Instrucciones de Operacion 4000

Technical Publication
Diesel Engine
16V 4000 G60
16V 4000 G80
Operating Instructions
M015465/30E
DaimlerChrysler Off-Highway
Printed in Germany
E 2002 Copyright MTU Friedrichshafen GmbH
Diese Veröffentlichung einschließlich aller seiner Teile ist urheberrechtlich geschützt. Jede Verwertung oder Nutzung bedarf der vorherigen
schriftlichen Zustimmung der MTU Friedrichshafen GmbH. Das gilt insbesondere für Vervielfältigung, Verbreitung, Bearbeitung,
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Wartungs- und Bedienungspersonal zur Verfügung zu stellen.
Änderungen bleiben vorbehalten.
Printed in Germany
This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior written permission of
MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, microfilming and storage or processing on
electronic systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage during operation.
Subject to alterations and amendments.
Imprimé en Allemagne
Tout droit réservé pour cet ouvrage dans son intégralité. Toute utilisation ou exploitation requiert au préalable l’accord écrit de MTU
Friedrichshafen GmbH. Ceci s’applique notamment à la reproduction, la diffusion, la modification, la traduction, l’archivage sur microfiches,
la mémorisation et / ou le traitement sur des systèmes électroniques, y compris les bases de données et les services en ligne.
Le manuel devra être observé en vue d’éviter des incidents ou des endommagements pendant le service. Aussi recommandons-nous à
l’exploitant de le mettre à la disposition du personnel chargé de l’entretien et de la conduite.
Modifications réservées.
Impreso en Alemania
Esta publicación se encuentra protegida, en toda su extensión, por los derechos de autor. Cualquier utilización de la misma, así como su
reproducción, difusión, transformación, traducción, microfilmación, grabación y/o procesamiento en sistemas electrónicos, entre los que se
incluyen bancos de datos y servicios en línea, precisa de la autorización previa de MTU Friedrichshafen GmbH.
El manual debe tenerse presente para evitar fallos o daños durante el servicio, y, por dicho motivo, el usario debe ponerlo a disposición del
personal de mantenimiento y de servicio.
Nos reservamos el derecho de introducir modificaciones.
Stampato in Germania
Questa pubblicazione è protetta dal diritto d’autore in tutte le sue parti. Ciascun impiego od utilizzo, con particolare riguardo alla
riproduzione, alla diffusione, alla modifica, alla traduzione, all’archiviazione in microfilm ed alla memorizzazione od all’elaborazione in
sistemi elettronici, comprese banche dati e servizi on line, deve essere espressamente autorizzato per iscritto dalla MTU Friedrichshafen
GmbH.
II manuale va consultato per evitare anomalie o guasti durante il servizio, per cui va messo a disposizione dall’ utente al personale addetto
alla manutenzione e alla condotta.
Con riserva di modifiche.
! Safety Instructions
Summary
A Product Summary
Engine layout, technical data
C Operating Instructions
Task descriptions
D Maintenance Schedule
Time schedule and maintenance task

chart
E Troubleshooting
Causes, remedies
G Task Description
Inspection and maintenance tasks
K Preservation
Engine preservation
T Transportation Locking Device
Drawing, instructions
? Keyword Index
Alphabetical index of key terms

Wichtig -- Important -- Importante
Bitte die Karte „Inbetriebnahmemeldung” abtrennen und ausgefüllt an MTU Friedrichshafen GmbH
zurücksenden.
Die Informationen der Inbetriebnahmemeldung sind Grundlage für den vertraglich vereinbarten Logistik-
Support (Gewährleistung, Ersatzteile etc.).
Please complete and return the “Commissioning Note” card below to MTU Friedrichshafen GmbH.
The Commissioning Note information serves as a basis for the contractually agreed logistic support
(warranty, spare parts, etc.).
Veuillez séparer la carte “Signalisation de mise en service” et la renvoyer à la MTU Friedrichshafen

GmbH.
Les informations concernant la signalisation de mise en service constituent la base pour l’assistance en
exploitation contractuelle (garantie, rechanges, etc.).
Rogamos separen la tarjeta “Aviso de puesta en servicio” y la devuelvan rellenada a MTU

Friedrichshafen GmbH.
Las informaciones respecto al aviso de puesta en servicio constituyen la base para el soporte logístico
contractual (garantía, piezas de repuesto, etc.).
Staccare “Avviso di messa in servizio” e rispedirlo debitamente compilato alla MTU Friedrichshafen
GmbH.
Le informazioni ivi registrate sono la base per il supporto logistico contrattuale (garanzia, ricambi, ecc.).
É gentileza cortar o cartão ”Participação da colocação em serviço”, preenché-lo e devolvé-lo a MTU

Friedrichshafen.
Os dados referentes à colocação em serviço representam a base para o suporte logístico (garantia, peças
sobressalentes, etc.) estabelecido contratualmente.
Postcard
MTU Friedrichshafen GmbH

Abteilung SCSD
88040 Friedrichshafen
GERMANY
Bitte in Blockschrift ausfüllen!
Please use block capitals!
Prière de remplir en lettres capitales!
¡A rellenar en letras de imprenta!
Scrivere in stampatello!
Favor preencher com letras de forma!!
Motornr.: Auftragsnr.:
Engine No.: MTU works order No.:
No du moteur: No de commande: Inbetriebnahmemeldung
No de motor: No de pedido:
Motore N.: N. commessa:
No. do motor No. do pedido
Commissioning Note
Motortyp: Inbetriebnahmedatum:
Engine model: Date put into operation:
Type du moteur: Mise en service le: Notice de mise en service
Tipo de motor: Fecha de puesta en servicio:
Motore tipo: Messa in servizio il:
Tipo do motor Data da colocação em serviço:
Aviso de puesta en servicio
Eingebaut in: Schiffstyp / Schiffshersteller:
Installation site: Vessel/type/class / Shipyard:
Lieu de montage: Type du bateau / Constructeur: Avviso di messa in servizio
Lugar de montaje: Tipo de bugue / Constructor:
Installato: Tipo di Barca / Costruttore:
Incorporado em: Tipo de embarcação/estaleiro naval:
Participação da colocação
Endabnehmer/Anschrift: em serviço
End user‘s address:
Adresse du client final:
Dirección del cliente final:
Indirizzo del cliente finale:
Usuário final/endereço:
Bemerkung:
Remarks:
Remarques:
Observaciones:
Commento:
Observações:
Amendment Service!
Any changes in contents will be sent to you in the form of an amendment,
provided you complete the reverse of this receipt card and return it to us.
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MTU Friedrichshafen GmbH

Department SCT
88040 Friedrichshafen
Germany
No. Date Name
Please mark all filed amendments here.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Please use block capitals! 14.

15.
16.
Receipt Amendment No. 1.

2.
3.
Publication number:
4.
M015465/30E
5.
6.
Name 7.
Manufacturer 8.
9.
Department
10.
Fax Telephone 11.
Street 12.
13.
Postal box number
14.
(Postal code) City 15.
Country 16.
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.
M015465/30E 01-06 E MTU

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 light-beam procedures and measurement work, only the following laser devices must be used:
• Laser devices of classes 1, 2 or 3A,
• Laser devices of class 3B, which have maximum output 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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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!
Note cooling period for components which are heated for installation or removal. ⇒ Risk of injury!
Take special care when removing ventilation or plugs from engine. 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 only 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).
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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 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.
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Page 5
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!
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Page 6
⇒ 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 air 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”!
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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!
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
A000.000.14 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
A000.000.17 Main engine specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
A000.000.19 Engine power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
A000.000.21 Operational data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
A000.000.25 Engine and exhaust noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
A050.000.01 Timing data (valve clearance adjusted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
A055.050.01 Valve clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
A170.000.01 Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
A180.000.01 Oil capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
A202.000.01 Coolant capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
A213.000.01 AC Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
M015465/30E 01-06 E MTU

Section A Product Summary
E MTU M015465/30E 01-06

Page 1
A000.000.01 Engine layout

Illustrations may show additional equipment
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
M015465/30E 01-06 E MTU

Page 2
1 Air filter 10 Oil pan

2 Crankcase ventilation 11 Oil dipstick
3 Charge air line 12 Oil drain plug
4 Exhaust turbocharger 13 Starter
5 Charge air coolant outlet 14 Flywheel
6 Cylinder head cover / cylinder head 15 Flywheel housing
7 Engine lifting eyes 16 Charge air line
8 Engine coolant pump 17 Governor / engine control system
9 Oil filler neck 18 Intercooler
A000.000.03 Engine model designation

Key to engine model designation 16V4000G60, 16V4000G80
16 = number of cylinders
V = Vee configuration
4000 = displacement per cylinder in cm3
G = application for stationary power generation
6, 8 = external charge air cooling
0 = design index
E MTU M015465/30E 01-06

Page 3
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. 2880 mm
B =
Overall width . . . . . . . . . . . . . . approx. 1340 mm
C =
Overall height . . . . . . . . . . . . . approx. 1710 mm
D =
Engine length to flange
surface . . . . . . . . . . . . . . . . . . . approx. 2620 mm
E = Crankshaft centerline to
oil pan . . . . . . . . . . . . . . . . . . . . . approx. 625 mm
F = Crankshaft centerline to
engine mount . . . . . . . . . . . . . . approx. 195 mm
M015465/30E 01-06 E MTU

Page 4
A000.000.13 Engine weight

Engine dry weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 6700 kg
A000.000.14 Transport
Illustration also applies to 16V 4000 G
ÇÇ Lift the engine only with the lifting eyes provided.
ÇÇ ÇÇ Use only the transport and lifting equipment ap-
ÇÇ ÇÇ proved by MTU.
ÇÇ The engine must only be transported in installation

position.
ÇÇ
ÇÇ
ÇÇÇ
ÇÇÇ
F000 0118a0
A000.000.17 Main engine specifications

Operating method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . four-stroke cycle, single-acting
Combustion method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . direct injection
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Displacement, total . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64.96 litres
Compression ratio (16V4000G60) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.6 : 1
Compression ratio (16V4000G80) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.7 : 1
Direction of rotation (viewed on driving end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c.c.w. (non-reversible)
Firing order . . . . . . . . . . . . . . . . . . . A1 - A7 - B4 - B6 - A4 - B8 - A2 - A8 - B3 - B5 - A3 - A5- B2 - A6 - B1 - B7
Final compression pressure at 120 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 to 24 bar
Firing speed at 40 °C engine coolant temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 80 - 120 1/rpm
Mean piston speed at 1500 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 m/s
Mean piston speed at 1800 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4 m/s
E MTU M015465/30E 01-06

Page 5
A000.000.19 Engine power

Continuous power at (16V4000G60) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 kW at 1500 1/rpm
Continuous power at (16V4000G80) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1495 kW at 1800 1/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
M015465/30E 01-06 E MTU

Page 6
A000.000.21 Operational data

The Engine Acceptance Test Records operational data are binding.
All figures relate to the engine at operating temperature.
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.
Coolant system Unit Normal Limit

Coolant preheat temperature °C > 40 -
Coolant temperature at engine outlet °C 93 -
Coolant temperature after engine - warning °C 95 -
Coolant temperature after engine - shutdown °C - 97
Coolant pump: pressure differential for 16V4000G60 bar 2.0 -
Coolant pump: pressure differential for 16V4000G80 bar 3.0 -
Pressure loss in engine-external cooling system, max. perm. bar - 0.7
Lube oil system
Lube oil operating temperature before engine °C 85 - 95
Lube oil operating temperature before engine - warning °C 95 -
Lube oil operating pressure before engine bar 5.0 - 6.0
Lube oil pressure before engine - warning bar 4.5 -
Lube oil pressure before engine - shutdown bar - 4.0
Fuel system
Priming pressure before engine delivery pump “min” bar - 0.1
Priming pressure before engine delivery pump “max” bar - 1.5
Fuel temperature differential before/after engine °C 35 -
Peripheral conditions for max. power
Intake depression mbar 15 30
Exhaust backpressure mbar 30 50
Air / Exhaust
Charge pressure before cylinder bar abs 2.6 -
Exhaust temperature, after turbocharger for 16V4000M60 °C 460 -
Exhaust temperature, after turbocharger for 16V4000M80 °C 420 -
Consumption
Spec. Fuel consumption for 16V4000G60 g/kWh(1) 192 202
Spec. Fuel consumption (emission-optimised as per
Clear-Air Standard) for 16V4000G60 g/kWh(1) 210 221
Spec. Fuel consumption for 16V4000G80 g/kWh(1) 195 205
(1) in
continuous operation and using fuel in accordance with the current MTU Fluids
and Lubricants Specification
Lube oil consumption after 100 hrs. running time, average %(1) 0.5 1.0
(1) of fuel consumption in continuous operation with run-in engine
E MTU M015465/30E 01-06

Page 7
A000.000.25 Engine and exhaust noise

Applicable to engine model 16V4000G60
Engine surface noise (free-field level) at distance of 1 m approx. 104dB (A)
Undamped exhaust noise (free-field level)
at distance of 1 m approx. 113dB (A)
Applicable to engine model 16V4000G80
Engine surface noise (free-field level) at distance of 1 m approx. 104dB (A)
Undamped exhaust noise (free-field level)
at distance of 1 m approx. 113dB (A)
A050.000.01 Timing data (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
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 oil dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 190 litres
- to upper mark on dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 230 litres
Total capacity
- for initial filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 290 litres
- for oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 250 litres
M015465/30E 01-06 E MTU

Page 8
A202.000.01 Coolant capacity

- Engine circuit (without cooler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 175 litres
- Charge air circuit (without cooler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 40 litres
A213.000.01 AC Alternator
- Rated voltage of alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 VDC
- Max. charge current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 A
E MTU M015465/30E 01-06

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
C000.000.17 Engine transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
M015465/30E 01-06 E MTU

Section C Operating Instructions
E MTU M015465/30E 01-06

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.
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 (B1)
- B2- Before-Operation Services after an extended operational shutdown (exceeding 1 week) (B2)
- B3- Before-Operation Services before initial start-up of a new or preserved engine (B3).
Correct engine installation and alignment according to our regulations are basic requirements for initial engine start-
ing.
In the event of an engine malfunction a decision must be made as to whether
- The engine is to be shut down
- Operation may be continued, for a short period, using emergency measures, until rectification can be effected.
Prior to engine shutdown it must be determined whether:
- A short, scheduled operational shutdown,
- An extended out-of-service period.
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.
M015465/30E 01-06 E MTU

Page 2
C000.000.03 Preparations for initial operation

Code No. Task Description B 1 2 3
G124.051.01 Charge air manifold Check drain bore for water discharge and obstruction
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
G202.651.01 Engine coolant system Check vent line for obstructions
G203.051.01 Charge air coolant system Check vent line for obstructions
G307.001.01 Accessories, mechanical Ensure guards are installed
G500.000.09 Engine wiring Check
K000 Depreservation Carry out before-operation services
G055.000.03 Valve gear Lubricate
G080.000.03 Fuel system Fill system
G083.101.01 Fuel prefilter Prime
G120.000.07 Air system Check
G140.000.03 Exhaust system Check
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
G203.051.01 Charge air coolant system Check vent line for obstructions
G213.051.05 Generator Install/replace drive belt
- Battery Before putting into operation, carry out tasks specified in Manufacturer’s Documentation.
G364.200.03 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
T036.051.01 Crankshaft Ensure transportation locking device is removed
T231.001.01 Engine mounting Ensure locking device is removed
E MTU M015465/30E 01-06

Page 3
C000.000.05 Initial operation
Code No. Task Description

G000.000.07 Engine Turn engine on starter:
- only for 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 startup 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 Check fuel delivery pump supply pressure
G120.000.05 Engine test run Intake air system - intake depression check
G140.000.09 Engine test run Exhaust system - exhaust overpressure check
C000.000.07 Operational checks -Maintenance Echelon W1-

Carry out tasks specified in Maintenance Schedule (Section D).
C000.000.09 Shutdown

G000.000.23 Engine Shut down engine
C000.000.11 After shutdown

G202.000.07 Engine coolant Drain (1)
G500.000.03 Engine control system Switch off
(1) only when freezing temperatures are expected and the engine is to remain out of service for an extended period and
- the engine coolant has no antifreeze additive
- 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 addi-
tive conforms to the current MTU/DDC Fluid and Lubricants Specification.
M015465/30E 01-06 E MTU

Page 4
C000.000.13 Out-of-service period

If the engine is to remain out of service for more than 1 week, seal the engine air and exhaust sides.
If the engine is to remain out of service for more than 3 months, carry out preservation in accordance with Section K.
C000.000.17 Engine transportation

Before transporting the engine, the transportation locking devices for the crankshaft (Section T) must be installed.
The engine must only be lifted using the lifting eyes provided.
E MTU M015465/30E 01-06

Maintenance Schedule Section D
Contents
D000.000.01 Maintenance schedule - Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

D000.000.03 Maintenance system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D000.000.05 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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
M015465/30E 01-06 E MTU

Section D Maintenance Schedule
E MTU M015465/30E 01-06

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 disassembly.
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.
D000.000.05 Application
3A: Continuous operation, unrestricted
M015465/30E 01-06 E MTU

Page 2
D000.000.07 Maintenance frequency chart
Maintenance echelon W1: Operational checks Daily

W2: Operating hours 500
Limit (months) 6
W3: Operating hours 1 000
Limit (year) 1
Limit (years) 2
Limit (years) 6
Limit (years) 16
D000.000.11 Maintenance schedule

Code 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 tightness of securing bolts
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 Maintenance Echelon W1

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 supply pipework 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
E MTU M015465/30E 01-06

Page 3
Code Maintenance Echelons W 2 3 4 5

G083.051.03 Fuel duplex filter Replace filter element
G083.101.09 Fuel prefilter Replace filter element
G083.101.15 Fuel prefilter Clean
G120.000.03 Air supply pipework 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
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
G075.051.05 Fuel injectors Replace
G121.051.01 Air filter Replace
G172.051.09 Starter Check condition (visual inspection)
G213.051.01 Generator drive Check drive belt condition and tension
G213.051.09 Generator Check condition (visual inspection)
G231.051.01 Engine mounting Check tightness of securing bolts
G231.051.03 Engine mounting Check condition of resilient mounts
G231.051.11 Engine mounting Check buffer clearance
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 heads Remove, check valve guides, recondition valves and valve seats
Replace O-rings on protective sleeves
Replace gaskets
Running gear Check piston crowns (visual inspection)
Crankcase Check wear pattern of cylinder liners
Vibration damper Remove, check, repair if necessary
Exhaust turbocharger Replace
Air supply pipework Remove, clean, and replace gaskets
Intercooler Remove, clean, check for leaks, replace gaskets
H.P. fuel pump Replace
H.P. fuel sensor Replace
Engine coolant pump Disassemble, check components, replace gaskets
M015465/30E 01-06 E MTU

Page 4
Charge air coolant pump Disassemble, check components, replace gaskets

Engine coolant cooler Clean, check for leaks
Charge air coolant cooler Clean, check for leaks
Engine coolant thermostat Check, replace thermal element
Charge air coolant thermostat Check, replace thermal element
Engine coolant preheating Overhaul
Engine oil heat exchanger Remove, clean and check for leaks, replace sealing rings
Crankcase breather Replace filter element
Centrifugal oil filter Check, replace bearing if necessary
D000.000.15 Maintenance echelon W6

The W6 echelon requires complete disassembly of the engine. Repair/overhaul of the relevant components is de-
termined by the actual condition of the components and their dimensions, which are referenced to the Tolerances
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 3 months, carry out engine preservation in accordance with
Section K.
E MTU M015465/30E 01-06

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
E070.000.01 Fuel pressure too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
E070.000.03 Fuel pressure too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
E073.051.01 H.P. pump leaking at relief bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
E080.000.01 Fuel pressure too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
E101.011.01 Abnormal turbocharger running noises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
E110.000.01 Charge air temperature too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
E110.000.03 Charge air pressure too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
E114.051.01 Coolant discharge at intercooler relief bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
E140.000.01 Exhaust gases black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
E140.000.02 Exhaust gases blue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
E140.000.03 Exhaust gases white . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
E140.000.05 Exhaust temperature too high (individual cylinder) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
E140.000.07 Exhaust temperature too low (individual cylinder) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
E140.000.09 Exhaust bulk temperature too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
E180.000.01 Engine oil consumption abnormally high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
E180.000.03 Engine oil level abnormally high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
E180.000.05 Engine oil temperature too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
E180.000.07 Engine oil pressure too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
E180.000.09 Engine oil pressure too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
E180.000.11 Engine oil in coolant system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
E202.000.01 Engine coolant temperature too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
E202.000.02 Engine coolant temperature too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
E202.000.05 Engine coolant pressure too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
E202.000.08 Engine coolant level too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
E202.000.09 Engine coolant level rising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
E202.051.01 Engine coolant pump leaking at relief bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
E202.400.01 Preheat temperature too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
E203.000.01 Charge air coolant temperature too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
E203.000.03 Charge air coolant temperature too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
E203.000.05 Charge air coolant pressure too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
E203.000.09 Charge air coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
E203.051.01 Charge air coolant pump leaking at relief bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
M015465/30E 01-06 E MTU

Section E Troubleshooting
E MTU M015465/30E 01-06

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:
The anti-corrosive protection is restricted to a few days. Repair the engine as soon as possible and thoroughly clean the components.
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 the 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
ÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ
Probable Causes
ÁÁÁÁÁÁÁÁÁÁÁÁÁ Check Remedial Action
Battery
ÁÁÁÁÁÁÁÁÁÁÁÁÁ Battery charge state Charge battery, replace if necessary
Starter
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
Cable connections
Starter/engine wiring
Connect, replace if necessary
Connect, replace if necessary
ÁÁÁÁÁÁÁÁÁÁÁÁÁ Start repeat relay Replace
Starter Replace
Ring gear Replace
Running gear blocked Whether engine can be turned by Repair running gear
hand
Engine wiring ÁÁÁÁÁÁÁÁÁÁÁÁÁ Engine wiring Check - see G500.000.09
E000.000.03 Engine turns but does not fire
Probable Causes
Fuel pressure too low
Engine does not reach firing
Fuel pressure
Battery
See E070.000.01
Charge, replace if necessary
speed
Engine wiring
ÁÁÁÁÁÁÁÁÁÁÁÁÁ Engine wiring (G500.000.09)
M015465/30E 01-06 E MTU

Page 2
E000.000.05 Engine fires unevenly

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Probable Causes
Engine coolant preheat tempera-
Check
Preheat temperature
Remedial Action
See E202.400.01
ture too low
Fuel system is not yet vented
Whether engine fires steadily after -
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ short period
Fuel injection equipment faulty Injectors Replace (G075.051.05)
Engine wiring
ÁÁÁÁÁÁÁÁÁÁÁÁÁ Engine wiring Check - see G500.000.09
E000.000.07 Engine does not reach full-load speed
Probable Causes ÁÁÁÁÁÁÁÁÁÁÁÁÁ Check Remedial Action
Á
bustion air ÁÁÁÁÁÁÁÁÁÁÁÁÁ
Engine receiving insufficient com- See E110.000.03
-
Engine receiving insufficient fuel See E080.000.01 -
H.P. pump generating insufficient
See E070.000.01 -
pressure
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)
E000.000.09 Engine speed not steady
Probable Causes Check Remedial Action
H.P. pump
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Fuel pressure with dialogue unit/ Contact MTU Service
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ data recorder
Suction valve sluggish
ÁÁÁÁÁÁÁÁÁÁÁÁÁ Check suction valve for ease of Repair, replace if necessary
Speed sensor faulty
movement
Crankshaft speed sensor -
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ (G510.000.01)
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Camshaft speed sensor
(G510.000.01)
-
E MTU M015465/30E 01-06

Page 3
E070.000.01 Fuel pressure too low

Probable Causes
Pressure sensor faulty Pressure sensor (G510.000.01) -
H.P. pump of fuel quantity regula-
tor/pressure regulator (actuating
Suction valve Repair, replace if necessary
solenoid)
Pressure relief valve leaking Fuel return from pressure relief Replace pressure relief valve
Fuel pressure less than 4 bar
valve
See E080.000.01 -
H.P. pump generating insufficient Fuel pressure with dialogue unit/ Replace H. P. fuel pump
pressure
ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ data recorder
Fuel injector faulty
ÁÁÁÁÁÁÁÁÁÁÁÁÁ Fuel pressure with dialogue unit/ Replace injector
data recorder (G075.051.05)
E070.000.03 Fuel pressure too high

Probable Causes
Check
Intake restrictor in control block of -

Remedial Action
Contact MTU Service
Pressure sensor faulty Pressure sensor (G510.000.01) Replace pressure sensor
E073.051.01 H.P. pump leaking at relief bore

Probable Causes
H.P. pump seals leaking For engine oil or fuel discharge Replace H. P. fuel pump
E080.000.01 Fuel pressure too low
Fuel prefilter
ÁÁÁÁÁÁÁÁÁÁÁÁÁ - Clean fuel prefilter (G083.101.15)
Fuel filter contaminated - Replace filter (G083.051.03)
Fuel system leaking
ÁÁÁÁÁÁÁÁÁÁÁÁÁ Engine for leaks Seal pipework
Fuel delivery pump faulty - Contact MTU Service
E101.011.01 Abnormal turbocharger running noises
Exhaust turbocharger faulty Replace - see Assembly Manual
M015465/30E 01-06 E MTU

Page 4
E110.000.01 Charge air temperature too high

Probable Causes
Intercooler dirty
Check
-
Remedial Action
Contact MTU Service
E110.000.03 Charge air pressure too low
Engine receiving insufficient com- Air filter contamination indicator
bustion air
ÁÁÁÁÁÁÁÁÁÁÁÁÁ (G121.052.01)
Replace air filter (G121.051.01)
Pressure sensor faulty
Exhaust turbocharger faulty
Pressure sensor (G510.000.01) -
Replace
E114.051.01 Coolant discharge at intercooler relief bore
Probable Causes
Check Remedial Action
Intercooler leaking
ÁÁÁÁÁÁÁÁÁÁÁÁÁ - Contact MTU Service
E140.000.01 Exhaust gases black
Probable Causes
Engine receiving insufficient com- Air filter contamination indicator Replace air filter (G121.051.01)
bustion air
(G121.052.01)
- Replace injector (G075.051.05)
Power take-off too high, engine Auxiliary PTO (power consumption Contact MTU Service
overload
too high) dialogue unit/data recorder
(speed-sensitive fuel limiter actual/
specified injection)
E140.000.02 Exhaust gases blue
chambers ÁÁÁÁÁÁÁÁÁÁÁÁÁ
Too much oil in combustion
Engine oil level (G180.000.01)
Exhaust turbocharger
Correct oil level (G180.000.01)
Replace - see Assembly Manual
ÁÁÁÁÁÁÁÁÁÁÁÁÁ Valve stem seals Replace - see Assembly Manual
Piston rings Replace - see Assembly Manual
Valve guides Replace - see Assembly Manual
ÁÁÁÁÁÁÁÁÁÁÁÁÁ Cylinder liners Replace - see Assembly Manual
E MTU M015465/30E 01-06

Page 5
E140.000.03 Exhaust gases white

Probable Causes
ÁÁÁÁÁÁÁÁÁÁÁÁÁ - Replace injector (G075.051.05)
Coolant in combustion chambers - Contact MTU Service
E140.000.05 Exhaust temperature too high (individual cylinder)

Probable Causes
Fuel injector faulty ÁÁÁÁÁÁÁÁÁÁÁÁÁ
Check
-
Remedial Action
Replace injector (G075.051.05)
Limiting valve
- Replace (G077.051.05)
E140.000.07 Exhaust temperature too low (individual cylinder)

Probable Causes
Fuel injector faulty - Replace injector (G075.051.05)
Limiting valve - Replace (G077.051.05)
E140.000.09 Exhaust bulk temperature too high

Probable Causes
Engine receiving insufficient com- Air filter contamination indicator Replace air filter (G121.051.01)
bustion air (G121.052.01)
Exhaust manifolds contaminated - Contact MTU Service
E180.000.01 Engine oil consumption abnormally high

Probable Causes
Engine oil system leaking
Check
Engine for leaks

Remedial Action
Seal pipework
externally
E180.000.03 Engine oil level abnormally high
Probable Causes
Fuel or engine coolant in engine Engine oil quality Contact MTU Service
oil (G180.000.04).
E180.000.05 Engine oil temperature too high

Probable Causes
Engine oil heat exchanger
Check
-
Remedial Action
Contact MTU Service
M015465/30E 01-06 E MTU

Page 6
E180.000.07 Engine oil pressure too high

Probable Causes
Oil viscosity too high
Check
Engine oil for viscosity

Remedial Action
Change engine oil (G180.000.05)
ÁÁÁÁÁÁÁÁÁÁÁÁ (G180.000.04)
Engine coolant in engine oil Engine oil quality (G180.000.04) Contact MTU Service
Pressure sensor faulty Pressure sensor (G510.000.01) -
E180.000.09 Engine oil pressure too low
After oil filter change, the pure oil Drain plugs on equipment carrier Close drain plugs
or contaminated oil drain plugs on
equipment carrier are still open
Oil level too low Engine oil level (G180.000.01) Add engine oil (G180.000.03)
Engine oil system leaking Engine for leaks Seal pipework
externally
Fuel in engine oil Engine oil quality See E180.000.03
Engine oil filter dirty - Replace filter (G183.052.03)
Engine oil pressure relief valve
Engine oil pump
Contact MTU Service
Contact MTU Service
Pressure loss in running gear Contact MTU Service
E180.000.11 Engine oil in coolant system
Probable Causes
Oil heat exchanger leaking - Contact MTU Service
E202.000.01 Engine coolant temperature too high
Probable Causes
Engine coolant level too low Engine coolant level (G202.000.03) Top up engine coolant (G202.000.01)
Engine coolant thermostat - Contact MTU Service
Engine coolant system contami- - Contact MTU Service
nated
E202.000.02 Engine coolant temperature too low
Probable Causes
Engine coolant thermostat - Contact MTU Service
E MTU M015465/30E 01-06

Page 7
E202.000.05 Engine coolant pressure too low

Probable Causes
Engine coolant system leaking
Check
Engine for leaks

Remedial Action
Seal pipework
externally
Engine coolant system leaking in-
Engine oil quality (G180.000.04) Contact MTU Service
ternally
Engine coolant pump faulty Engine coolant pump Replace - see Assembly Manual
E202.000.08 Engine coolant level too low
Engine coolant system leaking Engine for leaks Seal pipework
externally
Engine coolant system leaking in- Engine oil quality (G180.000.04) Contact MTU Service
ternally
E202.000.09 Engine coolant level rising
Probable Causes
Engine oil in engine coolant Coolant quality Contact MTU Service
(G202.000.05)
ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ Engine oil heat exchanger Repair, replace if necessary
Air in engine coolant
ÁÁÁÁÁÁÁÁÁÁÁÁÁ Vent lines Clean
E202.051.01 Engine coolant pump leaking at relief bore
Engine coolant pump leaking
For oil discharge Replace sealing ring.
Replace engine coolant pump if
necessary
For water discharge Replace rotary seal
ÁÁÁÁÁÁÁÁÁÁÁÁÁ Replace engine coolant pump if
E202.400.01 Preheat temperature too low
necessary
Probable Causes
Preheating unit not working Preheating unit switched on Switch on preheating unit
(G202.401.01)
No power supply for preheater Power supply available Provide power supply
E203.000.01 Charge air coolant temperature too high
Charge air coolant level too low
Charge air coolant level
(G203.000.03)
Fill system with charge air coolant
(G203.000.01).
M015465/30E 01-06 E MTU

Page 8
Probable Causes
ÁÁÁÁÁÁÁÁÁÁÁÁÁCheck Remedial Action
Charge air coolant system con- - Contact MTU Service
taminated
Charge air coolant thermostat - Contact MTU Service
Charge air coolant pressure too See E203.000.05 -
low
Temperature sensor faulty Temperature sensor (G510.000.01) -
E203.000.03 Charge air coolant temperature too low

Probable Causes
Charge air coolant thermostat - Contact MTU Service
Temperature sensor faulty Temperature sensor (G510.000.01) -
E203.000.05 Charge air coolant pressure too low
Charge air coolant system leaking Engine for leaks Seal pipework
externally
Intercooler leaking
ÁÁÁÁÁÁÁÁÁÁÁÁÁCoolant discharge from condensate -
ÁÁÁÁÁÁÁÁÁÁÁÁ drain bore (G124.051.01)
Charge air coolant pump faulty Engine coolant pump Replace - see Assembly Manual
E203.000.09 Charge air coolant level
Probable Causes
ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁCheck Remedial Action
Air in charge air coolant Vent lines Clean
E203.051.01 Charge air coolant pump leaking at relief bore

Probable Causes
Charge air coolant pump leaking For oil discharge Replace sealing ring
Engine coolant discharge Replace rotary seal
ÁÁÁÁÁÁÁÁÁÁÁÁÁ Replace coolant pump if necessary
E MTU M015465/30E 01-06

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
G000.000.09 Engine starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
G000.000.11 Engine warm-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
G000.000.13 Engine speed check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
G000.000.15 Pressure checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
G000.000.17 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
G000.000.25 Emergency shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
G000.000.27 Attachments security check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
G000.000.29 Attachments, hoses and hose connections check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
G000.000.33 Cylinder chamber endoscopic examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
G000.000.39 Cleaning engine externally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
G030.001.01 Engine barring tool installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
G030.001.03 Engine barring tool removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
G055.000.01 Valve gear oil supply check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
G055.000.03 Valve gear lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
G055.050.01 Valve clearance check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
G055.050.03 Valve clearance adjustment (valve bridge with adjusting screw M16
(Locknut 24 AF)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
(Locknut 19 AF)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
G055.101.01 Cylinder head cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
G055.101.03 Cylinder head cover installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
G073.051.07 High-pressure pump, relief bore obstruction check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
G075.051.01 Injector removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
G075.051.05 Injector replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
G075.051.09 Injector installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
G077.051.05 Limiting valve replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
G080.000.03 Fuel system filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
G080.000.05 Fuel system, fuel delivery pump supply check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
G083.051.03 Fuel duplex filter replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
G083.101.01 Fuel prefilter priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
G083.101.03 Fuel prefilter, water and contaminants draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
G083.101.09 Fuel prefilter, element and gasket replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
G083.101.15 Fuel prefilter cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
G101.011.05 Exhaust turbocharger connections check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
G120.000.03 Intake air system, intake side leak and damage check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
M015465/30E 01-06 E MTU

Section G Task Description
G120.000.05 Intake air system, intake depression check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

G120.000.07 Intake air system, cover removal check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
G121.051.01 Air filter element replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
G123.053.01 Contamination indicator, signal ring position check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
G123.053.10 Contamination indicator resetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
G124.051.01 Charge air manifold, drain water discharge and obstruction check . . . . . . . . . . . . . . . . . . . . . . . 35
G124.051.03 Charge air manifold drain cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
G140.000.01 Exhaust system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
G140.000.03 Exhaust system security check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
G140.000.05 Exhaust system, exhaust gas colour check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
G140.000.07 Exhaust system, cover removal check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
G140.000.09 Exhaust system, exhaust backpressure check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
G146.000.01 Exhaust system, security and exhaust manifold insulation checks . . . . . . . . . . . . . . . . . . . . . . . 37
G172.051.09 Starter condition check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
G180.000.01 Engine oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
G180.000.03 Engine oil system filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
G180.000.04 Engine oil sample extraction and analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
G180.000.05 Engine oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
G180.000.07 Engine oil draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
G180.000.09 Corrosion inhibitor oil filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
G180.000.11 Corrosion inhibitor oil draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
G183.052.03 Engine oil filter replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
G183.101.01 Centrifugal oil filter cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
G202.000.01 Engine coolant system filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
G202.000.03 Engine coolant level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
G202.000.05 Engine coolant sample extraction and analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
G202.000.07 Engine coolant draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
G202.000.09 Engine coolant change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
G202.051.01 Engine coolant pump relief bore check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
G202.400.01 Engine coolant preheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
G202.401.01 Engine coolant preheating unit initial operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
G202.401.07 Preheater draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
G202.651.01 Engine coolant system, vent line obstruction check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
G203.000.01 Charge air coolant system filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
G203.000.03 Charge air coolant level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
G203.000.05 Charge air coolant draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
G203.000.07 Charge air coolant sample extraction and analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
G203.000.09 Charge air coolant changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
G203.051.01 Charge air coolant pump relief bore check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
G203.551.01 Charge air coolant system, vent line obstruction check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
G205.051.01 Engine coolant cooler, external element contamination check . . . . . . . . . . . . . . . . . . . . . . . . . . 56
G205.051.01 Engine coolant cooler, external element contamination check . . . . . . . . . . . . . . . . . . . . . . . . . . 56
G205.051.03 Charge air coolant cooler, external element contamination check . . . . . . . . . . . . . . . . . . . . . . . 57
G208.101.01 Valve cover opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
E MTU M015465/30E 01-06

G208.101.03 Valve cover closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

G213.051.01 Generator drive, drive belt condition and tension check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
G213.051.08 Generator condition check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
G231.051.01 Engine mount security check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
G231.051.03 Engine mount resilient element check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
G231.051.07 Engine mount buffer clearance check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
G250.000.01 Drive system (driving end) security check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
G252.051.01 Coupling condition check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
G303.000.01 Compressed air system condensate draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
G303.000.03 Compressed air system, operating pressure check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
G307.001.01 Protective device check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
G309.001.01 Battery check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
G309.001.03 Battery filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
G309.001.05 Battery charge state check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
G364.050.01 Fuel supply check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
G364.200.01 Fuel supply system, shut-off valve closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
G364.200.03 Fuel supply system, shut-off valve opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
G365.000.01 Exhaust system condensate draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
G365.000.03 Exhaust system drain obstruction check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
G500.000.01 Engine control system switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
G500.000.03 Engine control system switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
G500.000.07 Engine control system initial operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
G500.000.09 Engine wiring check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
G510.000.01 Monitoring system, equipment function check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
G510.070.01 Monitoring equipment lamp test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
M015465/30E 01-06 E MTU

E MTU M015465/30E 01-06

Page 1
G000.000.01 Engine start disabling

Switch off power supply for Engine Control System at
control panel.
Note:
Control panel description - see Manufacturer’s Documenta-
tion.
Disconnect battery.
Shut off fuel supply to engine (G364.000.01).
Attach “Danger” sign to control panel.
G000.000.03 Engine start release

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

Special tools:
- Engine barring tool: 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).
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Page 2
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 protective
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.
Disconnect plug-in connection (X4) from ECU.

Engine start (engine barring) by pressing start button
- see G000.000.09.
Note:
Engine start is automatically interrupted after approx. 5 sec-
onds. If necessary, repeat engine start after approx. 10 sec-
onds.
Screw plug-in connection (X4) to ECU -

see G508.000.01.
G000.000.09 Engine starting
DANGER
After working on the engine, check that all protective
devices have been reinstalled and all tools removed
from the engine.
When the preparatory work has been carried out in

accordance with the Operating Instructions (Sec-
tion C), the engine can be restarted.
Note:
Always start the engine under no-load conditions.
Carry out engine start procedure.

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 speci-
fied in Engine Monitoring, the engine is shut down by the
Engine Control System.
Determine cause and rectify.
E MTU M015465/30E 01-06

Page 3
G000.000.11 Engine warm-up procedure

Operate the engine with load increasing as slowly as
possible until an engine coolant temperature of 40 °C
has been reached.
Note:
Operate the engine at full load only after coolant has reached
a temperature of 40 5C.
G000.000.13 Engine speed check

Check rated speed.
G000.000.15 Pressure checks

Check engine coolant temperature.
Specified values (A000.000.21)
G000.000.17 Temperature checks

Check engine coolant temperature (where gauges
are installed).
For specified values, see operational data
(A000.000.21).
G000.000.19 Engine running noise check

Operate engine at rated 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.
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Page 4
G000.000.23 Engine shutdown

Note:
Never shut down engine directly from full-load operation, as
this may result in overheating and wear of the engine compo-
nents.
Before shutting down, disengage the alternator and

run the engine at rated speed until a falling then con-
stant temperature is recorded.
Press shutdown button on control panel.
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)
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Page 5
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.
G000.000.33 Cylinder chamber endoscopic examination

Note:
For engines in service, if possible carry out a combustion
chamber endoscopic examination after operation under load.
Use an endoscope with an adequate light rating and a prism
(5) which pivots 95 (total viewing angle 1405), see -No. 1-.
If an endoscope with pivoting prism is not available, individ-
ual endoscopes with prism settings of 05, 455 and 905 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 at a position which permits unob-
structed and exact inspection of components for in-
specting piston crown and cylinder head lower side
and valves.
- all valves are open or closed for inspection of valves
and valve seats.
Endoscopic examination:
Connect endoscope to light source (4) and insert it
through the cylinder head (fuel injector bore) to the
combustion chamber.
Use the focussing device (2) to focus the eyepiece
(1) and adjuster ring (3) to align the prism (5) with
the area under inspection.
Visually assess the cylinder liners, piston crowns,
underside of the cylinder heads and valves.
To do this, rotate the endoscope through 360 in
each case and set the prism accordingly.
M015465/30E 01-06 E MTU

Page 6
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:
- 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).
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Page 7
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.
When removing deposits and/or cleaning, use only

non-chemical cleaning agents which do not damage
light-alloy, non-ferrous, steel, gray cast iron and elas-
tomers.
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 contamina-
tion, 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 (temperature
transmitter, pressure transmitter, terminal) may lead to mal-
functions and engine failure.
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Page 8
G030.001.01 Engine barring tool installation

Special tools:

Remove cover from flywheel housing.
Engage engine barring tool (1) with ring gear (2) and
attach to flywheel housing.
G030.001.03 Engine barring tool removal

Remove engine barring tool from flywheel housing.
Screw cover to flywheel housing.
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Page 9
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).

Remove cylinder head cover (G055.101.01).
Check that the rocker arms and the cylinder head
cover (inside) are coated with oil.
Install cylinder head cover (G055.101.03).
G055.000.03 Valve gear lubrication

Note:
The oil chambers must be filled with oil during initial oper-
ation, 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.
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Page 10
G055.050.01 Valve clearance check

Special tools:
- Feeler gauge: Y2 0010 128
Note:
Check with the valve closed and when coolant temperature
does not exceed 40 5C.

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.
Check 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.
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Page 11
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.

(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 equalisation be checked.

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Page 12
Adjusting valve clearance in two crankshaft posi-

tions.

X = Exhaust valve.
O = Inlet valve.
Checking valve bridge adjustment
Use feeler gauge to determine distance between

valve bridge and rocker arm.
Note:
gap.
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Page 13
Place feeler gauge with determined value between

valve bridge and valve shaft end (A).
At the other valve shaft end (B), a feeler gauge
which is either thicker or thinner by 0.05 mm, must
not pass through; if necessary, adjust valve bridge
equalisation.
Carry out this procedure on all valve bridges before
adjusting valve clearance.
Adjusting valve bridge
CAUTION
To release the locknut, the valve bridge must
be held firmly with the retaining device, other-
wise 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.
M015465/30E 01-06 E MTU

Page 14
Release locknut.
Withdraw locating pin of retaining device from oil

bore of valve bridge.
Place a feeler gauge of determined distance (dis-

tance between valve bridge and rocker arm) be-
tween valve bridge and valve stem ends (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:
Adjusting screws and locknuts that do not turn easily must
be reconditioned or replaced.
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Page 15
Insert locating pin of retaining device into oil bore of

valve bridge.
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.
Remove retaining device.
Again check valve bridge adjustment.
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
Release locknut (1).
Insert feeler gauge between valve bridge and rocker
arm.
Adjust adjusting screw (2) with Allen key until ap-
propriate valve clearance is achieved.
Valve clearance with engine cold:
Inlet valve (long rocker arm) = 0.20 mm
Exhaust valve (short rocker arm) = 0.50 mm.
It must be possible to just pull the feeler gauge
through the gap.
Use torque wrench to tighten locknut (1), holding ad-
justing screw (2) firmly in position.
Tightening torque: 90 Nm + 9 Nm.
Lubricant: Engine oil.
Note:
Check valve clearance.

M015465/30E 01-06 E MTU

Page 16
(Locknut 19 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 equalisation be checked.

Adjusting valve clearance in two crankshaft posi-

tions.

X = Exhaust valve.
O = Inlet valve.
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Page 17
Checking valve bridge adjustment
Use feeler gauge to determine distance between

valve bridge and rocker arm.
Note:
gap.
Place feeler gauge with determined value between

valve bridge and valve shaft end (A).
At the other valve shaft end (B), a 0.05 mm thick
feeler gauge must not pass through; if necessary
adjust valve bridge equalisation.
Carry out this procedure on all valve bridges before
adjusting valve clearance.
M015465/30E 01-06 E MTU

Page 18
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 wrench

and release locknut (2).
Place a feeler gauge of determined distance (dis-

tance between valve bridge and rocker arm) be-
tween valve bridge and valve stem ends (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:
E MTU M015465/30E 01-06

Page 19
Using torque wrench, tighten locknut (2), holding

valve bridge (1) firmly in position with wrench.
Tightening torque = 35 Nm + 5 Nm
Again check valve bridge adjustment.
Valve clearance adjustment

Release locknut (1).
Insert feeler gauge between valve bridge and rocker
arm.
Adjust adjusting screw (2) with Allen key until ap-
propriate valve clearance is achieved.
Valve clearance with engine cold:
Inlet valve (long rocker arm) = 0.20 mm
Exhaust valve (short rocker arm) = 0.50 mm.
It must be possible to just pull the feeler gauge
through the gap.
Use torque wrench to tighten locknut (1), holding ad-
justing screw (2) firmly in position.
Tightening torque: 90 Nm + 9 Nm.
Lubricant: Engine oil.
Note:
Check valve clearance.

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Page 20
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.
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 = 42 Nm
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Page 21
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.
Replace H.P. fuel pump if oil and/or fuel emerges
from the relief bore.
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

Shut off fuel supply to engine (G364.000.01).
M015465/30E 01-06 E MTU

Page 22
Release the cable terminal threaded connection on

the injector and remove cable terminals.
Unscrew H.P. fuel line (2) from injector (1) and con-
nector (limiting valve) (3) and remove H.P. line.
Remove screw (1) together with hold-down clamp

(2).
E MTU M015465/30E 01-06

Page 23
Install removal tool for removing injector.

For this purpose, place section (4) on injector (1).
Fit section (2) over section (4) and turn to correct
position - see next illustration.
Secure section (2) with hex nut (3).
Starting point for section (2) is position a.

End point is position b.
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.
Note:
Fuel must not penetrate the cylinder.
M015465/30E 01-06 E MTU

Page 24
Remove sealing ring (CE support ring) (1) from injec-

tor or use a wire hook to remove from cylinder head.
Cover all connections and bores, or seal with suit-
able plugs.
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).
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
- Lever for press-fitting lever: F6 555 197
- Press-fitting sleeve for injector: F3 0378 403
- Face spanner: F3 0379 005
Note:
Make sure fuel-carrying components are perfectly clean.
Fit new O-rings on injector and coat with petroleum

jelly.
E MTU M015465/30E 01-06

Page 25
Affix new sealing ring with grease on injector.

Fit sealing ring on injector so that flat contact surface
is facing injector.
Note:
Before installation, remove all plugs and covers.
Check sealing surface on cylinder head (heat protec-

tion sleeve) for contamination, clean if necessary.
Insert fuel injector (1) into cylinder head, ensuring
the H.P. line connection is correctly aligned.
Fit press-fitting sleeve (2).
Lock press-fitting lever (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 lever
into cylinder head.
Remove press-fitting tool.
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Page 26
Check security of thrust ring at both cable ends with

slotted-nut rotator.
Secure loose thrust ring.
- Tightening torque: 10 Nm
Install hold-down clamp (1), positioning correctly, and

fit screw (2).
Pretighten screw (2) with torque wrench.
- Tightening torque: 5 Nm to 10 Nm
- Lubricant engine oil
Fit or insert new O-rings (4) and (6) on H.P. line (5)
and coat with petroleum jelly.
Install H.P. line (5) pretighten to 10 Nm and tighten
with torque wrench.
- Tightening torque: 100 Nm + 10 Nm
Tighten screw (2) with torque wrench.
- Tightening torque: 100 Nm + 10 Nm
Fit cable terminals below the screws on injector and

tighten.
Tightening torque: 1.0 Nm +/- 0.2 Nm
Open fuel supply to engine (G364.000.03).
E MTU M015465/30E 01-06

Page 27
G077.051.05 Limiting valve replacement

Remove H.P. line (2).
Remove limiting valve (4).
Install new limiting valve (4).
Fit or insert new O-rings (1) and (3) on H.P. line (2)
and coat with petroleum jelly.
Connect H.P. line (2) and tighten with torque wrench.
Tightening torque: 100 Nm + 10 Nm
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Page 28
G080.000.03 Fuel system filling
WARNING
Fire hazard!
no naked flame
do not smoke
do not spill fuel.
In order to improve engine start-up characteristics,

the low-pressure must be filled with fuel in accord-
ance with certain criteria concerning the common rail
injection system.
Fill low-pressure system (L.P.) for

- Initial operation (new engines)
- Filter change (maintenance specification)
Fill system by means of a fuel pump.

For systems which do not have a fuel pump, MTU
has developed a special hydraulic filling device.
Special tools:
- Hydr. filling unit: B8 0144 852
Filling pressure: min. 0.5 bar / max. 2.0 bar
Filling device
Fuel supply (1)
Fuel return (2)
E MTU M015465/30E 01-06

Page 29
Low-pressure fuel system (L.P.)

Release flushing line (1) at high-pressure pump (2).
Connect the filling device fuel supply to connection
(P) of the filter block.
Fill fuel system until bubble-free fuel emerges at
Pos. 2.
Tighten flushing line (1) at Pos. 2.
Disconnect fuel supply and seal connection (P) with
plug and new sealing ring.
Note:
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.
Special tools:
- Oil filter wrench: F3 0379 104
M015465/30E 01-06 E MTU

Page 30
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.
E MTU M015465/30E 01-06

Page 31
G083.101.01 Fuel prefilter priming

Carry out tasks specified by manufacturer.
G083.101.03 Fuel prefilter, water and contaminants draining

G083.101.09 Fuel prefilter, element and gasket replacement

G083.101.15 Fuel prefilter cleaning
WARNING
Fire hazard!
No open flame, no electrical sparks.
Do not spill fuel.
Close fuel supply

Remove nuts from filter head.
Remove filter bowl and drain fuel into a suitable con-
tainer.
Remove securing nut for filter element and remove
filter element from below.
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Page 32
Using a clean brush, flush out filter element in clean

fuel.
Flush out filter bowl with clean fuel.
Insert filter insert in filter bowl and secure with the
nut.
Insert new sealing ring in groove in filter head.
Mount filter bowl taking care not to damage sealing
ring.
Tighten nuts diagonally and evenly.
Open fuel inlet.
G101.011.05 Exhaust turbocharger connections check
Check exhaust connections for leaks.
E MTU M015465/30E 01-06

Page 33
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.
G120.000.07 Intake air system, cover removal check

Check that the cover from the air filters has been
removed.
M015465/30E 01-06 E MTU

Page 34
G121.051.01 Air filter element replacement

Release clamp (2).
Remove air filter (3) from elbow (1).
Clean connection on elbow.
Install new air filter with clamp (see next illustration).
Reset contamination indicator (G123.053.10).
Before installation, check air filter for damage.

For this purpose, light up air filter with inspection
lamp.
Replace air filter if damaged.
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Page 35
G123.053.01 Contamination indicator, signal ring position check

Check position of signal ring at observation window.
If the signal ring is completely visible once the en-

gine has been shut down, and it remains in this posi-
tion, replace air filter (G121.051.01).
G123.053.10 Contamination indicator resetting

Press reset button. Signal ring returns to normal
position.
G124.051.01 Charge air manifold, drain water discharge and obstruction check
WARNING
Engine noise above 85 dB(A).
Risk of damage to hearing!
Wear ear protectors.
Engine coolant is hot and under pressure.
ËË
Risk of injury and scalding!
ËË
Allow engine to cool.
Wear protective clothing, protective gloves and
protective goggles / safety mask.
M015465/30E 01-06 E MTU

Page 36
Check water discharge at drain bores

(engine A and B sides):
Note:
If only a small amount of coolant is discharged, it is conden-
sate.
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 injection nozzles (G075.051.01).
- Bar engine manually (G000.000.05).
- Bar engine with starting system (G000.000.07) and
blow out combustion chambers.
Obstruction check
With the engine running, oil-containing air must
emerge at the drain bores.
G124.051.03 Charge air manifold drain cleaning
WARNING
Compressed air is pressurised.
Risk of injury!
- Never aim compressed air jet at persons.
- Wear protective goggles/safety mask and ear
protection.

Clean drain bores on engine A and B sides, blow out
with compressed air and check for obstructions.
E MTU M015465/30E 01-06

Page 37
G140.000.01 Exhaust system 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: Combustion incomplete
(E140.000.01).
Exhaust gases blue: Excessive engine oil in combus-
tion chamber (E140.000.02).
Exhaust gases white: Fuel not ignited (E140.000.03).
G140.000.07 Exhaust system, cover removal check

Check that the housing covers have been removed
from the exhaust turbocharger outlets.
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.
G146.000.01 Exhaust system, security and exhaust manifold insulation checks

Check tightness of the exhaust system securing
bolts (after engine) by torque wrench application and
the insulation for damage by visual inspection.
G172.051.09 Starter condition check

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.
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Page 38
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 only MTU-approved engine oil, see MTU Fluids
and Lubricants Specification A001061/...
Turn cover counterclockwise until the cover of the oil

filler neck can be removed.
Pour in engine oil via oil filler neck, up to max. mark
on oil dipstick.
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.
E MTU M015465/30E 01-06

Page 39
G180.000.04 Engine oil sample extraction and analysis
WARNING
Engine oil is hot and can contain combustion resi-
ËË dues which are harmful to health.
ËË
Risk of injury!
Wear protective gloves.
Avoid extended and intensive contact with skin.
Do not inhale oil vapour.
With engine running and at operating temperature,

open screw (arrow) on flange of centrifugal oil filter
by 1 - 2 rotations.
Drain approx. 0.25 litres of engine oil into a container
to flush out the oil sludge.
Drain approx. 0.25 litres of engine oil coolant into a
clean container.
Close screw.
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.

Fluids and lubricants (e.g. oils, greases, treated engine cool-
ant, fuels), cleaning agents and numerous auxiliary materials
are an environmental hazard and therefore constitute hazard-
ous materials.
manufacturer’s instructions, general environmental protection re-
gulations and local legal specifications.
posed of outdoors.
suitable bonding agents and disposed of in accordance with re-
gulations in appropriate vessels. The contents of these containers
must be specified.
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).
M015465/30E 01-06 E MTU

Page 40
G180.000.07 Engine oil draining
WARNING
ËË
Risk of injury!
Note:
Drain engine oil with the engine at operating temperature.
Provide a suitable container in which to collect and

dispose of the engine oil.
Drain engine oil from the oil pan.
Install oil drain plug with a new sealing ring.
Drain remaining oil from equipment carrier.

Install oil drain plug with a new sealing ring.
E MTU M015465/30E 01-06

Page 41

posed of outdoors.
G180.000.09 Corrosion inhibitor oil filling

Note:
Always use new corrosion inhibitor oil which conforms to the
MTU Fluids and Lubricants Specification A001061/...
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).
M015465/30E 01-06 E MTU

Page 42
G183.052.03 Engine oil filter replacement
WARNING
ËË
Risk of injury!
Special tools:
- Oil filter wrench: F3 0379 104
Use oil filter key to unscrew.

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.
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Page 43
G183.101.01 Centrifugal oil filter cleaning
WARNING
ËË
Risk of injury!

Release nut.
Release band clamp.
Release band clamp.

Remove housing cover.
Remove sealing ring.
M015465/30E 01-06 E MTU

Page 44
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.
E MTU M015465/30E 01-06

Page 45
WARNING
Risk of injury!
protection.
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. 30 mm.
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.
Assemble rotor cap and standpipe.

Insert new sealing ring and fit on rotor lower section.
Tighten knurled nut.
M015465/30E 01-06 E MTU

Page 46
Insert rotor in housing lower section.

Fit new sealing ring.
Mount housing cover.
Tighten nut.
Tighten band clamp.
When the engine is again started, check the centrifu-
gal oil filters for leaks.

posed of outdoors.
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Page 47
G202.000.01 Engine coolant system filling
WARNING
ËË Risk of injury!
ËË
Note:
Always use only treated coolant in accordance with MTU
Fluids and Lubricants Specification A001061/..
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.
Open valve cover (G208.101.01), so that the air can

escape from the engine when the coolant system is
filled.
Connect a suitable pump with a hose to the drain

valve (arrow).
Open drain valve and pump treated coolant into en-
gine.
Close drain valve.
Remove pump and hose.
Check engine coolant level (G202.000.03).
Close valve cover (G208.101.03).
Run engine a number of minutes at idling speed.
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Page 48
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.
Via expansion tank:
WARNING
ËË
Note:
Use only treated coolant in accordance with current MTU
Fluids and Lubricants Specification.
Open valve cover (G208.101.01).
The engine coolant level must be up to the marker

plate on the expansion tank.
Top up only with treated engine coolant, as required
(G202.000.01).
E MTU M015465/30E 01-06

Page 49
G202.000.05 Engine coolant sample extraction and analysis
WARNING
ËË
Take sample with the engine running.

Open drain valve.
Drain a small quantity of coolant to flush the drain
point.
Drain approx. 0.25 litres 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/...
G202.000.07 Engine coolant draining
WARNING
ËË
Risk of injury!
ËË

Note:
Drain engine coolant when engine has cooled.
M015465/30E 01-06 E MTU

Page 50
Provide a suitable container to collect and dispose of

the coolant.
Open drain valves or drain plugs:
- at elbow of coolant pump (arrow)
- at crankcase, A and B sides (arrow)
Drain and dispose of coolant.
Seal all drain points.

posed of outdoors.
G202.000.09 Engine coolant change

Drain engine coolant (G202.000.07).
Fill engine coolant system (G202.000.01).
G202.051.01 Engine coolant pump relief bore check

Check relief bore for oil and coolant discharge (visual
inspection).
Clean the bore if it is contaminated.
Permissible discharge quantities:
Coolant, up to 10 drops/hour
Oil, up to 5 drops/hour
Note:
Only in event of a greater number of drops, repair the engine
coolant pump.
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Page 51
G202.400.01 Engine coolant preheating

Open shut-off valves in the preheat line.
Switch on preheating unit.
Check pump direction of rotation.
Preheat engine coolant to preheat temperature
(A000.000.21).
Switch off the preheating unit.
G202.401.01 Engine coolant preheating unit initial operation

Add engine coolant.
Switch on preheating unit.
Check pump direction of rotation.
Check coolant preheating.
G202.401.07 Preheater draining
DANGER
The unit is live.
Risk of fatal injury through electric shock!
Work must only be carried out by qualified person-
nel.
Disconnect all current-carrying appliances before
working on them!
The coolant preheating unit must be switched off.

Open drain valve or unscrew drain plug.
Drain coolant.
Close drain valve or screw in drain plug with new
sealing ring.
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Page 52
G202.651.01 Engine coolant system, vent line obstruction check
WARNING
Risk of injury!
protection.
Remove vent lines and blow out with compressed
air.
Install vent lines.
G203.000.01 Charge air coolant system filling

Note:
Fluids and Lubricants Specification A001061/..

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.
Check charge air coolant level (G202.000.03).
E MTU M015465/30E 01-06

Page 53
G203.000.03 Charge air coolant level check

Note:
The “Min” charge air coolant level is automatically monitored
by the engine control system.
Via level sensor:

Switch on engine control system (G500.000.01) and
check indicator.
Via expansion tank:
CAUTION
Charge air coolant is hot and under pressure.
ËË
Note:
Fluids and Lubricants Specification A001061.
Never pour cold charge air coolant into a hot engine.
If, in an emergency, untreated charge air coolant is used to
top up the coolant system, the charge air coolant concentra-
tion must be checked and rectified at the earliest opportunity.
The charge air coolant level must be up to the

marker plate on the expansion tank.
Top up only with treated charge air coolant, as re-
quired (G202.000.01).
M015465/30E 01-06 E MTU

Page 54
G203.000.05 Charge air coolant draining
WARNING
ËË

Note:
Drain engine coolant when engine has cooled.

Provide a suitable container to collect and dispose of
the coolant.
Drain coolant via drain points from cooling system -
see Alternator Manufacturer’s Operating Instructions.
Seal all drain points.
Dispose of coolant.

posed of outdoors.
E MTU M015465/30E 01-06

Page 55
G203.000.07 Charge air coolant sample extraction and analysis
CAUTION
Charge air coolant is hot and under pressure.
ËË
Open breather valve (G208.101.01).
Draw off precipitated corrosion inhibitor oil from ex-

pansion tank via filler neck and dispose of oil in ap-
propriate manner.
Via the filler neck, draw off approx. 0.25 litres of
charge air coolant into a clean container.
Using the equipment and chemicals provided in the
MTU Test Kit, check charge air coolant for:
- Antifreeze,
- Corrosion-inhibitor
- pH value
Close breather valve (G208.101.03).

Change charge air coolant according to the coolant
operating times in the MTU Fluids and Lubricants
Specification A001061/.. (G203.000.09).

posed of outdoors.
G203.000.09 Charge air coolant changing

Drain charge air coolant (G203.000.05).
Fill system with charge air coolant (G203.000.01).
G203.051.01 Charge air coolant pump relief bore check

See G202.051.01.
M015465/30E 01-06 E MTU

Page 56
G203.551.01 Charge air coolant system, vent line obstruction check
WARNING
Risk of injury!
protection.
Remove vent lines and blow out with compressed
air.
Install vent lines.
G205.051.01 Engine coolant cooler, external element contamination check

Coolant cooler is not supplied by MTU.
Carry out tasks as specified by Manufacturer.
G205.051.01 Engine coolant cooler, external element contamination check
WARNING
Risk of injury!
protection.
Check cooler elements for contamination (visual in-
spection).
Clean heavily contaminated cooler elements.
Note:
The direction of the jet must be parallel to the cooling fins in
order to avoid deforming the blades.
Blow out cooler elements against direction of cooling

air with a compressed air jet or spray with a water
jet.
In even of heavily contaminated cooler elements,
before cleaning treat elements with a hot, grease-
dissolving alkali cleaning agent.

posed of outdoors.
E MTU M015465/30E 01-06

Page 57
G205.051.03 Charge air coolant cooler, external element contamination check

See G205.051.01.
G208.101.01 Valve cover opening
WARNING
ËË
Risk of injury!
ËË Wear protective gloves.
Turn valve cover counterclockwise to first catch.

Allow pressure to escape.
Continue to turn valve cover counterclockwise and
remove.
G208.101.03 Valve cover closing

Check that valve cover is in perfect condition.
Clean sealing surfaces.
Fit valve cover and turn clockwise as far as it will go.
M015465/30E 01-06 E MTU

Page 58
G213.051.01 Generator drive, drive belt condition and tension check
DANGER
After working on the engine, check that all protec-
tive devices have been reinstalled and all tools
removed from the engine.
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
E MTU M015465/30E 01-06

Page 59
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: from 57 kg to 70 kg
(from 125 lbs to lbs)
- Used V-ribbed belts: from 57 kg to 70 kg
(from 125 lbs to 155 lbs)
M015465/30E 01-06 E MTU

Page 60
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.
G213.051.08 Generator condition check

Check generator for mechanical damage.
Check security and condition of all cable connec-
tions.
Check all electric cables for damage.
G231.051.01 Engine mount security check

Check tightness of all engine mount 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.
E MTU M015465/30E 01-06

Page 61
G231.051.07 Engine mount buffer clearance check
Designation: Damper bearing

A: -existing marking “30” (corresponds to
bearing type RD 314 B)
-existing marking “40” (corresponds to
Bearing type RD 315 HD)
B: . . . . . . . . . . . . . . . . . . . . . . . . . unloaded 152.5 mm
C: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . serial number
D: . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shore hardness
E: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . type
F: . . . . . . . . . . . . . . . . . . . . . . . . . . . unloaded 50 mm
G: . . . . . . . . . . . . . . . . . . . . . . outlet dimension 5 mm
Note:
The engine must be filled with coolant and engine oil.
The blocking must be removed.
Check distance (A) for central buffer (2) by means of

feeler gauge on measuring groove (1).
- for type RD 314 B: . . . . . . . . . A = 3 mm ± 0.3 mm
- for type RD 315 HD: . . . . . . . A = 4 mm ± 0.3 mm
If the distance is incorrect, readjust the damping
mount. See under Engine mount transportation lock-
ing device (T231.001.01).
M015465/30E 01-06 E MTU

Page 62
Setting dimension check

Measure limit value (A) with caliper.
- for type RD 314 B : . . . . . . . . . Limit value: 25 mm
- for type RD 315 HD: . . . . . . . . Limit value: 21 mm
If limit value (A) is undershot, the damping mount
must be replaced - see Repair Manual.
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.
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.
E MTU M015465/30E 01-06

Page 63
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

G309.001.03 Battery filling

G309.001.05 Battery charge state check

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 bac-
teria.
G364.200.01 Fuel supply system, shut-off valve closing

Close shut-off valve in supply line before fuel pre-
filter.
G364.200.03 Fuel supply system, shut-off valve opening

Open shut-off valve in supply line before fuel pre-
filter.
M015465/30E 01-06 E MTU

Page 64
G365.000.01 Exhaust system condensate draining

Exhaust system is not supplied by MTU. Carry out
tasks specified by Manufacturer.
G365.000.03 Exhaust system drain obstruction check

Exhaust system is not supplied by MTU. Carry out
tasks specified by Manufacturer.
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

Contact MTU Service.
G500.000.09 Engine wiring check

Check all plug-in connection(s) for security and dam-

age at:
- Speed, pressure and temperature transmitters
- Level sensor
- Fuel prefilter
Check all mechanical fixtures and electrical connec-
tions.
- Injection pumps
- Battery
- Turbocharger control
- Starter
- Generator
NOTE:
When checking the electrical connection, it is essential to en-
sure that no ground short is created.
E MTU M015465/30E 01-06

Page 65
G510.000.01 Monitoring system, equipment function check

Check operation of level sensor on engine coolant
expansion tank.
The temperature sensor, pressure sensor and speed
sensor are continuously monitored with the Inte-
grated Test System (ITS) in the Engine Control Sys-
tem. If a monitoring unit fails, a warning is given.
In event of a fault signal, replace respective compo-
nent.
Remove speed sensor (crankshaft)
Note:
The speed sensor is an electronic component. Appropriate
care is required for removal.
Separate electrical plug-in connection.

Remove securing screw.
Withdraw speed sensor (arrow).
Remove O-rings.
Check speed sensor (crankshaft)

Visually check speed sensor for damage, replace as
necessary.
Use an ohmmeter to measure resistance between
Pin A and Pin B.
Required resistance = 135 ohms ± 20 ohms
In event of deviation from specified value, replace
speed sensor.
M015465/30E 01-06 E MTU

Page 66
Install speed sensor (crankshaft)
Note:
The speed sensor is an electronic component. Appropriate
care is required for removal.
Check that support bore in flywheel housing is clean

and clean if necessary.
Determine depth of support bore. For this purpose,
carefully insert reference mandrel (1) into support
bore until it contacts the graduated disc.
Measure projection “X” of reference mandrel over

mating face of speed sensor and subtract from total
length “L” of reference mandrel.
Depth of support bore from mating face of speed
sensor to graduated disc: T = L - X
Fit O-rings (1) on speed sensor (2) and coat with pe-
troleum jelly.
E MTU M015465/30E 01-06

Page 67
Check gap clearance “S” between graduated disc

and speed sensor: S = 1 mm to 2 mm
For this purpose measure installation length “E” of
speed sensor and compare with depth of support
bore. Installation length “E” must be smaller by di-
mension “S” than installation depth “T”.
If necessary, fit shims to achieve correct gap clear-
ance.
Note:
Before installing, check speed sensor for particular clean-
ness.
Insert speed sensor into support bore and press in

up to mating face on flywheel housing (arrow).
Tighten speed sensor with securing screw.
Connect electronic plug-in connection on speed sen-
sor.
Remove pressure and temperature sensors
Note:
Sensors are electronic components. Appropriate care is required for removal.
Store sensors so that they are protected from dirt and mechanical damage.
Use an open-end wrench to unscrew sensor.

Attach suitable dust caps to screw-in thread of sensors.
Store sensors so that they are protected from dirt and mechanical damage.
Seal removal bores with suitable plugs.
M015465/30E 01-06 E MTU

Page 68
Check pressure sensor (crankcase)

Visually check pressure sensor for damage, replace
as necessary.
Carry out DC voltage test on pressure sensor.
- Pin A = Earth
- Pin B = Voltage output
- Pin C = Voltage input
Input voltage at 25 °C = . . . . . . . . . . . . . . . 5.00 V DC
Specified output voltage = . . . . 2.5 V DC ± 0.1 V DC
pressure sensor.
Note:
These values apply only when the engine is shut down or the
pressure sensor is removed.
Check speed sensor

as necessary.
Carry out DC voltage test on pressure sensor.
- Pin A = Earth
- Pin B = Voltage output
- Pin C = Voltage input
Engine oil pressure sensor (1):
Charge air pressure sensor (2):
Specified output voltage = . . . . . . 1 V DC ± 0.1 V DC
pressure sensor.
Note:
E MTU M015465/30E 01-06

Page 69
Check pressure sensor (fuel high pressure)

as necessary.
Carry out DC voltage test on sensor.
- Pin A = Earth
- Pin B = Voltage input
- Pin C = Voltage output
sensor.
Note:
Check temperature sensor (engine coolant cir-

cuit, fuel, charge air coolant circuit, charge air,
engine oil)
as necessary.
Measure resistance between Pin A and Pin B with an
ohmmeter at different bath temperatures.
Specified resistance at 0 °C = from 8500 ohms to
14000 ohms
2992 ohms
190 ohms
In event of deviation from specified values, replace
sensor.
M015465/30E 01-06 E MTU

Page 70
Install pressure and temperature sensors
Note:
Sensors are electronic components. It is therefore necessary
to take due care and ensure cleanness during installation.
Remove blanking plug.

Check sealing surface and installation bore (thread)
for particular cleanness, and clean if necessary.
Screw in sensor with new sealing ring and tighten
with torque wrench.
Tightening torque:
- H.P. fuel sensor . . . . . . . . . . . . . . . . . . . . . . 70 Nm
- Charge air pressure sensor . . . . . . . . . . . . 30 Nm
- Crankcase pressure sensor . . . . . . . . . . . 20 Nm
- Engine oil pressure sensor . . . . . . . . . . . . 20 Nm
- Temperature sensor . . . . . . . . . . . . . . . . . . 16 Nm
- Lubricant . . . . . . . . . . . . . . . . . . . . . . . . Engine oil
Note:
After starting engine, visually inspect sensor connections for
leaks.
If leaks are found, slightly tighten sensor connec-

tions.
If correct sealing cannot be achieved in this way, re-
move sensor and replace gasket.
Switch on engine control system (G500.000.01).
G510.070.01 Monitoring equipment lamp test

The monitoring system is not supplied by MTU.
Carry out tasks as specified by Manufacturer.
E MTU M015465/30E 01-06

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
M015465/30E 01-06 E MTU

Section K Preservation
E MTU M015465/30E 01-06

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 stand run, 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 or 8-digit codes.
Task descriptions:
3-digit codes in Section K
8-digit codes in Section G
M015465/30E 01-06 E MTU

Page 2
K000.000.03 Preservation
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
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
K010 Spray V-belt pulleys with corrosion inhibitor oil

G213.051.05 Remove V-belts
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
E MTU M015465/30E 01-06

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 coolant system 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 with 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.
Lightly 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.
M015465/30E 01-06 E MTU

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.
E MTU M015465/30E 01-06

Transportation Locking Device Section T
Contents
T036.051.01 Crankshaft transportation locking device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

T231.001.01 Engine mount transportation locking device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
M015465/30E 01-06 E MTU

Section T Transportation Locking Device
E MTU M015465/30E 01-06

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.
M015465/30E 01-06 E MTU

Page 2
E MTU M015465/30E 01-06

Page 3
M015465/30E 01-06 E MTU

Page 4
T231.001.01 Engine mount transportation locking device
Applicable to: 230.00002; 230.00003
General
These transportation locking devices block the engine mounts.
The transportation locking devices protect the engine mounts against damage caused by impacts and vibrations
during engine transportation.
Transportation locking devices
- Do not remove until the engine has been aligned and secured on the machinery foundation, but in all cases before
the engine is put into operation.
- The locking devices must always be installed before the engine is transported.
Operation of the engine with engine mount locking devices in place is impermissible.
The transportation locking device must only be released when the mounts are fully loaded.
Transportation locking device removal

Release nuts (7) and remove screws (9) from base plate (5).
Check buffer clearance via control grooves (6) with feeler gauge.
- Specified value: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 mm
If buffer clearance adjustment is necessary:
Remove cover caps (1).
Release securing nut (3).
Screw central buffer (4) on hexagon (2) clockwise to the lower stop position.
Back off central buffer (4) counterclockwise and adjust to distance “H” = 3.0 mm ± 0.3 mm.
Tighten securing nut (3), holding central buffer (4) in position on hexagon (2).
- Tightening torque: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 580 Nm ±50 Nm
- Lubricant: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine oil
Fit cover caps (1).
Store screws, nuts and washers together with these instructions for any possible future installation.
Transportation locking device installation

Note:
Before the transportation locking devices are fitted, the engine mounts must be subjected to the load of the engine weight for at least
48 hrs owing to settlement of the rubber elements.
Screw in and tighten screws (9) with nuts (7) and washers (8) into base plate (5).
Attach these instructions to an engine carrier.
E MTU M015465/30E 01-06

Page 5
M015465/30E 01-06 E MTU

Page 6
E MTU M015465/30E 01-06

Keyword Index Section ?
Page 1
A
Abnormal turbocharger running noises, Troubleshooting, Section E, 3
AC alternator, A213.000.01, Section A, 8
After shutdown, C000.000.11, Section C, 3
Air filter element replacement, G121.051.01, Section G, 34
Application, D000.000.05, Section D, 1
Attachments security check, G000.000.27, Section G, 4
Attachments, hoses and hose connections check, G000.000.29, Section G, 5
B
Barring engine manually, G000.000.05, Section G, 1
Barring engine with starting system, G000.000.07, Section G, 2
Battery charge state check, G309.001.05, Section G, 63
Battery check, G309.001.01, Section G, 63
Battery filling, G309.001.03, Section G, 63
C
Centrifugal oil filter cleaning, G183.101.01, Section G, 43
Charge air coolant changing, G203.000.09, Section G, 55
Charge air coolant cooler, external element contamination check, G205.051.01, Section G, 57
Charge air coolant draining, G203.000.05, Section G, 54
Charge air coolant level check, G203.000.03, Section G, 53
Charge air coolant level rising, Troubleshooting, Section E, 8
Charge air coolant pressure too low, Troubleshooting, Section E, 8
Charge air coolant pump leaking at relief bore, Troubleshooting, Section E, 8
Charge air coolant pump relief bore check, Troubleshooting, Section E, 55
Charge air coolant sample extraction and analysis, G203.000.07, Section G, 55
Charge air coolant system filling, G203.000.01, Section G, 52
Charge air coolant system, vent line obstruction check, G202.651.01, Section G, 56
Charge air coolant temperature too high, Troubleshooting, Section E, 7
Charge air coolant temperature too low, Troubleshooting, Section E, 8
Charge air manifold drain cleaning, G124.051.03, Section G, 36
Charge air manifold, drain water discharge and obstruction check, G124.051.01, Section G, 35
Charge air pressure too low, Troubleshooting, Section E, 4
Charge air temperature too high, Troubleshooting, Section E, 4
Cleaning engine externally, G000.000.39, Section G, 7
Compressed air system condensate draining, G303.000.01, Section G, 62
Compressed air system, operating pressure check, G303.000.03, Section G, 63
Contamination indicator resetting, G123.053.10, Section G, 35
Contamination indicator, signal ring position check, G123.053.01, Section G, 35
M015465/30E 01-06 E MTU

Section ? Keyword Index
Page 2
Coolant capacity, A202.000.01, Section A, 8

Coolant discharge at intercooler relief bore, Troubleshooting, Section E, 4
Corrosion inhibitor oil draining, G180.000.11, Section G, 41
Corrosion inhibitor oil filling, G180.000.09, Section G, 41
Coupling condition check, G252.051.01, Section G, 62
Crankshaft transportation locking device, T036.051.01, Section T, 1
Cylinder chamber endoscopic examination, G000.000.33, Section G, 5
Cylinder head cover installation, G055.101.03, Section G, 20
Cylinder head cover removal, G055.101.01, Section G, 20
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, 49
Drain preheater, G202.401.07, Section G, 51
Drive system (driving end) security check, G250.000.01, Section G, 62
E
Emergency shutdown, G000.000.25, Section G, 4
End cover opening, G208.101.01, Section G, 57
Engine and exhaust noise, A000.000.25, Section A, 7
Engine and external lines leak check, G000.000.21, Section G, 3
Engine barring tool installation , G030.001.01, Section G, 8
Engine barring tool removal , G030.001.03, Section G, 8
Engine control system initial operation, G500.000.07, Section G, 64
Engine control system switching off, G500.000.01, Section G, 64
Engine control system switching on, G500.000.01, Section G, 64
Engine coolant change, G202.000.09, Section G, 50
Engine coolant cooler, external element contamination check, G205.051.01, Section G, 56, 56
Engine coolant level check, G202.000.03, Section G, 48
Engine coolant level rising, Troubleshooting, Section E, 7
Engine coolant level too low, Troubleshooting, Section E, 7
Engine coolant preheating, G202.400.01, Section G, 51
Engine coolant preheating unit initial operation, G202.401.01, Section G, 51
Engine coolant pressure too low, Troubleshooting, Section E, 7
Engine coolant pump leaking at relief bore , Troubleshooting, Section E, 7
Engine coolant pump relief bore check, Troubleshooting, Section E, 50
Engine coolant sample extraction and analysis, G180.000.04, Section G, 49
Engine coolant system filling, G202.000.01, Section G, 47
Engine coolant system, vent line obstruction check, G202.651.01, Section G, 52
Engine coolant temperature too high, Troubleshooting, Section E, 6
E MTU M015465/30E 01-06

Page 3
Engine coolant temperature too low, Troubleshooting, Section E, 6

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 buffer clearance check, G231.051.07, Section G, 61
Engine mount resilient element check, G231.051.03, Section G, 60
Engine mount security check, G231.051.01, Section G, 60
Engine mount transportation locking device, T231.001.01, Section T, 4
Engine oil change, G180.000.05, Section G, 39
Engine oil consumption abnormally high, Troubleshooting, Section E, 5
Engine oil draining, G180.000.07, Section G, 40
Engine oil filter replacement, G183.052.03, Section G, 42
Engine oil in coolant system, Troubleshooting, Section E, 6
Engine oil level abnormally high, Troubleshooting, Section E, 5
Engine oil level check, G180.000.01, Section G, 38
Engine oil pressure too high, Troubleshooting, Section E, 6
Engine oil pressure too low, Troubleshooting, Section E, 6
Engine oil sample extraction and analysis, G180.000.04, Section G, 39
Engine oil system filling, G180.000.03, Section G, 38
Engine oil temperature too high, Troubleshooting, Section E, 5
Engine power, A000.000.19, Section A, 5
Engine running noise check, G000.000.19, Section G, 3
Engine shutdown, G000.000.23, Section G, 4
Engine side and cylinder designations, A000.000.05, Section A, 3
Engine speed check, G000.000.13, Section G, 3
Engine speed not steady, Troubleshooting, Section E, 2
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 transportation, C000.000.17, Section C, 4
Engine turns but does not fire, Troubleshooting, Section E, 1
Engine warm-up procedure, G000.000.11, Section G, 3
Engine weight, A000.000.13, Section A, 4
Engine wiring check, G500.000.09, Section G, 64
Exhaust bulk temperature too high, Troubleshooting, Section E, 5
Exhaust gases black, Troubleshooting, Section E, 4
Exhaust gases blue, Troubleshooting, Section E, 4
Exhaust gases white, Troubleshooting, Section E, 5
Exhaust system check, G140.000.01, Section G, 37
M015465/30E 01-06 E MTU

Page 4
Exhaust system condensate draining, G365.000.01, Section G, 64

Exhaust system drain obstruction check, G365.000.03, Section G, 64
Exhaust system security check, G140.000.03, Section G, 37
Exhaust system, cover removal check, G140.000.07, Section G, 37
Exhaust system, exhaust backpressure check, G140.000.09, Section G, 37
Exhaust system, exhaust gas colour check, G140.000.05, Section G, 37
Exhaust system, security and exhaust manifold insulation checks, G146.000.01, Section G, 37
Exhaust temperature too high (individual cylinder), Troubleshooting, Section E, 5
Exhaust temperature too low (individual cylinder), Troubleshooting, Section E, 5
Exhaust turbocharger connections check, G101.011.05, Section G, 32
F
Fuel duplex filter replacement, G083.051.03, Section G, 29
Fuel prefilter cleaning, G083.101.15, Section G, 31
Fuel prefilter priming, G083.101.01, Section G, 31
Fuel prefilter, element and gasket replacement, G083.101.09, Section G, 31
Fuel prefilter, water and contaminants draining, G083.101.03, Section G, 31
Fuel pressure too high, Troubleshooting, Section E, 3
Fuel pressure too low, Troubleshooting, Section E, 3
Fuel supply check, G364.050.01, Section G, 63
Fuel supply system, shut-off valve closing, G364.200.01, Section G, 63
Fuel supply system, shut-off valve opening, G364.200.03, Section G, 63
Fuel system filling, G080.000.03, Section G, 28
Fuel system, fuel delivery pump supply check, G080.000.05, Section G, 29
G
General, Troubleshooting, Section E, 1
Generator condition check, G213.051.08, Section G, 60
Generator drive, drive belt condition and tension check, G213.051.01, Section G, 58
H
H.P. pump leaking at relief bore, Troubleshooting, Section E, 3
High-pressure pump, relief bore obstruction check, G073.051.07, Section G, 21
I
Initial operation, C000.000.05, Section C, 3
Injector installation, G075.051.09, Section G, 24
Injector removal, G075.051.01, Section G, 21
Injector replacement, G075.051.05, Section G, 24
Intake air system, cover removal check, G120.000.07, Section G, 33
E MTU M015465/30E 01-06

Page 5
Intake air system, intake depression check, G120.000.05, Section G, 33

Intake air system, intake side leak and damage check, G120.000.03, Section G, 33
L
Limiting valve replacement, G077.051.05, Section G, 27
M
Main engine dimensions, A000.000.09, Section A, 3
Main engine specifications, A000.000.17, Section A, 4
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 equipment lamp test, G510.070.01, Section G, 70
Monitoring system, equipment function check, G510.000.01, Section G, 65
O
Oil capacity, A180.000.01, Section A, 7
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, 6
Out-of-service period, C000.000.13, Section C, 4
Out-of-service periods, D000.000.17, Section D, 4
P
Preheat temperature too low , Troubleshooting, Section E, 7
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
Pressure checks, G000.000.15, Section G, 3
Protective device check, G307.001.01, Section G, 63
R
Represervation, K000.000.05, Section K, 2
S
Shutdown, C000.000.09, Section C, 3
Starter condition check, G172.051.09, Section G, 37
M015465/30E 01-06 E MTU

Page 6
T
Temperature checks, G000.000.17, Section G, 3
Timing data (valve clearance adjusted), A050.000.01, Section A, 7
Transport, A000.000.14, Section A, 4
V
Valve clearance adjustment (valve bridge with adjusting screw M12 (locknut 19 AF)), G055.050.03, Section G, 16
Valve clearance adjustment (valve bridge with adjusting screw M16 (locknut 24 AF)), G055.050.03, Section G, 11
Valve clearance check, G055.050.01, Section G, 10
Valve clearances, A055.050.01, Section A, 7
Valve cover closing, G208.101.03, Section G, 57
Valve gear lubrication, G055.000.03, Section G, 9
Valve gear oil supply check, G055.000.01, Section G, 9
E MTU M015465/30E 01-06

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Technical Publication

Engine layout, technical data

Time schedule and maintenance task

Inspection and maintenance tasks

T Transportation Locking Device

Alphabetical index of key terms

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MTU Friedrichshafen GmbH

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

M015465/30E 01-06 E MTU

E MTU M015465/30E 01-06

Maintenance and Repair

M015465/30E 01-06 E MTU

E MTU M015465/30E 01-06

Operation of Electrical Equipment

M015465/30E 01-06 E MTU

E MTU M015465/30E 01-06

In event of dangerous situations.

Take extreme care in these situations!

M015465/30E 01-06 E MTU

E MTU M015465/30E 01-06

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

M015465/30E 01-06 E MTU

E MTU M015465/30E 01-06

A000.000.01 Engine layout

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

M015465/30E 01-06 E MTU

1 Air filter 10 Oil pan

A000.000.03 Engine model designation

E MTU M015465/30E 01-06

A000.000.05 Engine side and cylinder designations

Applicable designations and abbreviations

A000.000.09 Main engine dimensions

M015465/30E 01-06 E MTU

A000.000.13 Engine weight

ÇÇ Lift the engine only with the lifting eyes provided.

ÇÇ ÇÇ Use only the transport and lifting equipment ap-

ÇÇ The engine must only be transported in installation

A000.000.17 Main engine specifications

E MTU M015465/30E 01-06

A000.000.19 Engine power

M015465/30E 01-06 E MTU

A000.000.21 Operational data

Coolant system Unit Normal Limit

E MTU M015465/30E 01-06

A000.000.25 Engine and exhaust noise

A050.000.01 Timing data (valve clearance adjusted)

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

A055.050.01 Valve clearances

A170.000.01 Engine starting system