12 V 2000 gx6f

Operating Instructions
Diesel Engine
12 V 2000 Gx6F
MS150111/01E
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Engine model kW/cyl. Application group
12V2000G56F 55.4 kW/cyl. 3B, continuous operation, variable
12V2000G66F 59.1 kW/cyl. 3B, continuous operation, variable
Table 1: Validity overview
© 2014 Copyright MTU Friedrichshafen GmbH

This publication is protected by copyright and may not be used in any way, whether in whole or in part, without the prior
written consent of MTU Friedrichshafen GmbH. This particularly applies to its reproduction, distribution, editing, transla-
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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 7 Task Description
1.1 Important requirements for all products 5 7.1 Engine 42
1.2 Personnel and organizational requirements 6 7.1.1 Engine – Barring manually 42
1.3 Transport 7 7.1.2 Engine – Barring with starting system 43
1.4 Safety requirements for maintenance and 7.2 Crankcase Breather 44
repair work 8 7.2.1 Crankcase breather – Oil mist fine separator
1.5 Fire prevention and environmental replacement 44
protection, fluids and lubricants, auxiliary
7.3 Valve Drive 45
materials 11 7.3.1 Valve clearance – Check and adjustment 45
1.6 Standards for safety notices in the text 13 7.3.2 Cylinder head cover – Removal and
installation 47
2 General Information
7.4 Injection Valve / Injector 48
2.1 Engine side and cylinder designations 14 7.4.1 Injector – Replacement 48
2.2 Engine overview 15 7.4.2 Injector – Removal and installation 49
7.4.3 Injector functions 54
3 Technical Data 7.5 Fuel System 55

7.5.1 HP fuel line and pressure pipe neck ‒
3.1 Engine data 12 V 2000 G56/66F 16 Replacement 55
3.2 Firing order 19 7.5.2 Fuel system – Venting 58
3.3 Engine – Main dimensions 20 7.5.3 Fuel – Draining 59
7.6 Fuel Filter 60

4 Operation 7.6.1 Fuel filter – Replacement 60
7.6.2 Fuel prefilter – Differential pressure gage
4.1 Putting the engine into operation after
check and adjustment of gage 61
extended out-of-service periods (>3 months) 21 7.6.3 Fuel prefilter – Draining 62
4.2 Putting the engine into operation after 7.6.4 Fuel prefilter – Flushing 63
scheduled out-of-service-period 22 7.6.5 Fuel prefilter – Filter element replacement 65
4.3 Tasks after extended out-of-service periods
(>3 weeks) 23 7.7 Air Filter 66
7.7.1 Air filter – Replacement 66
4.4 Checks prior to start-up 24
7.7.2 Air filter – Removal and installation 67
4.5 Fuel treatment system – Putting into
operation 25 7.8 Air Intake 68
4.6 Starting the engine 28 7.8.1 Service indicator – Signal ring position check
4.7 Fuel treatment system – Switching on 29 (optional) 68
4.8 Operational checks 30 7.9 Exhaust Gas Recirculation 69
4.9 Stopping the engine 31 7.9.1 Exhaust gas recirculation flaps – Overview 69
4.10 Emergency stop 32 7.9.2 Exhaust gas circulation ‒ Checking flap
4.11 After stopping the engine 33 operation 70
4.12 Fuel treatment system – Shutdown 34 7.10 Lube Oil System, Lube Oil Circuit 71
4.13 Plant – Cleaning 35 7.10.1 Engine oil – Level check 71
DCL-ID: 0000027885 - 004
7.10.2 Engine oil – Change 72

5 Maintenance
7.11 Oil Filtration / Cooling 73
5.1 Maintenance task reference table [QL1] 36 7.11.1 Engine oil filter – Replacement 73
7.11.2 Centrifugal oil filter – Cleaning and filter-
sleeve replacement 74
6 Troubleshooting
7.12 Coolant Circuit, General, High-Temperature
6.1 Fuel treatment system – Troubleshooting 38 Circuit 76
6.2 Troubleshooting 39 7.12.1 Drain and vent points 76
MS150111/01E 2014-05 | Table of Contents | 3

7.12.2 Engine coolant – Level check 81 7.16.4 Pump capacity – Check 103
7.12.3 Engine coolant – Change 82 7.16.5 Coalescer filter element – Replacement 104
7.12.4 Engine coolant ‒ Draining 83
7.12.5 Engine coolant – Filling 84
7.17 Engine Governor 106
7.17.1 Engine governor – Overview 106
7.12.6 Engine coolant pump – Relief bore check 86
7.17.2 Engine governor – Removal and installation 107
7.12.7 Engine coolant – Sample extraction and
7.17.3 Engine governor plug connections – Check 108
analysis 87
7.13 Low-Temperature Circuit 88 7.18 Wiring (General) for Engine/Gearbox/Unit 109

7.18.1 Engine wiring – Check 109
7.13.1 Intercooler – Venting and draining 88
7.18.2 Lambda, NOx and humidity sensors –
7.13.2 Charge-air coolant – Level check 89
Overview 110
7.13.3 Charge-air coolant – Change 90
7.18.3 Lambda sensor – Replacement 111
7.13.4 Charge-air coolant – Filling 91
7.18.4 NOx sensor – Replacement 113
7.13.5 Charge-air coolant ‒ Draining 93
7.18.5 Humidity sensor – Replacement 115
7.13.6 Charge-air coolant pump – Relief bore check 94
7.14 Belt Drive 95 7.19 Accessories for (Electronic) Engine

7.14.1 Drive belt – Condition check 95 Governor / Control System 117
7.14.2 Drive belt – Tension check 96 7.19.1 Engine governor and connectors – Cleaning 117
7.14.3 Drive belt – Tension adjustment 97 7.19.2 Engine governor plug connections – Check 118
7.14.4 Drive belt – Replacement 98
7.15 Battery-Charging Generator 99 8 Appendix A

7.15.1 Battery-charging generator drive – Drive belt
replacement 99 8.1 List of abbreviations 119
8.2 MTU contact persons/service partners 121
7.16 Fuel Supply System 100
7.16.1 Water drain valve – Check 100
9 Appendix B
7.16.2 Differential pressure gauge – Check 101
7.16.3 Water level probe (3-in-1 rod electrode) – 9.1 Special Tools 122
Check 102
9.2 Index 131
DCL-ID: 0000027885 - 004
4 | Table of Contents | MS150111/01E 2014-05

1 Safety
1.1 Important requirements for all products
Nameplate
The product is identified by a nameplate, model designation or serial number which must match the
information on the title page of this manual.
Nameplate, model designation or serial number can be found on the product.
General information
This product may pose a risk of injury or damage in the following cases:
• Improper use
• Operation, maintenance and repair by unqualified personnel
• Changes or modifications
• Noncompliance with the safety instructions and warning notices
Intended use
The product is intended for use in accordance with its contractually-defined purpose as described in the
relevant technical documents only.
Intended use entails operation:
• Within the permissible operating parameters in accordance with the (→ Technical data)
• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubri-
cants Specifications of the manufacturer)
• With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU
contact/Service partner)
• In the original as-delivered configuration or in a configuration approved by the manufacturer in writ-
ing (including engine management/parameters)
• In compliance with all safety regulations and in accordance with all warning notices in this manual
• With maintenance work performed in accordance with the (→ Maintenance Schedule) throughout the
useful life of the product
• In compliance with the maintenance and repair instructions contained in this manual, in particular
with regard to the specified tightening torques
• With the exclusive use of technical personnel trained in commissioning, operation, maintenance and
repair
• By contracting only workshops authorized by the manufacturer to carry out repair and overhaul
Any other use shall be considered non-intended. Such improper use increases the risk of injury and
damage when working with the product. The manufacturer shall not be held liable for any damage re-
sulting from improper, non-intended use.
Changes or modifications
Unauthorized changes to the product represent a contravention of its intended use and compromise
TIM-ID: 0000040530 - 004
safety.
Changes or modifications shall only be considered to comply with the intended use when expressly au-
thorized by the manufacturer. The manufacturer shall not be held liable for any damage resulting from
unauthorized changes or modifications.
MS150111/01E 2014-05 | Safety | 5

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

Wear proper protective clothing for all work.
When working, always wear the necessary personal protective equipment (e.g. ear protectors, protec-
tive gloves, goggles, breathing protection). Observe the information on personal protective equipment
in the respective activity description.
TIM-ID: 0000040531 - 002
6 | Safety | MS150111/01E 2014-05

1.3 Transport
Transport
Also valid for 12V engines
Only use the lifting eyes provided to lift the engine.

Only use transport and lifting devices approved by MTU.
Take the engine's center of gravity into account.
The engine must only be transported in installation position, max. permissible diagonal pull 10°.
If the engine is supplied with special aluminum foil packing, lift the engine at the lifting eyes of the bear-
ing pedestal or use a means of transportation which is appropriate for the given weight (forklift truck).
Install the crankshaft locking device and the locking screws for the engine mounts prior to engine trans-
portation.
Secure the engine against tilting during transport. In particular when going down inclines or ramps, the
engine must be secured against moving and tilting.
Setting the engine down after transport

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Only set down engine on a firm, level surface.

Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate.
Never set an engine down on the oil pan unless expressively authorized to do so by MTU on a case-to-
case basis .
MS150111/01E 2014-05 | Safety | 7

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

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

Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent
contact with other components. Never route fuel or oil lines in the vicinity of hot components.
Do not touch elastomeric seals (e.g. Viton sealing rings) with your bare hands if they have a carbonized
or resinous appearance.
Observe the cooling time for components which have been heated for installation or removal (risk of
burning!).
Always use suitable ladders and work platforms when working above head-height. Ensure that compo-
nents or assemblies are placed on stable surfaces.
8 | Safety | MS150111/01E 2014-05

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

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

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

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Observe the safety requirements of the battery manufacturer when working with batteries.
Gases released from the battery are explosive. Avoid sparks and naked flames.
Do not allow electrolyte (battery acid) to come into contact with skin or clothing.
Wear goggles and protective gloves.
Do not place tools on the battery.
Check polarity before connecting the cable to the battery. Battery polarity reversal may lead to injury by
the sudden discharge of acid or bursting of the battery unit.
MS150111/01E 2014-05 | Safety | 9

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

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

Workpieces, components and measuring instruments are within specified tolerances at a reference
temperature of 20°C. TIM-ID: 0000040535 - 005
10 | Safety | MS150111/01E 2014-05

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

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

The Fluids and Lubricants Specifications will be amended or supplemented as necessary. Prior to opera-
tion, make sure that the latest version is used. The latest version can be found on the website on the
"Technical Info" or "Spare Parts and Service" tabs at http://www.mtu-online.com.
Consumable fluids and materials may also be hazardous or toxic. When using fluids, lubricants, consum-
ables and other chemical substances, follow the safety regulations that apply to the product. Take spe-
cial care when using hot, chilled or caustic substances. When using flammable materials, prevent them
TIM-ID: 0000040536 - 005
coming into contact with ignition sources and do not smoke.
Used oil
Used oil contains combustion residues that are harmful to health.
Rub barrier cream into hands.
Wash hands after contact with used oil.
MS150111/01E 2014-05 | Safety | 11

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

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

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• When working with acids and alkaline solutions, wear goggles or face mask, gloves and protective
clothing.
• Do not inhale vapors.
• If urea solution is swallowed, rinse out mouth and drink plenty of water.
• If spilled onto clothing, remove the affected clothing immediately.
• After contact with skin, rinse affected parts of the body with plenty of water.
• Rinse eyes immediately with eye drops or clean tap water. Seek medical attention as soon as possi-
ble.
12 | Safety | MS150111/01E 2014-05

1.6 Standards for safety notices in the text
DANGER
In the event of immediate danger.
Consequences: Death, serious or permanent injury!
• Remedial action.
WARNING
In the event of a situation involving potential danger.
Consequences: Death, serious or permanent injury!
CAUTION
In the event of a situation involving potential danger.
Consequences: Minor or moderate injuries!
NOTICE
In the event of a situation involving potentially adverse effects on the product.
Consequences: Material damage!
• Additional product information.
Safety notices
1. This manual with all safety instructions and safety notices must be issued to all personnel involved in
operation, maintenance, repair or transportation.
2. The higher level warning notice is used if several hazards apply at the same time. Warnings related to
personal injury shall be considered to include a warning of potential damage.
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MS150111/01E 2014-05 | Safety | 13

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

2 Engine free end in accord- 4 Engine driving end in ac-
ance with DIN ISO 1204 cordance with
(KGS = Kupplungsgegen- DIN ISO 1204 (KS = Kup-
seite) plungsseite)
Engine sides are always designated (in accordance with DIN ISO 1204) as viewed from driving end (4).
For cylinder designation (in accordance with DIN ISO 1204), the letter "Ax" refers to the cylinders on
the left-hand side of the engine (1) and letter "Bx" refers to the cylinders on the right-hand side (3). The
cylinders of each bank are numbered consecutively, starting with x=1 at driving end (4).
The numbering of other engine components also starts with 1 at driving end (4).
TIM-ID: 0000002185 - 013
14 | General Information | MS150111/01E 2014-05

2.2 Engine overview
12 V 2000 G56/66F
1 Exhaust turbocharger 7 Power supply 13 Valve gear

2 Air intake/air supply 8 Cooling air system 14 Cylinder head
3 EGR cooler 9 Coolant system 15 Exhaust pipework
4 Intercooler 10 Mounting/support 16 PTO system, driving end
5 Monitoring, control and 11 Fuel system (low pressure) 17 Starting equipment
regulation system 12 Fuel system (high pres-
6 Lube oil system/lube oil sure)
circuit
Engine model designation

Key to the engine model designation
12 Number of cylinders
V Cylinder arrangement (V engine)
2000 Series
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G Application (G for Genset)

5/6 Application segment (0, 1, 2,...,9)
6 Design index (0, 1, 2,...,9)
F Additional characteristic (F = 50 Hz)
MS150111/01E 2014-05 | General Information | 15

3 Technical Data
3.1 Engine data 12 V 2000 G56/66F
Explanation:
DL Reference value: Continuous power (CP)
BL Reference value: Fuel stop power (FSP)
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 setting)
N Not yet defined value
- Not applicable
X Applicable
Engine model 12V2000 12V2000

G56F G66F
Application group 3B 3B
Intake air temperature °C 25 25
Charge-air coolant temperature °C 45 45
Barometric pressure mbar 1000 1000
Site altitude above sea level m 100 100
POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)
Number of cylinders 12 12
Rated engine speed A rpm 1500 1500
Net brake power (w/o fan) (fuel stop power ISO 3046) A kW 665 709
GENERAL CONDITIONS (for maximum power)

Intake depression (new filter) A mbar 15 15
Intake depression, max. L mbar 50 50
Exhaust overpressure A mbar 30 30
Exhaust overpressure, max. L mbar 50 50
Fuel temperature at engine inlet connection R °C 25 25
Fuel temperature at engine inlet connection, max. (w/o power re- L °C 65 65
duction)
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Fuel temperature at engine inlet connection, min. (w/o power re- L °C -25 -25
duction)
CONSUMPTION
Lube oil consumption after 100 h run time (B = hourly fuel con- R % of B 0.35 0.35
sumption)
16 | Technical Data | MS150111/01E 2014-05

MODEL RELATED DATA (basic design)
Cylinder arrangement: V angle Degrees 90 90
(°)
Bore mm 135 135
Stroke mm 156 156
Cylinder displacement Liters 2.233 2.233
Total displacement Liters 26.80 26.80
Inlet valves per cylinder 2 2
Exhaust valves per cylinder 2 2
COMBUSTION AIR / EXHAUST GAS

Charge-air pressure before cylinder R bar abs 3.3 3.3
Exhaust temperature after exhaust turbocharger R °C 430 450
COOLANT SYSTEM (HT circuit)

Coolant temperature (at engine connection: outlet to cooling A °C 100 100
equipment)
Coolant temperature after engine, warning R °C 106 106
Coolant temperature after engine, shutdown L °C 108 108
Coolant antifreeze content, max. L % 50 50
Coolant pump: inlet pressure, max. L bar 1.5 1.5
Thermostat: Starts to open R °C 79 79
Thermostat: Fully open R °C 92 92
COOLANT SYSTEM (LT circuit)

Coolant antifreeze content, max. L % 50 50
Charge-air temperature after intercooler, max. L °C 95 95
Thermostat: Starts to open R °C 38 38
Thermostat: Fully open R °C 51 51
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LUBE OIL SYSTEM

Lube oil operating temperature before engine, from R °C 80 80
Lube oil operating temperature before engine, to R °C 103 103
Lube oil temperature before engine, warning R °C 103 103
Lube oil temperature before engine, shutdown L °C 105 105
Lube oil pressure before engine, warning R bar 5.3 5.3
Lube oil pressure before engine, shutdown L bar 4.8 4.8
MS150111/01E 2014-05 | Technical Data | 17

FUEL SYSTEM
Fuel pressure at engine inlet connection, min. (during engine start) L bar -0.5 -0.5
Fuel pressure at engine inlet connection, min. (when engine is run- L bar -0.5 -0.5
ning)
Fuel pressure at engine inlet connection, max. (during engine L bar 0.5 0.5
start)
GENERAL OPERATING DATA

Coolant preheating: Preheating temperature (min.) R °C 32 32
INCLINATIONS, STANDARD OIL SYSTEM (reference: waterline)

Longitudinal inclination, continuous max., driving end down (op- L Degrees 5 5
tion: max. operating inclinations) (°)
Longitudinal inclination, continuous max., driving end up (option: L Degrees 5 5
max. operating inclinations) (°)
Transverse inclination, continuous max. (option: max. operating in- L Degrees 10 10
clinations) (°)
CAPACITIES
Engine coolant, engine-side (without cooling system) R Liters 63 63
Charge-air coolant, engine side R Liters 25 25
Total engine oil capacity, initial filling (standard oil system) (option: R Liters 99 99
max. operating inclinations)
Oil pan capacity at dipstick mark “min.” (standard oil system) (op- L Liters 73 73
tion: max. operating inclinations)
Oil pan capacity at dipstick mark “max.” (standard oil system) (op- L Liters 81 81
tion: max. operating inclinations)
ACOUSTICS
Exhaust noise, unsilenced - BL (free-field sound-pressure level Lp, R dB(A) 103 104
1m distance, ISO 6798, +3dB(A) tolerance)
Exhaust noise, unsilenced - BL (sound power level LW, ISO R dB(A) 116 117
TIM-ID: 0000043671 - 001
6798+3 db(A) tolerance)

Engine surface noise with attenuated intake noise (filter) - BL R dB(A) 99 99
(free-field sound-pressure level Lp, 1 m distance, ISO 6798,
+2dB(A) tolerance)
Engine surface noise with attenuated intake noise (filter) - BL R dB(A) 117 117
(sound power level LW, ISO 6798+2dB(A) tolerance)

3.2 Firing order
Firing order 12 V 2000 G56/66F
Number of cylin- Firing order
ders
12 V A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1
TIM-ID: 0000043670 - 001
MS150111/01E 2014-05 | Technical Data | 19

3.3 Engine – Main dimensions
Item Engine model/dimensions Engine model/dimensions

12 V 2000 G56F 16 V 2000 G66F
Length (A) Approx. 2028 mm Approx. 2028 mm
Width (B) Approx. 1278 mm Approx. 1278 mm
Height (C) Approx. 1493 mm Approx. 1493 mm
Table 2: Engine model/dimensions
TIM-ID: 0000043669 - 001

4 Operation
4.1 Putting the engine into operation after extended out-of-service
periods (>3 months)
Preconditions
☑Engine is stopped and starting disabled.
☑MTU Fluids and Lubricants Specifications (A001061/..) are available.
Putting into operation after long out-of-service periods (>3 months)

Item Action
Engine Depreserve (→ Preservation and Represervation Specifications (A001070/
…)).
Lube oil system Check engine oil level (→ Page 71).
Fuel system Connect appropriate equipment to fuel supply line to fill the system.
Fuel system Vent (→ Page 58).
Coolant circuit If engine is out of service for more than one year, change engine coolant
(→ Page 82). Change charge-air coolant (→ Page 90).
Coolant circuit Check engine coolant level (→ Page 81); Check charge-air coolant level
(→ Page 89).
Coolant circuit Preheat engine coolant with coolant preheating unit (if fitted).
Engine governor Check plug-in connections (→ Page 108).
Engine control system Switch on.
TIM-ID: 0000010073 - 003
MS150111/01E 2014-05 | Operation | 21

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

Item Action
Lube oil system Check engine oil level (→ Page 71).
Coolant circuit Check engine coolant level (→ Page 81), check charge-air coolant level
(→ Page 89).
Coolant circuit Preheat engine coolant with coolant preheating unit, if fitted.
Fuel prefilter (if fitted) Drain water and contaminants, see manufacturer's documentation.
Engine control system Switch on.
TIM-ID: 0000010642 - 002
22 | Operation | MS150111/01E 2014-05

4.3 Tasks after extended out-of-service periods (>3 weeks)
Tasks after extended out-of-service periods (>3 weeks)

Note: Operate fuel treatment system for at least 5 minutes.
1. Start up fuel treatment system (→ Page 25).
2. Shut down fuel treatment system (→ Page 34).
TIM-ID: 0000007730 - 005
MS150111/01E 2014-05 | Operation | 23

4.4 Checks prior to start-up
Checks prior to start-up

1. Check tank and the entire pipework for cleanness. If microorganisms are detected:
a) Clean affected components.
b) Disinfect affected components with biocides (→ MTU Fluids and Lubricants Specifications
A001061/..).
2. Close drain valves on housing.
3. Open all supply and discharge valves.
4. Switch on fuel treatment system (→ Page 29).
5. Check direction of rotation of pump.
6. Vent bypass and fuel lines of the system.
a) Open ball valve for pressure tank.
b) Open ball valve for overflow tank.
c) Close ball valve at the inlet to the fuel treatment system.
Result: Bypass line is vented via the overflow tank.
d) Open ball valve at the inlet to the fuel treatment system.
7. Check the fuel treatment system for leaks.
Result: The fuel treatment system is ready for operation.
TIM-ID: 0000007736 - 005
24 | Operation | MS150111/01E 2014-05

4.5 Fuel treatment system – Putting into operation
Overview of fuel treatment system
1 Pressure-free overflow 9 Ball valve, outlet 17 Automatic water drain

2 Bypass 1 10 Check valve 700 mbar 18 Water level electrode
3 Bypass 2 11 Check valve 5 mbar 19 Ball valve, sample extrac-
4 Safety valve, 3 bar 12 Return to overflow con- tion, inlet
5 Ball valve, inlet tainer 20 Switchgear cabinet
6 Pressure gage 13 Engine 21 Pump
7 Ventilation, sample extrac- 14 Overflow container 22 Coarse filter
tion 15 Water separator filter 23 Fuel supply from tank
8 Differential pressure gage 16 Ball valve, drain 24 Tank
Switching on fuel treatment system

2. Check differential pressure at differential pressure gage (8). Differential pressure in a new system:
0.1 bar to 0.3 bar.
Result: If no differential pressure is measured, the coalescer filter element is probably being bypassed.
TIM-ID: 0000015773 - 006
1. Remove coalescer filter element (→ Page 104).

2. Check sealing surfaces on coalescer filter element and in the pressure tank.
MS150111/01E 2014-05 | Operation | 25

Initial operation: HAT
1. Replace fuel filter on engine (→ Page 60).
Note: Determine the suction pressure upstream of the engine-mounted fuel delivery pump.
2. Install pressure gage in fuel supply line from Yard fuel system to engine.
3. Switch on fuel treatment system and operate it for some minutes (→ Page 29).
Result: The fuel is drawn from tank (24), cleaned by the water separator filter (15) and then routed via overflow
tank (14) back to tank (24). Water that collects in the tank is separated.
4. Start engine (→ Page 28).
5. Run engine at idling speed.
6. Check suction pressure (see technical data of the engine) at the engine-mounted fuel delivery pump.
Note: If the suction pressure is within the permissible limits and engine operation is satisfactory.
7. Increase engine speed to 1000 rpm and monitor suction pressure.
8. Check suction pressure at the engine-mounted fuel delivery pump.
Result: If the values are within the limits specified by the manufacturer, the system is ready to start filter re-
placement simulation with the engine running as part of the Harbor Acceptance Tests.
Simulation of filter replacement with the engine running: HAT

4. Close ball valve (5) at inlet to fuel treatment system.
Result: The pressure upstream of the fuel treatment system increases until the overflow valve at the pump unit
opens and fuel flows through bypass (3) and bypass (2).
5. Open ball valve (19) .
Result: Fuel emerges. If no fuel emerges:
• Open ball valve (5) at inlet to fuel treatment system.
• No function of bypasses (2) and (3); carry out functional test of bypasses (2) and (3) .
6. Check suction pressure (see technical data of the engine) at the fuel delivery pump.
Result: If all engine operating values are within the specified limits, open ball valve (5) at inlet to fuel treatment
system.
Simulation of power failure (emergency): HAT

4. Switch off pump (21) at switchgear cabinet (20).
Result: The engine-mounted fuel delivery pump draws fuel via bypass (2) directly from tank (24).
Result: If the suction pressure is within the specified limits, simulation was successful.
TIM-ID: 0000015773 - 006
26 | Operation | MS150111/01E 2014-05

Simulation of power failure (emergency): SAT
4. Switch off pump (21) at switchgear cabinet (20).
Result: The engine-mounted fuel delivery pump draws fuel via bypass (2) directly from tank (24).
6. Operate engine at full load and monitor suction pressure.
Result: If the suction pressure is within the specified limits, simulation was successful.
TIM-ID: 0000015773 - 006
MS150111/01E 2014-05 | Operation | 27

4.6 Starting the engine
Preconditions
☑Engine is not connected to load.
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Before cranking the engine with starter system, make sure that there are no persons in the en-
gine's danger zone.
WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.
Start engine (for required operations, refer to the documentation of the vehi-
cle/plant manufacturer).
TIM-ID: 0000010107 - 005
28 | Operation | MS150111/01E 2014-05

4.7 Fuel treatment system – Switching on
Preconditions
☑The on-board power supply is switched on.
NOTICE
Risk of damage to engine/system.
Risk of severe damage to property!
• Before switching on, ensure that the engine/system is ready for operation.
• Before switching on, ensure that all housings are closed.
• Before switching on, ensure that no work is in progress anywhere on the entire system.
Fuel treatment system – Switching on

1. Carry out checks prior to start-up (→ Page 24).
2. Switch on master switch on switchgear cabinet.
Result: Signal lamp “Control voltage present” lights up.
3. Switch on switch for pump.
Result: Signal lamp “Pump running” lights up.
TIM-ID: 0000007731 - 006
MS150111/01E 2014-05 | Operation | 29

4.8 Operational checks
DANGER
• Only run the engine at low power. Keep away from the engine's danger zone.
WARNING
Operational checks
Item Action
Control and display panels Check readings of operational data (speed, temperature, pressures).
Engine oil Check engine oil level (→ Page 71).
Engine operation Check engine visually for leaks and general condition;
Check engine for abnormal running noises, exhaust color and vibrations.
Air filter Check service indicator at air filter (if fitted), see manufacturer's docu-
mentation.
Exhaust system Check exhaust color (→ Page 39).
Fuel prefilter (if fitted) Check reading at differential pressure gauge of fuel prefilter, see manufac-
turer's documentation.
Intercooler Check condensate drain(s) for water discharge and obstruction.
Engine coolant pump Check relief bore (→ Page 86).
Charge-air coolant pump Check relief bore (→ Page 94).
TIM-ID: 0000025277 - 003
30 | Operation | MS150111/01E 2014-05

4.9 Stopping the engine
Preconditions
☑Engine is not connected to load.
NOTICE
Stopping the engine when it is running at full load subjects it to extreme thermal and mechanical
stresses.
Overheating of and, therefore, damage to components is possible!
• Before shutting down the engine, allow it to idle until the engine temperatures decrease and
constant levels are indicated.
Preparation
Item Action
Engine Allow the engine to cool down by running idle for approx. 5 minutes.
Stop engine (for required operations, refer to the documentation of the vehi-
cle/plant manufacturer).
TIM-ID: 0000010138 - 005
MS150111/01E 2014-05 | Operation | 31

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

Item Action
Switchgear cabinet, control Press pushbutton for alarm acknowledgment.
panel etc. (depending on • Audible and visual signalization stops.
manufacturer)
Engine Manually open emergency air shutoff flaps (if provided).
• Engine is ready for starting.
TIM-ID: 0000002307 - 003
32 | Operation | MS150111/01E 2014-05

4.11 After stopping the engine
Preconditions
☑MTU preservation and corrosion protection instructions (A001070/..) are available.
NOTICE
Coolant sensors may freeze if there is a risk of frost.
Risk of sensor damage!
• Protect sensors from frost.
After stopping the engine

Item Action
Coolant circuit Drain engine coolant (→ Page 83) and
Drain charge-air coolant (→ Page 93) if
• freezing temperatures are expected, the engine is to remain out of
service for an extended period, but engine coolant has no antifreeze
additive.
• the engine room is not heated.
• the coolant is not kept at a suitable temperature.
• the antifreeze concentration is insufficient for the engine-room tem-
perature.
• the antifreeze concentration is 50 % and the engine-room temperature
is below -40°C.
Engine Control System Switch off (see manufacturer's documentation).
Air intake and exhaust sys- If the engine is to remain out of service for more than one week, seal the en-
tem gine's air and exhaust sides.
If the engine is to remain out of service for more than one month, carry out
preservation (→ MTU preservation and corrosion protection instructions
A001070/..).
TIM-ID: 0000002709 - 006
MS150111/01E 2014-05 | Operation | 33

4.12 Fuel treatment system – Shutdown
Shutting down fuel treatment system

1. Press the illuminated pushbutton "Water drain" on the switch cabinet until water discharge from the
outlet stops.
2. Switch off fuel treatment system.
3. Close ball valve at the inlet to the fuel treatment system.
4. Close ball valve at the outlet of the fuel treatment system.
5. Open drain valve until pressure has escaped from fuel treatment system.
TIM-ID: 0000007732 - 005
34 | Operation | MS150111/01E 2014-05

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

Designation / Use Part No. Qty.
Steam jet cleaner - 1
Cleaner (Hakupur 312) 30390 1
WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.
WARNING
Steam jet cleaner ejects jet of pressurized water.
Risk of injury to eyes and scalding!
• Never direct water jet at people.
• Wear protective clothing, protective gloves and safety goggles/face mask.
NOTICE
Cleaning agents should not be left to take effect for too long.
Damage to components is possible!
• Observe manufacturer's instructions.
NOTICE
Blowing down product with compressed air.
Entry of dirt and damage to components is possible!
• Do not aim compressed air gun directly at seals or electronic components such as connectors
or ECUs.
Plant – Cleaning
1. Carry out plant cleaning only in areas where an appropriate oil separator is provided (environmental
protection).
2. Prior to putting the cleaning unit into operation, read the Operating Instructions of the water/steam jet
unit carefully and observe the safety precautions.
3. For external cleaning of the plant with water or steam-jet cleaners:
• The pressure of the high-pressure jet (cleaning jet) must not exceed 50 bar.
• A minimum distance between spray nozzle and plant of 1 m must be observed.
TIM-ID: 0000010171 - 028
• The temperature of the cleaning medium must not exceed 80°C.

4. For external cleaning with high-pressure jet, use a flat-mouth nozzle only.
Note: Never aim compressed air directly at electronic components.
5. Carry out external cleaning as follows:
a) Seal all openings in a suitable way.
b) Remove coarse dirt.
c) Spray on cleaner sparingly and leave it for 1 to 5 minutes.
d) Use the high-pressure jet to remove the loosened dirt.
e) Dry engine with compressed air.
MS150111/01E 2014-05 | Operation | 35

5 Maintenance
5.1 Maintenance task reference table [QL1]
The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The
Maintenance Schedule is a stand-alone publication.
The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance
Schedule.
Task Option Maintenance tasks
W0500 Check engine oil level. (→ Page 71)
W0501 Visually inspect engine for leaks and general (→ Page 30)
condition.
W0502 X Check intercooler drain(s). (→ Page 30)
W0503 Check signal ring position of maintenance indi- (→ Page 30)
cator on air filter.
W0505 Check relief bores of coolant pump(s). (→ Page 30)
W0506 Check engine for abnormal running noises, ex- (→ Page 30)
haust color and vibrations.
W0507 X Drain water and contaminants from fuel prefil- (→ Page 30)
ter.
W0508 X Check reading on differential pressure gage of (→ Page 30)
fuel prefilter.
W1001 Replace fuel filter or fuel filter element. (→ Page 60)
W1003 Check belt condition and tension, replace if (→ Page 95)
necessary.
W1005 Replace air filter. (→ Page 66)
W1006 Replace fuel injectors. (→ Page 48)
W1008 Replace engine oil filter when changing engine (→ Page 73)
oil, or when the interval (years) is reached, at
the latest.
W1009 X Check layer thickness of the oil residue, clean (→ Page 74)
out and replace filter sleeve when changing en-
gine oil at the latest.
W1178 Replace pressure pipe neck in cylinder head. (→ Page 55)
W1207 Check and adjust valve clearance. IMPORTANT! (→ Page 45)
First adjustment after 1,000 operating hours.
W1244 X Check function of rod electrode. (→ Page 102)
TIM-ID: 0000044041 - 002
W1245 X Check alarm function of differential pressure (→ Page 101)

gage.
W1246 X Check pump capacity. (→ Page 103)
W1523 Check operation of flaps and actuators. (→ Page 70)
W1525 Replace sensor. (→ Page 113)
W1526 Replace sensor. (→ Page 111)
36 | Maintenance | MS150111/01E 2014-05

Task Option Maintenance tasks
W1547 Replace fine oil mist separator. (→ Page 44)
W1636 Reset drift correction parameters (CDC) and (→ Page 54)
enter injector coding (IIG).
Table 3: Maintenance task reference table [QL1]

TIM-ID: 0000044041 - 002
MS150111/01E 2014-05 | Maintenance | 37

6 Troubleshooting
6.1 Fuel treatment system – Troubleshooting
Illuminated pushbutton 'water alarm' is lit.
Cause Corrective action
When the maximum water level 1. Press illuminated pushbutton 'Water alarm' for
is reached, the water level acknowledgment.
electrode opens the water drain 2. In addition to the automatic water drain function, water can also
valve and water is discharged. If be drained manually. To do so, press the illuminated pushbutton
the opening period of the valve 'Water drain' to open the drain valve.
exceeds a preset limit
(4 minutes), the pump will
switch off and an alarm is
initiated.
Signal lamp 'Pump fault' is lit.

The drive motor is equipped with u Reset motor protection relay.
an overload protection. If the
maximum permissible current
consumption is exceeded, e.g. in
case of a blockage or dry-
running, the motor protection
relay triggers and the pump is
switched off.
Signal lamp 'Pre-alarm' is lit.

The differential pressure u Replace coalescer filter element (→ Page 104).
exceeded 1.3 bar.
Illuminated pushbutton 'Replace filter element' is lit.

The max. permissible differential 1. Replace coalescer filter element (→ Page 104).
pressure of 1.5 bar was 2. Press illuminated pushbutton 'Replace filter element' for
exceeded. If the coalescer filter acknowledgment.
element is not replaced,
TIM-ID: 0000007734 - 008
pressure will increase further

and the safety valve will open.
Fuel will be led via the bypass
directly into the overflow tank.
38 | Troubleshooting | MS150111/01E 2014-05

6.2 Troubleshooting
Engine does not turn when starter is actuated

Component Probable Cause Action
Battery Low or faulty Charge or replace (see manufacturer's
documentation).
Cable connections faulty Check if cable connections are properly
secured (see manufacturer's documen-
tation).
Starter Engine cabling or starter faulty Check if cable connections are properly
secured, contact Service.
Engine cabling Faulty Check (→ Page 109).
Engine/generator Assemblies or connectors possibly loose Perform visual inspection (see manufac-
control system turer's documentation).
Engine governor Plug-in connections possibly loose Check plug-in connections (→ Page 108).
Engine Running gear blocked (engine cannot be Contact Service.
barred manually)
Engine turns but does not fire

Starter Poor rotation by starter Battery low or Charge or replace battery (see manufac-
faulty turer's documentation).
Fuel system Air in fuel system Vent fuel system (→ Page 58).
Engine governor Faulty Contact Service.
Engine fires unevenly

Fuel injection equip- Injector faulty Replace (→ Page 48).
ment Injection pump faulty Contact Service.
Engine does not reach rated speed

TIM-ID: 0000051898 - 001
Fuel supply Fuel prefilter clogged Replace (→ Page 65).

Fuel filter clogged Replace (→ Page 60).
Air supply Air filter clogged Check signal ring position of service in-
dicator (→ Page 68).
Engine Overloaded Contact Service.
MS150111/01E 2014-05 | Troubleshooting | 39

Engine speed not steady
Speed sensor Faulty Contact Service.
Charge air temperature too high

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

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

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

Engine Overloaded Contact Service.
Blue exhaust gas

TIM-ID: 0000051898 - 001
Engine oil Engine oil level too high Drain engine oil (→ Page 72).
Oil separator of crankcase breather con- Replace (→ Page 44).
taminated
Exhaust turbocharger, Faulty Contact Service.
cylinder head, piston
rings, cylinder liner
40 | Troubleshooting | MS150111/01E 2014-05

White exhaust gas
Engine Not at operating temperature Run engine to reach operating tempera-
ture.
Fuel system Water in fuel Check fuel system at fuel prefilter
Drain fuel prefilter (→ Page 62).
Intercooler Leaking Contact Service.
TIM-ID: 0000051898 - 001
MS150111/01E 2014-05 | Troubleshooting | 41

7 Task Description
7.1 Engine
7.1.1 Engine – Barring manually
Preconditions

Engine barring gear F6783914 1
Ratchet F30006212 1
DANGER
• Before barring the engine, make sure that there are no persons in the engine's danger zone.
• After finishing work on the engine, make sure that all safety devices are put back in place and all
tools are removed from the engine.
Barring engine manually

1. Fit ratchet with barring gear on barring gear connection at the vibration damper on engine free end.
2. Rotate crankshaft in engine direction of rotation. Apart from the normal compression resistance, there
should be no resistance.
Result: If the resistance exceeds the normal compression resistance, contact Service.
TIM-ID: 0000002527 - 004
42 | Task Description | MS150111/01E 2014-05

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

1. Press pushbutton “Bar engine without starting” and hold it.
2. Let the crankshaft rotate until oil pressure is indicated, but not longer than 10 seconds.
3. Repeat this procedure after approx. 20 seconds if required.
TIM-ID: 0000000013 - 005
MS150111/01E 2014-05 | Task Description | 43

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

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

1. Remove screws (1) and take off together
with holder (2).
2. Replace oil mist fine separator (3).
3. Replace O-ring (4) if necessary.
4. Replace further oil mist fine separators in
the same way.
TIM-ID: 0000018590 - 008

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

Feeler gauge Y4345893 1
Barring device for engine F6783914 1
Ratchet F30006212 1
Double box wrench F30002800 1
Angular screw driver F30002816 1
Socket wrench F30030450 1
Torque wrench, 10-60 Nm F30510423 1
Measuring instrument Y4345888 1
Preparatory steps
1. Remove air filter (→ Page 67).
2. Remove cylinder head cover (→ Page 47).
Positioning A1 piston at TDC

Note: With cylinder head and valve gear installed.
1. Insert preloaded measuring gauge (2) into
measuring device (4) and secure using
screw (1).
2. Install measuring device (4) in cylinder
head and secure using knurled screw (3).
3. Zero dial gauge (2).
4. Turn engine using barring device until pis-
ton A1 reaches firing TDC.
Result: The piston is at firing TDC when both rock-
er arms are unloaded, i.e. have clearance.
TIM-ID: 0000052123 - 001

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

1. Loosen locknut (1) and unscrew adjusting
screw (2) by a few threads.
2. Insert feeler gauge (3) between valve
bridge and rocker arm.
3. Readjust adjusting screw (2) so that the
feeler gauge (3) just passes through the
gap.
4. Tighten locknut (1) with torque wrench to the specified tightening torque, holding the adjusting
screw (2) to prevent it from turning.
Name Size Type Lubricant Value/Standard
TIM-ID: 0000052123 - 001
Locknut M18 Tightening torque 50 Nm + 5 Nm

5. Check if the feeler gauge (3) just passes through between valve bridge and rocker arm.
Result: If not, adjust valve clearance.
Final steps
1. Remove barring tool.
2. Install cylinder head cover (→ Page 47).
3. Install air filter (→ Page 67).

7.3.2 Cylinder head cover – Removal and installation
Preconditions

Ratchet F30027340 1
Gasket (→ Spare Parts Catalog)
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 pipe connection.
2. Tighten all clamps.
TIM-ID: 0000000019 - 004

7.4 Injection Valve / Injector
7.4.1 Injector – Replacement
Injector (→ Spare Parts Catalog)
Injector – Replacement
u Remove injector and install new one (→ Page 49).
TIM-ID: 0000042329 - 002

7.4.2 Injector – Removal and installation
Preconditions

Installation device F6790085 1
Puller F6790636 1
Fuel suction device F30378207 1
Torque wrench, 0.5-5 Nm 0015384230 1
Ratchet F30027340 1
Open-end socket wrench, 19 mm F30453236 1
Crowfoot wrench, 19 mm F30027424 1
Ring socket, 22 mm F30038494 1
Open-end socket wrench, 24 mm F30453238 1
Assembly compound (Hakuform 3015) X00067260 1
Engine oil
Sealing ring (→ Spare Parts Catalog)
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
WARNING
Preparatory steps
1. Shut off fuel supply line.
2. Drain fuel (→ Page 59).
3. Remove cylinder head cover (→ Page 47).
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Removing injector
1. Remove HP fuel line (1).
2. Unscrew union nut (2).
3. Pull off pressure pipe neck (3).
4. Extract fuel from the exposed bores using
the suction device.
5. Disconnect terminals (arrow) on injector

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

Note: Screw (3) may be installed only once.
8. Take off hold-down clamp (2).
9. Use the puller to pull out injector (1).
10. After removal, seal all openings with suita-
ble covers.
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Installing injector
1. Remove all covers before installation.
2. Clean sealing surface on cylinder head and
protective sleeve.
3. Coat sealing ring on injector (1) with as-
sembly compound.
Note: Use either the installation tool or the hold-
down clamp (2) to press injector (1) into
the cylinder head.
4. Align square on injector (1) with the seat in
the hold-down clamp (2) and insert injector
by hand straight into the cylinder head.
5. Fit hold-down clamp (2) in correct position
by hand.
Installation without installation device

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

1. Place installation tool on hold-down clamp (2) to press injector (1) carefully into the cylinder head.
2. Place hold-down clamp (2) in correct position, screw in screw (3) and tighten snug-fit.
Installing pressure pipe neck

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

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

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

3. Tighten union nut of HP fuel line (1) on rail to specified tightening torque using a torque wrench.
Union nut M20 Tightening torque (Engine oil) 50 Nm +5 Nm
4. Tighten union nut of HP fuel line (1) on pressure pipe neck (3) to the specified tightening torque using a
torque wrench.
Fitting gasket and connecting in-

jector cable
1. Place gasket on cylinder head, ensuring
correct installation position.
2. Push cable lugs under the terminals (arrow) on the injector and tighten with torque wrench to the speci-
fied tightening torque.
Nut M4 Tightening torque (Engine oil) 1.5 Nm ±0.25 Nm
Final steps
1. Install cylinder head cover (→ Page 47).
2. Open fuel supply line.
3. Vent fuel system (→ Page 58).
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7.4.3 Injector functions
Preconditions
Note: Failure to reset drift compensation parameters (CDC) will void the emissions certification for the en-
gine.
Resetting drift correction parameters (CDC) with DiaSys®

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

1. (→ Dialog system DiaSys® E531920/..).
2. If no DiaSys® is available, contact Service.
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7.5 Fuel System
7.5.1 HP fuel line and pressure pipe neck ‒ Replacement
Preconditions

Ratchet F30027340 1
Plug-in open-end wrench, 19 mm F30025897 1
Crowfoot wrench, 19 mm F30027424 1
Ring socket, 24 mm F30501562 1
Assembly compound (Hakuform 3015) X00067260 1
Engine oil
Pressure pipe neck (→ Spare Parts Catalog)
HP fuel line (→ Spare Parts Catalog)
WARNING
• Do not smoke.
Preparatory steps
1. Shut off fuel supply line.
2. Drain fuel (→ Page 59).
3. Remove engine governor (→ Page 107).
4. Remove charge-air manifolds and take off seals (only on engines with air-to-air charge-air cooling).
5. Remove fuel return line.
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HP fuel line and pressure pipe
neck ‒ Replacement
1. Remove union nuts (1, 3) on HP fuel
line (2).
2. Remove HP fuel line (2).
3. Remove nozzle union nut (4).
4. Pull out pressure pipe neck (5).
5. Coat sealing ring of new pressure pipe

neck (5) with assembly compound.
6. Coat sealing cone of 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. Install union nut (4).
10. Tighten union nut (4) with torque wrench to the specified tightening torque.
Union nut M24 Preload torque (Engine oil) 15 Nm +5 Nm
Union nut M24 Tightening torque 50 Nm +5 Nm
11. Coat mating surface with engine oil between union nut and HP fuel line, end of line and thread on both
sides of the new HP fuel line (1).
12. Install new HP fuel line (2).
13. Tighten union nut (1) on HP fuel line (2) with torque wrench to the specified tightening torque.
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14. Tighten union nut (3) on HP fuel line (2) with torque wrench to the specified tightening torque.

Final steps
1. Clean mating faces on cylinder head and charge-air manifold.
2. Check gaskets for damage and replace them, if required.
3. Coat gaskets with assembly compound and place onto cylinder head.
4. Install leak-off-fuel lines.
5. Install charge-air pipes.
6. Install engine governor (→ Page 107).
7. Open fuel supply line.
8. Vent fuel system (→ Page 58)
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7.5.2 Fuel system – Venting
Preconditions
☑Engine is shut down.
WARNING
• Do not smoke.
Venting fuel system

1. Open threaded vent plug (2) at filter head.
2. Actuate hand pump (1) until bubble-free
fuel emerges at the threaded vent plug.
3. Close threaded vent plug.
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7.5.3 Fuel – Draining
Preconditions
WARNING
• Do not smoke.
Fuel – Draining
1. Provide a suitable container in which to collect the fuel.
2. Remove fuel filter (→ Page 60).
3. Catch fuel as it runs out.
4. Install fuel filter (→ Page 60).
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7.6 Fuel Filter
7.6.1 Fuel filter – Replacement
Preconditions

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

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. Screw on easy-change filter and tighten by
hand.
5. Vent fuel system (→ Page 58)
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7.6.2 Fuel prefilter – Differential pressure gage check and adjustment of gage
DANGER
WARNING
Setting adjustable pointer of dif-

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

1. With the engine running at full load or rated power, read off pressure at gage (1).
2. If differential pressure as indicated between position of adjustable pointer (2) and pressure-indicating
pointer (3) of pressure gage is ≥ 0.3 bar, flush filter element of the cut-in filter (→ Page 63).
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7.6.3 Fuel prefilter – Draining
Preconditions

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

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

and take off cover.
6. Fill filter housing with clean fuel.
7. Insert new seal (3) in cover (1).
8. Fit cover (1) with seal (3) and tighten
screws (4).
9. When fuel emerges from system, close
vent plug (2).
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7.6.4 Fuel prefilter – Flushing
Fuel
Seal (→ Spare Parts Catalog)
DANGER
WARNING
• Do not smoke.
WARNING
Fuel prefilter – Flushing

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

1. Stop engine (→ Page 31) and disable engine start.
2. Remove screws securing the cover and take off cover (2).
4. Place new seal in cover (2).
5. Fit cover with gasket and secure it with screws.
6. Check differential pressure (→ Page 61).
Result: If flushing did not lead to an improvement of the differential pressure, replace filter element of fuel pre-
filter (→ Page 65).
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7.6.5 Fuel prefilter – Filter element replacement
Preconditions

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

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

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

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

1. Remove air filter(s) and install new one(s) (→ Page 67).
2. Reset signal ring of service indicator (→ Page 68).
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7.7.2 Air filter – Removal and installation
Preconditions
Variant A
1. Loosen clamp (2).
2. Remove air filter (1) and clamp (2) from
connecting 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 ele-
ment (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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7.8 Air Intake
7.8.1 Service indicator – Signal ring position check (optional)
Preconditions
Checking signal ring position

1. If the signal ring is completely visible in the
control window (2), replace air filter
(→ Page 66).
2. After installation of new filter, press reset
button (1).
Result: Engaged piston with signal ring moves
back to initial position.
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7.9 Exhaust Gas Recirculation
7.9.1 Exhaust gas recirculation flaps – Overview
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7.9.2 Exhaust gas circulation ‒ Checking flap operation
Preconditions
WARNING
Component is hot.
Risk of burning!
• Wear protective gloves.
Checking exhaust flap operation

1. For installation position of exhaust flaps, refer to overview (→ Page 69).
2. Check operability and ease of movement of
exhaust flaps and control linkage by mov-
ing the assembly at the points (arrowed)
shown in the illustration.
Result: If exhaust flap is jammed or sluggish: Con-
tact Service.
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7.10 Lube Oil System, Lube Oil Circuit
7.10.1 Engine oil – Level check
Preconditions
Oil level check prior to engine

start
1. Withdraw oil dipstick from guide tube and
wipe it.
2. Insert oil dipstick into guide tube up to the
stop, withdraw after approx. 10 seconds
and check oil level.
3. Oil level must be between "min." (2) and
"max." (1) marks.
4. Top up with oil up to the "max" (1) mark
(→ Page 72) 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 72).
5. Insert oil dipstick into guide tube up to the stop.
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7.10.2 Engine oil – Change
Preconditions
☑Engine is at operating temperature.

Engine oil
WARNING
Hot oil.
Oil change without semirotary hand pump: Draining oil at drain plug on oil
pan
1. Provide a suitable container to collect the oil.
2. Remove drain plug and drain oil.
3. Install drain plug with new sealing ring.
4. Replace engine oil filter (→ Page 73).
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 73).
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 71).
5. After oil change and filter replacement, bar
engine with starting system (→ Page 43).
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7.11 Oil Filtration / Cooling
7.11.1 Engine oil filter – Replacement
Preconditions

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

1. Remove oil filter 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 replace-
ment, bar engine with starting system
(→ Page 43).
7. Check oil level (→ Page 71).
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7.11.2 Centrifugal oil filter – Cleaning and filter-sleeve replacement
Preconditions

Cold cleaner (Hakutex 60) X00056750 1
Filter sleeve (→ Spare Parts Catalog)
WARNING
Hot oil.
WARNING
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Centrifugal oil filter – Cleaning
and filter-sleeve replacement
1. Remove clamp (14).
2. Release Tommy nut (2) and take off cov-
er (1).
3. Carefully lift rotor (11), allow oil to drain
and remove from housing.
4. Holding the rotor (11) firmly, release rotor
cover nut (3).
5. Take off rotor cover (4).
6. Remove filter sleeve (6).
7. Measure thickness of oil residues on filter
sleeve (6).
Result: If the oil residues exceed the maximum lay-
er thickness of 45 mm, shorten the mainte-
nance interval.
8. Disassemble rotor tube (7), conical disk (8)
and rotor base (10).
9. Wash rotor cover (4), rotor tube (7), conical
disk (8) and rotor base (10) with cold
cleaner.
10. Blow out with compressed air.
11. Check sealing ring (9), fit new one if neces-
sary.
12. Assemble rotor tube (7), conical disk (8)
and rotor base (10) with sealing ring (9).
13. Insert new filter sleeve (6) in rotor tube (7)
with the smooth paper surface facing the
outer wall.
14. Check sealing ring (5), fit new one if neces-
sary.
15. Mount rotor cover (4) with sealing ring (5).
16. Tighten rotor cover nut (3) with torque wrench to the specified torque.
Nut Tightening torque 35 Nm to 45 Nm
17. Place rotor (11) in housing (12) and check for ease of movement.
18. Check sealing ring (13), fit new one if necessary.
19. Fit sealing ring (13) on housing (12).
20. Fit cover (1).
21. Tighten Tommy nut (2) by hand.
22. Install clamp (14) and tighten with torque wrench to the specified torque.
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Clamp Tightening torque 8 Nm to 10 Nm

23. Tighten cover nut (2) with torque wrench to the specified torque.
Screw Tightening torque 5 Nm to 7 Nm

7.12 Coolant Circuit, General, High-Temperature Circuit
7.12.1 Drain and vent points
Plan view
1 Coolant venting, HT and LT

circuit
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Left side
1 Coolant drain plug, crank- 2 Coolant drain plug, crank- 3 Oil drain plug, oil pan
case free end case driving end
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Right side
1 Coolant drain plug, crank- 3 Coolant drain plug, coolant

case driving end line
2 Coolant drain plug, crank- 4 Oil drain plug, oil pan
case free end
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Driving end (KS)
1 Oil drain plug, oil pan

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Free end (KGS)
1 Coolant drain plug, lube-oil 3 Coolant filling plug

heat exchanger 4 Oil drain plug, oil pan
2 Oil drain plug, lube-oil heat
exchanger
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7.12.2 Engine coolant – Level check
Preconditions
WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
Checking coolant level at filler

neck:
1. Turn breather valve on coolant expansion
tank counterclockwise to the first stop and
allow pressure to escape.
2. Continue to turn breather valve counter-
clockwise and remove.
3. Check coolant level (coolant must be visi-
ble at the lower edge of the cast-in eye or
at the marking plate).
4. Top up with treated coolant as necessary
(→ Page 84).
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 84).
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7.12.3 Engine coolant – Change
Coolant
Engine coolant change

1. Drain engine coolant (→ Page 83).
2. Fill with engine coolant (→ Page 84).
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7.12.4 Engine coolant ‒ Draining
Preconditions
WARNING
Preparatory steps
1. Provide a suitable receptacle to catch the coolant.
2. Switch off preheating unit.
Engine coolant ‒ Draining

3. Draw off precipitated corrosion inhibitor oil
from the coolant expansion tank through
filler neck.
4. Open drain valves and/or drain plugs and
drain coolant at the following points:
• At the preheating unit;
• At the HT coolant pump (3);
• At the crankcase (1) and (2), right side.
5. Draining of residual coolant:

• At the crankcase (1) and (2), left side.
At the oil heat exchanger.
6. Close all open drain points.
close.
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7.12.5 Engine coolant – Filling
Preconditions

Coolant
WARNING
WARNING
NOTICE
Cold coolant in hot engine can cause thermal stress.
Possible formation of cracks in the engine!
• Fill / top up coolant only into cold engine.
Preparatory steps
1. Turn breather valve (1) on coolant expan-
sion tank counterclockwise to the first stop
and allow pressure to escape.
2. Continue to turn breather valve (1) counter-
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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 81), top up with coolant if required.
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7.12.6 Engine coolant pump – Relief bore check
DANGER
WARNING
Engine coolant pump – Relief

bore check
1. Check relief bore for oil and coolant dis-
charge.
• Permissible coolant discharge: up to 10
drops per hour;
• Permissible oil discharge: up to 5 drops
per hour.
Result: If discharge exceeds the specified limits,
contact Service.
2. If relief bore is dirty:
• Stop engine (→ Page 31) and disable en-
gine start.
• Clean relief bore with a wire.
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7.12.7 Engine coolant – Sample extraction and analysis
Preconditions

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

1. Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to
escape.
2. Continue to turn breather valve counterclockwise and remove.
3. Draw off precipitated corrosion inhibitor oil from expansion tank and dispose of oil.
4. Draw off approx. 1 liter coolant and drain into a clean container.
5. Using the equipment and chemicals from the MTU test kit, examine coolant for:
• antifreeze concentration;
• corrosion inhibitor concentration;
• pH value.
6. Fit breather valve and close it.
7. Engine coolant change intervals (→ MTU Fluids and Lubricants Specifications A001061/..).
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7.13 Low-Temperature Circuit
7.13.1 Intercooler – Venting and draining
Intercooler – Venting and draining
1 Intercooler vent plug 2 Coolant drain plug
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7.13.2 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 mark-
er plate.
3. Check charge-air coolant level.
4. Top up charge-air coolant as necessary
(→ Page 91).
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 91).
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7.13.3 Charge-air coolant – Change
Coolant
Charge-air coolant – Change

1. Drain charge-air coolant (→ Page 93).
2. Fill with charge-air coolant (→ Page 91).
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7.13.4 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 expan-
sion tank counterclockwise to the first stop
and allow pressure to escape.
2. Continue to turn breather valve (1) counter-
3. Remove plug screw from filling point on
coolant 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 89).
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7.13.5 Charge-air coolant ‒ Draining
Preconditions

WARNING
Charge-air coolant ‒ Draining

1. Provide a suitable receptacle to catch the
coolant.
4. Draw off precipitated corrosion inhibitor oil
from the coolant expansion tank through
filler neck.
5. Open drain plugs and drain coolant at the
following points:
• At the charge-air coolant pump (3),
• At the intercooler, engine driving end (1)
and free end (2).
6. Screw in drain plugs with new sealing rings.
close.
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7.13.6 Charge-air coolant pump – Relief bore check
DANGER
WARNING
Charge-air coolant pump – Relief

bore check
1. Check relief bore for oil and coolant dis-
charge.
• Permissible coolant discharge: up to 10
drops per hour;
• Permissible oil discharge: up to 5 drops
per hour.
Result: If discharge exceeds the specified limits,
contact Service.
2. If relief bore is dirty:
• Stop engine (→ Page 31) and disable en-
gine start.
• Clean relief bore with a wire.
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7.14 Belt Drive
7.14.1 Drive belt – Condition check
Preconditions
☑Guard is removed.
Drive belt – Condition check
Item Findings Action

Drive belt A Singular cracks None
Drive belt B Cracks on entire circumference Replace (→ Page 99)
Drive belt C Chunking
Drive belt Belt is oily, shows signs of over-
heating
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7.14.2 Drive belt – Tension check
Preconditions

Tester Y4345711 1
Belt tension tester, 150-600 N Y20097429 1
Fan drive – Checking belt ten-

sion
1. Remove protective cover.
2. Set belt tension tester onto the drive belt
in the middle between the belt pulleys (ar-
rowed).
3. Using pushbutton, press vertically on top
side of drive belt exerting even pressure
until spring engages noticeably.
4. Do not exert any more pressure as dis-
played value will otherwise be falsified.
5. Remove tension tester without changing
the position of the display arm.
6. Read off measured value at the intersec-
tion of display arm and “KG” scale. Refer to
table below for specifications.
Application Specification Specification

Initial installation (new belt) Operating tension (used belt)
Fan drive belt Frequency: 113 ±1 Hz Frequency: 103 ±1 Hz
Table 4: Measuring belt tension with frequency meter

Initial installation (new belt, (used belt, runtime 500 h)
runtime 0.5-2 h)
Fan drive belt Depression depth: 6 mm Depression depth: 5 mm
Test force: 188 N Test force: 188 N
Table 5: Measuring depression depth with tension tester

Initial installation (new belt, (used belt, runtime 500 h)
TIM-ID: 0000043677 - 002
runtime 0.5-2 h)
Fan drive belt Strand pull: 4500 N Strand pull: 3750 N
Table 6: Measuring static strand pull

7. If the measured values deviate from the specifications above, adjust drive belt tension (→ Page 97).
8. Install protective cover.

7.14.3 Drive belt – Tension adjustment
Preconditions

Ratchet F30027340 1
Engine oil
Adjusting drive belt tension

1. Undo screws (1).
2. Set distance (A) to 100 mm with screw (2).
3. Use torque wrench (1) to tighten screws to specified tightening torque.

Screw M16x50 Tightening torque (Engine oil) 180 Nm +18 Nm
4. Tighten screw (2) to specified torque using a torque wrench.
5. Undo screws (3).
6. Adjust belt tension with screw (4) (→ Page 96).
7. Tighten screws (3) to specified torque using a torque wrench.
TIM-ID: 0000043678 - 002

Screw M12 Tightening torque (Engine oil) 74 Nm +7 Nm
8. Tighten screw (4) to specified torque using a torque wrench.

7.14.4 Drive belt – Replacement
Preconditions

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

ment
1. Remove protective cover from radiator.
2. Remove fan.
3. Slacken off securing screws (1).
4. Screw out screw (2) as far as necessary to
allow drive belt removal.
5. Check belt pulley on radiator bearing
mount and crankshaft for contamination
and clean if necessary.
Note: When placing the drive belt in the grooves,
no force must be applied.
6. Fit new drive belt.
7. Screw in screw (2) until distance (A) is 100
mm.
8. Adjust and check drive belt tension
(→ Page 97).
9. Install fan.
TIM-ID: 0000025462 - 002

7.15 Battery-Charging Generator
7.15.1 Battery-charging generator drive – Drive belt replacement
Preconditions

Mandrel 8205892861/08 1
Preparatory steps
1. Remove safety equipment (if fitted).
2. Remove screws of protective cover (engine free end).
3. Remove protective cover.
Replacing drive belt

1. Hold adjusting lever at square.
2. Rotate adjusting lever until drive belt is released.
3. Use mandrel to lock adjusting lever in position.
4. Remove drive belt.
5. Check cleanness of belt pulleys.
6. Fit new drive belt.
7. Remove mandrel.
Final steps
2. Install screws of protective cover.
3. Install safety equipment (if fitted).
4. Check function of safety equipment (if fitted).
TIM-ID: 0000007424 - 004

7.16 Fuel Supply System
7.16.1 Water drain valve – Check
Water drain valve – Check

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

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

2. Set the alarm points at the differential pressure gauge to zero.
Result: Alarm is initiated with preset delay.
3. Reset the alarm points at the differential pressure gauge to the specified values.
TIM-ID: 0000023563 - 001

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

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

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

1. Install suitable pressure gauge in the intake connection of the pump.
2. Check pump pressure.
a) Switch on fuel treatment system (→ Page 29).
Note: The pressure limiting valve at the pump might respond and open. Audible noise is caused by overflow-
ing fuel and can be disregarded.
b) Close ball valve at the outlet of the fuel treatment system.
c) Check pressure at the pressure gauge in the inlet to the fuel treatment system and note down.
3. Checking pump pressure with reduced suction
a) Reduce suction pressure of pump to -0.8 bar with the shut-off valve at the pump intake side.
b) Check pressure at the pressure gauge in the inlet to the fuel treatment system and note down.
c) Open ball valve at inlet and outlet of fuel treatment system.
4. Calculate wear limit.
Example:
Measured value (normal condition). 3 bar
Measured value (reduced suction condition). 2.6 bar
If the measured value (reduced suction condition) is 10% lower than the measured value (normal condition),
the wear limit is reached. Repair pump (contact Service).
TIM-ID: 0000023567 - 001

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

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

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

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

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

7.17 Engine Governor
7.17.1 Engine governor – Overview
1 Screw 4 Engine governor 7 Connector X1

2 Washer 5 Connector X3 8 Screw for grounding strap
3 Damper 6 Screw
TIM-ID: 0000031588 - 002

7.17.2 Engine governor – Removal and installation
Preconditions

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

engine
1. Note or mark assignment of cables and
connectors.
2. Release latches on connectors (5) and (7).
3. Disconnect all connectors.
4. Remove screw for ground strap (8).
5. Unscrew all screws (1).
6. Remove engine governor (4).
Installing engine governor on engine

1. Install in reverse order. Ensure correct assignment of connectors and sockets in so doing.
2. Check resilient mount before installing.
Result: Replace resilient mount if porous or defective.
TIM-ID: 0000043679 - 002

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

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

7.18 Wiring (General) for Engine/Gearbox/Unit
7.18.1 Engine wiring – Check
Preconditions

Isopropyl alcohol X00058037 1
Engine wiring – Check

1. Check securing screws of cable clamps on engine and tighten loose threaded connections.
2. Ensure that cables are fixed in their clamps and cannot swing freely.
3. Verify that all cable clips are closed and in proper condition.
4. Replace cable clips if defective.
5. Check that cable clamps are firm, tighten loose cable clamps.
6. Replace faulty cable clamps.
7. Visually inspect the following electrical line components for damage:
• Connector housing
• Contacts
• Sockets
• Cables and terminals
• Plug-in contacts
Result: Contact Service if cable conductors are damaged.
Note: Close male connectors that are not plugged in with the protective cap supplied.
8. Clean dirty connector housings, sockets and contacts using isopropyl alcohol.
9. Ensure that all sensor connectors are securely engaged.
TIM-ID: 0000000029 - 020

7.18.2 Lambda, NOx and humidity sensors – Overview
1 Humidity sensor 2 Lambda sensor 3 NOx sensor
TIM-ID: 0000043680 - 001

7.18.3 Lambda sensor – Replacement
Preconditions

Ratchet F30027340 1
Assembly compound (Molykote P 37) 50564 1
Lambda sensor (→ Spare Parts Catalog) 1
WARNING
Component is hot.
Risk of burning!
NOTICE
Ceramic cell breakage due to shock or impact.
Risk of damage to components!
• Avoid shocks and impacts.
• Exercise extreme care when handling sensors.
NOTICE
High voltage.
• Switch off ignition before replacing components.
Removing Lambda sensor

1. Observe the following general information:
• Layout and position of sensor
(→ Page 110).
2. Unplug and remove male connector (1).
3. Remove sensor (2).
TIM-ID: 0000025194 - 009

Installing Lambda sensor
Note: When the sensor was subjected to shock
or impact load, it is deemed to be defective
and may not be used.
1. Remove protective cap on thread only just
before installation.
Note: Do not wipe off the thread lubricant applied
by the manufacturer.
2. Coat sensor thread with specified assembly
compound as required.
3. Screw in sensor by hand.
4. Tighten nut (2) to specified torque using a torque wrench.

Nut M18 x 1.5 Tightening torque (Assembly compound 40 Nm to 60 Nm
(Molykote P 37))
5. Fit male connector (1) and latch it.
TIM-ID: 0000025194 - 009

7.18.4 NOx sensor – Replacement
Preconditions

Ratchet F30027340 1
Assembly compound (Molykote P 37) 50564 1
NOx sensor (→ Spare Parts Catalog) 1
WARNING
Component is hot.
Risk of burning!
NOTICE
High voltage.
• Switch off ignition before replacing components.
NOTICE
Ceramic cell breakage due to shock or impact.
• Avoid shocks and impacts.
• Exercise extreme care when handling sensors.
Removing NOx sensor

(→ Page 110).
2. Unplug and remove male connector (1) on
control unit.
4. Remove control unit.
TIM-ID: 0000025205 - 009

Note: Always replace NOx sensor together with control unit.
Installing NOx sensor
Note:
1. Install control unit.
Note: When the sensor was subjected to shock
or impact load, it is deemed to be defective
and may not be used.
2. Remove protective cap on thread only just
before installation.
Note: Do not wipe off the thread lubricant applied
by the manufacturer.
3. Coat sensor thread with specified assembly
compound as required.
4. Screw in sensor by hand.
5. Tighten nut (2) to specified torque using a torque wrench.

Nut M20 x 1.5 Tightening torque (Assembly compound 50 Nm ±10 Nm
(Molykote P 37))
6. Fit male connector (1) and latch it.
TIM-ID: 0000025205 - 009

7.18.5 Humidity sensor – Replacement
Preconditions
☑Preparatory steps are completed.

Ratchet F30027340 1
Assembly compound Kluthe Hakuform 30-11C/Emulgier X00059351
Humidity sensor (→ Spare Parts Catalog) 1
NOTICE
Contamination of components.
• Check components for special cleanliness.
Removing humidity sensor

(→ Page 110).
2. Unplug and remove male connector.
3. Remove screws (1).
TIM-ID: 0000025206 - 004

Installing humidity sensor
Note: Apply assembly compound for O-ring spar-
ingly.
1. Insert sensor (2) in bore, ensuring correct
installation position.
Note: Observe air flow direction.
2. Screw in screws (1).
3. Use torque wrench (1) to tighten screws to specified tightening torque.

Sensor M6 Tightening torque 12 Nm +5 Nm
4. Fit male connector and latch.
TIM-ID: 0000025206 - 004

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

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

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

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

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

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

8 Appendix A
8.1 List of abbreviations
Abbrevia- Meaning Explanation
tion
AL Alarm -
ANSI American National Standards Institute Association of American standardization organiza-
tions
ATL Abgasturbolader Exhaust turbocharger (ETC)
BDM Backup Data Module -
BR Baureihe Series
BV Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU Publication
No. A01061/..
CAN Controller Area Network Data bus system, bus standard
CPP Controllable Pitch Propeller
DIN Deutsches Institut für Normung e. V. At the same time identifier of German standards (DIN
= “Deutsche Industrie-Norm”)
DIS Display Unit Display panel
DL Default Lost Alarm: CAN bus missing
ECS Engine Control System Engine management system
ECU Engine Control Unit Engine governor
EDM Engine Data Module Memory module for engine data
EMU Engine Monitoring Unit
ETC Exhaust turbocharger
GCU Gear Control Unit
GMU Gear Monitoring Unit
HAT Harbor Acceptance Test
HI High Range violation alarm (1st upper limit value)
HIHI High High Range violation alarm (2nd upper limit value)
IDM Interface Data Module Memory module for interface data
ISO International Organization for Stand- International umbrella organization of all standards
ardization institutes
KGS Kupplungsgegenseite Engine free end in accordance with DIN ISO 1204
KS Kupplungsseite Engine driving end in accordance with DIN ISO 1204
LCD Liquid Crystal Display, Liquid Crystal
TIM-ID: 0000026477 - 004
Device
LCU Local Control Unit LOP subassembly
LED Light Emitting Diode
LO Low Range violation alarm (1st lower limit value)
LOLO Low Low Range violation alarm (2nd lower limit value)
LOP Local Operating Panel
LOS Local Operating Station Local control unit
LPU Oil refill pump
MS150111/01E 2014-05 | Appendix A | 119

Abbrevia- Meaning Explanation
tion
MCS Monitoring and Control System
MG Message
MPU Microprocessor Unit, Microprocessing
Unit
OT Oberer Totpunkt Top dead center (TDC)
PAN Panel Control panel
PCU/PMU Propeller Control Unit Propeller controller
PIM Peripheral Interface Module
PPC Priming Pump Control
RCS Remote Control System
RL Redundancy Lost Alarm: Redundant CAN bus failure
SAT Sea Acceptance Test
SD Sensor Defect Alarm: Sensor failure
SDAF Shut Down Air Flap(s) Emergency air-shutoff flap(s)
SS Safety System Safety system alarm
SSK Schnellschlussklappen Emergency air-shutoff flap(s)
TD Transmitter Deviation Alarm: Sensor comparison fault
UT Unterer Totpunkt Bottom dead center (BDC)
TIM-ID: 0000026477 - 004
120 | Appendix A | MS150111/01E 2014-05

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

Fast, simple and correct identification of spare parts for your drive system or vehicle fleet. The right
spare part at the right time at the right place.
With this aim in mind, we can call on a globally networked spares logistics system, a central warehouse
at headquarters and on-site stores at our subsidiary companies, agencies and service workshops.
Your contact at Headquarters:
E-mail: spare.parts@mtu-online.com
Tel.: +49 7541 908555
Fax: +49 7541 908121
TIM-ID: 0000000873 - 015
MS150111/01E 2014-05 | Appendix A | 121

9 Appendix B
9.1 Special Tools
Angular screw driver
Part No.: F30002816
Qty.: 1
Used in: 7.3.1 Valve clearance – Check and adjustment
(→ Page 45)
Barring device for engine

Part No.: F6783914
Qty.: 1
(→ Page 45)
Belt tension tester, 150-600 N

Part No.: Y20097429
Qty.: 1
Used in: 7.14.2 Drive belt – Tension check (→ Page 96)
DCL-ID: 0000027885 - 004
122 | Appendix B | MS150111/01E 2014-05

Crowfoot wrench, 19 mm
Part No.: F30027424
Qty.: 1
Used in: 7.4.2 Injector – Removal and installation (→ Page 49)
Qty.: 1
Used in: 7.5.1 HP fuel line and pressure pipe neck ‒ Replace-
ment (→ Page 55)
Double box wrench

Part No.: F30002800
Qty.: 1
(→ Page 45)
Double box wrench

Part No.: F30011450
Qty.: 1
Qty.: 1
ment (→ Page 55)
Engine barring gear

Part No.: F6783914
Qty.: 1
Used in: 7.1.1 Engine – Barring manually (→ Page 42)
DCL-ID: 0000027885 - 004
MS150111/01E 2014-05 | Appendix B | 123

Feeler gauge
Part No.: Y4345893
Qty.: 1
(→ Page 45)
Filter wrench
Part No.: F30379104
Qty.: 1
Used in: 7.6.1 Fuel filter – Replacement (→ Page 60)
Qty.: 1
Used in: 7.11.1 Engine oil filter – Replacement (→ Page 73)
Fuel suction device

Part No.: F30378207
Qty.: 1
Installation device
Part No.: F6790085
Qty.: 1
DCL-ID: 0000027885 - 004
124 | Appendix B | MS150111/01E 2014-05

Mandrel
Part No.: 8205892861/08
Qty.: 1
Used in: 7.15.1 Battery-charging generator drive – Drive belt re-
placement (→ Page 99)
Measuring instrument
Part No.: Y4345888
Qty.: 1
(→ Page 45)
MTU test kit

Part No.: 5605892099/00
Qty.: 1
Used in: 7.12.7 Engine coolant – Sample extraction and analysis
(→ Page 87)
Open-end socket wrench, 19 mm

Part No.: F30453236
Qty.: 1
DCL-ID: 0000027885 - 004
MS150111/01E 2014-05 | Appendix B | 125

Open-end socket wrench, 24 mm
Part No.: F30453238
Qty.: 1
Plug-in open-end wrench, 19 mm

Part No.: F30025897
Qty.: 1
ment (→ Page 55)
Puller
Part No.: F6790636
Qty.: 1
Ratchet
Part No.: F30006212
Qty.: 1
Used in: 7.1.1 Engine – Barring manually (→ Page 42)
Qty.: 1
DCL-ID: 0000027885 - 004
(→ Page 45)
126 | Appendix B | MS150111/01E 2014-05

Ratchet
Part No.: F30027340
Qty.: 1
Used in: 7.3.2 Cylinder head cover – Removal and installation
(→ Page 47)
Qty.: 1
Qty.: 1
ment (→ Page 55)
Qty.: 1
Used in: 7.14.3 Drive belt – Tension adjustment (→ Page 97)
Qty.: 1
Used in: 7.18.3 Lambda sensor – Replacement (→ Page 111)
Qty.: 1
Used in: 7.18.4 NOx sensor – Replacement (→ Page 113)
Qty.: 1
Used in: 7.18.5 Humidity sensor – Replacement (→ Page 115)
Ratchet
Part No.: F30027339
Qty.: 1
Used in: 7.16.5 Coalescer filter element – Replacement
(→ Page 104)
Ring socket, 22 mm
Part No.: F30038494
Qty.: 1
DCL-ID: 0000027885 - 004
MS150111/01E 2014-05 | Appendix B | 127

Ring socket, 24 mm
Part No.: F30501562
Qty.: 1
ment (→ Page 55)
Socket wrench
Part No.: F30030450
Qty.: 1
(→ Page 45)
Steam jet cleaner

Part No.: -
Qty.: 1
Used in: 4.13 Plant – Cleaning (→ Page 35)
Tester
Part No.: Y4345711
Qty.: 1
Used in: 7.14.2 Drive belt – Tension check (→ Page 96)
DCL-ID: 0000027885 - 004
128 | Appendix B | MS150111/01E 2014-05

Torque wrench, 10-60 Nm
Part No.: F30510423
Qty.: 1
(→ Page 45)
Qty.: 1
Used in: 7.18.3 Lambda sensor – Replacement (→ Page 111)
Qty.: 1
Used in: 7.18.4 NOx sensor – Replacement (→ Page 113)
Qty.: 1
Used in: 7.18.5 Humidity sensor – Replacement (→ Page 115)

Part No.: F30452769
Qty.: 1
Used in: 7.11.2 Centrifugal oil filter – Cleaning and filter-sleeve
replacement (→ Page 74)

Part No.: F30026582
Qty.: 1
Qty.: 1
ment (→ Page 55)
Qty.: 1

Part No.: F30044239
Qty.: 1
Used in: 7.11.2 Centrifugal oil filter – Cleaning and filter-sleeve
replacement (→ Page 74)
DCL-ID: 0000027885 - 004
MS150111/01E 2014-05 | Appendix B | 129

Part No.: F30027337
Qty.: 1

Part No.: F30027336
Qty.: 1
Used in: 7.16.5 Coalescer filter element – Replacement
(→ Page 104)

Part No.: F30043446
Qty.: 1
Used in: 7.3.2 Cylinder head cover – Removal and installation
(→ Page 47)
Torque wrench, 0.5-5 Nm

Part No.: 0015384230
Qty.: 1
DCL-ID: 0000027885 - 004
130 | Appendix B | MS150111/01E 2014-05

9.2 Index
A D
After stopping the engine 33 Data
Air filter – Engine 16
– Removal and installation 67 Differential pressure
– Replacement 66 – Pressure gauge
– Check 101
B Differential pressure gage
Battery-charging generator drive – Adjustment
– Drive belt – Fuel prefilter 61
– Replacement 99 – Check
Belt – Fuel prefilter 61
– Drive Drain and vent points 76
– Replacement 98 Drift correction parameters
Belt drive – Reset 54
– Tension adjustment 97 Drive belt
– Tension check 96 – Condition check 95
– Replacement 98
C – Tension adjustment 97
CDC – Tension check 96
– Reset 54
Centrifugal oil filter E
– Cleaning 74 Emergency stop
Charge-air coolant – Engine 32
– Change 90 Engine
– Check – Barring
– Level at filler neck 89 – Manually 42
– Level via level sensor 89 – Barring with starting system 43
– Draining 93 – Data 16
– Filling 91 – Emergency stop 32
Charge-air coolant pump – Relief bore check 94 – Main dimensions 20
Checks – Overview 15
– Prior to start-up 24 – Starting 28
Coalescer filter element – Stopping 31
– Replacement 104 – Wiring check 109
Connectors Engine coolant
– Cleaning 117 – Change 82
Contact persons 121 – Draining 83
Coolant – Filling 84
– Change 82, 90 – Sample
– Charge air – Extraction and analysis 87
– Filling 91 Engine coolant level
– Filling 84 – Check 81
– Intercooler Engine coolant pump – Relief bore check 86
– Draining 93 Engine driving end
DCL-ID: 0000027885 - 004
– Sample – Definition 14

– Extraction and analysis 87 Engine free end
Coolant level – Definition 14
– Check 81 Engine governor
Crankcase breather – Cleaning 117
– Oil mist fine separator – Installation 107
– Replacement 44 – Overview 106
Cylinder – Plug connections
– Designation 14 – Check 108, 118
Cylinder head cover – Removal 107
– Removal and installation 47
MS150111/01E 2014-05 | Appendix B | 131

Engine oil HP fuel line
– Centrifugal oil filter – Replacement 55
– Cleaning 74 Humidity sensor
– Change 72 – Replacement 115
– Filter sleeve
– Replacement 74 I
Engine oil filter IIG
– Replacement 73 – Input 54
Engine oil level Injector
– Check 71 – Removal and installation 49
Engine sides – Replacement 48
– Designation 14 Injector coding
Engine wiring – Input 54
– Check 109 Injector functions 54
Exhaust gas circulation Intercooler
– Flaps – Venting and draining 88
– Function check 70
L
F Lambda sensor
Filter – Replacement 111
– Coalescer element List of abbreviations 119
– Replacement 104
Filter sleeve M
– Replacement 74 Main dimensions
Firing order 19 – Engine 20
Flaps Maintenance schedule
– Exhaust gas circulation – Maintenance task reference table [QL1] 36
– Function check 70 MTU contact persons 121
– Exhaust gas recirculation
N
– Overview 69
Fuel NOx sensor
– Draining 59 – Replacement 113
– Injector
O
– Removal and Installation 49
– Treatment system Operational checks 30
– Switching on 29 Overview
– Troubleshooting 38 – Exhaust gas recirculation
– treatment system – Flaps 69
– Shutdown 34 – Lambda, NOx and humidity sensors 110
Fuel filter
P
– Replacement 60
Fuel prefilter Plant
– Adjustment – Cleaning 35
– Differential pressure gage 61 Pressure gauge
– Check – Differential pressure
– Differential pressure gage 61 – Check 101
– Draining 62 Pressure pipe neck
– Replacement 55
DCL-ID: 0000027885 - 004
– Filter element replacement 65

– Flushing 63 Pump
Fuel system – Charge-air coolant
– Venting 58 – Relief bore check 94
Fuel treatment system – Engine coolant
– Putting into operation 25 – Relief bore check 86
– Shutdown 34 Pump capacity
– Switching on 29 – Check 103
Putting into operation
H – After scheduled out-of-service period
Hotline 121 – Preparation 22
132 | Appendix B | MS150111/01E 2014-05

Putting the engine into operation after extended out-of-
service periods (>3 months) 21
Putting the engine into operation after scheduled out-of-
service-period 22
S
Safety notices, standards 13
Safety regulations
– Auxiliary materials 11
– Environmental protection 11
– Fire prevention 11
– Fluids and lubricants 11
– Organizational requirements 6
– Personnel requirements 6
Safety requirements
– Important requirements 5
– Maintenance work 8
– Repair work 8
– Safety notices, standards 13
Sensors
– Lambda
– Replacement 111
– NOx
– Replacement 113
Service indicator
– Signal ring position check 68
Service partners 121
Spare parts service 121
T
Tasks
– After extended out-of-service periods 23
Tasks after extended out-of-service periods (>3 weeks) 23
Transport 7
Troubleshooting 39
– Fuel treatment system 38
V
Valve clearance
– Check and adjustment 45
Vent and drain points 76
Venting and draining
– Intercooler 88
W
Water drain valve
– Check 100
Water level probe
DCL-ID: 0000027885 - 004
– Check 102
MS150111/01E 2014-05 | Appendix B | 133


12 V 2000 gx6f

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12 V 2000 gx6f

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Operating Instructions

Downloaded from www.Manualslib.com manuals search engine

Table 1: Validity overview

© 2014 Copyright MTU Friedrichshafen GmbH

Downloaded from www.Manualslib.com manuals search engine

3 Technical Data 7.5 Fuel System 55

7.6 Fuel Filter 60

7.10.2 Engine oil – Change 72

MS150111/01E 2014-05 | Table of Contents | 3

7.13 Low-Temperature Circuit 88 7.18 Wiring (General) for Engine/Gearbox/Unit 109

7.14 Belt Drive 95 7.19 Accessories for (Electronic) Engine

7.15 Battery-Charging Generator 99 8 Appendix A

DCL-ID: 0000027885 - 004

4 | Table of Contents | MS150111/01E 2014-05

MS150111/01E 2014-05 | Safety | 5

Working clothes and personal protective equipment

TIM-ID: 0000040531 - 002

6 | Safety | MS150111/01E 2014-05

Only use the lifting eyes provided to lift the engine.

Setting the engine down after transport

Only set down engine on a firm, level surface.

MS150111/01E 2014-05 | Safety | 7

Safety requirements during maintenance and repair work

Ensure that all retainers and dampers are installed correctly.

8 | Safety | MS150111/01E 2014-05

Safety requirements after completing maintenance and repair work

Hydraulic installation and removal

Working with batteries

MS150111/01E 2014-05 | Safety | 9

Working with laser equipment

Measuring component deviations

10 | Safety | MS150111/01E 2014-05

Environmental protection and disposal

Fluids and lubricants and auxiliary materials

coming into contact with ignition sources and do not smoke.

MS150111/01E 2014-05 | Safety | 11

Paints and varnishes

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

• Observe the relevant safety data sheet for all materials.

12 | Safety | MS150111/01E 2014-05

MS150111/01E 2014-05 | Safety | 13

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

14 | General Information | MS150111/01E 2014-05

1 Exhaust turbocharger 7 Power supply 13 Valve gear

Engine model designation

G Application (G for Genset)

MS150111/01E 2014-05 | General Information | 15

Engine model 12V2000 12V2000

GENERAL CONDITIONS (for maximum power)

16 | Technical Data | MS150111/01E 2014-05

COMBUSTION AIR / EXHAUST GAS

COOLANT SYSTEM (HT circuit)

COOLANT SYSTEM (LT circuit)

LUBE OIL SYSTEM

MS150111/01E 2014-05 | Technical Data | 17

GENERAL OPERATING DATA

INCLINATIONS, STANDARD OIL SYSTEM (reference: waterline)

6798+3 db(A) tolerance)

18 | Technical Data | MS150111/01E 2014-05

MS150111/01E 2014-05 | Technical Data | 19

Item Engine model/dimensions Engine model/dimensions

Table 2: Engine model/dimensions

TIM-ID: 0000043669 - 001