Dvigatel Mtu 12v2000g65e

Operating Instructions
Diesel engine
12V2000G65, G65-TB
16V2000G65, G65-TB
18V2000G65, G65-TB
Application group 3A
MS15018/03E
Engine model kW/cyl. Application group
12V2000G65 42.9 kW/cyl. 3A, continuous operation, unrestricted
12V 2000 G65-TB 42.9 kW/cyl. 3A, continuous operation, unrestricted
Table 1: Applicability
© 2016 Copyright MTU Friedrichshafen GmbH

This publication is protected by copyright and may not be used in any way, whether in whole or in part, without the prior writ-
ten consent of MTU Friedrichshafen GmbH. This particularly applies to its reproduction, distribution, editing, translation, micro-
filming and storage or processing in electronic systems including databases and online services.
All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen GmbH
reserves the right to change, delete or supplement the information provided as and when required.
Table of Contents
1 Safety 6 Maintenance
1.1 Important provisions for all products 5 6.1 Maintenance task reference table [QL1] 42
1.2 Correct use for all products 6
1.3 Personnel and organizational requirements 7 7 Troubleshooting
1.4 Safety regulations for startup and operation 8
1.5 Safety precautions when working on the 7.1 Fault indication on SAM display – Genset
engine 10 applications 43
1.6 Fire prevention and environmental 7.2 Troubleshooting 67
protection, fluids and lubricants, auxiliary
materials 13 8 Task Description
1.7 Standards for safety notices in the text 15
8.1 Engine 70
8.1.1 Engine – Barring manually 70
2 Transport 8.1.2 Engine – Barring with starting system 71
8.1.3 Engine – Test run 72
2.1 Transportation 16
2.2 Lifting requirements 17 8.2 Cylinder Liner 73
8.2.1 Cylinder liner – Endoscopic examination 73
8.2.2 Instructions and comments on endoscopic and
3 General Information
visual examination of cylinder liners 75
3.1 Engine side and cylinder designations 18 8.3 Crankcase Breather 77
3.2 Engine overview 19 8.3.1 Crankcase breather – Wire mesh cleaning 77
3.3 Sensors and actuators – Overview 21 8.3.2 Crankcase breather – Oil separator
replacement, diaphragm check and
4 Technical Data replacement 78
4.1 12/16/18V2000G65 engine data, fuel 8.4 Valve Drive 80

8.4.1 Valve clearance – Check and adjustment 80
optimized 23
8.4.2 Cylinder head cover – Removal and
4.2 12/16/18V2000G65-TB engine data, fuel installation 83
optimized 27
4.3 Firing order 31 8.5 Injection Pump / HP Pump 84
4.4 Engine – Main dimensions 32 8.5.1 Injection pump – Replacement 84
8.5.2 Injection pump – Removal and installation 85
5 Operation 8.6 Injection Valve / Injector 88

8.6.1 Injector – Replacement 88
5.1 Putting the engine into operation after 8.6.2 Injector – Removal and installation 89
extended out-of-service periods (>3 months) 33
5.2 Putting the engine into operation after 8.7 Fuel System 94
8.7.1 Fuel injection line – Pressure pipe neck
scheduled out-of-service-period 34 replacement 94
5.3 Engine – Starting in manual mode (test run) 35 8.7.2 Fuel – Draining 97
5.4 Safety system – Override 36 8.7.3 Fuel pressure relief valve – Removal and
5.5 Operational monitoring 37 installation 99
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5.6 Engine – Stopping in manual mode (test 8.7.4 Fuel system – Venting 100
run) 38
8.8 Fuel Filter 102
5.7 Engine – Emergency stop 39 8.8.1 Fuel filter – Replacement 102
5.8 After stopping the engine – Engine remains 8.8.2 Fuel prefilter – Differential pressure gage
ready for operation 40 check and adjustment of gage 103
5.9 After stopping the engine – Putting the 8.8.3 Fuel prefilter – Draining 104
engine out of operation 41 8.8.4 Fuel prefilter – Flushing 106
8.8.5 Fuel prefilter – Cleaning 108
8.8.6 Fuel prefilter – Filter element replacement 109
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8.9 Charge-Air Cooling General, Left-Hand Side 111 8.17.1 Cooler – Checking cooler elements externally
8.9.1 Intercooler – Checking condensate drain for for dirt 130
coolant discharge and obstructions 111 8.17.2 Cooler – Cleaning cooler elements 131
8.10 Air Filter 112 8.18 Battery-Charging Generator 132

8.10.1 Air filter – Replacement 112 8.18.1 Battery-charging generator drive – Drive-belt
8.10.2 Air filter – Removal and installation 113 check and adjustment 132
8.18.2 Battery-charging generator drive – Drive belt
8.11 Air Intake 114 replacement 134
8.11.1 Service indicator – Signal ring position check 114
8.19 Fan Drive 135
8.12 Starting Equipment 115 8.19.1 Fan drive – Drive-belt check and adjustment 135
8.12.1 Air starter – Manual operation 115 8.19.2 Fan drive – Drive belt replacement 138
8.13 Lube Oil System, Lube Oil Circuit 116 8.20 Wiring (General) for Engine/Gearbox/Unit 139
8.13.1 Engine oil – Level check 116 8.20.1 Engine cabling – Check 139
8.13.2 Engine oil – Change 117
8.21 Accessories for (Electronic) Engine
8.14 Oil Filtration / Cooling 118 Governor / Control System 140
8.14.1 Engine oil filter – Replacement 118
8.21.1 Engine governor and connector – Cleaning 140
8.15 Coolant Circuit, General, High-Temperature 8.21.2 Engine governor plug connections – Check 141
Circuit 119 8.21.3 Engine governor ECU 7 – Removal and
8.15.1 Engine coolant – Level check 119 installation 142
8.15.2 Engine coolant – Change 120
8.15.3 Engine coolant – Draining 121
9 Appendix A
8.15.4 Engine coolant – Filling 122
8.15.5 Coolant pump – Relief bore check 124 9.1 Abbreviations 143
8.16 Low-Temperature Circuit 125 9.2 MTU Contact/Service Partners 146
8.16.1 Charge-air coolant – Filling 125
8.16.2 Charge-air coolant – Draining 127 10 Appendix B
8.16.3 Charge-air coolant – Change 128
8.16.4 Charge-air coolant – Level check 129 10.1 Special Tools 147
10.2 Index 154
8.17 Coolant System 130
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1 Safety
1.1 Important provisions for all products
Nameplate
The product is identified by nameplate, model designation or serial number and must match with the infor-
mation on the title page of this manual.
Nameplate, model designation or serial number can be found on the product.
All EU-certified engines delivered by MTU come with a second nameplate. When operating the machine in the
EU: The second nameplate must be affixed in a prominent position as described in the accompanying specifi-
cations.
General information
This product may pose a risk of injury or damage in the following cases:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Modifications or conversions
• Noncompliance with the safety instructions and warning notices
Emission regulations and emission labels

Responsibility for compliance with emission regulations
Modification or removal of any mechanical/electronic components or the installation of additional compo-
nents including the execution of calibration processes that might affect the emission characteristics of the
product are prohibited by emission regulations. Emission control units/systems may only be maintained, ex-
changed or repaired if the components used for this purpose are approved by the manufacturer.
Noncompliance with these regulations will invalidate the design type approval issued by the emissions regu-
lation authorities. The manufacturer does not accept any liability for violations of the emission regulations.
The maintenance schedules of the manufacturer must be observed over the entire life cycle of the product.
Replacing components with emission labels

On all MTU engines fitted with emission labels, these labels must remain on the engine throughout its opera-
tional life.
Engines used exclusively in land-based, military applications other than by US government agencies are ex-
cepted from this proviso.
Please note the following when replacing components with emission labels:
• The relevant emission labels must be affixed to the spare part.
• Do not transfer the emission labels from the replaced part to the spare part.
• Remove the emission labels from the replaced part and destroy them.
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MS15018/03E 2016-02 | Safety | 5

1.2 Correct use for all products
Correct use
The product is intended for use in accordance with its contractually-defined purpose as described in the rele-
vant technical documents only.
Intended use entails operation:
• Within the permissible operating parameters in accordance with the (→ Technical data)
• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubricants
Specifications of the manufacturer)
• With preservation approved by the manufacturer in accordance with the (→ Preservation and Represerva-
tion Specifications of the manufacturer)
• With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU con-
tact/Service partner)
• In the original as-delivered configuration or in a configuration approved by the manufacturer in writing (in-
cluding engine control/parameters)
• In compliance with all safety regulations and in adherence with all warning notices in this manual
• In compliance with the maintenance work and intervals specified in the (→ Maintenance Schedule)
throughout the useful life of the product
• In compliance with the maintenance and repair instructions contained in this manual, in particular with
regard to the specified tightening torques
• With the exclusive use of technical personnel trained in commissioning, operation, maintenance and re-
pair
• By contracting only workshops authorized by the manufacturer to carry out repair and overhaul
The product shall not be operated in explosive atmospheres unless the necessary approval has been grant-
ed.
Any other use, particularly misuse, is considered as being contrary to the intended purpose. Such improper
use increases the risk of injury and damage when working with the product. The manufacturer shall not be
held liable for any damage resulting from improper, non-intended use.
The specifications of the manufacturer will be amended or supplemented as necessary. Prior to operation,
make sure that the latest version is used. The latest version can be found on the websites:
• For drive systems: http://www.mtu-online.com
• For power generation: http://www.mtuonsiteenergy.com
Modifications or conversions
Unauthorized changes to the product represent a contravention of its intended use and compromise safety.
Changes or modifications shall only be considered to comply with the intended use when expressly author-
ized by the manufacturer. The manufacturer shall not be held liable for any damage resulting from unauthor-
ized changes or modifications.
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1.3 Personnel and organizational requirements
Organizational measures of the user/manufacturer
This manual must be issued to all personnel involved in operation, maintenance, repair, assembly, installa-
tion, or transportation.
Keep this manual handy in the vicinity of the product such that it is accessible to operating, maintenance,
repair, assembly, installation, and transport personnel at all times.
Personnel must receive instruction on product handling and maintenance based on this manual with a spe-
cial emphasis on safety requirements and warnings.
This is important in the case of personnel who only occasionally perform work on or around the product.
These personnel must be instructed repeatedly.
Personnel requirements
All work on the product shall be carried out by trained and qualified personnel only:
• Training at the Training Center of the manufacturer
• Technical personnel from the areas mechanical engineering, plant construction, and electrical engineering
The operator must define the responsibilities of the personnel involved in operation, maintenance, repair, as-
sembly, installation, and transport in writing.
Personnel shall not report for duty under the influence of alcohol, drugs or strong medication.
Clothing and personal protective equipment

Always wear appropriate personal protective equipment, e.g. safety shoes, ear protectors, protective gloves,
goggles, breathing mask. Follow the instructions concerning personal protective equipment in the descrip-
tions of the individual activities.
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MS15018/03E 2016-02 | Safety | 7

1.4 Safety regulations for startup and operation
Safety regulations for startup
Install the product correctly and carry out acceptance in accordance with the manufacturer's specifications
before putting the product into service. All necessary approvals must be granted by the relevant authorities
and all requirements for initial startup must be fulfilled.
Whenever the product is subsequently taken into operation ensure that:
• All personnel is clear of the danger zone surrounding moving parts of the machine.
Electrically-actuated linkages may be set in motion when the Engine Control Unit (governor) is switched
on.
• All maintenance and repair work has been completed.
• All loose parts have been removed from rotating machine components.
• All safety equipment is in place.
• No persons wearing pacemakers or any other technical body aids are present.
• The service room is adequately ventilated.
• In the first few hours of operation, the product emits gases as a result of smoldering e.g. lacquers or oil.
These gases may be hazardous to health. Always wear respiratory protection in the operating room during
this period.
• The exhaust system is leak-tight and that the gases are vented to atmosphere.
• Protect battery terminals, generator terminals or cables against accidental contact.
• Check that all connections have been correctly allocated (e.g. +/- polarity, direction).
Immediately after putting the product into operation, make sure that all control and display instruments as
well as the signaling and alarm systems work properly.
Smoking is prohibited in the area of the product.
Safety regulations during operation

The operator must be familiar with the control and display elements.
The operator must be familiar with the consequences of any operations performed.
During operation, the display instruments and monitoring units must be permanently observed with regard to
present operating status, violation of limit values and warning or alarm messages.
Malfunctions and emergency stop

Practice emergency procedures, especially emergency stopping, at regular intervals.
The following steps must be taken if a malfunction of the system is detected or reported by the system:
• Inform supervisor(s) in charge.
• Analyze the message.
• Respond by taking any necessary emergency action, e.g. emergency stop.
Operation
Do not remain in the operating room when the product is running for any longer than absolutely necessary.
Keep a safe distance away from the product if possible. Do not touch the product unless expressly instructed
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to do so following a written procedure.

Do not inhale the exhaust gases of the product.
The following requirements must be fulfilled before the product is started:
• Wear ear protection.
• Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binder agent.
Operation of electrical equipment

Parts of the electrical equipment are live, i.e. under voltage/high tension, during operation.
8 | Safety | MS15018/03E 2016-02

Follow the applicable warning instructions pertaining to such devices.
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MS15018/03E 2016-02 | Safety | 9

1.5 Safety precautions when working on the engine
Safety regulations prior to maintenance and repair work
Have maintenance or repair work carried out by qualified and authorized personnel only.
Allow the product to cool down to less than 50 °C (risk of explosion for oil vapors, fluids and lubricants, risk
of burning).
Relieve pressure in fluid and lubricant systems and compressed-air lines which are to be opened. Use suita-
ble collecting vessels of adequate capacity to catch fluids and lubricants.
When changing the oil or working on the fuel system, ensure that the service room is adequately ventilated.
Never carry out maintenance and repair work with the product in operation, unless:
• It is expressly permitted to do so following a written procedure.
• The product is running in the low load range and only for as long as absolutely necessary.
Lock-out the product to preclude undesired starting, e.g.
• Start interlock
• Key switch
• With hydraulic starting system: shut off supply line.
Attach “Do not operate” sign in the operating area or to control equipment.
Disconnect the battery cables or actuate the battery isolating switch, if fitted. Lock out circuit breakers.
Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic start-
ers are fitted.
Disconnect the control equipment from the product.
Use the recommended special tools or suitable equivalents when instructed to do so.
Elastomer components (e.g. engine mounts, damping elements, couplings and V-belts) must not be painted.
They may only be installed after painting the engine or must be covered before painting work is carried out.
The following applies to starters with copper-beryllium alloy pinions:
• Wear a respirator mask (filter class P3). Do not blow out the interior of the flywheel housing or the starter
with compressed air. Clean the flywheel housing inside with a class H dust extraction device.
• Observe the safety data sheet.
Safety regulations during maintenance and repair work

Take special care when removing ventilation or plug screws from the product.
Release residual pressure before removing or replacing a component in the supply line. To depressurize pres-
surized lines, shut off the lines first, then release the residual pressure.
Use only proper and calibrated tools. Observe the specified tightening torques during assembly or disassem-
bly.
Carry out work only on assemblies or plants which are properly secured.
Make sure components or assemblies are placed on stable surfaces. Adopt suitable measures to avoid that
components/tools fall down. Use the specified lifting equipment for all components.
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Never use the product as a climbing aid.

When working high on the equipment, always use suitable ladders and work platforms. Never work on en-
gines or components that are held in place by lifting equipment.
Keep fuel injection lines and connections clean.
Carry out appropriate cleaning procedures to clean and inspect components requiring special cleanness (e.g.
components carrying oil, fuel, or air).
Always seal connections with caps or covers if a line is removed or opened.
Fit new seals when re-installing lines.
10 | Safety | MS15018/03E 2016-02

Never bend lines and avoid damaging lines, particularly the fuel lines.
Ensure that all retainers and dampers are installed correctly.
Ensure that O-rings are not installed in a slanted/twisted condition.
Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent contact
with other components. Do not place fuel or oil lines near hot components.
Do not touch elastomeric seals (e.g. Viton sealing rings) with your bare hands if they have a carbonized or
resinous appearance.
Note cooling time for components which are heated for installation or removal (risk of burning).
Pay particular attention to cleanliness at all times.
Remove any condensate from components which were chilled before assembly. If necessary, coat the com-
ponents with a suitable corrosion inhibitor.
Safety regulations following maintenance and repair work

Before barring the engine, make sure that nobody is standing in the danger zone of the product.
Check that all access ports/apertures which have been opened to facilitate working are closed again.
Check that all safety equipment has been installed and that all tools and loose parts have been removed
(especially the barring gear).
Ensure that no unattached parts have been left in/on the product (e.g. including rags and cable straps).
Ensure that the grounding system is properly connected.
Welding work
Welding operations on the product or mounted units are not permitted. Cover the product when welding in
its vicinity.
Before starting welding work:
• Switch off the power supply master switch.
• Disconnect the battery cables or actuate the battery isolating switch.
• Separate the electrical ground of electronic equipment from the ground of the unit.
No other maintenance or repair work must be carried out in the vicinity of the product while welding is going
on. Risk of explosion or fire due to oil vapors and highly flammable process materials.
Do not use product as ground terminal.
Never position the welding power supply cable adjacent to, or crossing cabling harnesses of the product. The
welding current may otherwise induce an interference voltage in the cabling harnesses which could conceiv-
ably damage the electrical system.
Remove components (e.g. exhaust pipe) from the product before performing necessary welding work.
Hydraulic installation and removal

Check satisfactory function and safe operating condition of tools, jigs and fixtures to be used. Use only the
specified jigs and fixtures for hydraulic removal/installation procedures.
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Observe the max. permissible force-on pressure specified for the jig/fixture.
Do not attempt to bend or exert force on H.P. lines.
Before starting work, pay attention to the following:
• Vent the installation/removal device, the pumps and the pipework at the relevant designated points.
• During the installation procedure, screw on device with pushed-in plunger.
• During the removal procedure, screw on device with retracted plunger.
For a hydraulic installation/removal device with central expansion pressure supply, screw spindle into shaft
end until correct sealing is established.
MS15018/03E 2016-02 | Safety | 11

During hydraulic installation/removal of components, ensure that no persons are in the direct vicinity of the
component being pressed.
Working with batteries

Observe the safety instructions of the battery manufacturer when working with batteries.
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 clothing, goggles and protective gloves.
Do not place objects on the battery.
Before connecting the cable to the battery, check the battery polarity. Battery pole reversal may lead to in-
jury through the sudden discharge of acid or bursting of the battery body.
Working on electrical and electronic assemblies

Always obtain the permission of the person in charge before commencing maintenance and repair work or
switching off any part of the electronic system required to do so.
De-energize the appropriate areas prior to working on assemblies.
Do not damage cabling during removal work. When reconnecting, ensure that cabling cannot be damaged
during operation by:
• Contact with sharp edges
• Chafing on components
• Contact with hot surfaces.
Do not secure cables on lines carrying fluids.
Do not use cable straps to secure cables.
Always use connector pliers to tighten union nuts on connectors.
Subject the device as well as the product to a functional testing on completion of all repair work. Check cor-
rect execution of the emergency stop function in particular.
Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Package
faulty electronic components or assemblies properly before dispatching for repair:
• Moisture-proof
• Shock-proof
• Wrapped in antistatic foil if necessary.
Work with laser devices

Work with laser devices shall be carried out by trained and qualified personnel only. Follow the safety in-
structions in the manufacturer's user manual when working with laser equipment.
Wear special laser safety glasses when working with laser equipment (danger of concentrated radiation).
Laser devices must be equipped, in accordance with their class and usage, with protective devices for ensur-
ing safe operation.
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Measuring component dimensions

Workpieces, components and measuring equipment lie in the specified tolerance range at a reference tem-
perature of 20 °C.
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1.6 Fire prevention and environmental protection, fluids and
lubricants, auxiliary materials
Fire prevention
Flames, naked light and smoking are prohibited.
When working with combustible indirect materials, e.g. cleaning agent, ensure area is well ventilated. The
resultant steam/air mixture must be sufficiently diluted to prevent a potentially explosive atmosphere.
Rectify any fuel or oil leaks immediately. Oil or fuel on hot components can cause fires – therefore always
keep the product in a clean condition. Do not leave rags saturated with fluids and lubricants on the product.
Do not store combustible materials near the product.
Do not carry out welding work on pipes and components carrying oil or fuel. Before welding, clean with a
nonflammable fluid.
When starting the engine with an external power source, connect the ground lead last and remove it first. To
avoid sparks in the vicinity of the battery, connect the ground lead from the external power source to the
ground lead of the engine or to the ground terminal of the starter.
Always have a suitable extinguishing agent (fire extinguisher) on hand and familiarize yourself fully with its
handling.
Noise
Noise can lead to an increased risk of accidents if acoustic signals, warning shouts or sounds indicating dan-
ger are drowned.
Wear ear protectors in workplaces with a sound pressure level in excess of 85 dB (A).
Environmental protection and disposal

Dispose of used fluids, lubricants and filters in accordance with local regulations.
Within the EU, batteries can be returned free of charge to the manufacturer where they will be properly recy-
cled.
Auxiliary materials
Process materials may also be hazardous or toxic. When using consumables and auxiliary materials as well
as other chemical substances, observe the information contained in the safety data sheet for the product.
The safety data sheet may be obtained from the relevant manufacturer or from MTU.
Take special care when using hot, chilled or caustic materials.
Used oil
Used oil contains combustion residues that are harmful to health.
Wear protective gloves!
Wash relevant areas after contact with used oil.
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Lead
• Adopt suitable measures to avoid the formation of lead dust.
• Switch on extraction system.
• When working with lead or lead-containing compounds, avoid direct contact to the skin and do not inhale
lead vapors.
• Wash relevant areas after contact with lead or lead-containing substances.
MS15018/03E 2016-02 | Safety | 13

Compressed air
Observe special safety precautions when working with compressed air:
• Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII and B) out of con-
tainers, risks causing an explosion.
• Wear goggles when blowing dirt off workpieces or blowing away swarf.
• Blowing compressed air into thin-walled containers (e.g. containers made of sheet metal, plastic or glass)
for drying purposes or to check for leaks risks bursting them.
• Pay special attention to the pressure in the compressed air system or pressure vessel.
• Assemblies or products which are to be connected must be designed to withstand this pressure. Install
pressure-reducing or safety valves set to the admissible pressure if this is not the case.
• Hose couplings and connections must be securely attached.
• Provide the snout of the air nozzle with a protective disk (e.g. rubber disk).
• Release residual pressure before removing or replacing pneumatic equipment in the supply line. To de-
pressurize compressed-air lines, shut off the lines first, then release the residual pressure.
• Carry out leak test in accordance with the specifications.
Painting
• Observe the relevant safety data sheet for all materials.
• When carrying out painting work outside the spray stands provided with fume extraction systems, ensure
that the area is well ventilated. Make sure that neighboring work areas are not adversely affected.
• There must be no naked flames in the vicinity.
• No smoking.
• Observe fire-prevention regulations.
• Always wear a mask providing protection against paint and solvent vapors.
Liquid nitrogen
• Work with liquid nitrogen may be carried out only by qualified personnel.
• Store liquid nitrogen only in small quantities and always in specified containers without fixed covers.
• Avoid body contact (eyes, hands).
• Wear protective clothing, protective gloves, closed shoes and safety goggles.
• Make sure that working area is well ventilated.
• Avoid knocking or jolting the containers, valves and fittings or workpieces in any way.
Acids/alkaline solutions/urea (AdBlue®, DEF)

• When working with acids and alkaline solutions, wear goggles or face mask, gloves and protective cloth-
ing.
• Do not inhale vapors.
• If urea solution is swallowed, rinse out mouth and drink plenty of water.
• Remove any wet clothing immediately.
• After contact skin, wash body areas with plenty of water.
• Rinse eyes immediately with eyedrops or clean tap water. Seek medical attention as soon as possible.
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1.7 Standards for safety notices in the text
DANGER
In the event of immediate danger.
Consequences: Death, serious or permanent injury!
• Remedial action.
WARNING
In the event of a situation involving potential danger.
Consequences: Death, serious or permanent injury!
CAUTION
In the event of a situation involving potential danger.
Consequences: Minor or moderate injuries!
NOTICE
In the event of a situation involving potentially adverse effects on the product.
Consequences: Material damage!
• Additional product information.
Warning notices
1. This manual with all safety instructions and safety notices must be issued to all personnel involved in opera-
tion, maintenance, repair, assembly, installation, or transportation.
2. The higher level warning notice is used if several hazards apply at the same time. Warnings related to person-
al injury shall be considered to include a warning of potential damage.
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MS15018/03E 2016-02 | Safety | 15

2 Transport
2.1 Transportation
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Crossbeam T80092210 1
DANGER
Suspended load.
Danger to life!
• Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.
Transportation
1. Use lifting eyes provided for transporting the engine (→ Page 17).
2. Only use suitable transportation and lifting equipment.
3. The engine must only be transported in installation position: Max. admissible diagonal pull 10°. (→ Page 17)°
4. Remove any loose parts on engine.
5. Always raise/lower engine slowly. The lifting ropes or chains must not rub against the engine or its compo-
nents during the lifting procedure. Readjust lifting tackle as necessary.
6. For special packaging with aluminum foil: Attach engine to lifting eyes of bearing pedestal or transport with
means of transportation device suitable for the load (forklift truck).
7. Secure engine against tilting during transportation. Secure such as to preclude slipping and tipping when
driving up or down inclines and ramps.
Placement after transportation

1. Only set down engine on a firm, level surface.
2. Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate.
3. Never set engine down on oil pan unless expressively authorized to do so by MTU on a case-to-case basis.
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2.2 Lifting requirements
Lifting requirements
DANGER
Suspended load.
Danger to life!
• Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.
1 Lifting eye 2 Center of gravity
Take note of the engine center of gravity

See Installation/Arrangement drawings for details on engine center of gravity.
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3 General Information
3.1 Engine side and cylinder designations
1 Left engine side (A-side) 3 Right engine side (B-side)

2 Engine free end in accord- 4 Engine driving end in ac-
ance with DIN ISO 1204 cordance with
(KGS = Kupplungsgegen- DIN ISO 1204 (KS = Kup-
seite) plungsseite)
Engine sides are always designated (in accordance with DIN ISO 1204) as viewed from driving end (4).
For cylinder designation (in accordance with DIN ISO 1204), the letter "Ax" refers to the cylinders on the left-
hand side of the engine (1) and letter "Bx" refers to the cylinders on the right-hand side (3). The cylinders of
each bank are numbered consecutively, starting with x=1 at driving end (4).
The numbering of other engine components also starts with 1 at driving end (4).
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18 | General Information | MS15018/03E 2016-02

3.2 Engine overview
Engine with water-to-air charge-air cooling TB
1 Air filter 8 Oil filter 15 Cylinder head

2 Oil separator 9 Coolant pump 16 Flywheel housing
3 Intercooler 10 Fuel priming pump 17 Starter
4 Engine governor 11 Air outlet 18 Storage
5 Fuel filter 12 Exhaust turbocharger 19 Oil pan
6 Fan drive 13 Exhaust elbow 20 Crankcase breather
7 Oil heat exchanger 14 Charge-air manifold
Figure also applies similarly to 12V/16V/18V2000Gxy
TIM-ID: 0000009973 - 005
MS15018/03E 2016-02 | General Information | 19

Engine with air-to-air charge-air cooling TD
1 Air filter 7 Oil heat exchanger 13 Exhaust elbow

2 Oil separator 8 Oil filter 14 Charge-air manifold
3 Air outlet 9 Coolant pump 15 Cylinder head
4 Engine governor 10 Fuel priming pump 16 Flywheel housing
5 Fuel filter 11 Exhaust turbocharger 17 Storage
6 Fan drive 12 Oil pan 18 Crankcase breather
Figure also applies similarly to 12V/16V/18V2000Gxy
Engine type designation

Explanation of engine type designation 12V/16V/18V2000Gxy
12/16/18 Number of cylinders
V Cylinder arrangement: V engine
2000 Series
G Application
x Application segment (2, 4, 6, 8)
y Design status (0, 1, 2,...)
TIM-ID: 0000009973 - 005

3.3 Sensors and actuators – Overview
Engines with water-cooled intercooler TB
Item Name Monitoring of

1 B7 Lube oil temperature
2 B5 Lube oil pressure
3 B9 Charge-air coolant temperature
4 B10 Charge-air pressure
5 B1 Camshaft speed
6 B13 Crankshaft speed
7 B6 Coolant temperature
8 B33 Fuel temperature
The coolant level sensor F33 is located in the coolant expansion tank at the cooler
TIM-ID: 0000022704 - 003
MS15018/03E 2016-02 | General Information | 21

Engine with air-cooled intercooler TD
Item Name Monitoring of

1 B7 Lube oil temperature
2 B5 Lube oil pressure
3 B9 Charge-air coolant temperature
4 B10 Charge-air pressure
5 B1 Camshaft speed
6 B13 Crankshaft speed
7 B6 Coolant temperature
8 B33 Fuel temperature
The coolant level sensor F33 is located in the coolant expansion tank at the cooler TIM-ID: 0000022704 - 003

4 Technical Data
4.1 12/16/18V2000G65 engine data, fuel optimized
Explanation
Abbr. Meaning
DL Ref. value: Continuous power
BL Ref. value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power settings).
N Not yet defined value
- Not applicable
X Applicable
** Not sufficiently validated value (tolerance +/- 5%)
Reference condition
Description 12V2000 16V2000 18V2000
G65 G65 G65
Application group 3A 3A 3A
Intake air temperature °C 25 25 25
Barometric pressure mbar 1000 1000 1000
Site altitude above sea level M 100 100 100
Power-related data (power ratings are net brake power as per ISO 3046)
G65 G65 G65
Rated engine speed A rpm 1500 1500 1500
Continuous power ISO 3046 (10% overload pos- A kW 515 655 720
sible) (power range DIN 6280, ISO 8528)
General conditions (for maximum power)

G65 G65 G65
TIM-ID: 0000010804 - 002
Intake depression (new filter) A mbar 15 15 15

Intake depression, max. L mbar 50 50 50
Exhaust overpressure A mbar 30 30 30
Exhaust gas overpressure, max. L mbar 85 85 85
MS15018/03E 2016-02 | Technical Data | 23

Model related data (basic design)
G65 G65 G65
Engine with exhaust turbocharging (ETC) and x x x
charge-air cooling (CAC)
Uncooled exhaust lines x x x
Operating method: Four-stroke cycle, diesel, x x x
single-action
Combustion method: direct fuel injection x x x
Cooling method: conditioned water x x x
Direction of rotation: c.c.w. (facing driving end) x x x
Number of cylinders 12 16 18
Cylinder arrangement: V-angle degrees 90 90 90
Bore mm 130 130 130
Stroke mm 150 150 150
Displacement, cylinder Liter 1.99 1.99 1.99
Displacement, total Liter 23.88 31.84 35.82
Compression ratio 16 16 16
Cylinder heads: Individual cylinder heads x x x
Cylinder liners: wet, replaceable x x x
Number of inlet valves per cylinder 2 2 2
Number of exhaust valves, per cylinder 2 2 2
Standard housing connecting flange (engine SAE 0 0 0
main PTO)
Flywheel interface DISC 18" 18" 18"
Air / exhaust gas

G65 G65 G65
Charge-air pressure before cylinder - DL R bar abs 2.5 2.5 2.4
Coolant system (HT circuit)

G65 G65 G65
Coolant temperature (at engine connection: A °C 95 95 95
outlet to cooling equipment)
Coolant temperature after engine, alarm R °C 97 97 97
TIM-ID: 0000010804 - 002
Coolant temperature after engine, shutdown L °C 102 102 102

Coolant antifreeze content, max. L % 50 50 50
Pressure loss in off-engine cooling system, max. L bar 0.7 0.7 0.7
24 | Technical Data | MS15018/03E 2016-02

Lube oil system
G65 G65 G65
Lube-oil operating temperature before engine, R °C 88 88 88
from
to
Lube-oil temperature before engine, alarm R °C 100 100 100
Lube-oil temperature before engine, shutdown L °C 105 105 105
Lube-oil operating pressure before engine, from R bar 6.2 5.5 6.0
Lube-oil operating pressure before engine, to R bar 7.5 6.5 8.0
Lube-oil operating pressure before engine, R bar 4.4 4.4 4.4
warning
Lube-oil operating pressure before engine, shut- L bar 3.9 3.9 3.9
down
Fuel system
G65 G65 G65
Fuel pressure at engine inlet connection, min. L bar -0.3 -0.3 -0.3
(when engine is starting)
Fuel pressure at engine inlet connection, max. L bar +0.5 +0.5 +0.5
General operating data

G65 G65 G65
Cold start capability: air temperature (w/o start R °C 0** 0** 0**
aid. w/o preheating) - (case A)
Coolant preheating: preheating temperature R °C 32 32 32
(min.)
Firing speed, from R rpm 100 100 100
Firing speed. to R rpm 120 120 120
Oil and coolant capacity

G65 G65 G65
Engine coolant capacity, engine side (without R Liter 90 110 120
cooling equipment)
TIM-ID: 0000010804 - 002
Engine oil capacity, initial filling (standard oil R Liter 77 102 130
system)(Option: max. operating inclinations)
Oil change capacity, max. (standard oil system) R Liter N N N
Oil change quantity max. (standard oil system) R Liter 74 99 114
(design: max. operating inclinations)
Oil pan capacity dipstick mark min. (standard L Liter 50 69 87
oil system) (design: max. operating inclinations)
Oil pan capacity dipstick mark max. (standard L Liter 67 92 110

Weights / main dimensions
G65 G65 G65
Engine weight, dry (basic engine configuration R kg 2490 3100 3500
acc. to scope of delivery specification)
Acoustics
G65 G65 G65
Exhaust noise, unsilenced - DL (sound power R dB(A) 123 124 125
level LW, ISO 6798, +3 dB(A) tolerance)
Engine surface noise with attenuated intake R dB(A) 115 119 119
noise (filter) - DL (sound power level LW, ISO
6798, +2 dB(A) tolerance)
TIM-ID: 0000010804 - 002

4.2 12/16/18V2000G65-TB engine data, fuel optimized
Explanation
Abbr. Meaning
DL Ref. value: Continuous power
BL Ref. value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power settings).
N Not yet defined value
- Not applicable
X Applicable
** Not sufficiently validated value (tolerance +/- 5%)
Reference condition
G65-TB G65-TB G65-TB
Application group 3A 3A 3A
Intake air temperature °C 25 25 25
Charge air coolant temperature °C 55 55 55
Raw water inlet temperature °C - - -
Barometric pressure mbar 1000 1000 1000
Site altitude above sea level M 100 100 100
Power-related data (power ratings are net brake power as per ISO 3046)
Rated engine speed A rpm 1500 1500 1500
Continuous power ISO 3046 (10% overload pos- A kW 515 655 720
sible) (power range DIN 6280, ISO 8528)
General conditions (for maximum power)

Intake depression (new filter) A mbar 15 15 15
TIM-ID: 0000010846 - 002
Intake depression, max. L mbar 50 50 50

Exhaust overpressure A mbar 30 30 30
Exhaust gas overpressure, max. L mbar 85 85 85

Model related data (basic design)
Engine with exhaust turbocharging (ETC) and x x x
charge-air cooling (CAC)
Uncooled exhaust lines x x x
Operating method: Four-stroke cycle, diesel, x x x
single-action
Combustion method: direct fuel injection x x x
Cooling method: conditioned water x x x
Direction of rotation: c.c.w. (facing driving end) x x x
Number of cylinders 12 16 18
Cylinder arrangement: V-angle degrees 90 90 90
Bore mm 130 130 130
Stroke mm 150 150 150
Displacement, cylinder Liter 1.99 1.99 1.99
Displacement, total Liter 23.88 31.84 35.82
Compression ratio 16 16 16
Cylinder heads: Individual cylinder heads x x x
Cylinder liners: wet, replaceable x x x
Number of inlet valves per cylinder 2 2 2
Number of exhaust valves, per cylinder 2 2 2
Standard housing connecting flange (engine SAE 0 0 0
main PTO)
Flywheel interface DISC 18" 18" 18"
Air / exhaust gas

Charge-air pressure before cylinder - DL R bar abs 2.5 2.5 2.4
Coolant system (HT circuit)

Coolant temperature (at engine connection: A °C 95 95 95
outlet to cooling equipment)
Coolant temperature after engine, alarm R °C 97 97 97
TIM-ID: 0000010846 - 002
Coolant temperature after engine, shutdown L °C 102 102 102


Coolant system (LT circuit)
Coolant temperature before intercooler (at en- A °C 55 55 55
gine inlet from cooling equipment)
Lube oil system

from
to
Lube-oil temperature before engine, alarm R °C 100 100 100
Lube-oil temperature before engine, shutdown L °C 105 105 105
Lube-oil operating pressure before engine, from R bar 6.2 5.5 6.0
Lube-oil operating pressure before engine, to R bar 7.5 6.5 8.0
Lube-oil operating pressure before engine, R bar 4.4 4.4 4.4
warning
Lube-oil operating pressure before engine, shut- L bar 3.9 3.9 3.9
down
Fuel system
Fuel pressure at engine inlet connection, min. L bar -0.3 -0.3 -0.3
Fuel pressure at engine inlet connection, max. L bar +0.5 +0.5 +0.5
General operating data

Cold start capability: air temperature (w/o start R °C 0** 0** 0**
aid. w/o preheating) - (case A)
Coolant preheating: preheating temperature R °C 32 32 32
(min.)
TIM-ID: 0000010846 - 002
Firing speed, from R rpm 100 100 100

Firing speed. to R rpm 120 120 120

Oil and Coolant Capacity
Engine coolant capacity, engine side (without R Liter 110 130 140
cooling equipment)
Charge-air coolant, engine side R Liter 20 20 20
Engine oil capacity, initial filling (standard oil R Liter 77 102 130
system) (Option: max. operating inclinations)
Oil change capacity, max. (standard oil system) R Liter N N N
Oil change quantity max. (standard oil system) R Liter 74 99 114
(design: max. operating inclinations)
Oil pan capacity dipstick mark min. (standard L Liter 50 69 87
Oil pan capacity dipstick mark max. (standard L Liter 67 92 110
Weights / main dimensions

Engine weight, dry (basic engine configuration R kg 2570 3180 3580
acc. to scope of delivery specification)
Sound
Description 12 16 18
Exhaust noise, unsilenced - DL (sound power R dB(A) 123 124 125
level LW, ISO 6798, +3 dB(A) tolerance)
Engine surface noise with attenuated intake R dB(A) 115 119 119
noise (filter) - DL (sound power level LW, ISO
6798, +2 dB(A) tolerance)
TIM-ID: 0000010846 - 002

4.3 Firing order
Firing order
Number of cylinders Firing order
12V A1-B2-A5-B4-A3-B1-A6-B5-A2-B3-A4-B6
16V A1-B5-A3-A5-B2-B8-A2-A8-B3-A7-B4-B6-A4-A6-B1-B7
18V A1-B6-A3-B4-A5-B2-A7-B1-A9-B3-A8-B5-A6-B7-A4-B9-A2-B8
TIM-ID: 0000002793 - 004

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

12V2000Gx5 approx. 1882 mm approx. 1580 mm approx. 1570 mm
12V2000Gx5-TB approx. 1836 mm approx. 1580 mm approx. 1585 mm
TIM-ID: 0000010030 - 005

5 Operation
5.1 Putting the engine into operation after extended out-of-service
periods (>3 months)
Preconditions
☑ Engine is stopped and starting disabled.
☑ MTU Preservation and Represervation Specifications (A001070/..) are available.
Putting the PowerPack into operation after extended out-of-service-periods

(>3 months)
Item Action
Engine Depreserve (→ MTU Preservation and Represervation Specifications
A001070/..).
Lube oil system Check engine oil level (→ Page 116);
Fuel prefilter Fill with fuel (→ Page 106).
Fuel prefilter, pressure Align adjustable pointer with position of pressure indicator (→ Page 103).
gauge
Fuel system Vent (→ Page 100).
Coolant circuit If engine is out of service for more than one year, change engine coolant
(→ Page 120).
Change charge-air coolant (→ Page 128).
Coolant circuit Check engine coolant level (→ Page 119);
Check charge-air coolant level (→ Page 129).
Coolant circuit Heat engine coolant with coolant preheating unit.
Engine governor Check plug-in connections (→ Page 141).
Monitoring system Carry out lamp test (see manufacturer's documentation).
Engine/generator control Switch ON;
system select operating mode, e.g. MANUAL, AUTOMATIC OPERATION.
TIM-ID: 0000002190 - 002
MS15018/03E 2016-02 | Operation | 33

5.2 Putting the engine into operation after scheduled out-of-
service-period
Preconditions
Putting the engine into operation

Item Task
Lube oil system Check oil level (→ Page 116);
Cooling system Check engine coolant level (→ Page 119);
Check charge-air coolant level (→ Page 129).
Cooling system Preheat coolant with preheating unit.
Fuel prefilter Drain (→ Page 104).
Monitoring equipment Carry out lamp test (see manufacturer's documentation).
Engine/generator control Switch ON;
system Select operating mode, e.g. MANUAL OPERATION, AUTOMATIC OPERATION.
TIM-ID: 0000002677 - 001
34 | Operation | MS15018/03E 2016-02

5.3 Engine – Starting in manual mode (test run)
Preconditions
☑ Generator (if fitted) is not connected to network.
☑ External start interlock is not active.
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Before cranking the engine with starter system, make sure that there are no persons in the engine's
danger zone.
WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.
Preparation
Item Action
Operating mode switch (if Change to manual mode.
fitted)
Preheating pump (if fitted) Switch on.
Starting the engine

Item Action
Switchgear cabinet, control If coolant temperature is
panel etc. (depending on • > 40 °C (with preheating system), or
manufacturer) • > 5 °C (without preheating system):
Press start button.
• Automatic starting sequence is performed;
• Engine speed display instrument indicates increasing speed;
• After the starting sequence is completed, engine is running at rated
speed.
Connecting the generator (if fitted) to network, engine warm-up procedure to

reach operating temperature
Item Action
Switchgear cabinet, control Close the generator circuit breaker.
panel etc. (depending on
manufacturer)
TIM-ID: 0000002226 - 004
Engine Apply full load only after engine has reached operating temperature (coolant
temperature approx. 75 °C).
MS15018/03E 2016-02 | Operation | 35

5.4 Safety system – Override
NOTICE
Safety functions and engine shutdown alarms will be disregarded.
Severe material damage!
• Initiate emergency start only in emergency situations.
NOTICE
Inadmissible operating status.
Severe damage to property!
• Use override function only in hazardous situations to ensure full capability in the event of engine
faults.
Preparation
Note: This function is only available when a pushbutton is provided.
Safety system – Override

Item Action
Switchgear cabinet, control Activate pushbutton for Override input of the ECU.
panel etc. (depending on • Certain shutdown criteria and/or starting prerequisites are ignored.
manufacturer)
Switchgear cabinet, control Actuate start button, for further starting sequence, refer to engine start
panel etc. (depending on (→ Page 35).
manufacturer)
Control and display panels During operation, check the displayed operational data (speed, temperature,
pressures).
Constantly monitor plant limit values.
TIM-ID: 0000000984 - 003
36 | Operation | MS15018/03E 2016-02

5.5 Operational monitoring
DANGER
• Only run the engine at low power. Keep away from the engine's danger zone.
WARNING
Operational monitoring
Item Measure
Control and display panels Check readings of operational data (speed, temperature, pressures).
Engine under load, Check engine/plant and all pipework visually for leaks, rectify any leaks with
engine at nominal speed the engine stopped;
Check for abnormal running noises and vibration.
Fuel prefilter Check reading on differential pressure gage to ensure that maximum admis-
sible value is not exceeded (→ Page 103).
Exhaust system Check exhaust color (→ Page 67).
Intercooler Check condensate drain(s) for water discharge and obstruction
(→ Page 111).
Air filter Check signal ring position of service indicator (→ Page 114).
Replace air filter (→ Page 112), if the signal ring is completely visible in the
red area of the service indicator observation window.
Coolant pump Check relief bore (→ Page 124).
Compressed-air system (if Check operating pressure on pressure gauge;
installed) Always fill compressed-air tank to max. pressure;
Drain condensate from compressed-air tank, pressure drop must not exceed
1 bar .
TIM-ID: 0000010120 - 003
MS15018/03E 2016-02 | Operation | 37

5.6 Engine – Stopping in manual mode (test run)
Preconditions
☑ Generator (if fitted) is not connected to network
☑ Engine in manual mode
NOTICE
Stopping the engine when it is running at full load subjects it to extreme thermal and mechanical stress-
es.
Overheating of and, therefore, damage to components is possible!
• Before shutting down the engine, allow it to idle until the engine temperatures decrease and constant
levels are indicated.
Preparing a generator drive (only if generator circuit breaker is provided)

Item Action
Engine After the generator breaker (if provided) has been opened, allow the engine
to cool down by running it idle for approx. 5 minutes.
Preparing a pump drive (diesel-mechanical/diesel-electric)

Item Action
Engine Allow the engine to cool down by running it at reduced speed for approx. 5
minutes. Observe the natural frequencies (plant-specific values) of the en-
gine!
Stopping the engine

Item Action
Switchgear cabinet, control Press stop button.
panel etc. (depending on • Automatic stopping sequence is performed;
manufacturer) • Engine at a standstill.
After stopping the engine

Item Action
Coolant circulation pump Operate pump for a sufficient period of time after the engine is stopped.
TIM-ID: 0000002285 - 004
38 | Operation | MS15018/03E 2016-02

5.7 Engine – Emergency stop
NOTICE
An emergency stop subjects the engine system to an extremely high load.
Risk of overheating, damage to components!
• Trigger an emergency stop only in emergency situations.
Emergency engine stop from LOP

Item Action
Emergency stop pushbutton Press pushbutton.
• Engine is stopped by disconnecting the power supply to the ECU;
• Signaling (e.g. by horn, flashing lamp) is tripped.
After emergency engine stop from LOP

Item Action
Control cabinet, control pan- Press pushbutton for alarm acknowledgment.
el etc. (depending on manu- • Audible and visual alarm signaling stops.
facturer)
TIM-ID: 0000002305 - 004
MS15018/03E 2016-02 | Operation | 39

5.8 After stopping the engine – Engine remains ready for
operation

Item Action
Engine/generator/pump Select operating mode, e.g. MANUAL, AUTOMATIC OPERATION.
control
TIM-ID: 0000000983 - 003
40 | Operation | MS15018/03E 2016-02

5.9 After stopping the engine – Putting the engine out of
operation
Preconditions
☑ MTU Preservation and Represervation Specifications (A001070/..) are available.

Item Action
Coolant circuit Drain engine coolant (→ Page 121);
Drain charge-air coolant (→ Page 127) if:
• freezing temperatures are to be expected and the engine is to remain out
of service for an extended period and if no antifreeze has been added to
the coolant;
• the engine room is not heated;
• the coolant is not kept at a suitable temperature;
• the antifreeze concentration is insufficient for the engine-room tempera-
ture;
• antifreeze concentration is 50 % and engine-room temperature is below
-40 °C.
Engine/generator/pump Switch off.
control
Air intake and exhaust sys- If the engine is to remain out of service for more than 1 week, seal the en-
tem gine's air and exhaust sides. If the engine is to remain out of service for more
than 1 month, carry out preservation (→ Preservation and Represervation
Specifications A001070/..).
TIM-ID: 0000002706 - 003
MS15018/03E 2016-02 | Operation | 41

6 Maintenance
6.1 Maintenance task reference table [QL1]
The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Mainte-
nance Schedule is a stand-alone publication.
The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance
Schedule.
Task Maintenance tasks
W0500 Check engine oil level. (→ Page 116)
W0501 Visually inspect engine for leaks and general condition. (→ Page 37)
W0502 Check intercooler drain. (→ Page 111)
W0503 Check service indicator of air filter. (→ Page 114)
W0505 Check relief bores of coolant pump(s). (→ Page 124)
W0506 Check engine for abnormal running noises, exhaust color and (→ Page 37)
vibrations.
W0507 Drain water and contaminants from fuel prefilter. (→ Page 104)
W0508 Check reading on differential pressure gage of fuel prefilter. (→ Page 103)
W0534 Carry out test run, minimum duration: until steady-state tem- (→ Page 72)
perature is reached, no less than 1/3 load (monthly).
W1001 Replace fuel filter or fuel filter element. (→ Page 102)
W1002 Check valve clearance. (→ Page 80)
W1003 Check belt condition and tension, replace if necessary. (→ Page 132)
W1005 Replace air filter. (→ Page 112)
W1006 Replace injectors. (→ Page 88)
W1007 Replace fuel injection pump(s). (→ Page 85)
W1008 Replace engine oil filter when changing engine oil, or when the (→ Page 118)
time limit (years) is reached, at the latest.
W1010 Coolant cooler: Check exterior of cooler elements for dirt. (→ Page 130)
W1011 Perform endoscopic examination. (→ Page 73)
W1056 Replace fuel pressure maintaining valve. (→ Page 99)
W1178 Replace pressure pipe neck in cylinder head. (→ Page 94)
TIM-ID: 0000037729 - 003
42 | Maintenance | MS15018/03E 2016-02

7 Troubleshooting
7.1 Fault indication on SAM display – Genset applications
SAM fault messages
1 2-line LC display 3 Fault type

2 Time indicator for alarms 4 Node number
The structure of the display is as follows:
• First line
– Time indicator for alarms (e.g. #)
– Type of fault (e.g. SE03)
– Node number at which the fault occurred (e.g. nd11)
• Second line (option)
– Running text, providing more information about the fault currently displayed
Time indicator for alarms Meaning
# Alarm is no longer active, does not appear on next power-up.
TIM-ID: 0000008508 - 003
A Alarm is active.
B Alarm was active during the last hour.
C Alarm was active during the last four hours.
D Alarm was active during the last four to twelve hours.
E Alarm was active more than twelve hours ago.
Proceed to the next alarm by pressing key (↓ ↑).
MS15018/03E 2016-02 | Troubleshooting | 43

Fault type – fault message text
SE no. Error message text
0 Sensor Temperatur Defect
1 Temperature failure
2 Sensor Voltage Defect
3 Voltage failure
4 CAN Bus- 1 Error/Bus Defec
5 CAN Bus- 1 Overrun
8 Temperatur Compensation Error
9 I/O-Module Slot2 Defect
12 Serial Conection Lost
15 S/A Bus Faulty
16 PAN 1 Defect
17 PAN 2 Defect
18 PAN 3 Defect
19 PAN 4 Defect
20 PAN 5 Defect
21 PAN 6 Defect
27 Download Server Collision
28 not projected node
Engine governor messages
Recommended action in case of alarm

Yellow alarm:
TIM-ID: 0000008508 - 003
The engine can still be operated providing that automatic engine shutdown to protect the engine has not
been configured or is not tripped. Contact Service immediately/start fault rectification.
Red alarm:
Caution, the engine is running at its limits. Shut down manually without further delay if the engine does not
shut itself down immediately after a red alarm is signaled.
Fault and alarm messages

The fault code numbers are generated by the engine governor and transmitted to the display below.
44 | Troubleshooting | MS15018/03E 2016-02

The fault code (1) comprises three digits.
Fault messages can also be caused by faulty sensors/actuators. Contact Service to have sensors/actuators
checked and replaced as necessary if the troubleshooting measures listed in the table below prove unsuc-
cessful.
IMPORTANT NOTE:
The information provided in the columns “Meaning” and “Action” applies to the standard default state of the
genset on delivery. Differing system responses requiring different action may result when settings are
changed by the OEM. The OEM is responsible for documenting any changes and defining appropriate coun-
teraction.
The table below lists possible fault codes:
Fault Setting parame-
code no. Full designation Meaning Action ter no.
003 HI T-Fuel Prewarning: Fuel tempera- Check tank temper- 2.0122931
ture too high (limit value 1, ature, contact Serv-
alarm configuration parame- ice if no fault detect-
ter, see PR 2.8008.100 for ed.
explanation).
004 SS T-Fuel Main warning: Fuel tempera- Check tank temper- 2.0122932
TIM-ID: 0000008508 - 003
ture too high (limit value 2, ature, contact Serv-

alarm configuration parame- ice if no fault detect-
ter, see PR 2.8008.100 for ed.
explanation).
005 HI T-Charge Air Prewarning: Charge-air tem- Check cooler, check 2.0121.931
perature too high (limit value intercooler, contact
1, alarm configuration pa- Service if no fault
rameter, see PR 2.8008.100 detected.
for explanation).

006 SS T-Charge Air Main warning: Charge-air Check cooler, check 2.0121.932
temperature too high (limit intercooler, contact
value 2, alarm configuration Service if no fault
parameter, see PR detected.
2.8008.100 for explanation).
009 HI T-Coolant Intercool- Prewarning: Coolant temper- Check cooler, con- 2.0124.931
er ature in intercooler too high tact Service if no
(limit value 1, alarm configu- fault detected.
ration parameter, see PR
010 SS T-Coolant Intercool- Main warning: Coolant tem- Check cooler, con- 2.0124.932
er perature in intercooler too tact Service if no
high (limit value 2, alarm con- fault detected.
figuration parameter, see PR
015 LO P-Lube Oil Prewarning: Lube-oil pres- Check oil level, con- 2.0100.921
sure too low (limit value 1, tact Service if no
alarm configuration parame- fault detected.
ter, see PR 2.8008.100 for
explanation).
016 SS P-Lube Oil Main warning: Lube-oil pres- Check oil level, con- 2.0100.922
sure too low (limit value 2, tact Service.
alarm configuration parame-
explanation). Automatic en-
gine shutdown.
024 SS Coolant Level Coolant level too low (limit Check coolant level 2.0152.912
value 2, alarm configuration in expansion tank,
parameter, see PR check for leakage
2.8008.100 for explanation). and seal any leaks
Automatic engine shutdown. as necessary.
030 SS Engine Overspeed Engine overspeed (limit value Attempt to restart 2.2510.932
2, alarm configuration pa- engine.
rameter, see PR 2.8008.100
for explanation). Automatic
engine shutdown.
044 LO Coolant Level Inter- Intercooler coolant level too Check coolant level 2.0153.921
cooler low (limit value 1, alarm con- in expansion tank,
figuration parameter, see PR check for leakage
2.8008.100 for explanation). and seal any leaks
Automatic engine shutdown. as necessary.
051 HI T-Lube Oil Lube-oil temperature too Check cooling sys- 2.0125.931
TIM-ID: 0000008508 - 003
high (limit value 1, alarm con- tem.

Warning.
052 SS T-Lube Oil Lube-oil temperature too Check cooling sys- 2.0125.932
high (limit value 2, alarm con- tem, contact Service
figuration parameter, see PR if cooling system is
2.8008.100 for explanation). in order.
Automatic engine shutdown.

065 LO P-Fuel Fuel inlet pressure too low Check filter, check 2.0102.921
(limit value 1, alarm configu- genset fuel supply.
Warning.
066 SS P-Fuel Fuel inlet pressure too low Check filter, check 2.0102.922
(limit value 2, alarm configu- genset fuel supply.
Warning.
067 HI T-Coolant Coolant temperature too high Check cooling sys- 2.0120.931
(limit value 1, alarm configu- tem.
Warning.
068 SS T-Coolant Coolant temperature too high Check cooling sys- 2.0120.932
(limit value 2, alarm configu- tem. Contact Serv-
ration parameter, see PR ice if cooling system
2.8008.100 for explanation). is in order.
Automatic engine shutdown.
081 AL Rail Leakage Pressure gradient in rail too On stopping: Seal 1.8004.046
low on starting or too high on off system, contact
stopping, HP system leaking Service; On starting:
(alarm configuration parame- Check engine for
ter, see PR 2.8008.100 for leakage, if none
explanation). found, attempt re-
starting as per oper-
ating instructions
(air in system).
082 HI P-Fuel (Common Rail pressure is greater than Check HP fuel con- 2.0104.931
Rail) set value (alarm configura- trol block wiring, if
tion parameter, see PR no fault detected,
2.8008.100 for explanation). contact Service.
Warning.
083 LO P-Fuel (Common Rail pressure is less than set Check HP fuel con- 2.0104.921
Rail) value (alarm configuration trol block wiring,
parameter, see PR check HP system for
2.8008.100 for explanation). leakage, if no fault
Warning. detected, contact
Service.
089 SS Engine Speed too Engine speed too low (alarm Check for additional 2.2500.030
Low configuration parameter, see messages.
TIM-ID: 0000008508 - 003
PR 2.8008.100 for explana-

tion). Engine stop.
090 SS Idle Speed Not Idling speed not reached Check for additional 2.1090.925
Reached (alarm configuration parame- messages.
explanation). Start terminat-
ed.

091 SS Release Speed Not Runup speed not reached Check for additional 2.1090.924
Reached (alarm configuration parame- messages. Recharge
ter, see PR 2.8008.100 for battery. Engine un-
explanation). Start terminat- der load: Check fuel
ed. supply; if no fault
detected, contact
Service.
092 SS Starter Speed Not Starter speed not reached Check for additional 2.1090.923
Reached (alarm configuration parame- messages. Recharge
ter, see PR 2.8008.100 for battery. Engine un-
explanation). Start terminat- der load: Check fuel
ed. Starter does not turn or supply; if no fault
turns slowly. detected, contact
Service.
093 SS T-Preheat Preheating temperature too Engine start inter- 2.1090.922
low (limit value 2, alarm con- lock is active as
figuration parameter, see PR coolant temperature
2.8008.100 for explanation). is too low for engine
start, preheating
necessary.
094 LO T-Preheat Preheating temperature too Engine start inter- 2.1090.921
low (limit value 1, alarm con- lock is active as
figuration parameter, see PR coolant temperature
2.8008.100 for explanation). is too low for engine
start, preheating
necessary.
095 AL Prelubrication Fault Oil priming pressure not Contact Service. 2.1090.920
reached (alarm configuration
parameter, see PR
102 AL Fuel Cons. Counter Electronic fault: Consump- Replace engine gov- 1.8004.624
Defect tion counter faulty (alarm ernor at next oppor-
configuration parameter, see tunity.
tion).
104 AL Eng Hours Counter Electronic fault: Hour meter Replace engine gov- 1.8004.623
Defect faulty (alarm configuration ernor at next oppor-
parameter, see PR tunity.
118 LO ECU Power Supply Supply voltage too low (limit Check batteries and 2.0140.921
Voltage value 1, alarm configuration charge as necessa-
parameter, see PR ry; check generator.
TIM-ID: 0000008508 - 003

Warning.
119 LOLO ECU Power Sup- Supply voltage too low (limit Check batteries and 2.0140.922
ply Voltage value 2, alarm configuration charge as necessa-
parameter, see PR ry; check generator.
Warning.

120 HI ECU Power Supply Supply voltage too high (limit Check batteries and 2.0140.931
Voltage value 1, alarm configuration generator.
parameter, see PR
Warning.
121 HIHI ECU Power Sup- Supply voltage too high (limit Check batteries and 2.0140.932
ply Voltage value 2, alarm configuration generator.
parameter, see PR
Warning.
122 HI T-ECU Electronics temperature too Check engine room 2.0132.921
high (limit value 1, alarm con- ventilation.
Warning.
176 AL LifeData not availa- No (suitable) LifeData back- Contact Service. 2.4000.004
ble up system available, backup
system has no LifeData func-
tion when timeout following
ECU reset expires or CAN
bus to backup system is dis-
rupted (alarm configuration
parameter, see PR
177 AL LifeData restore in- This fault message is gener- Contact Service. 2.4000.006
complete ated when a CRC is faulty
(stated for each module) or
upload is incomplete during a
restore data upload process
(into ADEC) (alarm configura-
tion parameter, see PR
180 AL CAN1 Node Lost Connection to a node on Test devices con- 2.0500.680
CAN bus 1 has failed (alarm nected to CAN, test
configuration parameter, see wiring.
tion).
181 AL CAN2 Node Lost Connection to a node on Check devices con- 2.0500.681
CAN bus 2 has failed (alarm nected to CAN.
configuration parameter, see
tion).
TIM-ID: 0000008508 - 003
182 AL CAN Wrong Param- Incorrect parameter values 2.0500.682

eters entered in data record (alarm
PR 2.8008.100).

183 AL CAN No PU-Data The selected CAN mode initi- Check devices con- 2.0500.683
alizes communication by nected to CAN.
means of the PU data mod-
ule. However, the required
PU data module is unavaila-
ble or invalid (alarm configu-
184 AL CAN PU-Data Flash Programming error on at- Contact Service. 2.0500.684
Error tempting to copy a received
PU data module into the
Flash module (alarm configu-
186 AL CAN1 Bus Off CAN controller 1 is in "Bus Contact Service. 2.0500.686
Off" state, automatic switch-
ing to CAN2 results. Causes
are e.g. short circuit, massive
disruptions or baud rate in-
compatibility (alarm configu-
187 AL CAN1 Error Passive CAN controller 1 has indicat- Contact Service. 2.0500.687
ed a warning. Causes are e.g.
missing associate nodes, mi-
nor disruptions and tempora-
ry bus overload (alarm con-
188 AL CAN2 Bus Off CAN controller 2 is in "Bus Contact Service. 2.0500.688
Off" state, automatic switch-
ing to CAN1 results. Causes
are e.g. short circuit, massive
disruptions or baud rate in-
compatibility (alarm configu-
189 AL CAN2 Error Passive CAN controller 2 has indicat- Contact Service. 2.0500.689
ed a warning. Causes are e.g.
missing associate nodes, mi-
nor disruptions and tempora-
ry bus overload (alarm con-
TIM-ID: 0000008508 - 003

201 SD T-Coolant SD alarm configuration, cool- Check sensor and 1.8004.570
ant temperature sensor faul- wiring (B6), replace
ty, short circuit or wire break. as necessary.
202 SD T-Fuel SD alarm configuration, fuel Check sensor and 1.8004.572
temperature sensor faulty, wiring (B33), replace
short circuit or wire break. as necessary.

203 SD T-Charge Air SD alarm configuration, Check sensor and 1.8004.571
charge-air temperature sen- wiring (B9), replace
sor faulty, short circuit or as necessary.
wire break.
205 SD T-Coolant Intercool- SD alarm configuration, cool- Check sensor and 1.8004.574
er ant temperature sensor of in- wiring (B26), replace
tercooler faulty, short circuit as necessary.
or wire break.
208 SD P-Charge Air SD alarm configuration, Check sensor and 1.8004.566
charge-air pressure sensor wiring (B10), replace
faulty, short circuit or wire as necessary.
break.
211 SD P-Lube Oil SD alarm configuration, lube- Check sensor and 1.8004.563
oil pressure sensor faulty, wiring (B5), replace
215 SD P-HD SD alarm configuration, rail Check sensor and 1.8004.567
pressure sensor faulty, HP wiring (B48), replace
controller in emergency as necessary.
mode, short circuit or wire
break.
216 SD T-Lube Oil SD alarm configuration, lube- Check sensor and 1.8004.575
oil temperature sensor faulty, wiring (B7), replace
219 SD T-Intake Air SD alarm configuration, in- Check sensor and 1.8004.573
take air temperature sensor wiring (B3), replace
faulty, short circuit or wire as necessary.
break.
220 SD Level Coolant Wa- SD alarm configuration, cool- Check sensor and 1.8004.584
ter ant level sensor faulty, short wiring (F33), replace
circuit or wire break. as necessary. Fault
is rectified when
electronics are
switched back on
223 SD Level Coolant Inter- SD alarm configuration, cool- Check sensor and 1.8004.583
cooler ant level sensor faulty, short wiring (F57), replace
circuit or wire break. as necessary. Fault
is rectified when
electronics are
switched back on.
TIM-ID: 0000008508 - 003

229 AL Stop Camshaft Sen- Engine stop due to camshaft Check connector 1.8004.562
sor Defect sensor fault (and a previous and wiring to sensor
crankshaft sensor fault in the B1, replace as nec-
same operating cycle). Alarm essary. Fault is rec-
configuration parameter, see tified when engine is
PR 2.8008.100 for explana- restarted. If cam-
tion. shaft and crankshaft
sensor are both faul-
ty, check connector
and wiring to sensor
B1 and B13. Re-
start. Fault is recti-
fied when engine is
restarted, contact
Service if this is not
the case.
230 SD Crankshaft Speed SD alarm configuration, Check sensor and 1.8004.498
crankshaft sensor faulty, wiring (B13), at-
short circuit or wiring dam- tempt restart, fault
age, engine remains opera- may be rectified
tional. when engine is re-
started. Contact
Service if this is not
the case
231 SD Camshaft Speed SD alarm configuration, cam- Check sensor and 1.8004.499
shaft sensor faulty, short cir- wiring (B1), attempt
cuit or wiring damage, engine restart, fault may be
remains operational. rectified when en-
gine is restarted.
Contact Service if
this is not the case.
240 SD P-Fuel SD alarm configuration, en- Check sensor and 1.8004.565
gine remains operational, wiring (B34), replace
fuel pressure sensor faulty, as necessary.
short circuit or wiring dam-
age.
245 SD ECU Power Supply SD alarm configuration, inter- Execute engine gov- 2.8006.589
Voltage nal engine governor fault. ernor self-test, re-
place engine gover-
nor in case of fault.
266 SD Speed Demand SD alarm configuration, ana- Check speed setting 2.8006.586
log speed setting faulty, transmitter and wir-
short circuit or wiring dam- ing, replace as nec-
TIM-ID: 0000008508 - 003
age. essary. Fault is rec-

tified when engine is
restarted.
269 SD Loadp.Analog filt. SD alarm configuration, fil- Check wiring, re- 2.8006.588
tered analog signal of load place as necessary.
pulse not available, short cir- Fault is rectified
cuit or wiring damage when engine is re-
started.

270 SD Frequency Input SD alarm configuration, fre- Contact Service. 2.8006.590
quency input faulty, short cir-
cuit or wiring damage.
301 AL Timing Cylinder A1 Time-of-flight measuring fault Replace plug-in 1.8004.500
injector cylinder A1: Time-of- pump if this occurs
flight value measured ex- frequently.
tremely small or large (alarm
tion).
injector cylinder A2 Time-of- pump if this occurs
tion).
injector cylinder A3: Time-of- pump if this occurs
tion).
tion).
tion).
TIM-ID: 0000008508 - 003

tion).
tion).

tion).
tion).
injector cylinder A10: Time- pump if this occurs
of-flight value measured ex- frequently.
tion).
311 AL Timing Cylinder B1 Time-of-flight measuring fault Replace plug-in 1.8004.510
injector cylinder B1: Time-of- pump if this occurs
tion).
tion).
313 AL Timing Cylinder B3 Time-of-flight measuring fault Replace plug-in 18004.512
tion).
TIM-ID: 0000008508 - 003

tion).

tion).
tion).
tion).
tion).
tion).
injector cylinder B10: Time- pump if this occurs
of-flight value measured ex- frequently.
tion).
321 AL Wiring Cylinder A1 Wiring fault in injector wiring Check injector wir- 1.8004.520
TIM-ID: 0000008508 - 003
cylinder A1. Result: Misfiring ing, rectify injector

(alarm configuration parame- solenoid valve short
ter, see PR 2.8008.100 for circuit (positive to
explanation). negative) (e.g. by
exchanging injec-
tors). Fault rectifica-
tion: When engine is
restarted.

exchanging injec-
restarted.
exchanging injec-
restarted.
exchanging injec-
restarted.
exchanging injec-
restarted.
exchanging injec-
TIM-ID: 0000008508 - 003

restarted.
exchanging injec-
restarted.

exchanging injec-
restarted.
exchanging injec-
restarted.
cylinder A10. Result: Misfir- ing, rectify injector
ing (alarm configuration pa- solenoid valve short
rameter, see PR 2.8008.100 circuit (positive to
for explanation). negative) (e.g. by
exchanging injec-
restarted.
331 AL Wiring Cylinder B1 Wiring fault in injector wiring Check injector wir- 1.8004.530
cylinder B1. Result: Misfiring ing, rectify injector
exchanging injec-
restarted.
exchanging injec-
TIM-ID: 0000008508 - 003

restarted.
exchanging injec-
restarted.

exchanging injec-
restarted.
exchanging injec-
restarted.
336 AL Wiring Cylinder B6 Wiring fault in injector wiring Check injector wir- 1.8004535
exchanging injec-
restarted.
exchanging injec-
restarted.
exchanging injec-
TIM-ID: 0000008508 - 003

restarted.
exchanging injec-
restarted.

340 AL Wiring Cylinder B10 Wiring fault in injector wiring Check injector wir- 1.8004539
cylinder B10. Result: Misfir- ing, rectify injector
ing (alarm configuration pa- solenoid valve short
rameter, see PR 2.8008.100 circuit (positive to
for explanation). negative) (e.g. by
exchanging injec-
restarted.
341 AL Open Load Cylinder Disruption fault in injector Check injector wir- 1.8004.540
A1 wiring to cylinder A1. Result: ing, exclude disrup-
Misfiring (alarm configuration tion in solenoid
parameter, see PR valve (e.g. by injec-
2.8008.100 for explanation). tor replacement).
Fault rectification:
After each working
cycle.
A2 wiring cylinder A2. Result: ing, exclude disrup-
After each working
cycle.
After each working
cycle.
After each working
cycle.
TIM-ID: 0000008508 - 003

After each working
cycle.

After each working
cycle.
After each working
cycle.
After each working
cycle.
After each working
cycle.
After each working
cycle.
B1 wiring cylinder B1. Result: ing, exclude disrup-
TIM-ID: 0000008508 - 003

After each working
cycle.

After each working
cycle.
After each working
cycle.
After each working
cycle.
After each working
cycle.
After each working
cycle.
TIM-ID: 0000008508 - 003

After each working
cycle.

After each working
cycle.
After each working
cycle.
After each working
cycle.
361 AL Power Stage Low Internal electronic fault (elec- Start engine gover- 1.8004.496
tronics may be defective). If nor self-test. Re-
parameter 1.1020.021 (Pow- place engine gover-
er Stage Failure: Stop En- nor in case of fault;
gine) is set, engine is stop- if self-test diagnoses
ped here additionally (alarm “Electronics OK”
configuration parameter, see check for additional
PR 2.8008.100 for explana- fault messages (e.g.
tion). wiring fault).
362 AL Power Stage high Internal electronic fault (elec- Start engine gover- 1.8004.497
363 AL Stop Power Stage Internal electronic fault (elec- Start engine gover- 1.8004.560
TIM-ID: 0000008508 - 003


365 AL Stop MV-Wiring Injector wiring fault. Engine Check wiring, re- 1.8004.561
Ground stop configurable (alarm con- place wiring harness
figuration parameter, see PR as necessary.
Possible causes: 1. Short cir-
cuit of injector positive con-
nection to ground of one or
more injectors. 2. Short cir-
cuit of injector negative con-
nection to ground of one or
more injectors.
381 AL Wiring TOP 1 Short circuit or wire break at Check wiring. 2.8006.638
transistor output 1 plant side
(TOP 1, alarm configuration
parameter, see PR
parameter, see PR
parameter, see PR
parameter, see PR
390 AL MCR exceeded DBR/MCR function: MCR None. 1.1085.009
(maximum continuous rate)
exceeded. Engine power is
limited to admissible continu-
ous power (alarm configura-
400 AL Open Load Digital Line disruption at digital in- Check wiring. 2.8006.625
Input 1 put 1, wiring faulty or no re-
sistance via switch, (alarm
TIM-ID: 0000008508 - 003
tion).
tion).

402 AL Open Load Digital Line disruption at digital in- Check wiring. 2.8006627
tion).
tion).
tion).
tion).
tion).
tion).
408 AL Open Load Emerg. Line disruption at input for Check wiring. 2.8006.633
Stop Input ESI emergency stop, wiring faulty
or no resistance via switch
410 LO U-PDU Injector voltage too low (limit Execute engine gov- 2.0141.921
value 1, alarm configuration ernor self-test, re-
parameter, see PR place engine gover-
TIM-ID: 0000008508 - 003
2.8008.100 for explanation). nor in case of fault.

411 LOLO U-PDU Injector voltage too low (limit Execute engine gov- 2.0141.922
value 2, alarm configuration ernor self-test, re-
parameter, see PR place engine gover-
412 HI U-PDU Injector voltage too high (lim- Execute engine gov- 2.0141.931
it value 1, alarm configura- ernor self-test, re-
tion parameter, see PR place engine gover-

413 HIHI U-PDU Injector voltage too high (lim- Execute engine gov- 2.0141.932
it value 2, alarm configura- ernor self-test, re-
tion parameter, see PR place engine gover-
444 SD U-PDU SD alarm configuration, sen- Replace engine gov- 1.8004.578
sor fault at injector output ernor.
stage. Engine governor inter-
nal fault. Engine governor re-
placement.
450 SD Idle/End-Torque In- SD alarm configuration, input Check signal trans- 2.8006.592
put [%] signal for initial/final torque mitter and wiring,
faulty, short circuit or wiring replace as necessa-
damage ry. Fault is rectified
when engine is re-
started.
454 SS Power Reduction Power reduction activated, None. 2.7000.011
Active engine operating outside
standard limits. The following
variables may also combine
to lead to this message: In-
take depression, exhaust
back pressure, charge-air
coolant temperature, intake
air temperature. Alarm con-
2.8008.100 for explanation.
463 SD AUX 2 SD alarm configuration, ana- Check signal trans- 1.8004.591
log input signal for Aux 2 mitter and wiring,
damage. ry.
464 SD P-AUX 1 SD alarm configuration, ana- Check pressure 1.8004.589
log input signal for pressure transmitter and wir-
Aux 1 faulty, short circuit or ing, replace as nec-
wiring damage. essary.
468 SD T-AUX 1 Analog input for temperature Check signal trans- 1.8004.579
Aux 1 faulty, short circuit or mitter and wiring,
wiring damage replace as necessa-
ry.
469 SD AUX 1 SD alarm configuration, ana- Check signal trans- 1.8004.590
log input signal for Aux 1 mitter and wiring,
damage. ry.
TIM-ID: 0000008508 - 003
470 SD T-ECU Engine governor defective. Replace engine gov- 1.8004.587

ernor at next oppor-
tunity.
471 SD Coil Current SD alarm configuration, HP Check sensor and 1.8004.592
fuel control block activation, wiring, replace as
short circuit or wiring dam- necessary. Fault is
age. rectified when en-
gine is restarted.

Downloaded from www.Manualslib.com manuals search engine
472 AL Stop SD Engine stop as shutdown Contact Service. 2.8006.593
channels have "sensor fault"
(alarm configuration parame-
explanation).
474 AL Wiring FO Line break or short circuit at Contact Service. 2.8006.655
channel FO (alarm configura-
475 AL CR Trigger Engine Tripped by crash recorder Replace engine gov- 1.8010.009
Stop triggering due to engine shut- ernor at next oppor-
down. tunity.
476 AL Crash Rec. Init. Er- Initialization error of crash re- Contact Service. 1.8010.007
ror corder.
478 AL Comb. Alarm Yel YELLOW combined alarm Contact Service. 2.8006.001
(Plant) from plant (alarm configura-
479 AL Comb. Alarm Red RED combined alarm from Contact Service. 2.8006.002
(Plant) plant (alarm configuration pa-
rameter, see PR 2.8008.100
for explanation).
480 AL Ext. Engine Protec- External engine protection Contact Service. 2.0291.921
tion function active (alarm config-
uration parameter, see PR
555 AL Call MTU Field Serv- Power reduction caused by Contact Service. 2.0555.001
ice maintenance function (main-
tenance concept, alarm con-
TIM-ID: 0000008508 - 003

7.2 Troubleshooting
Engine does not turn when starter is actuated
Cause Corrective action
Battery flat or faulty. u Charge or replace battery (see manufacturer's documentation).
Cable connections on battery are u Check if cable connections are properly secured (see
faulty. manufacturer's documentation).
Engine wiring or starter faulty. u Check if cable connections are properly secured, contact Service.
Engine wiring is faulty. u Check (→ Page 139).
Loose plug connections at u Perform visual inspection (see manufacturer's documentation).
engine/generator control system.
Loose plug connection are loose u Check plug connections (→ Page 141).
at engine governor.
Engine blocked (cannot be rotated u Contact Service.
by hand).
Engine turns but does not fire

Poor rotation by starter: Battery u Charge or replace battery (see manufacturer's documentation).
flat or faulty.
Air in fuel system u Vent fuel system (→ Page 100).
Engine governor is faulty. u Contact Service.
Engine fires unevenly

Injector is faulty. u Replace (→ Page 88).
Injection pump is faulty. u Replace (→ Page 85).
Engine does not reach rated speed

Fuel prefilter clogged. u Replace filter element (→ Page 109).
Easy-change fuel filter clogged. u Replace (→ Page 102).
TIM-ID: 0000066976 - 001
Air filter clogged. u Check signal ring position of contamination indicator (→ Page 114).
Overload. u Contact Service.

Engine speed not steady
Speed sensor is faulty. u Contact Service.
Charge-air temperature too high.

Incorrect engine coolant u Check (MTU test kit).
concentration.
Charge-air cooler is contaminated. u Contact Service.
Air inlet temperature in engine u Check fans and air supply / ventilation ducts.
room is too high.
Charge-air pressure too low

Charge-air cooler is contaminated. u Contact Service.
Exhaust turbocharger is faulty. u Contact Service.
Coolant leaks at intercooler

Major coolant discharge at u Contact Service.
charge-air cooler. Charge-air
cooler leaky.
Black exhaust gas

Overload. u Contact Service.
TIM-ID: 0000066976 - 001

Blue exhaust gas
Too much engine oil in the engine u Drain engine oil (→ Page 117).
Oil separator of crankcase u Replace (→ Page 78).
breather contaminated.
Exhaust turbocharger is faulty. u Contact Service.
Cylinder head is faulty. u Contact Service.
Piston rings are faulty. u Contact Service.
Cylinder liner is faulty. u Contact Service.
White exhaust gas

Engine is not at operating u Run engine to reach operating temperature.
temperature.
Water in fuel u Check fuel system at fuel prefilter.
Drain water from fuel prefilter (→ Page 104).
Charge-air cooler leaky. u Contact Service.
TIM-ID: 0000066976 - 001

8 Task Description
8.1 Engine
8.1.1 Engine – Barring manually
Preconditions

Barring device for 12V engines F6558556 1
Barring device for 16V, 18V engines F6558557 1
DANGER
• Before barring the engine, make sure that there are no persons in the engine's danger zone.
• After finishing work on the engine, make sure that all safety devices are put back in place and all
tools are removed from the engine.
Engine – Barring manually

1. Remove access cover from flywheel housing.
2. Install barring device (arrow) on flywheel
housing.
3. Rotate crankshaft in engine direction of rota-
tion. Apart from the normal compression re-
sistance, there should be no resistance.
Result: If the resistance exceeds the normal com-
pression resistance, contact Service.
4. For barring device removal, follow reverse se-
quence of working steps.
TIM-ID: 0000000012 - 003
70 | Task Description | MS15018/03E 2016-02

8.1.2 Engine – Barring with starting system
Preconditions
☑ External pushbutton 'Bar engine without starting' is provided.
DANGER
danger zone.
Engine – Barring with starting system

1. Press pushbutton 'Bar engine without starting' and keep depressed.
2. Let the crankshaft rotate until oil pressure is indicated, but not longer than 10 seconds.
3. Repeat procedure after approx. 20 seconds if necessary.
TIM-ID: 0000000013 - 006
MS15018/03E 2016-02 | Engine | 71

8.1.3 Engine – Test run
DANGER
danger zone.
WARNING
Engine – Test run

1. Start engine (→ Page 35).
2. Perform test run not below 1/3 load and at least until steady-state temperature is reached.
3. Carry out operational checks (→ Page 37).
4. Stop engine (→ Page 38).
TIM-ID: 0000000870 - 008
72 | Engine | MS15018/03E 2016-02

8.2 Cylinder Liner
8.2.1 Cylinder liner – Endoscopic examination
Preconditions
☑ Engine is stopped and starting disabled

Rigid endoscope Y20097353 1
Preparatory steps
1. Remove cylinder head cover (→ Page 83).
2. Remove injector (→ Page 89).
Positioning crankshaft at BDC

1. Using barring gear, turn crankshaft until crankshaft journal of the cylinder to be inspected has reached BDC.
2. Insert endoscope into cylinder liner through injector seat.
Cylinder liner – Endoscopic examination

Findings Task
• Thin carbon coating around circumference of carbon scraper ring No action required.
• Slight localized additive deposits at top edge
• Localized smooth areas at bottom edge
• Carbon deposits around circumference between top piston ring and
bottom edge of carbon scraper ring
• First signs of marks left by top piston ring
• Bright mark around circumference
• Faultless, even honing pattern
• First signs of marks left by lower cooling bores
• Running pattern seems darker
• Darker areas of even or varying color intensity Further endoscopic examina-
• Beginning and end of the discoloration are not sharply defined and do tion required as part of mainte-
not cover the entire stroke area nance work.
• Dark areas in the upper section of the cooling bore, remaining circum-
ference cannot be faulted
• Piston rings faultless
• On the entire circumference not only bright discoloration (not critical Cylinder liner must be replaced,
for operation) clearly visible darker stripes that begin at the top piston contact Service.
ring
• Heat discoloration in the direction of stroke and honing pattern dam-
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age
• Heat discoloration of piston rings
1. Compile endoscopy report using the table.

2. Use technical terms for description of the liner surface (→ Page 75).
3. Depending on findings:
• Do not take any action or
• Carry out further endoscopic examination as part of maintenance work or
• Contact Service; cylinder liner must be replaced.
MS15018/03E 2016-02 | Cylinder Liner | 73

Final steps
1. Install injector (→ Page 89).
2. Install cylinder head cover (→ Page 83).
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74 | Cylinder Liner | MS15018/03E 2016-02

8.2.2 Instructions and comments on endoscopic and visual examination of cylinder
liners
Terms used for endoscopic examination
Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic examina-
tion report.
Findings Explanations/Action
Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing products,
particles, broken-off burrs). Removed cylinders clearly show such scoring on the
running surface under endoscope magnification. Cannot be felt with the fingernail.
Findings not critical.
Single scores Clearly visible scores caused by hard particles. They usually start in the TDC area
and cross through the hone pattern in the direction of stroke.
Scored area These areas consist of scores of different length and depth next to one another. In
most cases, they are found at the 6-o'clock and 12-o'clock positions (inlet/
exhaust) along the transverse engine axis.
Smoothened area Smoothened areas are on the running surface but almost the whole honing pattern
is still visible. Smoothened areas appear brighter and more brilliant than the sur-
rounding running surface.
Bright area Bright areas are on the running surface and show local removal of the honing pat-
tern. Grooves from honing process are not visible any more.
Discoloration This is caused by oxidation (surface discoloration through oil or fuel) and tempera-
ture differences around the liner. It appears rather darker within the honed struc-
ture in contrast to the bright metallic running surface. The honing pattern is undis-
turbed. Discolorations extend in stroke direction and may be interrupted.
Corrosion fields / Corrosion fields / spots result from water (condensed water) with the valves in the
spots overlap (open) position. They are clearly visible due to the dark color of the honing
groove bottom.
This corrosion is not critical unless there is corrosion pitting.
Black lines Black lines are a step towards heat discoloration. They are visible as a clear discol-
oration from TDC to BDC in the running surface and the start of localized damage
to the honing pattern.
Cylinder liners with a large number of black lines around the running surface have
limited service life and should be replaced.
Burn mark This is caused by a malfunction in the liner / ring tribosystem. Usually they run
over the whole ring-travel area (TDC/BDC), starting at the first TDC-ring and be-
coming more visible from the second TDC-ring 2 onwards and less pronounced
from TDC-ring 1. The honing pattern is usually no longer visible and displays a
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clearly defined (straight) edge to the undisturbed surface. The damaged surface is
usually discolored. The circumferential length varies.
Liners with burn marks, or heat discoloration, starting in TDC-ring 1 have to be re-
placed.
Seizure marks, scuff- Irregular circumference lengths and depths. Can be caused either by the piston
ing skirt or the piston crown. Material deposits on the liner (smear), heavy discolora-
tion. Severe, visible scoring.
Replace liner.
MS15018/03E 2016-02 | Cylinder Liner | 75

Evaluation of findings and further measures
The findings in the start phase of oxidation discoloration and heat discoloration are similar. A thorough inves-
tigation and compliance with the above evaluation criteria allow an unambiguous evaluation. To avoid unnec-
essary disassembly work, it is recommended that another inspection be carried out after further operation of
the engine.
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76 | Cylinder Liner | MS15018/03E 2016-02

8.3 Crankcase Breather
8.3.1 Crankcase breather – Wire mesh cleaning
Cleaner
Diesel fuel
Petroleum jelly
Sealing ring (→ Spare Parts Catalog)
WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.
WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.
NOTICE
Cleaning agents should not be left to take effect for too long.
Damage to components is possible!
• Observe manufacturer's instructions.
Crankcase breather – Wire

mesh cleaning
1. Remove hose.
2. Loosen clamp (5).
3. Remove oil separator cover (7).
4. Remove individual parts from cover (7).
5. Wash filter element (wire mesh) (3) with die-
sel fuel.
6. Blow out filter element (wire mesh) (3) with
compressed air.
7. Clean remaining components with cleaner.
8. Remove cleaner.
9. Coat sealing ring (6) with petroleum jelly and
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insert in groove in cover (7).

10. Insert both retainers (2, 4) and filter element
(wire mesh) (3) into the cover (7), ensuring
correct installation sequence.
11. Install cover (7) with clamp (5) on cylinder
head cover (1).
12. Install hose, ensuring that it is not subjected
to tension.
MS15018/03E 2016-02 | Crankcase Breather | 77

8.3.2 Crankcase breather – Oil separator replacement, diaphragm check and
replacement
Preconditions

Torque wrench, 8–40 Nm F30043446 1
Ratchet adapter F30027340 1
Engine oil
Filter element (→ Spare Parts Catalog)
Diaphragms (→ Spare Parts Catalog)
Gasket (→ Spare Parts Catalog)
WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Wear protective clothing, gloves, and goggles / safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.
Replacing oil separator filter el-

ement
1. Remove cover (2) with O-ring (3).
2. Remove filter element (1) from housing (4).
3. Insert new filter element in housing (4).
4. Install cover (2) with new O-ring.
5. Use torque wrench to tighten the screws of cover (2) to the specified torque.
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Name Size Type Lubricant Value/Standard

Screw Tightening torque (Engine oil) 10 Nm −2 Nm
6. Replace further oil separator elements in the same way.
78 | Crankcase Breather | MS15018/03E 2016-02

Checking diaphragm
1. Remove cover (4).
2. Remove spring (5), gasket (2) and dia-
phragm (3).
3. Check diaphragm (3) for damage, fit new dia-
phragm if used one is damaged.
4. Install diaphragm (3) on housing (1).
5. Install new gasket (2) and spring (5) together
with cover (4).
6. Use torque wrench to tighten the screws of cover (4) to the specified torque.
Screw Tightening torque (Engine oil) 10 Nm −2 Nm
7. Check diaphragm in other oil separators in the same manner.

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MS15018/03E 2016-02 | Crankcase Breather | 79

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

Feeler gage Y4342013 1
Engine oil
Preparatory steps
2. Install barring tool (→ Page 70).
3. Bar crankshaft with barring tool in engine di-
rection of rotation until TDC pointer and TDC
mark on the flywheel are aligned.
Checking valve clearance at two crankshaft positions

1. Check TDC position of piston in cylinder A1:
• The piston is at firing TDC when the rocker arms at cylinder A1 are unloaded.
• The piston is at overlap TDC when the rocker arms at cylinder A1 are loaded.
2. Check valve clearance with cold engine:
• Inlet = 0.4 mm;
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• Exhaust = 0.6 mm.
80 | Valve Drive | MS15018/03E 2016-02

3. Check clearance of all valves at two crankshaft positions (firing TDC and overlap TDC at cylinder A1) in ac-
cordance with the table:
Position Cylinder 1 2 3 4 5 6 7 8 9 10
12V
Firing TDC at cylinder A1 Side A IX I– –X I– –X ––
Side B –X IX I– –X –– I–
Overlap TDC at cylinder A1 Side A –– –X I– –X I– IX
Side B I– –– –X I– IX –X
16V
Firing TDC at cylinder A1 Side A IX –X –X I– –X I– –– ––
Side B I– –X –– I– IX I– IX –X
Overlap TDC at cylinder A1 Side A –– I– I– –X I– –X IX IX
Side B –X I– IX –X –– –X –– I–
18V
Firing TDC at cylinder A1 Side A IX I– IX I– –X I– –X –– ––
Side B –X –X –– –X –– IX I– IX I–
Overlap TDC at cylinder A1 Side A –– –X –– –X I– –X I– IX IX
Side B I– I– IX I– IX –– –X –– –X
I Inlet: Inlet valve adjustment admissible
X Exhaust: Exhaust valve adjustment admissible
– Valve adjustment not admissible
Table 2: Valve clearance settings
4. Use feeler gage to determine the distance between valve bridge and rocker arm.
5. Adjust valve clearance if the deviation from the desired value exceeds 0.1 mm.
Adjusting valve clearance

1. Loosen locknut (1) and unscrew adjusting
screw (2) by a few threads.
2. Insert feeler gage between valve bridge and
rocker arm.
3. Readjust adjusting screw (2) so that the feel-
er gage just passes through the gap.
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4. Tighten locknut (1) to specified torque using a torque wrench while holding adjusting screw (2) firmly with a
screwdriver.
Locknut M12 x 1 Tightening torque (Engine oil) 50 Nm
MS15018/03E 2016-02 | Valve Drive | 81

5. Insert feeler gage between valve bridge and rocker arm to verify that the gage just passes through the gap.
Result: Adjust valve clearance if this is not the case.
Final steps
1. Remove barring tool (→ Page 70).
3. Install cap.
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82 | Valve Drive | MS15018/03E 2016-02

8.4.2 Cylinder head cover – Removal and installation
Preconditions

Preparatory steps
1. On cylinder head covers with crankcase breather: Loosen clamps.
2. Slide rubber sleeves onto the pipe.
Cylinder head cover – Removal

and installation
1. Remove cylinder head cover (2) with gas-
ket (1) from cylinder head.
2. Clean installation surface.
3. Check condition of gasket (1) in cylinder
head cover (1).
4. Replace damaged gasket(s) (1).
5. Install cylinder head cover (2) with screws (4)
and washers (3).
Final steps
1. Slide rubber sleeves onto the relevant fitting.
2. Tighten all clamps.
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MS15018/03E 2016-02 | Valve Drive | 83

8.5 Injection Pump / HP Pump
8.5.1 Injection pump – Replacement
Injection pump (→ Spare Parts Catalog)
Injection pump – Replacement

u Remove injection pump and install new one (→ Page 85).
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84 | Injection Pump / HP Pump | MS15018/03E 2016-02

8.5.2 Injection pump – Removal and installation
Preconditions

Adapter F30006234 1
Crowfoot wrench, 19 mm F30027424 1
Crowfoot box wrench, 22 mm F30027425 1
Torque wrench, 0.5–5 Nm 0015384230 1
Assembly compound (Kluthe Hakuform 30-15) X00067260 1
Engine oil
DANGER
danger zone.
WARNING
• Do not smoke.
Preparatory steps
1. Close fuel supply line upstream of fuel filter.
2. Drain fuel (→ Page 97).
3. Remove engine governor as necessary (→ Page 142).
4. Remove charge-air manifolds and remove gaskets (only on engines with air-to-air charge-air cooling).
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MS15018/03E 2016-02 | Injection Pump / HP Pump | 85

Removing injection pump
1. Mark installation position of injection pump.
2. Disconnect cabling (1) from injection pump.
3. Disconnect fuel line (2).
4. Unscrew securing screws of injection pump
by approx. 6 mm.
Result: The preloaded compression spring presses
the injection pump out of the crankcase. If
not:
• Turn crankshaft with barring tool
(→ Page 70).
Pump cam of camshaft presses the injec-
tion pump out of the crankcase. If not:
• Carefully press out injection pump at the
recess in the injection pump head.
5. Remove injection pump securing screws.
6. Remove injection pump.
7. Remove sealing rings from injection pump.
8. After removal, seal all openings with suitable
covers.
Installing injection pump

1. Remove all blanking plugs and covers.
2. Clean mating face of injection pump and roll-
er.
Note: Sealing ring (1) Ø47 mm
3. Coat sealing ring (1) with assembly com-
pound and fit onto injection pump.
Note: Sealing ring (2) Ø45 mm
pound and fit onto injection pump.
5. Coat roller (arrowed) with engine oil.
6. Clean sealing face and fuel bores in crank-
case.
7. Using barring tool (→ Page 70), set pump cam
on camshaft to base circle.
8. Install injection pump, observing marked in-

stallation position.
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86 | Injection Pump / HP Pump | MS15018/03E 2016-02

9. Install injection pump securing screws and tighten to specified torque using a torque wrench.
Screw M10 Tightening torque (Engine oil) 60 Nm +12 Nm
10. Coat the mating face between union nut and fuel line, ball seal and thread on both ends of the fuel line (3)
with engine oil.
11. Install fuel line (3).
Note: Observe the lettering on the union nuts (2) and 4).
12. Tighten union nuts (2) and (4) marked with “35 +3 Nm” (see arrow) to specified torque using a torque
wrench.
Union nut M14 Tightening torque (Engine oil) 35 Nm +3 Nm
13. Tighten union nuts (2) and (4) marked with “30 +3 Nm” (see arrow) to specified torque using a torque
wrench.
14. Install injection pump cabling (1).

15. Tighten screws to specified torque using a torque wrench.
Screw Tightening torque (Engine oil) 1.5 Nm ±0.2 Nm
Final steps
1. Remove barring tool (→ Page 70).
2. Clean mating faces on cylinder head and charge-air manifold.
3. Check gaskets for damage and replace as necessary.
4. Coat gaskets with assembly compound and place onto cylinder head.
5. Install charge-air pipes.
6. Install engine governor (→ Page 142).
7. Open fuel supply line.
8. Vent fuel system (→ Page 100).
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MS15018/03E 2016-02 | Injection Pump / HP Pump | 87

8.6 Injection Valve / Injector
8.6.1 Injector – Replacement
Injector (→ Spare Parts Catalog)
Replacing injector
u Remove injector and install new injector (→ Page 89).
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88 | Injection Valve / Injector | MS15018/03E 2016-02

8.6.2 Injector – Removal and installation
Preconditions

Barring tool F6557929 1
Puller 3555890163/00 1
Fuel suction device F30378207 1
Adapter F30006234 1
Open-end socket wrench, 19 mm F30025897 1
Double-head box wrench F30011450 1
Engine oil
Sealing (→ Spare Parts Catalog)
WARNING
• Do not smoke.
WARNING
Preparatory steps
1. Close fuel supply line before fuel filter.
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4. Remove charge-air manifolds and take off seals (only on engines with air-to-air charge-air cooling).
MS15018/03E 2016-02 | Injection Valve / Injector | 89

Removing injector
1. Disconnect leak-off fuel line from cylinder
head.
3. Remove thrust screw (2).
4. Pull off pressure pipe neck (3).
5. Extract fuel from the exposed bores using the
suction device.
6. Remove sealing ring from pressure pipe
neck (3).
7. Remove screw (1).

8. Take off clamp (2).
9. Screw puller into injector.

10. Remove injector with puller.
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11. Remove sealing rings (1) and (2) of injec-
tor (3) with a self-made hook.
12. After removal, seal all openings with suitable
covers.
13. Remove sealing cap from cylinder head with

screwdriver.
14. Remove sealing ring.
Installing injector
1. Remove all covers before installation.
2. Clean sealing surface on cylinder head and
protective sleeve.
3. Coat sealing ring with grease and insert in
groove of sealing cap.
4. Insert sealing cap in bore.
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5. Use engine barring device to turn engine sev-
eral times to blow out remaining fuel.
6. Fit sealing ring (2) with assembly compound
on to injector (3).
pound to secure it on injector (3).
8. Press injector (3) into cylinder head by hand.
Result: • The pin is at 11-o'clock position to the
transversal axis of the engine.
9. Install clamp (2) with screw (3) in correct po-

sition.
Result: • The pin (1) on the injector is engaged in
the groove of the clamp (2).
• Forked clamp end (2) is engaged in the
cover recess.
10. Tighten screw (3) of the clamp by hand.
Result: Injector can still be turned.
11. Blow out fuel line (2) and pressure pipe

neck (5) with compressed air.
12. Coat sealing ring with assembly compound
and fit onto pressure pipe neck (5).
13. Coat the taper of the pressure pipe neck (5)
with engine oil.
14. Insert pressure pipe neck (5) into cylinder
head until the sealing ring is in contact with
cylinder head.
15. Fully press in pressure pipe neck (5) by hand.
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16. Tighten thrust screw (4) with torque wrench to the specified tightening torque.
Thrust screw M22 x 1.5 Tightening torque (Engine oil) 45 Nm ±2.5 Nm
17. Loosen thrust screw (4) and tighten it again with torque wrench to the specified tightening torque.
18. Use torque wrench to tighten screw for clamp at injector to the specified tightening torque.
Screw M10 Tightening torque (Engine oil) 50 Nm
with engine oil.
20. Connect fuel line (2) to injection pump and pressure pipe neck (5).
21. Tighten union nut (1) on injection pump hand-tight.
22. Tighten union nut (3) on pressure pipe neck (5) hand-tight.
Note: Observe the lettering on the union nuts (1) and 3).
23. Tighten union nuts (1) and (3) marked with “35 +3 Nm” (see arrows) to specified torque using a torque
wrench.
24. Tighten union nuts (1) and (3) marked with “30 +3 Nm” (see arrows) to specified torque using a torque
wrench.
25. Connect leak-off fuel line to cylinder head.
Final steps
3. Check gaskets for damage and replace them, if required.
4. Coat gaskets with assembly compound and place onto cylinder head.
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8.7 Fuel System
8.7.1 Fuel injection line – Pressure pipe neck replacement
Preconditions

Adapter F30006234 1
Open-end socket wrench, 19 mm F30025897 1
Double-head box wrench F30011450 1
Engine oil
Pressure pipe tube (→ Spare Parts Catalog)
Sealing (→ Spare Parts Catalog)
WARNING
• Do not smoke.
WARNING
Preparatory steps
1. Close fuel supply line upstream of fuel filter.
4. Remove charge-air manifolds and take off seals (only on engines with air-to-air charge-air cooling).
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94 | Fuel System | MS15018/03E 2016-02

Replacing pressure pipe neck
2. Blow out fuel line (2) with compressed air.
3. Remove thrust screw (4).
4. Withdraw pressure pipe neck (5).
5. Coat sealing ring with grease and fit on new
pressure pipe neck (5).
6. Coat the tape of the pressure pipe neck (5)
with engine oil.
7. Insert pressure pipe neck (5) into cylinder
head until the sealing ring is in contact with
cylinder head.
8. Fully press in pressure pipe neck (5) by hand.
9. Tighten thrust screw (4) with torque wrench to the specified tightening torque.
10. Loosen thrust screw (4) and tighten it again with torque wrench to the specified tightening torque.
with engine oil.
12. Connect fuel line (2) to injection pump and pressure pipe neck (5).
13. Tighten union nut (1) on injection pump hand-tight.
14. Tighten union nut (3) on pressure pipe neck (5) hand-tight.
Note: Observe the tightening torque according to the lettering on the union nuts (1) and 3).
15. Tighten union nuts (1) marked with "35 +3 Nm" (see arrows) with torque wrench to the specified tightening
torque.
torque.
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torque.
torque.
MS15018/03E 2016-02 | Fuel System | 95

Final steps
2. Check gaskets for damage and replace them, if required.
3. Coat gaskets with grease and place onto cylinder head.
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96 | Fuel System | MS15018/03E 2016-02

8.7.2 Fuel – Draining
Preconditions

Plug-in open-end wrench, 17 mm F30028341 1
Engine oil
WARNING
• Do not smoke.
Draining fuel
1. Loosen nut (arrowed) on banjo union.
2. Disconnect fuel line on non-return valve (ar-

rowed).
3. Remove non-return valve and collect emerg-
ing fuel in a suitable container.
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MS15018/03E 2016-02 | Fuel System | 97

4. When fuel no longer emerges, install non-return valve and tighten to specified torque using a torque wrench.
Non-return valve Tightening torque (Engine oil) 10 Nm +1 Nm
5. Install fuel line.

6. Tighten nut on banjo union.
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98 | Fuel System | MS15018/03E 2016-02

8.7.3 Fuel pressure relief valve – Removal and installation
Preconditions

Pressure relief valve (→ Spare Parts Catalog)
WARNING
• Do not smoke.
Removing and installing pres-

sure relief valve
1. Close fuel supply.
2. Remove fuel line (6).
3. Remove banjo screws (1) and (4).
4. Remove sealing rings (2) and (5).
5. Remove screws (9) with washer (8).
6. Remove screws (7) and take off holder.
7. Install new pressure relief valve (3) with new
sealing rings (2) and (5) in reverse order.
8. Open fuel inlet.
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MS15018/03E 2016-02 | Fuel System | 99

8.7.4 Fuel system – Venting
Preconditions

Engine oil
WARNING
• Do not smoke.
Venting fuel system

1. Unlock fuel priming pump, unscrew handle.
2. Loosen nut (arrowed) on banjo union.

3. Operate the pump with the handle until bub-
ble-free fuel emerges.
4. Tighten nut on banjo union. TIM-ID: 0000000026 - 003
100 | Fuel System | MS15018/03E 2016-02

5. Loosen banjo screw (arrowed).
7. Tighten banjo screw.
8. Loosen union nut of fuel return line.

9. Loosen non-return valve (arrowed).
11. Tighten non-return valve to specified torque using a torque wrench.

Non-return valve Tightening torque (Engine oil) 10 Nm +1 Nm
12. Tighten union nut of fuel return line.

13. Lock fuel priming pump, screw in handle.
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MS15018/03E 2016-02 | Fuel System | 101

8.8 Fuel Filter
8.8.1 Fuel filter – Replacement
Preconditions

Filter wrench F30379104 1
Diesel fuel
Easy-change filter (→ Spare Parts Catalog)
WARNING
• Do not smoke.
Replacing fuel filter

1. Remove easy-change filter using the filter
wrench.
2. Clean the sealing surface on the bracket.
3. Fill the new easy-change filter with clean fuel.
4. Install and tighten easy-change filter by hand.
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102 | Fuel Filter | MS15018/03E 2016-02

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

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

1. With the engine running at full load or rated power, read off pressure at gage (1).
2. If differential pressure as indicated between position of adjustable pointer (2) and pressure-indicating point-
er (3) of pressure gage is ≥ 0.3 bar, flush filter element of the cut-in filter (→ Page 106).
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MS15018/03E 2016-02 | Fuel Filter | 103

8.8.3 Fuel prefilter – Draining
Preconditions
☑ Engine is stopped and starting disabled (only in the case of single fuel prefilter).

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

Note: Only in the case of double fuel prefilter:
1. Switch off filter to be drained.
1 Left filter cut in
2 Right filter cut in
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104 | Fuel Filter | MS15018/03E 2016-02

2. Open threaded vent plug (5) of the filter to be
drained.
3. Unlock drain valve (6) by pressing toggle and
open it.
4. Drain water and contamination from the filter
until pure fuel emerges.
5. Close drain valve (6).
6. Remove screws securing the cover and take
off cover (2).
7. Fill filter housing with clean fuel.
8. Place new seal in cover (2).
9. Fit cover with seal and secure it with screws.
10. Cut in the cut-out filter again.
11. When fuel emerges from system, close
threaded vent plug (5).
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MS15018/03E 2016-02 | Fuel Filter | 105

8.8.4 Fuel prefilter – Flushing
Preconditions
☑ Engine is stopped and starting disabled (only in the case of single fuel prefilter).

Diesel fuel
Seal (→ Spare Parts Catalog)
DANGER
WARNING
• Do not smoke.
WARNING
Liquid or gaseous media, e.g. fuel, are poisonous.
Escaping vapors of highly volatile media, e.g. fuel or ether.
Risk of fatal injury through swallowing; risk of poisoning through inhalation; irritation to eyes
and skin!
• Seek medical attention immediately; do not induce vomiting.
• Do not inhale vapors or mist.
• Wear protective clothing, protective gloves, and safety glasses.
• If contact is made with skin, wash off with water and soap.
WARNING
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106 | Fuel Filter | MS15018/03E 2016-02

Fuel prefilter – Flushing
1. Cut out the contaminated filter.
2. Open threaded vent plug (5) of filter to be

flushed.
3. Unlock drain valve (6) by pressing toggle,
open it and drain fuel.
Result: Fuel flows from filtered side back to the unfil-
tered side, flushing the filter deposits down-
wards out of the filter.
4. Close threaded vent plug (5) and drain
valve (6).
Fuel prefilter – Filling with fuel

1. Remove screws securing cover and take off cover (2).
3. Place new seal in cover (2).
4. Fit cover with seal and secure it with screws.
5. Check differential pressure (→ Page 103).
Result: If flushing did not lead to an improvement of the differential pressure, replace filter element (→ Page 109).
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MS15018/03E 2016-02 | Fuel Filter | 107

8.8.5 Fuel prefilter – Cleaning
Preconditions

Diesel fuel
WARNING
• Do not smoke.
Cleaning fuel prefilter

1. Close fuel supply.
2. Remove nuts from filter head.
3. Unscrew filter bowl and drain fuel into a suit-
able container.
4. Remove securing nut for filter element and
pull off filter element downwards.
5. Use a soft brush to wash filter element in
clean fuel.
6. Wash filter bowl with clean fuel.
7. Insert filter element in filter head and secure
with nut.
8. Insert new sealing ring in groove in filter
head.
9. Fit cover with gasket and tighten nuts cross-
wise.
10. Open fuel inlet.
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108 | Fuel Filter | MS15018/03E 2016-02

8.8.6 Fuel prefilter – Filter element replacement
Preconditions

Diesel fuel
WARNING
• Do not smoke.
Replacing filter element

1. Switch off filter to be drained.
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2. Open threaded vent plug (5) of contaminated
filter.
3. Unlock drain valve (6) by pressing toggle and
open it.
4. Drain water and contamination from filter.
5. Close drain valve (6).
6. Remove screws securing the cover and take
off cover (2).
7. Remove spring housing (4) and filter ele-
ment (3).
8. Insert new filter element (3) and spring hous-
ing (4).
10. Place new gasket in cover (2).
11. Fit cover with gasket and secure it with
screws.
12. Cut in the cut-out filter again.
13. Close threaded vent plug (5) when fuel
emerges.
14. Set adjustable pointer of differential pressure
display instrument (→ Page 103).
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110 | Fuel Filter | MS15018/03E 2016-02

8.9 Charge-Air Cooling General, Left-Hand Side
8.9.1 Intercooler – Checking condensate drain for coolant discharge and obstructions
Preconditions

WARNING
Checking intercooler condensate drain for coolant discharge and obstruc-

tions
1. Remove plug screw(s) from charge-air manifold.
2. Check drain bore(s) for air discharge. If no air escapes:
3. Clean drain bore(s) and blow out with compressed air.
4. More significant coolant leakage indicates a leaking charge-air cooler. Contact Service.
5. Install plug screw(s) with new sealing ring and tighten.
Emergency measures prior to engine start with a leaking intercooler

1. Remove injectors (→ Page 89).
2. Bar engine manually (→ Page 70).
3. Bar engine with the starting system to blow out cylinder chambers (→ Page 71).
4. Install injectors (→ Page 89).
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8.10 Air Filter
8.10.1 Air filter – Replacement
Air filter (→ Spare Parts Catalog)
Filter insert (→ Spare Parts Catalog)
Air filter – Replacement

1. Remove air filter(s) and install new one(s) (→ Page 113).
2. Reset signal ring of service indicator (→ Page 114).
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112 | Air Filter | MS15018/03E 2016-02

8.10.2 Air filter – Removal and installation
Preconditions
Variant A
1. Loosen clamp (2).
2. Remove air filter (1) and clamp (2) from con-
necting flange of intake housing (3).
3. Verify that there are no objects in the flange
of the intake housing (3) and clean it.
4. Fit air filter (1) and clamp (2) on connecting
flange of intake housing (3).
5. Tighten clamp (2).
Variant B
1. Release latches (1).
2. Take off cover (2).
3. Remove filter insert (3) and filter element (4).
4. Wipe out filter housing (5) and cover (2) with
moist cloth.
5. Insert new filter element (4) and filter in-
sert (3).
6. For installation, follow reverse sequence of
working steps.
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8.11 Air Intake
8.11.1 Service indicator – Signal ring position check
Preconditions
Checking signal ring position

1. Replace air filter if the signal ring (2) is com-
pletely visible in the red area of the observa-
tion window (3) (→ Page 112).
2. After installation of new filter, press reset
button (1).
Result: Signal ring returns to initial position.
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114 | Air Intake | MS15018/03E 2016-02

8.12 Starting Equipment
8.12.1 Air starter – Manual operation
DANGER
danger zone.
WARNING
Air starter – Manual operation

1. Press pushbutton for manual start (arrow)
and hold.
2. Allow compressed air to enter the starter un-
til the engine fires evenly.
3. Release pushbutton.
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8.13 Lube Oil System, Lube Oil Circuit
8.13.1 Engine oil – Level check
Preconditions
Oil level check prior to engine

start
1. Withdraw oil dipstick from guide tube and
wipe it.
2. Insert oil dipstick into guide tube up to the
stop, withdraw after approx. 10 seconds and
check oil level.
3. Oil level must be between "min." (2) and
"max." (1) marks.
4. Top up with oil up to the "max" (1) mark
(→ Page 117) if required.
5. Insert oil dipstick into guide tube up to the
stop.
Oil level check after the engine is stopped

1. 5 minutes after stopping the engine, remove oil dipstick from the guide tube and wipe it.
2. Insert oil dipstick into guide tube up to the stop, withdraw after approx. 10 seconds and check oil level.
3. Oil level must be between "min." and "max." marks.
4. Top up to "max." if required (→ Page 117).
5. Insert oil dipstick into guide tube up to the stop.
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8.13.2 Engine oil – Change
Preconditions
☑ Engine is at operating temperature.
☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.

Engine oil
WARNING
Hot oil.
Oil change without semirotary hand pump: Draining oil at drain plug on oil
pan
1. Provide a suitable container to collect the oil.
2. Remove drain plug and drain oil.
3. Install drain plug with new sealing ring.
4. Replace engine oil filter (→ Page 118).
Oil change with semirotary hand pump: Oil extraction

1. Provide a suitable container to collect the oil.
2. Extract all oil from oil pan using the semirotary hand pump.
3. Replace engine oil filter (→ Page 118).
Filling with new oil

1. Open cover on filler neck.
2. Pour oil in at filler neck up to "max." mark at
oil dipstick.
3. Close cover on filler neck.
4. Check engine oil level (→ Page 116).
5. After oil change and filter replacement, bar
engine with starting system (→ Page 71).
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8.14 Oil Filtration / Cooling
8.14.1 Engine oil filter – Replacement
Preconditions

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

1. Remove oil filter with filter wrench.
2. Clean the sealing face on the adapter.
3. Check condition of the new sealing ring and
coat it with oil.
4. Screw on and tighten new engine oil filter by
hand.
5. Replace other engine oil filters in the same
way.
6. After each oil change and filter replacement,
bar engine with starting system (→ Page 71).
7. Check oil level (→ Page 116).
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8.15 Coolant Circuit, General, High-Temperature Circuit
8.15.1 Engine coolant – Level check
Preconditions
WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
Checking coolant level at filler

neck:
1. Turn breather valve on coolant expansion
tank counterclockwise to the first stop and
allow pressure to escape.
2. Continue to turn breather valve counterclock-
wise and remove.
3. Check coolant level (coolant must be visible
at the lower edge of the cast-in eye or at the
marking plate).
4. Top up with treated coolant as necessary
(→ Page 122).
5. Check and clean breather valve.
6. Place breather valve on filler neck and close.
Coolant-level check by means of level sensor:

1. Switch on engine control system and check readings on the display.
2. Top up with treated coolant as necessary (→ Page 122).
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8.15.2 Engine coolant – Change
Engine coolant
Engine coolant – Change

1. Drain engine coolant (→ Page 121).
2. Fill with engine coolant (→ Page 122).
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120 | Coolant Circuit, General, High-Temperature Circuit | MS15018/03E 2016-02

8.15.3 Engine coolant – Draining
Preconditions

WARNING
Preparatory steps
1. Provide an appropriate container to drain the coolant into.
2. Switch off preheating unit.
Engine coolant – Draining

wise and remove.
3. Draw off precipitated corrosion inhibitor oil
from the expansion tank through filler neck.
4. Open drain valves and/or drain plugs and
drain coolant at the following points:
• At the preheating unit;
• At the engine coolant pump;
• At the crankcase, left and right sides;
• At oil heat exchanger.
5. Close all open drain points.
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8.15.4 Engine coolant – Filling
Preconditions

Coolant
WARNING
WARNING
NOTICE
Cold coolant in hot engine can cause thermal stress.
Possible formation of cracks in the engine!
• Fill / top up coolant only into cold engine.
Preparatory steps
1. Turn breather valve (1) on coolant expansion
2. Continue to turn breather valve (1) counter-
clockwise and remove.
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Engine coolant – Filling

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

Final steps
1. Start the engine and operate it at idle speed for some minutes.
2. Check coolant level (→ Page 119), top up with coolant if required.
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8.15.5 Coolant pump – Relief bore check
DANGER
WARNING
Coolant pump – Relief bore

check
1. Check relief bore for oil and coolant dis-
charge.
2. Permissible discharge:
• Up to 10 drops of coolant per hour
• Up to 5 drops of oil per hour
3. If discharge exceeds the specified limits, con-
tact Service.
4. If relief bore is dirty:
a) Stop engine (→ Page 38) and disable en-
gine start.
b) Clean relief bore with a wire.
c) Start engine (→ Page 35) and operate it
at idle speed for some minutes.
d) Check relief bore again for oil and cool-
ant discharge.
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8.16 Low-Temperature Circuit
8.16.1 Charge-air coolant – Filling
Preconditions

Coolant
WARNING
WARNING
NOTICE
Cold coolant in hot engine can cause thermal stress.
Possible formation of cracks in the engine!
• Fill / top up coolant only into cold engine.
Preparatory steps
1. Turn breather valve (1) on coolant expansion
2. Continue to turn breather valve (1) counter-
clockwise and remove.
3. Remove plug screw from filling point on cool-
ant line to intercooler.
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Charge-air coolant – Filling
1. Fill treated coolant through filling line or through filler neck of coolant expansion tank until coolant level
reaches marking plate.
2. Install plug screws of filling points with new sealing rings.
3. Check proper condition of breather valve (1), clean sealing faces if required.
4. Fit breather valve (1) and close it.
Final steps
1. Start the engine and operate it at idle speed for some minutes.
2. Check coolant level (→ Page 129).
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126 | Low-Temperature Circuit | MS15018/03E 2016-02

8.16.2 Charge-air coolant – Draining
Preconditions

WARNING
Charge-air coolant – Draining

1. Provide an appropriate container to drain the
coolant into.
wise and remove.
4. Draw off precipitated corrosion inhibitor oil
from the expansion tank through filler neck.
5. Open drain plugs and drain coolant at the fol-
lowing points:
• At the charge-air coolant pump;
• At the intercooler, engine driving end and
free end sides.
6. Screw in drain plugs with new sealing rings.
TIM-ID: 0000000040 - 003

8.16.3 Charge-air coolant – Change
Coolant
Charge-air coolant – Change

1. Drain charge-air coolant (→ Page 127).
2. Fill with charge-air coolant (→ Page 125).
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8.16.4 Charge-air coolant – Level check
Preconditions
WARNING
Checking charge-air coolant level at filler neck:

1. Turn cap on coolant expansion tank counterclockwise to the first stop and allow pressure to escape.
2. Continue to turn cap counterclockwise and remove.
Note: Charge-air coolant must be visible at marker
plate.
3. Check charge-air coolant level.
4. Top up charge-air coolant as necessary
(→ Page 125).
5. Check that cap is in serviceable condition.
6. Clean sealing surfaces as necessary.
7. Fit cap and close tight.
Checking charge-air coolant level by means of level sensor:

Note: Coolant level is automatically monitored by engine control system.
1. Switch on engine control system and check readings on the display.
2. Top up charge-air coolant as necessary (→ Page 125).
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8.17 Coolant System
8.17.1 Cooler – Checking cooler elements externally for dirt
Preconditions
Check cooler elements externally for dirt

1. Inspect cooler elements visually for dirt.
2. Clean badly soiled cooler elements (→ Page 131).
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130 | Coolant System | MS15018/03E 2016-02

8.17.2 Cooler – Cleaning cooler elements
Preconditions
WARNING
WARNING
Chemical substances in cleaners.
Risk of irritation and chemical burns!
• Always obey manufacturer's instructions for use.
NOTICE
Cleaning agents should not be left to take effect for too long.
Damage to components is possible!
NOTICE
Inappropriate cleaning tool.
Risk of damage to component!
• Use appropriate cleaning tool.
Cleaning cooler elements

1. Blow out the cooler elements with a jet of compressed air working against the direction of the cooling air
parallel to the cooling fins.
2. If cooler elements are badly soiled, treat cooling fins with a hot, grease-dissolving alkaline cleaning agent
before cleaning.
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MS15018/03E 2016-02 | Coolant System | 131

8.18 Battery-Charging Generator
8.18.1 Battery-charging generator drive – Drive-belt check and adjustment
Preconditions

Belt tension tester, 150–600 N Y20097429 1
Engine oil
Preparatory steps
u Remove protective cover.
Drive belt – Condition check
u Visually inspect condition of drive belt.

Item Findings Action
Drive belt A Singular cracks None
Drive belt B Cracks on entire circumference Replace (→ Page 134)
Drive belt C Chunking
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Drive belt Belt is oily, shows signs of over-

heating
132 | Battery-Charging Generator | MS15018/03E 2016-02

Checking drive belt tension
1. Position pretension gage on drive belt mid-
way between belt pulleys.
2. Actuate pushbutton to press the tester uni-
formly on the drive belt surface until the
spring disengages.
3. Do not press any further, otherwise the dis-
play value will be falsified.
4. Take off tension tester without changing the
position of the display arm.
5. Read off measured value at the intersection
of display arm and "KG" scale. The specified
values are listed in the table below.
Application Specified value (new drive belt) Specified value (used drive belt)
Battery-charging generator drive 450 N -50 N 350 N -50 N
belt
6. If the measured value does not correspond to the specified measured value, adjust the drive belt tension.
Adjusting drive belt tension

1. Release screws (2, 3).
2. Tension drive belt with tensioning nut (1) and
check belt tension.
3. Tighten screw (2) to specified torque using a torque wrench.

Screw M18 Tightening torque (Engine oil) 40 Nm +4 Nm
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4. Tighten screw (3).

5. Check drive belt tension.
Final steps
u Install protective cover.
MS15018/03E 2016-02 | Battery-Charging Generator | 133

8.18.2 Battery-charging generator drive – Drive belt replacement
Preconditions

Engine oil
Drive belt (→ Spare Parts Catalog)
Battery-charging generator
drive – Drive belt replacement
1. Remove protective cover.
2. Remove drive belt for fan drive (→ Page 138).
3. Undo securing screws (2) and (3).
4. Release tensioning nut (1) until the drive belt
can be removed.
5. Check belt pulleys for cleanliness, remove
dirt, if any.
6. Fit new drive belt.
7. Tension drive belt with tensioning nut (1) and
check belt tension (→ Page 132).
8. Tighten securing screw (2) to specified torque using a torque wrench.

Screw M18 Tightening torque (Engine oil) 40 Nm + 4 Nm
9. Tighten securing screw (3).

10. Install drive belt for fan drive (→ Page 138).
11. Install protective cover.
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134 | Battery-Charging Generator | MS15018/03E 2016-02

8.19 Fan Drive
8.19.1 Fan drive – Drive-belt check and adjustment
Preconditions

Belt tension tester 5505890119/00 1
Engine oil
Preparatory steps
u Remove protective cover.
Drive belt – Condition check

1. Visually inspect condition of drive belt.
2. Replace drive belt (→ Page 138):
• If belt is oily;
• If belt shows signs of overheating;
• If belt is cracked;
• If belt is worn;
• If belt is chunked
Drive belt – Tension check, var-

iant A
1. Place belt-tension tester onto drive midway
between the belt pulleys (arrowed).
spring disengages.
4. Take off belt-tension tester without changing
the position of the indication arm.
of indication arm and "KG" scale. The speci-
fied values are listed in the table below.
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Drive belt of fan drive 660 N 510 N
MS15018/03E 2016-02 | Fan Drive | 135

Drive belt – Tension check, var-
iant B
1. Place belt-tension tester onto drive midway
between the belt pulleys (arrowed).
spring disengages.
4. Take off belt-tension tester without changing
the position of the indication arm.
of indication arm and "KG" scale. The speci-
fied values are listed in the table below.
Drive belt of fan drive 670 N -50 N 570 N -50 N
Drive belt – Tension adjustment,

variant A
1. Release screws (3).
2. Release locknut (2).
3. Screw in screw (1) to tension drive belt.
4. Tighten locknut (2).
6. Tighten screws (3) to specified torque using a torque wrench.

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136 | Fan Drive | MS15018/03E 2016-02

Drive belt – Tension adjustment,
variant B
1. Release screws (1, 4).
Note: Bolt (3) is in position A for variant 50 Hz, and
in position B for variant 60 Hz.
2. Screw in screw (2) to tension drive belt.
4. Tighten screws (1) and (4) to specified torque using a torque wrench.
Final steps
u Install protective cover.
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8.19.2 Fan drive – Drive belt replacement
Preconditions

Drive belt (→ Spare Parts Catalog)
Preparatory steps
1. Remove protective cover from cooler.
2. Remove fan.
Drive belt replacement, variant

A
1. Loosen securing screwsBelt replacement (3).
2. Release locknut (2).
3. Screw out tensioning screw (1) until drive
belts can be removed.
4. Check belt pulley on fan bearing pedestal and
crankshaft for contamination, clean if neces-
sary.
Note: Drive belts must only be fitted in the grooves
as a set and without applying any force.
5. Fit new set of drive belts.
6. To check drive tension, the fan bearing ped-
estal must rest against the gearcase.
7. Adjust and check drive belt tension
(→ Page 135).
Drive belt replacement, variant

B
1. Release securing screws (1, 4).
2. Unscrew tensioning screw (2) with bolt (3)
until the drive belts can be removed.
3. Check belt pulley on fan bearing pedestal and
crankshaft for contamination, clean if neces-
sary.
Note: Drive belts must only be fitted in the grooves
as a set and without applying any force.
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4. Fit new set of drive belts.

5. To check drive tension, the fan bearing ped-
estal must rest against the gearcase.
6. Adjust and check drive belt tension
(→ Page 135).
Final steps
1. Install fan.
2. Install protective cover.
138 | Fan Drive | MS15018/03E 2016-02

8.20 Wiring (General) for Engine/Gearbox/Unit
8.20.1 Engine cabling – Check
Preconditions

Solvent (isopropyl alcohol) X00058037 1
Engine cabling – Check

1. Check securing screws of cable clamps on engine and tighten loose screw connections.
2. Ensure that cables are securely seated in clamps and cannot move freely.
3. Check if all cable clips are closed and intact.
4. Replace faulty cable clips.
5. Check cable clamps for secure fit, tighten loose clamps.
6. Replace faulty cable clamps.
7. Visually inspect the following electrical components for damage:
• Connector housings
• Contacts
• Plug connectors
• Cables and terminals
• Plug-in contacts
Result: If cable conductors are damaged, contact Service.
Note: Close connectors that are not plugged in with the protective cap supplied.
8. Use isopropyl alcohol to clean dirty connector housings, plug connectors and contacts.
9. Ensure that all connecting plugs of the sensors are correctly engaged.
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8.21 Accessories for (Electronic) Engine Governor / Control System
8.21.1 Engine governor and connector – Cleaning
Preconditions

Solvent (isopropyl alcohol) X00058037 1
NOTICE
Insertion of unsuitable test probe, e.g. test prod.
The contacts in the plug connection can be bent!
• Carry out check of plug connection only with test connectors.
Engine governor and connector – Cleaning

1. Use isopropyl alcohol to remove coarse dirt from housing surface.
2. Use isopropyl alcohol to remove dirt from the connector and cable surfaces.
3. Check legibility of cable labels. Clean or replace illegible labels.
Heavily contaminated connectors on engine governor – Cleaning

Note: Close connectors that are not plugged in with the protective cap supplied.
1. Release latches of connectors and withdraw connectors.
2. Clean connector housings, connector socket housings and all contacts with isopropyl alcohol.
3. When connectors, sockets and all contacts are dry: Fit connectors and latch them.
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140 | Accessories for (Electronic) Engine Governor / Control System | MS15018/03E 2016-02
8.21.2 Engine governor plug connections – Check
Preconditions
☑ Engine stopped and starting disabled.
☑ Electronic engine management system is de-energized.
NOTICE
Insertion of unsuitable test probe, e.g. test prod.
The contacts in the plug connection can be bent!
• Carry out check of plug connection only with test connectors.
Checking plug connections at engine governor

1. Check all plug connections for secure seating.
2. Lock loose connectors.
3. Check dust cap on ECU and EXU connectors for damage and correct seating.
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MS15018/03E 2016-02 | Accessories for (Electronic) Engine Governor / Control System | 141
8.21.3 Engine governor ECU 7 – Removal and installation
Preconditions
☑ Engine electronics is powered off.
NOTICE
Wrong engine governor installed.
Engine damage!
• When reassembling an engine, make sure that the governor with the data record for the given engine
is installed.
Removing engine governor from

engine
1. Note or mark assignment of cables and
plugs.
2. Remove all screws (3).
3. Undo clips (2) on connectors.
4. Remove all male connectors.
5. Remove screws (1).
6. Take off engine governor.
Installing engine governor on engine

1. Install in reverse order. Ensure correct assignment of plugs and sockets.
2. Check resilient mount before installing.
Result: If resilient mount is porous or defective then replace it.
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9 Appendix A
9.1 Abbreviations
Abbre- Meaning Explanation
viation
A/D Analog/Digital converter Converter: converts sensor voltages into digital val-
ues
ADEC Advanced Diesel Engine Controller Engine management system
AFRS Air Filter Restriction Sensor
AGR Abgasrückführung Exhaust Gas Recirculation
AL Alarm
ANSI American National Standards Institute Association of American standardization organiza-
tions
ATL Abgasturbolader/Abgasturboaufladung Exhaust turbocharger/exhaust turbocharging
ATS Air Temperature Sensor
BR Baureihe Series
BV Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU Publica-
tion No. A01061/..
CAN Controller Area Network Data bus system, bus standard
CDC Calibration Drift Compensation Drift correction setting with DiaSys in engine gover-
nor
CEL Check Engine Lamp 1st function: Warning lamp (rectify fault as soon as
possible)
2nd function: Read out fault codes
CKT Circuit
CLS Coolant Level Sensor Monitors coolant level
CM Current Measurement Current measured value
CPS Coolant Pressure Sensor Monitors coolant pressure
CR Common Rail
CTS Coolant Temperature Sensor Monitors coolant temperature
DDEC Detroit Diesel Electronic Controls Engine control system made by Detroit Diesel
DDL Diagnostic Data Link Diagnostic lines
DDR Diagnostic Data Reader Diagnostic unit
Dia- Electronic dialog system
Sys®
DIN Deutsches Institut für Normung e. V. German national standards institute. At the same
TIM-ID: 0000000858 - 015
time identifier of German standards (DIN = “Deut-

sche Industrie-Norm”)
DL Default Lost Alarm: Default CAN bus failure
DMC Data Matrix Code
DOC Diesel Oxidation Catalyst Oxidation catalyst upstream of the diesel particulate
filter
DPF Diesel Particulate Filter
DT Diagnostic Tool Diagnostic unit
ECM Electronic Control Module Electronic control unit of the DDEC system
MS15018/03E 2016-02 | Appendix A | 143

viation
ECU Engine Control Unit Engine governor
EDM Engine Data Module Memory module for engine data
EE- Electrically Erasable Programmable Read Electrically Erasable Programmable Read Only Mem-
PROM Only Memory ory
EFPA Electronic Foot Pedal Assembly Electronic accelerator pedal
EGR Exhaust Gas Recirculation
EIL Engine Ident Label
EIM-ID Emission Identification Number
EMU Engine Monitoring Unit
ESCM Extreme Site Condition Management Power reduction for operation in extreme conditions
ESD Single accumulator pressure
ETK Ersatzteilkatalog Spare Parts Catalog
EUI Electronic Unit Injector Electronic injection nozzle unit
FO Frequency Output
FPS Fuel Pressure Sensor Monitors fuel pressure
FRS Fuel - Differential Pressure Sensor
FTS Fuel Temperature Sensor Monitors fuel temperature
FWCP Fire Water Control Panel Control cabinet
GND Ground
HP High Pressure
HI High Alarm: Measured value exceeds 1st maximum limit
HIHI High High Alarm: Measured value exceeds 2nd maximum limit
HT High Temperature
IDM Interface Data Module Memory module for interface data
IIG Initial injector equalization Initial input of injector code in Engine Control Unit
with DiaSys in
INJ Injector
ISO International Organization for Standardiza- International umbrella organization for all national
tion standardization institutes
KGS Kupplungsgegenseite Engine free end in accordance with DIN ISO 1204
KS Kupplungsseite Engine driving end in accordance with DIN ISO 1204
L1 Limit 1 Limit value, limit 1
L2 Limit 2 Limit value, limit 2
LED Light Emitting Diode
LLK Ladeluftkühlung Charge-air cooling
TIM-ID: 0000000858 - 015
LO Low Alarm: Measured value lower than 1st minimum limit

value
LOLO Low Low Alarm: Measured value lower than 2nd minimum lim-
it value
LSG Limit Speed Governor Maximum-speed governor
LSU Lambda Sonde Universal Universal Lambda probe
LT Low Temperature
MCR Maximum Continuous Rating Torque limitation curve
144 | Appendix A | MS15018/03E 2016-02

viation
N/A Not Applicable
LP Low Pressure
NN Normal Null Reference surface for heights above sea level
NT Niedertemperatur Low temperature
OEM Original Equipment Manufacturer
OI Optimized Idle
OLS Oil Level Sensor Monitors oil level
OPS Oil Pressure Sensor Monitors oil pressure
OTS Oil Temperature Sensor Monitors oil temperature
OT Oberer Totpunkt Top Dead Center
PAN Panel Control panel
PIM Peripheral Interface Module
PWM Pulse Width Modulation Modulated signal
P-xyz Pressure-xyz Pressure measuring point xyz
RL Redundancy Lost Alarm: Redundant CAN bus failure
SAE Society of Automotive Engineers U.S. standardization organization
SD Sensor Defect Alarm: Sensor failure
SEL Stop Engine Lamp 1st function: Warning lamp (stop engine and rectify
fault)
2nd function: Read out fault codes
SID System Identifier
SRS Synchronous Reference Sensor TDC cylinder 1
SS Safety System / Security Shutdown Safety system alarm
TBS Turbocharger Boost Sensor Monitors charge-air pressure
TCI Turbo Compressor Inlet
TCO Turbo Compressor Outlet
TD Transmitter Deviation Alarm: Sensor comparison fault
TPS Throttle Position Sensor
TRS Timing Reference Sensor
T-xyz Temperature-xyz Temperature measuring point xyz
U_PDU Voltage Power Driver Unit Distribution voltage for solenoid valve output stages
UDV Pressure relief valve
UT Unterer Totpunkt Bottom Dead Center
VNT Variable Nozzle Turbine
TIM-ID: 0000000858 - 015
VSG Variable-Speed Governor

VSS Vehicle Speed Sensor
WZK Werkzeugkatalog Tool Catalog
ZKP Zuordnung - Kategorie - Parameter Assignment - Category - Parameter. A number allo-
cated to a parameter describing its function and as-
signment
MS15018/03E 2016-02 | Appendix A | 145

9.2 MTU Contact/Service Partners
The worldwide network of the sales organization with subsidiaries, sales offices, representatives and custom-
er service centers ensure fast and direct support on site and ensure the high availability of our products.
Local Support
Experienced and qualified specialists place their knowledge and expertise at your disposal.
For locally available support, go to the MTU Internet site: http://www.mtu-online.com
24h Hotline
With our 24h hotline and high flexibility, we're your contact around the clock: during each operating phase,
preventive maintenance and corrective operations in case of a malfunction, for information on changes in
conditions of use and for supplying spare parts.
Your contact person in our Customer Assistance Center:
E-mail: [email protected]
Tel.: +49 7541 9077777
Fax.: +49 7541 9077778
Asia/Pacific: +65 6100 2688
North and Latin America: +1 248 560 8000
Spare Parts Service

Fast, simple and correct identification of spare parts for your drive system or vehicle fleet. The right spare
part at the right time at the right place.
With this aim in mind, we can call on a globally networked spares logistics system, a central warehouse at
headquarters and on-site stores at our subsidiary companies, agencies and service workshops.
Your contact at Headquarters:
E-mail: [email protected]
Tel.: +49 7541 9077777
Fax.: +49 7541 9077778
TIM-ID: 0000000873 - 016
146 | Appendix A | MS15018/03E 2016-02

10 Appendix B
10.1 Special Tools
Adapter
Part No.: F30006234
Qty.: 1
Used in: 8.5.2 Injection pump – Removal and installation
(→ Page 85)
Qty.: 1
Used in: 8.6.2 Injector – Removal and installation (→ Page 89)
Qty.: 1
Used in: 8.7.1 Fuel injection line – Pressure pipe neck replacement
(→ Page 94)
Barring device for 12V engines

Part No.: F6558556
Qty.: 1
Used in: 8.1.1 Engine – Barring manually (→ Page 70)
Barring device for 16V, 18V engines

Part No.: F6558557
Qty.: 1
Used in: 8.1.1 Engine – Barring manually (→ Page 70)
DCL-ID: 0000019467 - 005
MS15018/03E 2016-02 | Appendix B | 147

Barring tool
Part No.: F6557929
Qty.: 1
Belt tension tester

Part No.: 5505890119/00
Qty.: 1
Used in: 8.19.1 Fan drive – Drive-belt check and adjustment
(→ Page 135)
Belt tension tester, 150–600 N

Part No.: Y20097429
Qty.: 1
Used in: 8.18.1 Battery-charging generator drive – Drive-belt check
and adjustment (→ Page 132)
Crossbeam
Part No.: T80092210
Qty.: 1
Used in: 2.1 Transportation (→ Page 16)
DCL-ID: 0000019467 - 005
148 | Special Tools | MS15018/03E 2016-02

Crowfoot box wrench, 22 mm
Part No.: F30027425
Qty.: 1
(→ Page 85)
Qty.: 1
Qty.: 1
(→ Page 94)
Crowfoot wrench, 19 mm
Part No.: F30027424
Qty.: 1
(→ Page 85)
Qty.: 1
Qty.: 1
(→ Page 94)
Double-head box wrench

Part No.: F30011450
Qty.: 1
Qty.: 1
(→ Page 94)
Feeler gage
Part No.: Y4342013
Qty.: 1
Used in: 8.4.1 Valve clearance – Check and adjustment
(→ Page 80)
DCL-ID: 0000019467 - 005
MS15018/03E 2016-02 | Special Tools | 149

Filter wrench
Part No.: F30379104
Qty.: 1
Used in: 8.8.1 Fuel filter – Replacement (→ Page 102)
Qty.: 1
Used in: 8.14.1 Engine oil filter – Replacement (→ Page 118)
Fuel suction device

Part No.: F30378207
Qty.: 1
Open-end socket wrench, 19 mm

Part No.: F30025897
Qty.: 1
Qty.: 1
(→ Page 94)
Plug-in open-end wrench, 17 mm

Part No.: F30028341
Qty.: 1
Used in: 8.7.2 Fuel – Draining (→ Page 97)
DCL-ID: 0000019467 - 005

Puller
Part No.: 3555890163/00
Qty.: 1
Ratchet adapter
Part No.: F30027340
Qty.: 1
Used in: 8.3.2 Crankcase breather – Oil separator replacement, di-
aphragm check and replacement (→ Page 78)
Qty.: 1
(→ Page 80)
Qty.: 1
Used in: 8.4.2 Cylinder head cover – Removal and installation
(→ Page 83)
Qty.: 1
(→ Page 85)
Qty.: 1
Qty.: 1
(→ Page 94)
Qty.: 1
Qty.: 1
Used in: 8.18.2 Battery-charging generator drive – Drive belt re-
placement (→ Page 134)
Qty.: 1
(→ Page 135)
DCL-ID: 0000019467 - 005

Rigid endoscope
Part No.: Y20097353
Qty.: 1
Used in: 8.2.1 Cylinder liner – Endoscopic examination (→ Page 73)
Torque wrench, 0.5–5 Nm

Part No.: 0015384230
Qty.: 1
(→ Page 85)
Torque wrench, 20–100 Nm

Part No.: F30026582
Qty.: 1
(→ Page 80)
Qty.: 1
(→ Page 85)
Qty.: 1
Qty.: 1
(→ Page 94)
Qty.: 1
Qty.: 1
Used in: 8.18.2 Battery-charging generator drive – Drive belt re-
DCL-ID: 0000019467 - 005
placement (→ Page 134)

Qty.: 1
(→ Page 135)

Torque wrench, 8–40 Nm
Part No.: F30043446
Qty.: 1
Used in: 8.3.2 Crankcase breather – Oil separator replacement, di-
aphragm check and replacement (→ Page 78)
Qty.: 1
Used in: 8.4.2 Cylinder head cover – Removal and installation
(→ Page 83)
Qty.: 1
Used in: 8.7.2 Fuel – Draining (→ Page 97)
DCL-ID: 0000019467 - 005

10.2 Index
A D
Abbreviations 143 Differential pressure gage
After stopping the engine – Adjustment
– Engine remains ready for operation 40 – Fuel prefilter 103
– Putting the engine out of operation 41 – Check
Air filter – Fuel prefilter 103
– Removal and installation 113 Drive belt
– Replacement 112 – Condition check 132, 135
– Service indicator check 114 – Replacement 134
Air starter – Tension adjustment 132, 135
– Manual operation 115 – Tension check 132, 135
C E
Cabling ECU 7
– Check – Installation 142
– On engine 139 – Removal 142
Charge-air coolant Engine
– Change 128 – Barring
– Check – With starting system 71
– Level at filler neck 129 – Barring manually 70
– Level via level sensor 129 – Emergency stop 39
– Draining 127 – Main dimensions 32
– Filling 125 – Overview 19
Connector – Starting in manual mode (test run) 35
– Cleaning 140 – Stopping in manual mode (test run) 38
Contact persons 146 – Test run 72
Coolant Engine cabling
– Change 128 – Check 139
– Charge air Engine coolant
– Draining 127 – Change 120
– Filling 125 – Draining 121
– Filling 122 – Filling 122
Coolant level Engine coolant level
– Check 119 – Check 119
Coolant pump Engine data
– Relief bore check 124 – 12V2000G65
Cooler – Fuel optimized 23
– Cooler elements – 12V2000G65-TB
– Cleaning 131 – Fuel optimized 27
Cooler elements – 16V2000G65
– Cleaning – Fuel optimized 23
– On Cooler 131 – 16V2000G65-TB
Cooler – Checking cooler elements externally for dirt 130 – Fuel optimized 27
DCL-ID: 0000019467 - 005
Crankcase breather – 18V2000G65

– Diaphragm check 78 – Fuel optimized 23
– Oil separator element replacement 78 – 18V2000G65-TB
– Wire mesh cleaning 77 – Fuel optimized 27
Cylinder Engine driving end
– Designation 18 – Definition 18
Cylinder head cover Engine free end
– Removal and installation 83 – Definition 18
Cylinder liner Engine governor
– Endoscopic examination 73 – Cleaning 140
– Instructions and comments on endoscopic and visual – Plug connections
examination 75 – Check 141
154 | Index | MS15018/03E 2016-02

Engine governor ECU 7 L
– Installation 142 Lifting requirements 17
– Removal 142
Engine oil M
– Change 117 MTU contact persons 146
Engine oil filter
– Replacement 118 O
Engine oil level Operational checks 37
– Check 116 Overview
Engine sides – Engine 19
– Designation 18
P
F Putting the engine into operation after extended out-of-
Fan drive service periods (>3 months) 33
– Drive belt replacement 138 Putting the engine into operation after scheduled out-of-
Fault indication on SAM display service-period 34
– Genset applications 43
Firing order 31 S
Fuel Safety notices, standards 15
– Draining 97 Safety regulations
Fuel filter – Auxiliary materials 13
– Replacement 102 – Environmental protection 13
Fuel prefilter – Fire prevention 13
– Adjustment – Fluids and lubricants 13
– Differential pressure gage 103 – Important provisions 5, 6
– Check – Maintenance work 10
– Differential pressure gage 103 – Operation 8
– Cleaning 108 – Organizational requirements 7
– Draining 104 – Personnel requirements 7
– Filter element – Repair work 10
– Replacement 109 – Startup 8
– Flushing 106 Safety requirements
Fuel pressure relief valve – Safety notices, standards 15
– Installation 99 Safety system
– Removal 99 – Override 36
Fuel system SAM
– Venting 100 – Genset applications 43
Sensors and actuators
H – Overview 21
Hotline 146 Service indicator
HP fuel line – Check 114
– Pressure pipe neck replacement 94 Service partners 146
Spare parts service 146
I
Starting valve
Injection pump – Manual operation 115
– Installation 85
– Removal 85 T
DCL-ID: 0000019467 - 005
– Replacement 84 Transportation

Injector – Description 16
– Installation 89 – Lifting requirements 17
– Removal 89 Troubleshooting 67
– Replacement 88
Intercooler V
– Condensate drain for coolant discharge Valve clearance
– Check 111 – Adjustment 80
– Condensate drain for obstructions – Check 80
– Check 111
MS15018/03E 2016-02 | Index | 155

Dvigatel Mtu 12v2000g65e

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Operating Instructions

© 2016 Copyright MTU Friedrichshafen GmbH

4.1 12/16/18V2000G65 engine data, fuel 8.4 Valve Drive 80

5 Operation 8.6 Injection Valve / Injector 88

MS15018/03E 2016-02 | Table of Contents | 3

8.10 Air Filter 112 8.18 Battery-Charging Generator 132

DCL-ID: 0000019467 - 005

4 | Table of Contents | MS15018/03E 2016-02

Emission regulations and emission labels

Replacing components with emission labels

MS15018/03E 2016-02 | Safety | 5

6 | Safety | MS15018/03E 2016-02

Clothing and personal protective equipment

MS15018/03E 2016-02 | Safety | 7

Safety regulations during operation

Malfunctions and emergency stop

to do so following a written procedure.

Operation of electrical equipment

8 | Safety | MS15018/03E 2016-02

MS15018/03E 2016-02 | Safety | 9

Safety regulations during maintenance and repair work

Never use the product as a climbing aid.

10 | Safety | MS15018/03E 2016-02

Safety regulations following maintenance and repair work

Hydraulic installation and removal

MS15018/03E 2016-02 | Safety | 11

Working with batteries

Working on electrical and electronic assemblies

Work with laser devices

Measuring component dimensions

12 | Safety | MS15018/03E 2016-02

Environmental protection and disposal

MS15018/03E 2016-02 | Safety | 13

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

14 | Safety | MS15018/03E 2016-02

MS15018/03E 2016-02 | Safety | 15

Placement after transportation

TIM-ID: 0000067353 - 001

16 | Transport | MS15018/03E 2016-02

1 Lifting eye 2 Center of gravity

Take note of the engine center of gravity

MS15018/03E 2016-02 | Transport | 17

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

18 | General Information | MS15018/03E 2016-02

1 Air filter 8 Oil filter 15 Cylinder head

MS15018/03E 2016-02 | General Information | 19

1 Air filter 7 Oil heat exchanger 13 Exhaust elbow

Engine type designation

20 | General Information | MS15018/03E 2016-02

Item Name Monitoring of

MS15018/03E 2016-02 | General Information | 21

Item Name Monitoring of

22 | General Information | MS15018/03E 2016-02

General conditions (for maximum power)

Intake depression (new filter) A mbar 15 15 15

MS15018/03E 2016-02 | Technical Data | 23

Air / exhaust gas

Coolant system (HT circuit)

Coolant temperature after engine, shutdown L °C 102 102 102