current MTU Fluids and
Lubricants Specification.
Engine oil 0.5%* max. 1.0%*

* of fuel consumption in continuous operation with run-in engine
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 the
prescribed service life is reached.
If the limit values are exceeded, determine and rectify the cause.
A000.000.25 Engine and Exhaust Noise

Applicable 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)
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)
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 Clearances

With engine cold
– Inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm
– Exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50 mm
15340/20 E 00–01
Page 7
A170.000.01 Engine Starting System

Electric 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 Capacity

Oil 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
15340/20 E 00–01
Page 8
15340/20 E 00–01
Operating Instructions Section C
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
15340/20 E 00–01
Section C Operating Instructions
15340/20 E 00–01
Page 1
C000.000.01 Operating Instructions – Preface

Low operating and maintenance costs as well as operational reliability and availability depend on maintenance and
servicing being carried out in compliance with our specifications and instructions.
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 engine
start-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.
15340/20 E 00–01
Page 2
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 change
after engine oil filter change
after 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
15340/20 E 00–01
Page 3
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 Period

If 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 transportation
Prior to transporting the engine, it is imperative to install transportation locking devices for crankshaft and engine
mount (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.
15340/20 E 00–01
Page 4
15340/20 E 00–01
Maintenance Schedule Section D
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
15340/20 E 00–01
Section D Maintenance Schedule
15340/20 E 00–01
Page 1
D000.000.01 Maintenance Schedule – Preface

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 water
Preventive 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 System

The MTU maintenance concept is a preventive maintenance concept and features the W1 to W6 Maintenance
Echelons 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 ensure
correct engine operation until the next scheduled maintenance echelon. Particular operating conditions may require
the 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.
15340/20 E 00–01
Page 2
D000.000.05 Application
3B : Continuous operation, variable
3C : Continuous operation, with time limit
D000.000.07 Maintenance Frequency Chart
Maintenance echelon W1: Operational checks daily X

W2: Operating hours 250
Limit (months) 6
W3: Operating hours 500
Limit (year) 1
W4: Operating hours 1 500
Limit (years) 3
Limit (years) 9
Limit (years) 18
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
15340/20 E 00–01
Page 3
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
−For oil category 2 without additional cleaning
−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 centrifuges
Replace 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 bridges
Check 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
15340/20 E 00–01
Page 4
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 their
dimensions, 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 this
procedure.
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 with
Section K.
15340/20 E 00–01
Troubleshooting Section E
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
15340/20 E 00–01
Section E Troubleshooting
15340/20 E 00–01
Page 1
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 out
the 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 valves
It 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 components
should, 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 Lubricants
Specification.
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 from
the 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 engine
running-in procedure.
E000.000.02 Engine does not turn when starter is actuated
ÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ
Probable causes
Check Remedial Action
Battery
ÁÁÁÁÁÁÁÁÁÁÁÁÁ Battery charge state Charge battery, replace if necessary
Cable connections Connect, replace if necessary
Starter
Starter/engine wiring Connect, replace if necessary
Start repeat relay Replace
Starter Replace
Ring gear Replace
Monitoring (electronics)
Monitoring start release See Operating Instructions of Plant
Manufacturer
Running gear blocked
Whether engine can be turned by
hand
Repair running gear
15340/20 E 00–01
Page 2
E000.000.03 Engine turns but does not fire

Probable causes
ÁÁÁÁÁÁÁÁÁÁÁÁÁ Check Remedial Action
Engine coolant preheat tempera-
ture too low
ÁÁÁÁÁÁÁÁÁÁÁÁÁ See E202.400.01 –
lease ÁÁÁÁÁÁÁÁÁÁÁÁÁ
Fuel pressure too low, no start re-
ÁÁÁÁÁÁÁÁÁÁÁÁÁ See E070.000.01 –
Engine receiving insufficient com-
bustion air
Air filter contamination indicator
(G121.051.01)
–
–
Air filter Replace (G121.051.01)
Intercooler Clean, replace if necessary
Compression pressure too low Compression pressure
(G000.000.31)
See E000.000.11
speed ÁÁÁÁÁÁÁÁÁÁÁÁÁ
Engine does not reach firing
Battery
Starter
Charge, replace if necessary
Replace
Engine wiring
ÁÁÁÁÁÁÁÁÁÁÁÁÁ Engine wiring Check – see G500.000.09
E000.000.05 Engine fires unevenly
Probable causes Check Remedial Action
ture too low
See E202.400.01 –
Fuel system is not yet vented Whether engine fires steadily after –
short period
Fuel injection equipment faulty Injectors Replace (G075.051.05)
Pressure maintaining valves Replace
Injection pump solenoid valve
Engine wiring
ÁÁÁÁÁÁÁÁÁÁÁÁÁ Engine wiring Check – see G500.000.09
E000.000.07 Engine does not reach full-load speed
Probable causes
bustion air See E110.000.03 –
Engine receiving insufficient fuel
Fuel injection equipment faulty
See under E080.000.01
Injectors
–
Replace (G075.051.05)
Pressure maintaining valves Replace
H.P. fuel pump generating insuffi-
cient pressure
See E070.000.01 –
Charge air temperature too high See E110.000.01 –
Power take-off too high
Auxiliary PTO (power consumption
too high) dialogue unit/data recorder
Contact MTU-Service
(speed-sensitive fuel limiter actual/
specified injection)
15340/20 E 00–01
Page 3
E000.000.09 Engine speed not steady

Probable causes ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Injectors
Pressure maintaining valves
Replace (G075.051.05)
Replace
H. P. fuel pump
Fuel pressure with dialogue unit/
data recorder Contact MTU-Service
Suction valve sluggish
Check suction valve for ease of Repair, replace if necessary
movement
Speed sensor
Speed sensor with dialogue unit /
data recorder
Replace speed sensor
E000.000.11 Compression pressure too low
Probable causes
Cylinder head gasket leaking
Valve seats in cylinder head worn
Cylinder head gasket
Cylinder head (G000.000.33)
Replace
Repair if necessary
Valves do not close
Valve clearances (G055.050.01)
Valves
Adjust (G055.050.03)
Recondition, replace if necessary
Piston rings worn
Piston rings Replace
Combustion chamber
Cylinder liner (G000.000.33)
Piston (G000.000.33)
Replace if necessary
E070.000.01 Fuel pressure too low
Probable causes
H.P. fuel sensor faulty H.P. fuel with dialogue unit/data re- Replace H.P. fuel sensor
corder or fault display in monitoring
module
H.P. fuel pump of fuel quantity
regulator/pressure regulator
(actuating solenoid) Suction valve Repair, replace if necessary
Pressure relief valve leaking
Fuel return from pressure relief
valve
Replace pressure relief valve
Fuel pressure less than 4 bar See E080.000.01 –
cient pressure ÁÁÁÁÁÁÁÁÁÁÁÁÁ
H.P. fuel pump generating insuffi-
data recorder
Replace H. P. fuel pump
Fuel injector faulty
data recorder
Replace injector
(G075.051.05)
15340/20 E 00–01
Page 4
E070.000.03 Fuel pressure too high

Probable causes
H.P. fuel pump of fuel quantity
regulator/pressure regulator Harsh engine running noise at idling, Repair, replace if necessary
(actuating solenoid)
connector and wiring
Suction valve
H.P. fuel sensor not working Fuel pressure with dialogue unit/ Replace H.P. fuel sensor if necessary
data recorder
E073.051.01 H.P. fuel pump leaking at relief bore
H.P. fuel pump seals leaking For engine oil or fuel discharge Replace H. P. fuel pump
E080.000.01 Fuel pressure too low
Fuel supply blocked
Fuel level too low
Shut-off valve in fuel system
Fuel supply
Open (G364.000.01)
Top up fuel
Fuel line
Seals
Renew seals, replace if necessary
Fuel filter contaminated Fuel prefilter Clean filter (G083.101.15), replace if
necessary (G083.101.09)
Fuel duplex filter
Fuel delivery pump faulty Fuel delivery pump, fuel delivery
Replace filter (G083.051.03)
pump drive Repair, replace if necessary
El. fuel delivery pump does not
operate before engine start Operation and direction of rotation Replace safety device, if necessary re-
(wiring ) place pump and repair wiring
Pressure relief valve Clean, replace if necessary
E101.011.01 Abnormal turbocharger running noises
Probable causes
Check
Remedial Action
Exhaust turbocharger dirty Exhaust turbocharger
Exhaust turbocharger faulty Turbocharger bearing
Clean
Replace
Rotor assembly Replace
E110.000.01 Charge air temperature too high
Probable causes
Check
Remedial Action
Intercooler dirty Intercooler Clean
Charge air coolant temperature
too high See under E203.000.01 –
15340/20 E 00–01
Page 5
Probable causes
Á
ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ
Antifreeze concentration too high Charge air coolant Rectify concentration as per specifica-
tions
Incorrect corrosion inhibitor
(deposits in intercooler) Charge air coolant Clean coolant system. Treat engine
Corrosion inhibitor coolant in accordance with the current
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ MTU Fluids and Lubricants Specifica-
tion, replace intercooler if necessary
E110.000.03 Charge air pressure too low

bustion air Air filter-contamination indicator –
(G121.052.01)
Charge air pressure (A000.000.21) –
Air filter Replace (G121.051.01)
Intercooler Clean, replace if necessary
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Charge pressure control valve Replace
Air flow control flap control Replace
Exhaust turbocharger control Replace
Air flow control flap does not close
if only one exhaust turbocharger
is operating Function of air flow control flap Repair
Pressure sensor faulty
Pressure sensor with dialogue unit /
fault recorder, fault display in moni-
Repair, replace if necessary
Exhaust turbocharger faulty
toring module
Exhaust turbocharger Repair
E114.051.01 Coolant discharge at intercooler relief bore
Probable causes
Intercooler leaking
ÁÁÁÁÁÁÁÁÁÁÁÁÁ Whether coolant discharges from
condensate drain line (not conden-
sate) Replace intercooler
E140.000.01 Exhaust gases black
bustion air
See E110.000.03
See E000.000.07
–
Resistance in exhaust system Exhaust backpressure Clean exhaust silencer
Power take-off too high, engine
overload Auxiliary PTO (power consumption Contact MTU-Service
too high) dialogue unit/data recorder
(speed-sensitive fuel limiter actual/
specified injection)
15340/20 E 00–01
Page 6
E140.000.02 Exhaust gases blue

Probable causes
chambers
Too much oil in combustion
Engine oil level (G180.000.01) Correct oil level (G180.000.01)
Exhaust turbocharger
Crankcase breather
Repair
Replace (G018.101.03)
Valve stem seals Replace
Valve guides
Cylinder liners
Replace
Replace
Compression pressure too low
Compression pressure
(G000.000.31)
See E000.000.11
E140.000.03 Exhaust gases white

Probable causes
ture too low
See E202.400.01 –
Engine cold Engine coolant temperature See E202.000.02
Coolant in combustion chambers Exhaust turbocharger Repair
Intercooler Replace
Cylinder head gaskets Replace
Cylinder heads (G000.000.33)
Cylinder liners (G000.000.33)
E172.000.01 Power supply faulty

Probable causes
charged
Battery not or insufficiently
Generator drive belt Adjust tension (G213.051.01), replace
drive belt if necessary (G213.051.05)
Repair
Generator Replace
Battery
Charge indicator lamp does not
Connection cable Secure
light up when engine is inoperat-
ive and propulsion control lever is
Charge indicator lamp
Battery
Replace
Replace
switched on Generator voltage regulator Replace
Generator Repair
15340/20 E 00–01
Page 7
Probable causes
With engine inoperative, charge
indicator lamp burns brightly but Connection cable Secure
becomes dark when engine run- Generator Repair
ning
Charge indicator lamp still lights
up brightly at higher speed
Connection cable from generator to
starter/battery
Secure
Replace
Generator drive Repair
Generator
Charge indicator lamp flickers
Generator
Generator drive belt
Tighten cable fixtures
Adjust tension (G213.051.01)
Replace drive belt if necessary
(G213.051.05)
Wiring faulty Wiring Check G500.000.09
E180.000.01 Engine oil consumption abnormally high

Crankcase ventilation faulty Crankcase breather Replace
Engine oil system leaking exter-
nally External subassemblies Seal pipework
External pipework
Engine oil drains
Check connections, tighten if necessary
Seal (G180.000.05)
Shaft seals Replace
Oil pan Seal pipework
Intake air depression too high
Crankcase
Air filter-contamination indicator
Repair
Replace air filter (G121.051.01)
(G121.052.01)
Oil pipes to engine oil heat ex-
changer leaking Oil in coolant system Replace sealing rings
Exhaust turbocharger leaking Exhaust turbocharger Replace bearings
Engine wear Valve stem seal Replace
Valve guides Replace
Combustion chamber
Cylinder liners
Combustion chamber (G000.000.33) –
Replace
15340/20 E 00–01
Page 8
E180.000.03 Engine oil level abnormally high

ÁÁÁÁÁÁÁÁÁÁÁÁÁCheck Remedial Action
oil
Fuel or engine coolant in engine
Engine oil quality See – “Fuel in engine oil”
Fuel in engine oil
ÁÁÁÁÁÁÁÁÁÁÁÁÁInjectors
– “Coolant in engine oil”
Replace seal to cylinder head
H.P. pump In event of fluid discharge, replace H.P.
Relief bore pump
Coolant in engine oil Cylinder heads Replace if necessary
Cylinder liner seals Replace
Cylinder liners
Crankcase
Coolant distribution housing
Replace
Repair
Replace
E180.000.05 Engine oil temperature too high

Probable causes
Engine oil heat exchanger dirty Engine oil heat exchanger Clean, replace if necessary
Engine coolant temperature too
high See E202.000.01 See E202.000.01
Temperature sensor faulty
Temperature sensor Check temperature sensor – see Repair
Manual
Combustion chamber
ÁÁÁÁÁÁÁÁÁÁÁÁÁ Combustion chamber (G000.000.33) –
E180.000.07 Engine oil pressure too high
Probable causes
Oil viscosity too high
Engine oil system
Engine oil viscosity
Engine oil pressure relief valve
Change engine oil
Replace
Coolant in engine oil
Engine oil quality
Pressure sensor
See under E180.000.03
Check pressure sensor – see Repair
ÁÁÁÁÁÁÁÁÁÁÁÁÁ Manual
E180.000.09 Engine oil pressure too low
Probable causes
After oil filter change, the pure oil
or contaminated oil drain plugs on
equipment carrier are still open Drain plugs on equipment carrier Close drain plugs
Engine oil level too low Engine oil level Top up engine oil
Engine oil system leaking exter-
nally See under E180.000.01 See under E180.000.01
Fuel in engine oil Engine oil quality See under E180.000.03
Engine oil filter dirty – Replace filter (G183.052.03)
Engine oil pressure relief valve Opening pressure Adjust or replace
Engine oil pump
ÁÁÁÁÁÁÁÁÁÁÁÁÁ Engine oil pump Repair, replace if necessary
15340/20 E 00–01
Page 9
Probable causes
Pressure loss in running gear Running gear lubrication points Replace bearings
Pressure sensor Check pressure transmitter – see Re-
pair Manual
E202.000.01 Engine coolant temperature too high

Probable causes
Engine coolant level too low Engine coolant level Top up engine coolant
Engine coolant system contami-
nated Engine coolant system Clean
Vent lines Clean
Engine coolant pressure too low
Engine coolant heat exchanger
See E202.000.05
Clean, replace if necessary
See E202.000.05
Engine coolant thermostat
Engine coolant thermostat Replace
Temperature sensor faulty Temperature sensor Check temperature sensor – see Re-
pair Manual
E202.000.02 Engine coolant temperature too low
Temperature sensor
Replace
Check pressure transmitter – see Re-
ÁÁÁÁÁÁÁÁÁÁÁÁÁ pair Manual
E202.000.05 Engine coolant pressure too low
Probable causes
Coolant system not sealed Cover closed Close cover
Breather valve Replace cover
Engine coolant system leaking
externally External pipework Check connections, tighten if necessary
External subassemblies Check connections, tighten if necessary
Coolant drain points
Engine coolant heat exchanger,
Seal
Repair
crankcase Check for leaks, replace if necessary
Engine coolant level too low Engine coolant level Top up engine coolant
Engine coolant pump faulty Engine coolant pump Replace
Engine coolant system leaking in-
ternally Engine oil quality Change engine oil (G180.000.05)
Cylinder heads Replace
Injector protective sleeve gasket Replace
Cylinder liner gaskets
Pressure sensor
Replace
Check pressure transmitter – see Re-
ÁÁÁÁÁÁÁÁÁÁÁÁÁ pair Manual
15340/20 E 00–01
Page 10
E202.000.07 Coolant loss

Probable causes
ternally
Engine coolant system leaking ex-
See under E202.000.05 –
ternally ÁÁÁÁÁÁÁÁÁÁÁÁÁ
Engine coolant system leaking in-
ÁÁÁÁÁÁÁÁÁÁÁÁÁ See under E202.000.05 –
Engine coolant pump leaking
Level monitor display error
Engine coolant pump
Level monitor, wiring
Repair
E202.000.09 Engine coolant level rising
Probable causes
Engine oil in engine coolant
Engine coolant quality
Engine oil heat exchanger
(G202.000.05)
Air in engine coolant
Vent lines Clean
Incorrect cylinder compression pres- Replace cylinder head gaskets
sures
E202.051.01 Engine coolant pump leaking at relief bore
Probable causes
Engine coolant pump leaking For oil discharge Replace sealing ring.
For water discharge Replace engine coolant pump if
necessary
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Replace rotary seal
Replace engine coolant pump if
necessary
E202.400.01 Preheat temperature too low
Probable causes
Preheater not working ÁÁÁÁÁÁÁÁÁÁÁÁÁ
Power supply for preheater
Power supply available
Preheater switched on
Provide power supply
See Operating Instructions of Manufac-
turer
E203.000.01 Charge air coolant temperature too high
Charge air coolant level too low
Charge air coolant system con-
Charge air coolant level
Charge air coolant system
Top up charge air coolant
Clean
taminated
Vent lines
Charge air coolant heat exchanger
Clean
Clean, replace if necessary
Engine wiring
Charge air coolant thermostat
Engine wiring
Check (G500.000.09)
Replace
low ÁÁÁÁÁÁÁÁÁÁÁÁÁ
Charge air coolant pressure too
ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ See E203.000.05 –
Temperature sensor Repair, replace if necessary
Check temperature sensor – see Repair
Manual
15340/20 E 00–01
Page 11
E203.000.03 Charge air coolant temperature too low

Probable causes
Charge air coolant thermostat Replace
Temperature sensor faulty Temperature sensor Repair, replace if necessary
Check temperature sensor – see Repair
E203.000.05 Charge air coolant pressure too low
Manual
Probable causes
Charge air coolant system not
sealed
Cover closed
Breather valve
Close cover
Replace cover
externally ÁÁÁÁÁÁÁÁÁÁÁÁÁ
Charge air coolant system leaking External pipework
ÁÁÁÁÁÁÁÁÁÁÁÁÁ External subassemblies
Charge air coolant drain points Check for leaks, replace if necessary
Intercooler Check for leaks, replace if necessary
Charge air coolant heat exchanger Repair
Charge air coolant level too low Charge air coolant level Top up charge air coolant
Charge air coolant pump faulty Charge air coolant pump Replace
Charge air coolant system leaking See E114.051.01 –
internally
E203.000.07 Charge air coolant loss
Probable causes
externally
internally
Charge air coolant pump leaking Charge air coolant pump Repair
Charge air coolant level trans- Charge air coolant level transmitter Repair, replace if necessary
mitter display error
E203.000.09 Charge air coolant level
Probable causes
Air in charge air coolant
Check
Vent lines
Remedial Action
Clean
E203.051.01 Charge air coolant pump leaking at relief bore
Probable causes
Charge air coolant pump leaking
For oil discharge
Engine coolant discharge
Replace sealing ring
Replace rotary seal
Replace coolant pump if necessary
15340/20 E 00–01
Page 12
15340/20 E 00–01
Task Description Section G
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
15340/20 E 00–01
Section G Task Description
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
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
15340/20 E 00–01
15340/20 E 00–01
Page 1
G000.000.01 Engine Start Disabling

Switch off power supply for Engine Control System at
control 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 Release

Remove “Danger” sign from control panel / master
switch.
Connect battery.
Open fuel supply to engine (G364.000.03).
Switch on power supply for Engine Control System
at control panel / master switch.
G000.000.05 Barring Engine Manually

Special 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 should
be 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
DANGER
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 tools
removed from the engine.
Before barring or starting the engine, ensure that
nobody is in the danger zone.
15340/20 E 00–01
Page 2
Do not actuate starter for longer than max. 10 sec-

onds. Before repeating a start attempt, wait at least
20 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 in

accordance 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’s
documentation.
Do not actuate starter for longer than max. 10 sec-
onds. Before repeating a start attempt, wait at least
20 seconds so that the starter cools down.
Do not increase engine speed until oil pressure is
displayed.
Note: If the engine oil pressure is not built up within the time
specified in Engine Monitoring, the engine is shut down by
the Engine Control System.
Determine cause and rectify.
G000.000.11 Engine Warm-Up Procedure

Increase 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 engine
coolant temperature reaches 40 C.
G000.000.13 Engine Speed check

Check idle and full-load speeds.
G000.000.15 Engine Pressure Checks

Check engine oil pressure.
Specified values (A000.000.21)
15340/20 E 00–01
Page 3
G000.000.17 Engine Temperature Checks

Check engine coolant temperature.
Specified values (A000.000.21)
G000.000.19 Engine Running Noise Check

Run engine at idling speed.
Apart from the usual running noises, no abnormal
sounds must be heard.
G000.000.21 Engine and External Lines Leak Check
DANGER
Exhaust gases in closed areas are harmful to
health.
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 at

idling speed until falling and then constant tempera-
tures are indicated.
Press shutdown button on control panel.
15340/20 E 00–01
Page 4
G000.000.25 Emergency Shutdown

Press emergency shutdown button on control panel.
G000.000.27 Attachments Security Check

Exhaust system (G146.000.01)
PTO system, driving end (G250.000.01)
Engine (G231.051.01)
G000.000.29 Attachments, Hoses and Hose Connections Check

Check all hoses and hose connections on the engine
for condition and leaks.
Immediately replace hoses showing signs of scuf-
fing, aging or cracking.
15340/20 E 00–01
Page 5
G000.000.31 Compression Pressure Check

Special tools:
Compression measuring unit
Connector: Y4343683
Threaded union: Y4343684
Connector: Y4343685
Adapter for compression measuring unit.

Remove cylinder head cover (G055.101.01).
Remove injector (G075.051.01).
Bar engine with starting system to remove any loose
carbon deposits from the combustion chambers
(G000.000.07).
Install adapter with sealing ring in the injection
nozzle bore and tighten with clamping element.
Connect the compression pressure recorder to the
adapter.
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 not
exceed 3 bar (300 kPa).
Install injector (G075.051.09).
Install cylinder head cover (G055.101.03).
15340/20 E 00–01
Page 6
G000.000.33 Cylinder Chamber Endoscopic Examination

NOTE: For engines in service, if possible carry out a combus-
tion chamber endoscopic examination after operation under
load.
Use an endoscope with an adequate light rating and a prism
(5) which pivots 95 (total viewing angle 140), see –No. I–.
If an endoscope with pivoting prism is not available, individ-
ual endoscopes with prism settings of 0, 45 and 90 are
required, 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).
Use engine barring tool to turn engine until, for the
respective 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 the
cylinder head and valves.
– all valves are open or closed for inspection of valves
and valve seats.
Endoscopic examination:
Connect endoscope to light source (4) and insert it
through the cylinder head (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) with
the area under inspection.
Visually assess the cylinder liners, piston crowns,
underside of the cylinder heads and valves.
To do this, rotate the endoscope through 360° in
each case and set the prism accordingly.
15340/20 E 00–01
Page 7
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 or
thermal 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 as
necessary.
After the endoscopic examination

Install injector (G075.051.09).
15340/20 E 00–01
Page 8
G000.000.39 Cleaning Engine Externally
WARNING
When 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 cast
iron and elastomers.
Clean the engine only at places where there is an
appropriate oil separator (environmental protection).
Before using the H.P. cleaner or steam jet, read the
respective operating instructions, paying particular
attention to safety instructions.
For cleaning externally with the H.P. jet, use only a
flat-jet nozzle.
Carry out external cleaning as follows:

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-pressure
cleaner or steam jet, the jet pressure must not exceed 100 bar
(1450 PSI).
Do not go any closer than 20 cm (8 inches) to the

object that is being sprayed.
The temperature of the cleaning agent must not rise
above a max. of 80 °C (176 °F).
NOTE: Moisture penetrating electrical components (tempera-
ture transmitter, pressure transmitter, terminal) may lead to
malfunctions and engine failure.
15340/20 E 00–01
Page 9
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 through
the 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 wiring
harnesses, which could damage the electrical unit).
The ground connection for the welding unit must not
be attached more than 60 cm from the welding 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 compo-
nents, it is not necessary to remove connectors pro-
vided that the master switch for power supply has
been moved from “ON” to “OFF” and the cable is
disconnected from the battery negative and positive
terminals.
15340/20 E 00–01
Page 10
G018.101.01 Crankcase Ventilation, Oil Separator Check
Check oil separator (visual inspection) for external

damage and oil discharge from breather (arrow).
If external damage is detected, or if oil emerges
through defective rubber diaphragms, always replace
the oil separator.
NOTE: A slight film of oil at the breather is normal.
G030.001.01 Engine Barring Tool Installation

Special tools:
Engine barring tool No. F6 555 766

Remove cover from flywheel housing.
Engage engine barring tool (1) with ring gear (2) and
attach to flywheel housing.
15340/20 E 00–01
Page 11
G030.001.03 Engine Barring Tool Removal

Remove engine barring tool from flywheel housing.
Screw cover to flywheel housing.
G055.000.01 Valve Gear Oil Supply Check
CAUTION
With the engine running, hot oil emerges at the
rocker arm bearings under high pressure.
Risk of eye injury and burning!
Run engine only when cylinder head covers are
installed.
Shut down engine (G000.000.23).

Check that the rocker arms and the cylinder head
cover (inside) are coated with oil.
15340/20 E 00–01
Page 12
G055.000.03 Valve Gear Lubrication

Note: The oil chambers must be filled with oil during initial
operation, extended out-of-service periods and after cleaning
valve gear.

Fill oil chambers of the valve bridges with oil.

Fill oil chambers of the rocker arms and adjusting
screws with oil.
G055.050.01 Valve Clearance Check

Special tools:
Valve clearance adjusting gauge: Y2 0010 128
Engine barring tool: F6 555 766
NOTE: Check with the valve closed and when coolant tem-
perature does not exceed 40 C.

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 ring
gear and arrow on flywheel housing are aligned.
15340/20 E 00–01
Page 13
Adjust all valve clearances at two crankshaft posi-

tions (firing TDC and overlap TDC, cylinder A1) as
per the diagram shown. The crankshaft must be
turned in the engine direction of rotation.
If the rocker arms are unloaded on cylinder A1, the
piston is in firing TDC.
1 = Firing TDC for cylinder A1
If the rocker arms are loaded on cylinder A1, the pis-
ton is in overlap TDC.
2 = Overlap TDC for cylinder A1
X = Exhaust valve
O = Inlet valve
Inlet valves: long rocker arm.

Exhaust valves: short rocker arm.
Valve clearance (A055.050.01).
Use feeler gauge to check distance between valve
bridge 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 gauge
through the gap.

15340/20 E 00–01
Page 14
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:
Retaining device: F6 557 950
Adjust with the valve closed and when coolant temperature
does not exceed 40 C.
NOTE: Before valve clearance is adjusted, it is essential that
the valve bridge be checked.

Adjusting valve clearance in two crankshaft posi-

tions

X = Exhaust valve
O = Inlet valve
15340/20 E 00–01
Page 15
Checking valve bridge adjustment
Use feeler gauge to determine distance between

valve bridge and rocker arm.
NOTE: It must be possible to just pull the feeler gauge
through the gap.
Place feeler gauge with determined value between

valve 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 bridge
is less than 0.05 mm.
Valve bridge must be adjusted if deviation from de-
termined value is greater than 0.05 mm.
15340/20 E 00–01
Page 16
Adjusting valve bridge
CAUTION
To release the locknut, the valve bridge must be
held firmly with the retaining device, otherwise
the valves will be deformed.
Install retaining device.

Insert locating pin of retaining device into oil bore of
valve bridge.
NOTE: The locating pin can be inserted into the valve bridge
oil bore only when the valves are closed / unloaded.
Release locknut.
15340/20 E 00–01
Page 17
Withdraw locating pin of retaining device from oil

bore 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 both
feeler gauges can just be pulled through.
Hold adjusting screw securely in position with Allen
key and fit locknut by hand on valve bridge.
Insert locating pin of retaining device into oil bore of
valve 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 Nm
Lubricant = Engine oil
Withdraw locating pin of retaining device from oil
bore of valve bridge.
15340/20 E 00–01
Page 18
Again check valve bridge adjustment.

Remove retaining device.
CAUTION
Before barring the engine, the retaining device
must be removed, otherwise with a secured
valve bridge the valve gear or retaining device
will be damaged.
Valve clearance adjustment
Valve clearance, see (A055.050.01).
Release locknut (1) and adjusting screw (2) with
Allen key.
Insert feeler gauge between valve bridge and rocker
arm.
Set adjusting screw so that feeler gauge just passes
through gap when locknut is tightened.
Tighten locknut with torque wrench, holding adjusting
screw firm.
NOTE: The locknut and adjusting screw must move easily.
Tightening torque = 90 Nm + 9 Nm.

Again check valve clearance.
15340/20 E 00–01
Page 19
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:
Adjust with the valve closed and when coolant temperature
does not exceed 40 C:
Note:
Before valve clearance is adjusted, it is essential that the
valve bridge be checked.

Adjusting valve clearance in two crankshaft posi-

tions

X = Exhaust valve
O = Inlet valve
15340/20 E 00–01
Page 20
Checking valve bridge adjustment
Use feeler gauge to determine distance between

valve bridge and rocker arm.
Note:
It must be possible to just pull the feeler gauge through the
gap.
Place feeler gauge with determined value between

valve 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 from
determined value (B) to (A) valve stem end to valve
bridge is greater than 0.05 mm.
15340/20 E 00–01
Page 21
Adjusting valve bridge
CAUTION
When releasing the locknut, the valve bridge must
be held firmly, as otherwise the valves will be bent.
Hold valve bridge (1) firmly in position with open-end

wrench 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 both
feeler gauges can just be pulled through.
Hold adjusting screw securely in position with Allen
key and fit locknut by hand on valve bridge.
Note:
The locknut and adjusting screw must be free to move.
15340/20 E 00–01
Page 22
Using torque wrench, tighten locknut (2); for this pur-

pose hold valve bridge (1) in position with open-end
wrench.
Tightening torque = 35 Nm + 5 Nm
Again check valve bridge adjustment.
15340/20 E 00–01
Page 23
Valve clearance adjustment

Valve clearance, see (A055.050.01).
Release locknut (1) and adjusting screw (2) with
Allen key.
Insert feeler gauge between valve bridge and rocker
arm.
Set adjusting screw so that feeler gauge just passes
through gap when locknut is tightened.
Tighten locknut with torque wrench, holding adjusting
screw firm.
Note:
The locknut and adjusting screw must move easily.
Tightening torque = 90 Nm + 9 Nm.

Again check valve clearance.
G055.101.01 Cylinder Head Cover Removal
WARNING
With the engine running, hot oil emerges at the
rocker arm bearings under high pressure.
Risk of eye injury and burning!
Run engine only when cylinder head covers are
installed.

Remove screws.
Remove cylinder head cover from cylinder head.
15340/20 E 00–01
Page 24
G055.101.03 Cylinder Head Cover Installation
Clean mating faces.

Check that profile gasket in cylinder head cover is in
perfect condition, replace if necessary.
Place cylinder head cover on cylinder head.
Insert screws with washers and tighten with torque
wrench.
Tightening torque = 45 Nm
G073.051.07 High-Pressure Pump, Relief Bore Obstruction Check
Check relief bore for oil and fuel discharge (visual

inspection).
Clean the bore if it is contaminated.
NOTE: Replace H.P. fuel pump if oil and / or fuel emerges
from the relief bore.
15340/20 E 00–01
Page 25
G075.051.01 Injector Removal
WARNING
Fuels are combustible.
Fire hazard!
When working on the fuel system:
no naked flame
no electrical sparks
do not smoke
do not spill fuel.
Note:
The fuel injectors can only be replaced completely, as the
injection nozzle can only be replaced at MTU.
Special tools:
Extractor sleeve for injector: F3 0377 769
Extractor: F6557991

Remove fuel return line on cylinder head and on fuel

collecting line.
Note:
Fuel must not penetrate the cylinder chamber.
15340/20 E 00–01
Page 26
Release the cable terminal threaded connection on

the 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.
15340/20 E 00–01
Page 27
Place extractor sleeve (section 1) (4) on injector (1).

Fit section 2 (2) over section 1 and turn to correct
position – 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) and

secure with hex nut (4).
Place extractor (2) on cylinder head.
Turn nut (1) clockwise to withdraw injector.
Remove special tool.
Remove injector manually.
15340/20 E 00–01
Page 28
Remove CE support ring (1) from injector or use wire

hook 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
WARNING
Fire hazard!
no naked flame
do not smoke
do not spill fuel.
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
WARNING
Fire hazard!
no naked flame
do not smoke
do not spill fuel.
Special tools:
Press-fitting lever for injector: F6 557 952
Press-fitting sleeve for injector: F3 0378 403
Lever: F6 555 197
15340/20 E 00–01
Page 29
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.
15340/20 E 00–01
Page 30
Note:
Before installation, remove all plugs and covers.
Insert fuel injector (1) into cylinder head, ensuring

the 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, and

fit hex screw (1) by hand.
15340/20 E 00–01
Page 31
Tighten screw of hold-down clamp with torque

wrench.
Tightening torque: 5 Nm to 10 Nm
Coat new O-ring (2) with petroleum jelly and fit on

H.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 installation
position is correct.
Using torque wrench, tighten H.P. line (2) at injector

(1) and connector (limiting valve) (3).
Tightening torque: 5 Nm to 10 Nm
Note:
15340/20 E 00–01
Page 32
Tighten hex screw of hold-down clamp with torque

wrench.
Tightening torque: 100 Nm + 10 Nm
Using torque wrench, tighten threaded connection of

H.P. line at injector (1) and connector (limiting valve)
(2).
Tightening torque: 100 Nm + 10 Nm
Note:
15340/20 E 00–01
Page 33
Fit cable terminals below the screws on injector and

tighten.
Tightening torque: 1.0 Nm +/– 0.2 Nm
Attach fuel return line between cylinder head and

manifold and tighten.
15340/20 E 00–01
Page 34
G080.000.03 Fuel System Filling
WARNING
Fire hazard!
no naked flame
do not smoke
do not spill fuel.
Special tools:
Filling device: B8 014 485 22
On initial operation/restart or after a fuel filter

change, the L.P. fuel system must be refilled.

Fill L.P. fuel system.
Remove flushing line (1) from the H.P. pump (3) and
release from filter block (2).
Connect the fuel return hose of the filling device to
the 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 bar
must be achieved.
The fuel system is filled by the hand pump until

bubble-free fuel is seen to emerge in the hose.
Filling device
Fuel system (1)
Fuel return (2)
15340/20 E 00–01
Page 35
Remove fuel return hose from the H.P. pump (3).

Screw flushing line (1) onto the H.P. pump (3) and
filter 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 and
tighten.
The H.P. system is filled when the engine is started.
Disposal of Hazardous Materials

Fluids and lubricants (e.g. oils, greases, treated engine
coolant, fuels), cleaning agents and numerous auxiliary
materials are an environmental hazard and therefore consti-
tute hazardous materials.
When disposing of these hazardous materials, always follow the
manufacturer’s instructions, general environmental protection
regulations and local legal specifications.
Under no circumstances must even small amounts of hazardous
materials be allowed to drain into water, or be discarded or dis-
posed of outdoors.
Leaked hazardous materials must immediately be absorbed with
suitable bonding agents and disposed of in accordance with
regulations in appropriate vessels. The contents of these con-
tainers must be specified.
G080.000.05 Fuel System, Fuel Delivery Pump Supply Check

Connect 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
Fire hazard!
no naked flame
do not smoke
do not spill fuel.
15340/20 E 00–01
Page 36
Special tools:
Strap wrench F3 0006 199
Remove filter and dispose of in accordance with

local regulations.
Clean sealing surface at connector.
Check sealing ring of new filter and moisten with
fuel.
Install filter and tighten by hand.
Replace second filter in same way.

posed of outdoors.
G083.101.01 Fuel Prefilter Priming
WARNING
Fire hazard!
no naked flame
do not smoke
do not spill fuel.
Fuel prefilter not supplied by MTU.

See Operating Instructions of Plant Manufacturer.
G083.101.03 Fuel Prefilter, Water and Contaminants Draining

15340/20 E 00–01
Page 37
G083.101.09 Fuel Prefilter, Element and Gasket Replacement
WARNING
Fire hazard!
no naked flame
do not smoke
do not spill fuel.

G083.101.15 Fuel Prefilter Cleaning
WARNING
Fire hazard!
no naked flame
do not smoke
do not spill fuel.

G101.011.01 Exhaust Turbocharger, Engine Operation in Event of Turbocharger Failure

In the event of turbocharger failure, determine the
cause and assess whether the engine can continue
in operation without risk.
If, in the event of turbocharger failure (e.g. if rotor is
seized), the engine must continue in operation, run
the engine only under partial load.
Run the engine in this condition only until it is poss-
ible to replace or repair the turbocharger.
15340/20 E 00–01
Page 38
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 Check
Check intake side of engine for condition and leaks
with the engine running.
G120.000.05 Intake Air System, Intake Depression Check

Connect U-pipe pressure gauges to turbocharger air
intake housings.
Run engine at full load and read off indicated pres-
sures. Specified value, see (A000.000.21).
Remove U-pipe pressure gauges.
15340/20 E 00–01
Page 39
G120.000.07 Intake Air System Check

Check that cover is removed.
Check for cleanliness.
G121.051.01 Air Filter Replacement

Remove guard and loose material on intake housing
or 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).
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 normal
position.
15340/20 E 00–01
Page 40
G124.051.01 Charge Air Line, Drain Water Discharge and Obstruction Check
WARNING
Engine noise above 85 dB(A).
Risk of damage to hearing!
Wear ear protectors.
ËË
Engine coolant is hot and under pressure.
Risk of injury!
ËË
Wear protective gloves.
Coolant discharge check

If the coolant is continuously discharged and the
coolant 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) and
blow out combustion chambers.
NOTE: If the intercooler is leaking, activate engine only in an
emergency.
Obstruction check
NOTE: Check drain bore on engine A and B sides.
With the engine running, oil-containing air must

emerge at the drain bore.
G124.051.03 Charge Air Line Drain Cleaning
CAUTION
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!
15340/20 E 00–01
Page 41

Clean drain bore, blow out with compressed air and
check for obstructions.
NOTE: Clean and check drain bore on engine A and B sides.
G140.000.01 Exhaust System Leak Check

Check engine exhaust system (visual inspection) for
leaks and damage.
G140.000.03 Exhaust System Security Check

When the engine is cold, check tightness of securing
screws by torque wrench application.
G140.000.05 Exhaust System, Exhaust Gas Colour Check

Exhaust 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 Check

Check that cover is removed.
Check for cleanliness.
G140.000.09 Exhaust System, Exhaust Backpressure Check

Connect 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.
15340/20 E 00–01
Page 42
G140.000.11 Exhaust System Drain Obstruction Check

Check drain for obstruction (if applicable).
Drain exhaust system (if drain provided).
G146.000.01 Exhaust System, Security and Exhaust Manifold Insulation Checks

Check tightness of the exhaust system securing
screws (after engine) by torque wrench application
and the insulation for damage by visual inspection.
G172.051.09 Starter Condition Check (Visual Inspection)

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.
15340/20 E 00–01
Page 43
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.
G180.000.03 Engine Oil System Filling
Note: Always use MTU-approved engine oil, see MTU Fluids

and Lubricants Specification.
Turn cover counterclockwise until the cover of the oil

filler neck can be removed.
Pour engine oil in at oil filler neck up to Max. mark on
oil 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.
NOTE: Do not fill engine oil above the Max. mark.

Reinstall oil filler neck cover.
15340/20 E 00–01
Page 44
G180.000.04 Engine Oil – Used Oil Sample Extraction and Analysis
DANGER
ËË
Engine oil is hot and can contain combustion resi-
dues which are harmful to health.
ËË
Risk of injury!
Avoid extended and intensive contact with skin.
Do not inhale oil vapour.
Open shut-off cock with engine running and engine

at operating temperature.
Drain approx. 2 litres engine oil to flush out the oil
sludge in the shut-off cock.
Drain approx. 1 litre of engine oil coolant into a clean
container.
Using equipment and chemicals from the MTU Test
Kit, inspect the engine oil for dispersion capability
(spot test), coolant content and fuel dilution – see
Publication for MTU Test Kit.

posed of outdoors.
G180.000.05 Engine Oil Change

Drain engine oil (G180.000.07).
Replace engine oil filter (G183.052.03).
Pour in new engine oil (G180.000.03).
Note: After each engine oil change and filter replacement, bar
the engine with the starting system (G000.000.07).
15340/20 E 00–01
Page 45
G180.000.07 Engine Oil Draining
DANGER
ËË
ËË
Risk of injury!
NOTE: Drain engine oil with the engine at operating tempera-

ture.
Provide a suitable container to collect and dispose of

the engine oil.
Drain engine oil from oil pan at oil drain plug.
Install oil drain plug with a new sealing ring.
15340/20 E 00–01
Page 46
Drain remaining oil from equipment carrier.

Install oil drain plug with a new sealing ring.

posed of outdoors.
G180.000.09 Corrosion Inhibitor Oil Filling

NOTE: Always use only approved corrosion inhibitor oil – see
MTU Fluids and Lubricants Specifications.
Fill engine with corrosion inhibitor oil in same way as

engine oil (G180.000.03).
G180.000.11 Corrosion Inhibitor Oil Draining

Drain corrosion inhibitor oil in same way as engine
oil (G180.000.07).
NOTE: Drain the corrosion inhibitor oil with the engine at
operating temperature.
15340/20 E 00–01
Page 47
G183.052.03 Engine Oil Filter Replacement
DANGER
ËË
ËË
Risk of injury!
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 coat
with oil.
Install new engine oil filter and tighten by hand.
Replace other engine oil filters in same way.

posed of outdoors.
15340/20 E 00–01
Page 48
G183.101.01 Centrifugal Oil Filter Cleaning
DANGER
ËË
ËË
Risk of injury!

Release Tommy nut.
Release band clamp.
Release band clamp.

Remove housing cover.
Remove sealing ring.
15340/20 E 00–01
Page 49
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.
15340/20 E 00–01
Page 50
CAUTION
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!
Remove insertion sleeve.

Assess the layer thickness and weight of the oil resi-
dues on the sleeve and compare to the values noted
during the previous check.
Note: Layer thickness max 20 mm (approx. 1800 gr.)
If the two values deviate greatly, the oil must be

changed.
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.
15340/20 E 00–01
Page 51
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.
When the engine is again started, check the centrifu-
gal oil filters for leaks.
15340/20 E 00–01
Page 52

posed of outdoors.
G202.000.01 Engine Coolant System Filling
WARNING
ËË
Risk of injury!
Open breather valve (G208.101.01), so that the air

can escape from the engine when the coolant sys-
tem is filled.
15340/20 E 00–01
Page 53
Note:
Always use only treated coolant in accordance with MTU
Fluids and Lubricant Specifications.
Never pour cold coolant into a hot engine.
If, in an emergency, untreated water is used to top up the
coolant system, the coolant concentration must be checked
and rectified at the earliest opportunity.
Connect suitable hose to the drain valve (arrow).

Open drain valve and pour in engine coolant via the
hose.
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.
G202.000.03 Engine Coolant Level Check

Note:
The Min. coolant level is automatically monitored by the En-
gine Control System.
Via level sensor

Switch on engine control system (G500.000.01) and
check indicator.
WARNING
ËË
Risk of injury!
ËË
Note:
Always use only treated coolant in accordance with MTU
Fluids 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).
15340/20 E 00–01
Page 54
G202.000.05 Engine Coolant Sample Extraction and Analysis
WARNING
ËË
Risk of injury!
ËË

Open drain valve.
Drain a small quantity of coolant to flush the drain
point.
Drain approx. 1 litre of engine coolant into a clean
container.
Close drain valve.
Using the equipment and chemicals in the MTU Test
Kit, examine the coolant for:
– antifreeze
– corrosion inhibitor
– pH value
See MTU Test Kit instructions.
Change engine coolant according to the coolant op-
erating times in the Fluids and Lubricants Specifica-
tion A001061.
15340/20 E 00–01
Page 55
G202.000.07 Engine Coolant
WARNING
ËË
Risk of injury!
ËË

Note:
Drain engine coolant when engine has cooled.
Open breather valve (G208.101.01).

the coolant.
Open lower drain valve on coolant inlet elbow and
drain coolant.
Drain residual coolant from engine via the upper
drain point on crankcase (A and B sides).
Seal all drain points.
Dispose of engine coolant.

posed of outdoors.
G202.000.09 Engine Coolant Change

Drain engine coolant (G202.000.07).
Fill engine coolant system (G202.000.01).
15340/20 E 00–01
Page 56
G202.051.01 Engine Coolant Pump Relief Bore Check
Check relief bore for oil and coolant discharge (visual

inspection).
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 Preheating

Switch 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 Operation

Engine coolant preheating unit not supplied by MTU.
Carry out tasks as specified by Manufacturer.
G202.651.01 Engine Coolant System, Vent Line Obstruction Check

Remove vent lines and blow out with compressed
air.
Install vent lines.
15340/20 E 00–01
Page 57
G203.000.01 Charge Air Coolant System Filling

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

Pour in treated engine coolant via filler neck.
Check charge air coolant level (G202.000.03).
Run engine a number of minutes at idling speed.
G203.000.03 Charge Air Coolant Level Check

NOTE: The Min. coolant level is automatically monitored by
the Engine Control System.
Via level sensor

Switch on Engine Control System (ECS) and check
display – see MTU Elektronik Documentation.
WARNING
ËË
Risk of injury!
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 treated
engine coolant.
NOTE: Never pour cold coolant into a hot engine.
15340/20 E 00–01
Page 58
G203.000.05 Charge Air Coolant Draining
WARNING
ËË
Risk of injury!
ËË

Note:
Drain engine coolant when engine has cooled.

the coolant.
Drain the coolant expansion tank via the filler neck.
Drain engine coolant from cooling system via the
drain points.
Seal all drain points.
Dispose of coolant.

posed of outdoors.
G203.000.07 Charge Air Coolant Sample Extraction and Analysis

Open blanking plug.
By means of the blanking union, drain approx. 1 litre
coolant into a clean container.
Close blanking plug.
Using MTU Test Kit, check coolant for:
– Antifreeze
– Corrosion-inhibitor oil
– Check pH value.
15340/20 E 00–01
Page 59
G203.051.01 Charge Air Coolant Pump Relief Bore Check
Check relief bore for oil and coolant discharge (visual

inspection).
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 Check

Vent lines not supplied by MTU.
G205.051.01 Engine Coolant Cooler, External Element Contamination Check

Coolant cooler not delivered by MTU.
G205.051.03 Charge Air Coolant Cooler, External Element Contamination Check

Coolant cooler not delivered by MTU.
15340/20 E 00–01
Page 60
G208.101.01 Open Breather Valve
WARNING
ËË
Risk of injury!
ËË
Turn breather valve counterclockwise to first stop.

Allow pressure to escape.
Continue to turn breather valve counterclockwise
and 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 will
go.
15340/20 E 00–01
Page 61
G213.051.01 Generator Drive, Drive Belt Condition and Tension Check
DANGER
Special tools:
V-ribbed belt tension tester
Condition check
Remove guard plate.
Check V-ribbed belts for cracks, oil, overheating and
wear; clean or replace as necessary.
NOTE: Solvents such as petroleum or benzol must not be
used. Sharp-edged objects are not cleaning agents.
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.
F2130001 0a
15340/20 E 00–01
Page 62
The V-ribbed belts must be replaced if the ribs are

broken around the entire circumference.
F2130002 0a
The V-ribbed belt must be replaced immediately if

the ribbed material has broken through and the ribs
are broken around the entire circumference.
F2130003 0a
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)
15340/20 E 00–01
Page 63
If the measured value does not correspond to the

specified set value, V-ribbed belt tension must be
corrected.
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.
G213.051.05 Generator Drive Belt Installation / Replacement

Remove guard plate.
Release securing screws (1).
Release locknut (2) and clamping nut (3) so that both
V-ribbed belts can be removed.
Check that V-ribbed belt pulleys are clean; clean if
necessary.
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.
NOTE: After the engine has run for 30 minutes, again check
V-ribbed belt tension; readjust if necessary. After the engine
has run for 8 hours, again check V-ribbed belt tension; read-
just if necessary.
15340/20 E 00–01
Page 64
G213.051.10 Generator Connecting Bridge Removal
Remove bridge between cable connections 61 and

B–.
G231.051.01 Engine Mount Security Check

Check tightness of all securing screws by torque
wrench application.
G231.051.03 Engine Mount Resilient Element Check

Check resilient mounts for cracks and deformation
(visual inspection).
Replace cracked rubber elements.
NOTE: Wipe rubber surfaces with dry cloth only, never clean
with organic detergents.
G250.000.01 Drive System (Driving End) Security Check

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).
G252.051.01 Coupling Condition Check

Coupling is not supplied by MTU. Carry out tasks
specified by Manufacturer.
15340/20 E 00–01
Page 65
G303.000.01 Compressed Air System Condensate Draining

Open drain valves on compressed air system and
allow condensate to drain.
NOTE: The pressure drop on the pressure gauge must not be
more 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 Check

Open 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 and
subject them to a pressure test.
Observe the local safety regulations.
G307.001.01 Protective Device Check

Check that all guards are correctly installed on the
generator and PTO systems, driving end and free
end.
Guard plates on PTO system, driving end.
G309.001.01 Battery Check
WARNING
Battery acid is highly caustic and may splash into
eyes.
During filling or charging, explosive gases may
develop.
Metal objects between battery terminals cause
short-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 immediately
with water and seek medical attention.
Do not place metal objects on battery.
The battery is not supplied by MTU. Carry out tasks

specified by manufacturer.
G309.001.05 Battery Charge State Check

Check fluid viscosity and electrolyte level. Carry out
tasks specified by manufacturer.
15340/20 E 00–01
Page 66
G364.050.01 Fuel Supply Check
WARNING
Fire hazard!
no naked flame
do not smoke
do not spill fuel.
Check fuel supply in fuel tank, top up if necessary.

NOTE: A full fuel tank reduces condensation and the growth
of bacteria.
G364.200.01 Fuel Supply Opening

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

Open shut-off valve in supply line before fuel pre-
filter.
G364.200.05 Fuel Supply System Filling

Fill fuel intake line to engine with fuel.
G365.000.03 Exhaust System Drain Obstruction Check

Exhaust system not supplied by MTU.
G500.000.01 Engine Control System Switching On

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

Move power supply master switch from “On” to “Off”.
G500.000.07 Engine Control System Initial Operation

See MTU Elektronik Documentation.
15340/20 E 00–01
Page 67
G500.000.09 Engine Wiring Check
WARNING
Battery acid is highly caustic and may splash into
eyes.
During filling or charging, explosive gases may
develop.
Metal objects between battery terminals cause
short-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 immediately
with water and seek medical attention.
Do not place metal objects on battery.

Disconnect battery.
Check security of all plug-in connections as follows:

Try to turn the bayonet union nuts of the connectors
by hand using little force.
If this is possible, tighten the respective bayonet
union nut clockwise with pliers.
Note: It is not sufficient to tighten the bayonet union
nuts by hand. There is the risk that the lock does not
properly engage and the connector may then come
loose during engine operation. Pliers must therefore
be 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 valves
For other plug-in connections, see Manufacturer’s
Electronics 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
– Battery
Connect battery.
15340/20 E 00–01
Page 68
G510.000.01 Monitoring System, Equipment Function Check

Check operation of level sensor on engine coolant
expansion tank – see Electronics Documentation.
The temperature transmitter, speed transmitter and
pressure transmitter are continuously monitored with
the Integrated Test System (ITS) in the Engine Con-
trol System. If a monitoring unit fails, a warning is
given – see Electronics Documentation.
15340/20 E 00–01
Preservation Section K
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
15340/20 E 00–01
Section K Preservation
15340/20 E 00–01
Page 1
K000.000.01 Preservation – Preface

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
15340/20 E 00–01
Page 2
K000.000.03 Preservation
Code No. Task Description
G000.000.23 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
K001 Clean engine
G000.000.05 Bar engine manually, and
K005 spray corrosion inhibitor oil into air manifolds
K000.000.07 Depreservation
K001 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
15340/20 E 00–01
Page 3
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 preservation
run, 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 compressor
wheels.
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 moisture
penetration.
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 way as
to 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.
15340/20 E 00–01
Page 4

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, with 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 tension
roller.
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.
15340/20 E 00–01
Transportation Locking Device Section T
Contents
T036.051.01 Crankshaft transportation locking device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
15340/20 E 00–01
Section T Transportation Locking Device
15340/20 E 00–01
Page 1
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
General
The 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 Removal

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

Transportation 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.
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Page 4
15340/20 E 00–01
Keyword Index Section ?
Page 1
A
Abnormal 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
B
Barring 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
C
Centrifugal 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
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Section ? Keyword Index
Page 2
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
D
Depreservation, 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
E
Emergency 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
15340/20 E 00–01
Page 3
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
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Page 4
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
F
Fuel 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
G
General, 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
H
H.P. fuel pump leaking at relief bore, Troubleshooting, Section E, 4
High-pressure pump, relief bore obstruction check, G073.051.07, Section G, 24
I
Initial 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
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Page 5
M
Main 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
O
Oil 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
P
Power 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
R
Represervation, K000.000.05, Section K, 2
S
Shutdown, C000.000.09, Section C, 3
Starter condition check (visual inspection), G172.051.09, Section G, 42
T
Timing data (valve clearance adjusted), A050.000.01, Section A, 6
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V
Valve 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
15340/20 E 00–01

MTU Diesel Engine Use and Maintenance Manual

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MTU Diesel Engine Use and Maintenance Manual

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Use and maintenance manual

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

Time schedule and maintenance

Using the Table of Contents E Troubleshooting

Heading ? Keyword Index

Alphabetical index of key terms

Please complete and return

MTU Motoren- und Turbinen-Union

Please use block capitals! 14.

Receipt Amendment No. 1.

Safety, Accident Prevention and Environmental Protection Instructions

These instructions must be read and followed by every person involved in

Working Clothes and Protective Equipment

Maintenance and Repair

Operation of Electrical Equipment

In event of dangerous situations.

Take extreme care in these situations!

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

A000.000.01 Engine Layout

1 Coolant system vent connection 11 Engine oil filter (easy-change filter)

1 Air filter 11 Oil dipstick

A000.000.03 Engine Model Designation

A000.000.05 Engine Side and Cylinder Designations

Applicable designations and abbreviations

A000.000.09 Main Engine Dimensions

A = Overall length . . . . . . . . . . . . . . approx. 2410 mm

A000.000.13 Engine Weight

A000.000.17 Main Engine Specifications

Injection method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . common rail (accumulator injection)

A000.000.19 Engine Power

A000.000.21 Operational Data

Pressures Normal bar Limit bar

Intake depression, at compressor inlet 25 mbar 35 mbar

Temperatures Normal Limit

Consumptions Normal Limit

Fuel with 12V4000G80 193 g/kWh* 203 g/kWh*

Engine oil 0.5%* max. 1.0%*

A000.000.25 Engine and Exhaust Noise

A050.000.01 Timing Data (Valve Clearance Adjusted)

Valve clearance adjusted ° Crank angle

I . . . . . . . . . . . . . . . . . . . . . . . . Top dead center (TDC)

A055.050.01 Valve Clearances

A170.000.01 Engine Starting System

A180.000.01 Oil Capacity

A202.000.01 Coolant Capacity

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

C000.000.01 Operating Instructions – Preface

C000.000.03 Preparations for Initial Operation

G000.000.05 Running gear Bar engine manually

K000 Depreservation Carry out before-operation services

C000.000.05 Initial Operation

C000.000.07 Operational Checks –Maintenance Echelon W1–

C000.000.11 After Shutdown

C000.000.13 Out-of-Service Period

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

D000.000.01 Maintenance Schedule – Preface

D000.000.03 Maintenance System

W1: Operational checks.

D000.000.07 Maintenance Frequency Chart

Maintenance echelon W1: Operational checks daily X

D000.000.11 Maintenance Schedule

Code No. Maintenance echelon W1