Operating Instructions: Diesel Engine 12V4000Bx4 12V4000Gx4 16V4000Bx4 16V4000Gx4

Operating Instructions
Diesel Engine
12V4000Bx4
12V4000Gx4
16V4000Bx4
16V4000Gx4
MS15038/00E
Engine model Frequency Application * Engine model Frequency Application *
12V4000B14S 60 Hz 3A 16V4000B14S 60 Hz 3A
12V4000B24F 50 Hz 3A 16V4000B24F 50 Hz 3A
12V4000B24S 60 Hz 3A 16V4000B24S 60 Hz 3A
12V4000B24X 50/60 Hz 3A 16V4000B24X 50/60 Hz 3A
12V4000G14F 50 Hz 3B, 3E, 3F, 3G 16V4000G14F 50 Hz 3B, 3E, 3F, 3G
12V4000G14RF 50 Hz 3B
12V4000G14S 60 Hz 3B, 3F, 3G 16V4000G14S 60 Hz 3B, 3F, 3G
12V4000G14X 50/60 Hz 3B 16V4000G14X 50/60 Hz 3B
12V4000G24F 50 Hz 3B, 3E, 3F, 3G 16V4000G24F 50 Hz 3B, 3E, 3F, 3G
12V4000G24S 60 Hz 3B, 3F, 3G 16V4000G24S 60 Hz 3B, 3F, 3G
12V4000G24X 50/60 Hz 3B 16V4000G24X 50/60 Hz 3B
12V4000G74F 50 Hz 3D 16V4000G74F 50 Hz 3D
12V4000G74S 60 Hz 3D 16V4000G74S 60 Hz 3D
12V4000G74X 50/60 Hz 3D 16V4000G74X 50/60 Hz 3D
12V4000G84F 50 Hz 3D 16V4000G84F 50 Hz 3D
12V4000G84S 60 Hz 3D 16V4000G84S 60 Hz 3D
12V4000G84X 50/60 Hz 3D 16V4000G84X 50/60 Hz 3D
16V4000G94S 60 Hz 3D
*
3A Continuous operation, unrestricted
3B Continuous operation, variable load, ICXN
3D Standby power, fuel stop power, IFN
3E Standby power, overload capability according to
ICXN
3F Mains backup mode, unlimited, ICXN
3G Continuous operation, time-limited, ICXN
Table 1: Applicability
© 2018 Copyright MTU Friedrichshafen GmbH

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ten consent of MTU Friedrichshafen GmbH. This particularly applies to its reproduction, distribution, editing, translation, micro-
filming and storage or processing in electronic systems including databases and online services.
All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen GmbH
reserves the right to change, delete or supplement the information provided as and when required.
Table of Contents
1 Safety 4.15 Product data 16V4000B24F, application 3A;
16V4000B14S, application 3A;
1.1 Important provisions for all products 6 16V4000B24S, application 3A 102
1.2 Correct use of all products 8 4.16 Product data 16V4000G14F, application 3B 106
1.3 Personnel and organizational requirements 9 4.17 Product data 16V4000G14F, application 3E 111
1.4 Initial start-up and operation – Safety 4.18 Product data 16V4000G14F, application 3F 116
regulations 10 4.19 Product data 16V4000G14F, application 3G 121
1.5 Assembly, maintenance, and repair work – 4.20 Product data 16V4000G14S, applications
Safety regulations 12 3B, 3F, 3G 126
1.6 Fire and environmental protection, fluids 4.21 Product data 16V4000G24F, application 3B 132
and lubricants 16 4.22 Product data 16V4000G24F, application 3E 137
1.7 Standards for warning notices in the text 4.23 Product data 16V4000G24F, application 3F 142
and highlighted information 18 4.24 Product data 16V4000G24F, application 3G 147
4.25 Product data 16V4000G24S, applications
2 Transport 3B, 3F, 3G 152
2.1 Transport 19 4.26 Product data 16V4000G74F, application 3D;
2.2 Lifting specifications 20 16V4000G74S, application 3D 158
2.3 Crankshaft transport locking device 21 4.27 Product data 16V4000G84F, application 3D;
16V4000G84S, application 3D 164
4.28 Product data 16V4000G94S, application 3D 170
3 General Information
4.29 Product data 12V4000B24X, application 3A;
3.1 Engine side and cylinder designations 24 12V4000G14X, application 3B;
3.2 Engine – Overview 25 12V4000G24X, application 3B;
3.3 Sensors and actuators – Overview 27 12V4000G74X, application 3D;
12V4000G84X, application 3D 174
4 Technical Data 4.30 Product data 16V4000B24X, application 3A;
16V4000G14X, application 3B;
4.1 Product data 12V4000B14S, application 3A; 16V4000G24X, application 3B;
12V4000B24F, application 3A; 16V4000G74X, application 3D;
12V4000B24S, application 3A 32 16V4000G84X, application 3D 175
4.2 Product data 12V4000G14F, application 3B 36 4.31 Firing order 176
4.3 Product data 12V4000G14F, application 3E 41 4.32 Main engine dimensions 177
4.4 Product data 12V4000G14F, application 3F 45
4.5 Product data 12V4000G14F, application 3G 49 5 Operation
4.6 Product data 12V4000G14RF, application
3B 53 5.1 Putting the engine into operation after
4.7 Product data 12V4000G14S, applications extended out-of-service periods (>3 months) 178
3B, 3F, 3G 58 5.2 Putting into operation after scheduled out-
4.8 Product data 12V4000G24F, application 3B 64 of-service-period 179
4.9 Product data 12V4000G24F, application 3E 69 5.3 Starting the engine in manual mode (test
4.10 Product data 12V4000G24F, application 3F 74 run) 180
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4.11 Product data 12V4000G24F, application 3G 79 5.4 Re-starting the engine following an
4.12 Product data 12V4000G24S, applications automatic safety shutdown 181
3B, 3F, 3G 84 5.5 Safety system – Override 182
4.13 Product data 12V4000G74F, application 3D; 5.6 Engine – Emergency start (Override mode) 183
12V4000G74S, application 3D 90 5.7 Operational monitoring 184
4.14 Product data 12V4000G84F, application 3D; 5.8 Emission label – Check 185
12V4000G84S, application 3D 96 5.9 Engine – Stopping in Manual mode (test
run) 186
5.10 Engine – Emergency stop 188
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5.11 After stopping the engine – Engine remains 8.8.5 Fuel prefilter (switchable) – Low pressure
ready for operation 189 indicator check 268
5.12 After stopping the engine – Putting the 8.8.6 Fuel prefilter (non-switchable) – Filter element
replacement 269
engine out of operation 190
8.8.7 Fuel prefilter (switchable) – Filter element
5.13 Plant – Cleaning 191
replacement 271
8.8.8 Fuel prefilter – Venting 274
6 Maintenance
8.9 Charge-Air Cooling 276
6.1 Maintenance task reference table [QL1] 192 8.9.1 Intercooler – Checking condensate drain for
coolant leakage and obstruction 276
7 Troubleshooting 8.10 Air Filter 277
8.10.1 Air filter ‒ Replacement 277
7.1 Troubleshooting 194
8.10.2 Air filter – Check 278
7.2 Fault messages 197 8.10.3 Air filter – Removal and installation 279
8 Task Description 8.11 Air Intake 280

8.11.1 Contamination indicator – Signal ring position
8.1 Engine 218 check 280
8.1.1 Engine – Barring manually 218
8.12 Starting Equipment 281
8.1.2 Engine – Cranking on starting system 220
8.12.1 Air starter – Manual operation 281
8.1.3 Engine – Test run 221
8.13 Lube Oil System, Lube Oil Circuit 282
8.2 Cylinder Liner 222 8.13.1 Engine oil – Change 282
8.2.1 Cylinder liner – Endoscopic examination 222
8.13.2 Engine oil level – Check 284
8.2.2 Cylinder liner – Instructions and comments on
8.13.3 Engine oil – Sample extraction and analysis 285
endoscopic and visual examination 224
8.13.4 Oil priming pump – Visual inspection 287
8.3 Crankcase Breather 226 8.14 Oil Filtration / Cooling 288
8.3.1 Crankcase breather – Oil separator element
8.14.1 Engine oil filter – Replacement 288
replacement 226
8.14.2 Centrifugal oil filter – Cleaning and filter
8.3.2 Crankcase breather – Filter element
sleeve replacement 289
replacement 229
8.15 Coolant Circuit, General, High-Temperature
8.4 Valve Drive 231
Circuit 292
8.4.1 Valve protrusion – Measurement 231
8.15.1 Engine coolant – Level check 292
8.4.2 Valve gear – Lubrication 235
8.15.2 Engine coolant – Change 293
8.4.3 Valve clearance – Check and adjustment 236
8.15.3 Engine coolant – Draining 294
8.4.4 Cylinder head cover – Removal and
8.15.4 Engine coolant – Filling 296
installation 240
8.15.5 Engine coolant pump – Relief bore check 298
8.5 Injection Pump / HP Pump 241 8.15.6 Engine coolant – Sample extraction and
8.5.1 HP fuel pump – Filling with engine oil 241 analysis 299
8.15.7 Preheater – Overview 301
8.6 Injector 244 8.15.8 Preheater – Function and leak check 302
8.6.1 Injector – Replacement 244
8.15.9 Preheater – Overhaul 303
8.6.2 Injector – Removal and installation 245
8.15.10 Preheater – Solenoid switch replacement 304
8.6.3 Injector rings – Replacement 250
8.15.11 Preheater – Heating element and housing
8.7 Fuel System 256 check 306
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8.7.1 Fuel system – Venting 256 8.15.12 Preheater thermostats – Replacement 309
8.7.2 Fuel cooler – External contamination and leak- 8.15.13 Coolant expansion tank valve cover –
tightness check 258 Replacement 312
8.7.3 Fuel cooler – Cleaning 259 8.16 Low-Temperature Circuit 313
8.8 Fuel Filter 261 8.16.1 Charge-air coolant – Level check 313
8.8.1 Fuel filter – Replacement 261 8.16.2 Charge-air coolant – Change 314
8.8.2 Fuel prefilter – Pressure ratios 262 8.16.3 Charge-air coolant – Draining 315
8.8.3 Fuel prefilter (non-switchable) – Draining 263 8.16.4 Charge-air coolant – Filling 317
8.8.4 Fuel prefilter (switchable) – Draining 265 8.16.5 Charge-air coolant pump – Relief bore check 320
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8.17 Belt Drive 321 8.21 Accessories for (Electronic) Engine
8.17.1 Drive belt – Condition check 321 Governor / Control System 330
8.21.1 Engine governor and connector – Cleaning 330
8.18 Battery-Charging Generator 322
8.21.2 Engine Control Unit plug connections – Check 331
8.18.1 Battery-charging generator – Drive belt
8.21.3 Engine governor ECU 9 – Removal and
tension adjustment 322
installation 332
8.18.2 Battery-charging generator drive – Drive belt
8.21.4 Parameters for drift correction (CDC) –
replacement 323
Resetting with DiaSys® 333
8.19 Engine Mounting / Support 324
8.19.1 Engine mounting – Checking resilient element 324
8.19.2 Engine mounting – Checking securing screws 9 Appendix A
for firm seating 325
9.1 Abbreviations 334
8.19.3 Generator mounting – Check 327
8.19.4 Generator mounting – Securing screw firm
9.2 MTU Contact/Service Partners 337
seating check 328
10 Appendix B
8.20 Wiring (General) for Engine/Gearbox/Unit 329
8.20.1 Engine cabling – Check 329 10.1 Special Tools 338
10.2 Index 347
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MS15038/00E 2018-06 | Table of Contents | 5

1 Safety
1.1 Important provisions for all products
General
This product may pose a risk of injury or damage in the following cases:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Changes or modifications which are neither made nor authorized by the manufacturer
• Noncompliance with the safety instructions and warning notices
Nameplates
The product is identified by nameplate, model designation or serial number. This data must match the speci-
fications in these instructions.
Nameplates, model designation or serial number can be found on the product.
All EU-certified engines delivered by MTU come with a second nameplate. When operating the machine in the
EU: The second nameplate must be affixed in a prominent position as described in the accompanying specifi-
cations.
Emission regulations and emission labels

Responsibility for compliance with emission regulations
Modification or removal of any mechanical/electronic components or the installation of additional compo-
nents including the execution of calibration processes that might affect the emission characteristics of the
product are prohibited by emission regulations. Emission-related components must only be serviced, ex-
changed or repaired if the components used for this purpose are approved by the manufacturer.
Noncompliance with these specifications will invalidate the design type approval or certification issued by
the emissions regulation authorities. The manufacturer does not accept any liability for violations of the
emission regulations.
The product must be operated over its entire life cycle according to the conditions defined as "Intended use"
(→ Page 8).
Emission certification applicable to engines with EPA Nonroad Tier 4 emission

certification in accordance with 40 CFR 1039
Extract from the standard:
Failing to follow these instructions when installing a certified engine in a piece of nonroad equipment violates
federal law (40 CFR 1068.105(b)), subject to fines or other penalties as described in the Clean Air Act.
Extract from the standard:
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If you install the engine in a way that makes the engine's emission control information label hard to read
during normal engine maintenance, you must place a duplicate label on the equipment, as described in 40
CFR 1068.105.
When fitting the second label, the requirements of 40 CFR 1068.105(c) must be followed and observed. This
paragraph describes the process for requesting and fitting the label, the documentation obligations and stor-
age obligations for the required documents.
Replacing components with emission labels

On all MTU engines fitted with emission labels, these labels must remain on the engine throughout its opera-
tional life.
6 | Safety | MS15038/00E 2018-06

Exception: Engines used exclusively in land-based, military applications other than by US government agen-
cies.
Please note the following when replacing components with emission labels:
• The relevant emission labels must be affixed to the spare part.
• Emission labels shall not be transferred from the replaced part to the spare part.
• The emission labels must be removed from the replaced part and destroyed.
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MS15038/00E 2018-06 | Safety | 7

1.2 Correct use of all products
Correct use
The product is intended for use in accordance with its contractually-defined purpose as described in the rele-
vant technical documents only.
Intended use entails operation:
• Within the permissible operating parameters in accordance with the (→ Technical data)
• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubricants
Specifications of the manufacturer)
• With preservation approved by the manufacturer in accordance with the (→ Preservation and Represerva-
tion Specifications of the manufacturer)
• With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU con-
tact/Service partner)
• In the original as-delivered configuration or in a configuration approved by the manufacturer in writing (al-
so applies to engine control/parameters)
• In compliance with all safety regulations and in adherence with all warning notices in this manual
• In compliance with the maintenance work and intervals specified in the (→ Maintenance Schedule)
throughout the useful life of the product
• In compliance with the maintenance and repair instructions contained in this manual, in particular with
regard to the specified tightening torques
• With the exclusive use of technical personnel trained in commissioning, operation, maintenance and re-
pair
The product must not be operated in explosive atmospheres unless the engine fulfills the conditions for such
use and approval has been granted.
Any other use, particularly misuse, is considered as being contrary to the intended purpose. Such improper
use increases the risk of injury and damage when working with the product. The manufacturer shall not be
held liable for any damage resulting from improper, non-intended use.
The specifications of the manufacturer will be amended or supplemented as necessary. Prior to operation,
make sure that the latest version is used. The latest version can be found on the websites:
• For drive systems: http://www.mtu-online.com
• For power generation: http://www.mtuonsiteenergy.com
Modifications or conversions
Unauthorized changes to the product represent a contravention of its intended use and compromise safety.
Changes or modifications shall only be considered to comply with the intended use when expressly author-
ized by the manufacturer. The manufacturer shall not be held liable for any damage resulting from unauthor-
ized changes or modifications.
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8 | Safety | MS15038/00E 2018-06

1.3 Personnel and organizational requirements
Organizational measures of the user/manufacturer
This manual must be issued to all personnel involved in operation, maintenance, repair, assembly, installa-
tion, or transportation.
Keep this manual handy in the vicinity of the product such that it is accessible to operating, maintenance,
repair, assembly, installation, and transport personnel at all times.
Personnel must receive instruction on product handling and repair based on this manual. In particular, per-
sonnel must have read and understood the safety requirements and warnings before starting work.
This is important in the case of personnel who only occasionally perform work on or around the product.
Such personnel must be instructed repeatedly.
Personnel requirements
All work on the product must be carried out by trained, instructed and qualified personnel only:
• Training at the Training Center of the manufacturer
• Qualified personnel from the areas mechanical engineering, plant construction, and electrical engineering
The operator must define the responsibilities of the personnel involved in operation, maintenance, repair, as-
sembly, installation, and transport in writing.
Personnel shall not report for duty under the influence of alcohol, drugs or strong medication.
Clothing and personal protective equipment

Always wear appropriate personal protective equipment, e.g. safety shoes, ear protectors, protective gloves,
goggles, breathing mask. Follow the instructions concerning personal protective equipment in the descrip-
tions of the individual activities.
Safe handling of Substances of Very High Concern pursuant to the REACH regulation (Registration, Evalua-
tion, Authorisation and restriction of CHemicals): We recommend wearing protective gloves at all times in
order to reduce risk when working.
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MS15038/00E 2018-06 | Safety | 9

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

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

Practice emergency procedures, especially emergency stopping, at regular intervals.
Take the following steps if any system malfunctions are detected or signaled by the system:
• Inform supervisor(s) in charge.
• Analyze the message.
• Respond by taking any necessary emergency action, e.g. emergency stop.
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After a safety shutdown, the engine must only be started after the cause of the shutdown has been eliminat-
ed.
Contact Service if the root cause of the malfunction cannot be clearly identified.
Operation
Do not remain in the operating room when the product is running unless absolutely necessary. Keep your
stay as short as possible.
Keep a safe distance away from the product if possible. Do not touch the product unless expressly instructed
to do so following a written procedure.
10 | Safety | MS15038/00E 2018-06

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

When electrical equipment is in operation, certain components of these appliances are electrically live.
Follow the applicable operating and safety instructions when operating the devices and heed warnings at all
times.
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MS15038/00E 2018-06 | Safety | 11

1.5 Assembly, maintenance, and repair work – Safety regulations
Safety regulations for work prior to assembly, maintenance, and repair
Have assembly, 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 from oil vapors, fluids and lubricants,
risk of burning).
Relieve pressure in fluid and lubricant systems and compressed-air lines which are to be opened. Use suita-
ble containers of adequate capacity to catch fluids and lubricants.
Release residual pressure before removing or replacing a component in the supply line. To depressurize pres-
surized lines, shut off the lines first, then release the residual pressure.
Work must only be carried out on lines when they are free of fluids and lubricants.
When changing the oil or working on the fuel system, ensure that the service room is adequately ventilated.
Never carry out assembly, maintenance, or repair work with the product in operation, unless:
• It is expressly permitted to do so following a written procedure.
Lock-out the product to preclude undesired starting, e.g.
• Start interlock
• Key switch
• Close supply line for hydraulic starting.
Attach “Do not operate” sign in the operating area or to control equipment.
Disconnect the battery cables or actuate the battery isolating switch, if fitted. Lock circuit breakers.
Before starting work on CaPoS, if used:
• Switch off the charging system (DC/DC converter).
• Discharge the UltraCap modules using the appropriate discharger.
• Short-circuit the UltraCap modules with a suitable wire jumper.
Close the main valve on the compressed-air system and vent the compressed-air line when air starters are
fitted.
Before working on the exhaust gas aftertreatment system, close the shutoff valve on the reducing agent
tank. Note that the reducing agent pumps continue to run for a certain period when the engine is stopped.
Disconnect the control equipment from the product.
Use the recommended special tools or suitable equivalents when instructed to do so.
Safety regulations when performing assembly, maintenance, and repair work

Special tools and lifting equipment
Use only proper and calibrated tools. Observe the specified tightening torques during assembly or disassem-
bly.
Setting down, lifting and climbing

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Carry out work only on assemblies or plants which are properly secured.
Use appropriate lifting equipment for all components. Use all specified attachment points and observe the
center of gravity.
Never work on engines or components when they are held in place by lifting equipment.
Make sure components or assemblies are placed on stable surfaces. Adopt suitable measures to prevent
components/tools from falling down.
Assume a safe standing position when performing assembly work.
Never use the product as a climbing aid.
12 | Safety | MS15038/00E 2018-06

When working high on the equipment, always use suitable ladders and work platforms. Special instructions
for outdoor areas: There must be no risk of slipping e.g. due to icing.
Removing, installing and cleanliness

Pay particular attention to cleanliness at all times.
Completely wipe up escaped fluids and lubricants due to the risk of slipping.
Take special care when removing ventilation or plug screws from the product.
Ensure that O-rings are not installed in a slanted/twisted condition.
Carry out appropriate cleaning procedures to clean and inspect components requiring special cleanness
(e.g. components carrying oil, fuel, or air).
Note cooling time for components which are heated for installation or removal (risk of burning).
Ensure that all mounts and dampers are installed correctly.
Remove any accumulation of condensate after assembling chilled components. Coat the components with a
suitable corrosion inhibitor as necessary.
Lines
Ensure that lines for all fluids and lubricants and their connections are clean.
Always seal connections with caps or covers if a line is removed or opened.
Fit new seals when re-installing lines.
Never bend lines and avoid damaging lines, particularly the fuel lines.
Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent contact
with other components. Do not place fuel or oil lines near hot components.
Miscellaneous
Sufficient ventilation must be guaranteed during the work.
Wear a breathing mask offering protection against soot, dust, and mineral fibers (filter class P3) when work-
ing on exhaust components. Clean the work area with a dust extraction machine of class H. Wear protective
gloves and goggles for protection against acidic condensate.
Do not touch elastomeric seals (e.g. Viton sealing rings) with your bare hands if they have a carbonized or
resinous appearance.
Elastomer components (e.g. engine mounts, damping elements, couplings and V-belts) must not be painted.
Only install them after painting the engine or mask them prior to painting.
The following applies to starters with copper-beryllium alloy pinions:
• Wear a respirator mask (filter class P3). Do not blow out the interior of the flywheel housing or the starter
with compressed air. Clean the flywheel housing inside with a class H dust extraction device.
• Observe the safety data sheet.
Safety regulations after performing assembly, maintenance, and repair work

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Before barring the engine, make sure no one is in the danger zone of the engine.
Check that all access ports/apertures which have been opened to facilitate working are closed again.
Check that all safeguards have been installed and that all tools and loose parts have been removed (especial-
ly the barring tool).
Ensure that no unattached parts have been left in/on the product (e.g. including rags and cable straps).
Ensure that the grounding system is properly connected.
MS15038/00E 2018-06 | Safety | 13

Welding work
Welding operations on the product or mounted units are not permitted. Cover the product when welding in
its vicinity.
Before starting welding work:
• Switch off the power supply master switch.
• Disconnect the battery cables or actuate the battery isolating switch.
• Separate the electrical ground of electronic equipment from the ground of the unit.
No other assembly, maintenance, or repair work must be carried out in the vicinity of the product while weld-
ing is in progress. There is a risk of explosion or fire due to oil vapors or highly flammable fluids and lubri-
cants.
Do not use product as ground terminal.
Never position the welding power supply cable adjacent to, or crossing wiring harnesses of the product. The
welding current can induce interfering voltages in the wiring harnesses which may damage the electrical sys-
tem.
Remove components (e.g. exhaust pipe) from the product before performing necessary welding work.
Hydraulic installation and removal

Check the function and safe operating condition of tools and fixtures to be used. Use only the specified devi-
ces for hydraulic removal/installation procedures.
Observe the max. permissible push-on pressure specified for the equipment.
Do not attempt to bend or apply force to lines which are under pressure.
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 a hydraulic installation/removal jig with central expansion pressure supply, screw spindle into shaft end
until correct sealing is established.
During hydraulic installation and removal of components, ensure that nobody is standing in the immediate
vicinity of the component to be installed/removed.
Working with batteries

Observe the safety instructions of the manufacturer when working on batteries.
Gases released from the battery are explosive. Avoid sparks and naked flames.
Do not allow battery acids to come into contact with skin or clothing.
Wear protective clothing, goggles and protective gloves.
Do not place objects on the battery.
Before connecting the cable to the battery, check the battery polarity. The battery may explode and spray
acid if the battery terminals are connected incorrectly.
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Working on electrical and electronic assemblies

Always obtain the permission of the person in charge before commencing assembly, maintenance, and repair
work or switching off any part of the electronic system required to do so.
De-energize the relevant areas prior to working on assemblies.
ESD (Electrostatic Discharge): Work on components which could be damaged by electrostatic discharge
must always be carried out with appropriate equipment. Appropriate equipment is e.g. electrically conductive
work surfaces or antistatic wristbands.
14 | Safety | MS15038/00E 2018-06

Do not damage wiring during removal work. When reconnecting, ensure that cabling cannot be damaged dur-
ing operation by:
• Contact with sharp edges
• Chafing on components
• Contact with hot surfaces.
Do not secure cables on lines carrying fluids.
Do not use cable ties to secure lines.
Always use connector pliers to tighten union nuts on connectors.
Subject the device as well as the product to functional testing on completion of all repair work. The emergen-
cy stop function must be tested in particular. The functional check of the emergency stop, during which the
voltage supply of the ECU is switched off, must only be carried out when the product is cold.
Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Package
faulty electronic components or assemblies properly before dispatching for repair:
• Moisture-proof
• Shock-proof
• Wrapped in antistatic foil (as necessary)
Working with laser equipment

Work with laser devices shall be carried out by trained and qualified personnel only. Follow the safety in-
structions in the manufacturer's user manual when working with laser equipment.
Wear special laser safety glasses when working with laser equipment (danger of concentrated radiation).
Laser equipment must be fitted with the protective devices necessary for safe operation according to type
and application.
Measuring component dimensions

Workpieces, components and measuring equipment lie in the specified tolerance range at a reference tem-
perature of 20 °C.
TIM-ID: 0000040535 - 021
MS15038/00E 2018-06 | Safety | 15

1.6 Fire and environmental protection, fluids and lubricants
Fire prevention and fire
Fire, naked light and smoking are prohibited.
In case of a fire, stop the fuel supply if this is possible without endangering personnel.
The product has hot surfaces that can ignite combustible gases and other substances in the immediate area.
The operating company must install and operate the product a safe distance away from danger sources and
observe any relevant safety regulations or recommendations. Products that comply with the SOLAS Conven-
tion do not constitute such as danger.
After working with combustible fluids and lubricants (e.g. cleaning agents), ensure the area is well ventilated.
The resultant steam/air mixture must be sufficiently diluted to prevent a potentially explosive atmosphere.
Eliminate leaks of fluids and lubricants immediately. Fluids and lubricants on hot components can cause
fires, so keep the product clean at all times. Do not leave rags saturated with fluids and lubricants on the
product. Do not store combustible materials near the product.
Before welding, clean the area to be welded with a nonflammable fluid. Do not carry out welding work on
pipes and components carrying oil or fuel.
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 cable from the external power source to the
ground cable of the engine or to the ground terminal of the starter.
Ensure that suitable extinguishing agents (fire extinguishers) are always available and that staff are familiar
with their correct handling.
A fire can result in the creation of toxic substances. Always wear protective gloves when handling compo-
nents and wear additional personal protective equipment is necessary.
Noise
Wear ear protectors in workplaces with a sound pressure level in excess of 85 dB (A).
Noise can lead to an increased risk of accidents if acoustic signals, warning shouts or sounds indicating dan-
ger are compromised.
Environmental protection and disposal

Dispose of used fluids, lubricants and components in accordance with local regulations.
Within the EU, batteries can be returned free of charge to the manufacturer where they will be properly recy-
cled.
Fluids and lubricants/auxiliary materials (process materials)

Process materials can also be or contain hazardous or toxic substances. When using process materials and
other chemical substances, observe the associated safety data sheet. The safety data sheet may be obtained
from the relevant manufacturer or from MTU.
Only process materials approved by the manufacturer in accordance with the Fluids and Lubricants Specifi-
TIM-ID: 0000040536 - 017
cations must be used. The most recent respective version must be requested from the manufacturer.
Contamination of process materials with reducing agent (e.g. AdBlue®, DEF): Store process materials in sep-
arate containers and their own drip trays. Even extremely small amounts of reducing agent contamination
can result in malfunctions in sensors and other components.
Used oil contains combustion residues that are harmful to health.
When handling used oil, protective gloves must be used.
Wash relevant areas after contact with used oil.
16 | Safety | MS15038/00E 2018-06

Registration, evaluation, approval and restriction of chemicals (REACH
ordinance)
Particularly hazardous substances used with our products are named in a list:
www.mtu-online.com/mtu/technische-info → SVHC as per REACH in MTU products
Compressed air
• Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII and B) out of con-
tainers, risks causing an explosion.
• Wear goggles when blowing dirt off workpieces or blowing away chips.
• Blowing compressed air into thin-walled containers (e.g. containers made of sheet metal, plastic or glass)
for drying purposes or to check for leaks risks bursting them.
• Pay special attention to the pressure in the compressed air system or pressure vessel.
• Assemblies or products which are to be connected must be designed to withstand this pressure. Install
pressure-reducing or safety valves set to the admissible pressure if this is not the case.
• Hose couplings and connections must be securely attached.
• Provide the snout of the air nozzle with a protective disk (e.g. rubber disk).
• Release residual pressure before removing a compressed air device from the supply line. To depressurize
compressed-air lines, shut off the lines first, then release the residual pressure.
• Carry out a leak test in the specified manner.
Painting
• Observe the relevant safety data sheet for all materials.
• When carrying out painting work outside the spray stands provided with fume extraction systems, ensure
that the area is well ventilated. Make sure that neighboring work areas are not adversely affected.
• Avoid open flames in the surrounding area.
• No smoking.
• Observe fire-prevention regulations.
• Always wear a mask providing protection against paint and solvent vapors.
Liquid nitrogen
• Work with liquid nitrogen may be carried out only by qualified personnel.
• Store liquid nitrogen only in small quantities and always in specified containers without fixed covers.
• Avoid body contact (eyes, hands).
• Wear protective clothing, protective gloves, closed shoes and safety goggles.
• Make sure that the working area is well ventilated.
• Avoid knocking or jolting the containers, valves and fittings or workpieces in any way.
Acids/alkalines/reducing agents (e.g. AdBlue®, DEF)

• When working with acids and alkaline solutions, wear goggles or face mask, gloves and protective cloth-
ing.
• Do not inhale vapors.
TIM-ID: 0000040536 - 017
• If reducing agent is swallowed, rinse out mouth and drink plenty of water.
• Remove any wet clothing immediately.
• After skin contact, wash affected body areas with plenty of water.
• Rinse eyes immediately with eyedrops or clean mains water. Consult a doctor as soon as possible.
Contamination of reducing agent with other process materials: Store reducing agent in separate contain-
ers and use separate drip trays. Even extremely slight contamination can lead to malfunctions in the ex-
haust aftertreatment system.
MS15038/00E 2018-06 | Safety | 17

1.7 Standards for warning notices in the text and highlighted
information
DANGER
In the event of immediate danger.
Consequences: Death, serious or permanent injury!
• Remedial action.
WARNING
In the event of a situation involving potential danger.
Consequences: Death, serious or permanent injury!
CAUTION
In the event of a situation involving potential danger.
Consequences: Minor or moderate injuries!
NOTICE
In the event of a situation involving potentially adverse effects on the product.
Consequences: Material damage!
• Additional product information.
Warning notices
1. This manual with all safety instructions and warning notices must be issued to all personnel involved in oper-
ation, maintenance, repair, assembly, installation, or transportation.
2. The highest level warning notice is used if several hazards apply at the same time. Warnings related to per-
sonal injury shall be considered to include a warning of potential damage.
Highlighted information
Important
This field contains product information which is important or useful for the user.
This information must not refer to hazards related to personal injury or material damage.
TIM-ID: 0000040578 - 006
18 | Safety | MS15038/00E 2018-06

2 Transport
2.1 Transport
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Crossbeam T80091826 1
Crossbeam T80092360 1
DANGER
Suspended load.
Danger to life!
• Use suitable equipment and lifting devices.
• Never stand beneath a suspended load and keep a safe distance.
• Wear personal protective equipment (e.g. protective helmet, safety shoes).
Transport
1. Install engine mounting locking devices and engine transportation lock prior to transport (→ Page 21).
2. Use lifting eyes provided to transport engine/generator (→ Page 20).
3. Use suitable transport and lifting gear only.
4. Engine/generator must only be transported in installation position: max. admissible diagonal pull 10°
(→ Page 20).
5. Remove any loose parts on engine/generator.
6. Raise and lower engine/generator slowly. Do not allow hoist slings or chains to contact engine/generator or
any of their component parts. Adjust lifting gear as necessary.
7. For special packaging with aluminum foil: Suspend engine by lifting eyes on bearing pedestal or transport by
means of handling equipment (forklift truck) capable of bearing load.
8. Secure engine/generator such as to preclude tipping during transport. Secure such as to preclude slipping
and tipping when driving up or down inclines and ramps.
Setting down after transport

1. Set system down on a firm, flat surface only.
2. Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate.
3. Never set the engine down on its oil pan unless expressly authorized to do so by MTU.
TIM-ID: 0000065840 - 003
MS15038/00E 2018-06 | Transport | 19

2.2 Lifting specifications
Lifting specifications
DANGER
Suspended load.
Danger to life!
• Use suitable equipment and lifting devices.
• Never stand beneath a suspended load and keep a safe distance.
• Wear personal protective equipment (e.g. protective helmet, safety shoes).
1 Max. permissible diagonal 2 Center of gravity

pull: 10°
Taking note of the engine center of gravity

Refer to the installation/arrangement drawings for details of the center of gravity of the system or the center
of gravity of the engine/generator.
TIM-ID: 0000065772 - 002
20 | Transport | MS15038/00E 2018-06

2.3 Crankshaft transport locking device
Torque wrench, 10–60 Nm F30452769 1
Engine oil
Transport locking devices

Note: The transport locking device on both sides protects the crankshaft bearings from shocks and vibration dam-
age during engine transport.
For installation and removal of the transport locking device, follow the in-
structions below:
1. The transport locking device must remain installed on both engine sides as long as possible during engine
installation in order to avoid damage.
2. Prior to every engine transport, the transport locking device must be reinstalled on both engine sides accord-
ing to the instructions.
3. If the engine is to be moved together with the generator, the transport locking device for the generator must
also be installed.
4. Always use the screws supplied with or installed in the transport locking device to secure it on the engine.
5. Starting or barring the engine is allowed only with the transport locking device removed. If the generator is
already mounted on the engine, ensure that the transport locking device of the generator is also removed.
Removing guard plates and en-

gine mounting brackets (if appli-
cable) on driving end (KS)
1. Remove screws (4) on both sides and take off
with washers (3), guard plates (1) and engine
supports (2).
2. Store the removed parts of the transport
locking device carefully for possible reuse.
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MS15038/00E 2018-06 | Transport | 21

Installing the transport locking
device on driving end (KS)
Note: Install plate (6) on the upper part of the openings only.
1. Secure the plates (6) with screws (4) and washers (5) at the lateral openings on both sides of the flywheel
housing and tighten to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw M16 Tightening torque (Engine oil) 250 nm +25 nm
2. Screw locknut (2) onto screws (1) up to the end of the thread.
3. The long side of holder (3) must point downwards. Insert holder (3) through the openings of plate (6).
Note: Holder (3) must lock only the flywheel, not the ring gear.
4. Screw in screw (1) in bores of holder (3) until holder (3) is locked in position.
Note: Screw (1) must be tightened stepwise and alternately on both sides of the flywheel housing.
5. Tighten screw (1) to specified tightening torque.
Screw M10 Tightening torque (Engine oil) 30 Nm +3 Nm
6. Install locknut (2) of screw (1) on plate (6) and tighten.
Removing the transport locking

device from driving end (KS)
1. Release the locknuts (2) on both sides of the
flywheel housing, remove screw (1) and take
off holder (3).
2. Remove screws (4) and take off with wash-
ers (5) and plates (6).
3. Store the removed parts of the transport
TIM-ID: 0000004010 - 016
locking device carefully together with this

documentation for possible reuse.
22 | Transport | MS15038/00E 2018-06

Installing guard plates and en-
gine mounting brackets (if appli-
cable) on driving end (KS)
Note: Always use the screws supplied with the equipment or removed from the guard plates and engine supports
to secure them on the engine.
u Install engine supports (2) on both sides with guard plates (1) washers (3) and screws (4) and tighten to
specified tightening torque tightening.
Screw M16 Tightening torque (Engine oil) 250 Nm +25 Nm
TIM-ID: 0000004010 - 016
MS15038/00E 2018-06 | Transport | 23

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

2 Engine free end in accord- 4 Engine driving end in ac-
ance with DIN ISO 1204 cordance with
(KGS = Kupplungsgegen- DIN ISO 1204 (KS = Kup-
seite) plungsseite)
Engine sides are always designated (in accordance with DIN ISO 1204) as viewed from driving end (4).
For cylinder designation (in accordance with DIN ISO 1204), the letter "Ax" refers to the cylinders on the left-
hand side of the engine (1) and letter "Bx" refers to the cylinders on the right-hand side (3). The cylinders of
each bank are numbered consecutively, starting with x=1 at driving end (4).
The numbering of other engine components also starts with 1 at driving end (4).
TIM-ID: 0000002185 - 014
24 | General Information | MS15038/00E 2018-06

3.2 Engine – Overview
Engine overview, free end
1 Cylinder head cover 6 Fuel filter 11 Coolant distribution housing

2 Charge-air pipe 7 Fuel priming pump 12 Centrifugal oil filter (option)
3 Engine lifting eye 8 HP fuel pump 13 Crankcase breather
4 Oil filler neck 9 Vibration damper KGS Free end
5 Engine mounting 10 Engine oil filter
Illustration also applies to 12V engines.
TIM-ID: 0000081811 - 001
MS15038/00E 2018-06 | General Information | 25

Engine overview, driving end
1 Intercooler 6 LT thermostat housing 11 Starter

2 Air filter 7 HT thermostat housing 12 Flywheel
3 Exhaust outlet 8 Oil pan KS Driving end
4 Exhaust turbocharger 9 Crankcase
5 Oil heat exchanger 10 Engine Control Unit (ECU9)
Engine model designation

Key to the engine model designation 12V/16V4000B/Gx4y
12/16 Number of cylinders
V Cylinder arrangement: V-engine
4000 Series
B/G Application
x Application segment
4 Design status
y F (50 Hz)
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S (60 Hz)
X (switchable 50/60 Hz)
RF (50 Hz reduced power/speed)

3.3 Sensors and actuators – Overview
Sensors, left engine side
Designation Monitors
A19 EIL (Engine Ident Label)
B9 Charge-air temperature
B34 Fuel pressure after filter
B38 Fuel temperature, low pressure
B48.1 HP fuel pressure
Y39.Ax-A1 Injectors, left engine side

TIM-ID: 0000081812 - 001

Sensors, free end
B1 Camshaft speed
B5.1 Oil pressure after filter
B6 Coolant temperature at engine outlet
B7 Lube oil temperature, engine inlet
B26 Charge-air coolant temperature
B50 Crankcase pressure
B54 Lube oil pressure, replenishment pump
XB54 Adaption oil replenishment pump
M8 Fuel pump (suction restrictor valve)

TIM-ID: 0000081812 - 001

Sensors, right engine side
B10 Charge-air pressure
B48.2 HP fuel pressure
XF33 HT coolant level (external expansion tank)
XF57 LT coolant level (external expansion tank)
Y39.B1-Bx Injectors, right engine side

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Sensors, driving end
B13 Crankshaft speed
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Sensors, top
B44 Exhaust turbocharger speed

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4 Technical Data
4.1 Product data 12V4000B14S, application 3A; 12V4000B24F,
application 3A; 12V4000B24S, application 3A
Key
DL Reference value: Continuous power. continuously attainable power at standard conditions.
BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli-
cations (margin for load fluctuations).
A Design value. Value required to design an external system (plant).
R Guideline value. Typical average value for information, only partially suitable for design purposes.
L Limit value. Value which must not be violated (lower limit value, min. value / upper limit value, max.
value), not suitable for design purposes.
N Not yet defined value. Value has not yet been defined or will not be defined.
- Not applicable. Module is not applicable to the given product type.
X Applicable. Module is applicable to the given product type.
> Actual value must be greater than the specified value.
< Actual value must be less than the specified value.
* Not sufficiently validated value (+/- 10% tolerance).
** Not sufficiently validated value (+/- 5% tolerance).
ID Product type Application Speed Nominal pow-

er
1 12V4000B14S Power generation 1800 rpm 1190 kW Ref. 25 °C/55 °C
3A continuous opera- 60 Hz 1596 bhp Optimized fuel con-
tion, unlimited sumption
2 12V4000B24F Power generation 1500 rpm 1310 kW Ref. 25 °C/55 °C
Reference conditions
ID 1 2 3
Intake air temperature °C 25 25 25
Charge-air coolant temperature °C 55 55 55
Barometric pressure mbar 1000 1000 1000
Site altitude above sea level m 100 100 100
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0. Data-relevant engine specification

ID 1 2 3
Engine without sequential turbocharging (exhaust tur- - X X X
bochargers without cut-in / cut-out control)
32 | Technical Data | MS15038/00E 2018-06

1. Power-related data
ID 1 2 3
Rated engine speed A rpm 1800 1500 1800
Continuous power ISO 3046 (10% overload capability) A kW 1190 1310 1420
(power range DIN 6280, ISO 8528)
Fuel stop power ISO 3046 A kW 1310 1440 1562
2. General conditions (for maximum power)

ID 1 2 3
Intake depression (new filter) A mbar 15 15 15
Intake depression, max. L mbar 50 50 50
Exhaust gas overpressure A mbar 30 30 30
Exhaust gas overpressure, max. L mbar 85 85 85
Fuel temperature at engine inlet connection R °C 25 25 25
Fuel temperature at engine inlet connection, max. L °C 55 55 55
(w/o power reduction)
3. Consumption
ID 1 2 3
Specific fuel consumption (be) – 100% DL (+5%; EN R g/kWh 201 192 200
590; 42.8 MJ/kg)
Specific fuel consumption (be) – 100% BL (+5%; EN R g/kWh - - -
590; 42.8 MJ/kg)
Fuel consumption at zero load R kg/h 29.0 21.0 29.0
4. Model-related data (basic design)

ID 1 2 3
Engine with exhaust turbocharging (ETC) and charge- - X X X
air cooling (intercooler)
Uncooled exhaust lines - X X X
Operating method: four-stroke cycle, diesel, single- - X X X
acting
Combustion method: direct injection - X X X
Cooling method: treated water - X X X
Direction of rotation: c.c.w. (facing driving end) - X X X
Number of cylinders - 12 12 12
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Cylinder arrangement: V angle Degrees 90 90 90

(°)
Bore mm 170 170 170
Stroke mm 210 210 210
Cylinder displacement Liters 4.77 4.77 4.77
Total displacement Liters 57.2 57.2 57.2
Compression ratio - 16.4 16.4 16.4
MS15038/00E 2018-06 | Technical Data | 33

5. Air / exhaust gas
ID 1 2 3
Combustion air volumetric flow – DL R m³/s 1.9 1.6 2.1
Combustion air volumetric flow – BL R m³/s 2.0 1.7 2.2
Exhaust gas volume (at exhaust gas temperature) – R m³/s 4.4 3.8 4.7
DL
BL
Exhaust gas temperature after engine – DL R °C 400 425 410 *
Exhaust gas temperature after engine – BL R °C 405 450 420 *
7. Coolant system (HT circuit)

ID 1 2 3
Coolant temperature (at engine connection: outlet to A °C 100 100 100
cooling system)
Coolant temperature after engine, limit 1 L °C 102 102 102
Coolant antifreeze content, max. L % 50 50 50
8. Coolant system (LT circuit)

ID 1 2 3
Coolant temperature (at engine connection: outlet to R °C 65 62 65
cooling system)
Coolant temperature before intercooler, limit 1 L °C 75 75 75
Coolant temperature before intercooler, limit 2 L °C - - -
10. Lube oil system

ID 1 2 3
Lube oil temperature before engine, limit 1 L °C 99 99 99
12. General operating data

ID 1 2 3
High idling speed, max. (static) L rpm 1900 1700 1900
Limit speed for overspeed alarm / emergency shut- L rpm 1950 1950 1950
down
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Limit speed for overspeed message L rpm 1950 1950 1950

Firing speed, from R rpm 80 80 80
Firing speed, to R rpm 120 120 120
18. Capacities
ID 1 2 3
Engine coolant, engine side (w/o cooling equipment) R Liters 160 160 160
Charge-air coolant, engine side R Liters 40 40 40

ID 1 2 3
Fuel, engine side R Liters 7 7 7
Total engine oil capacity, initial filling (standard oil R Liters 260 260 260
system) (option: max. operating inclinations)
Oil change quantity, max. (standard oil system) (op- R Liters 200 200 200
tion: max. operating inclinations)
Oil pan capacity at dipstick mark “min.” (standard oil L Liters 160 160 160
Oil pan capacity at dipstick mark “max.” (standard oil L Liters 200 200 200
19. Masses / main dimensions

ID 1 2 3
Engine mass, dry (basic engine configuration acc. to R kg 6200 * 6200 * 6200 *
scope of delivery specification)
22. Acoustics
ID 1 2 3
Exhaust noise, unsilenced – DL (free-field sound pres- R dB(A) 111 111 112
sure level Lp, 1 m distance, ISO 6798, +3 dB(A) toler-
ance)
Exhaust noise, unsilenced – DL (sound power level R dB(A) 124 123 125
LW, ISO 6798, +3 dB(A) tolerance)
Engine surface noise with attenuated intake noise (fil- R dB(A) 103 102 104
ter) – DL (free-field sound power level Lp, 1 m dis-
tance, ISO 6798, +2 dB(A) tolerance)
ter) – DL (sound power level LW, ISO 6798, +2 db(A)
tolerance)
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4.2 Product data 12V4000G14F, application 3B
Key

er
1 12V4000G14F Power generation 1500 rpm 1420 kW Ref. 25 °C/55 °C
3B continuous opera- 50 Hz 1904 bhp Optimized fuel con-
tion, variable load, sumption
ICXN
3B continuous opera- 50 Hz 1904 bhp NEA Singapore for
tion, variable load, ORDE
ICXN
3B continuous opera- 50 Hz 1904 bhp China NRMM Stage III
tion, variable load, (GB20891-2014)
ICXN
3B continuous opera- 50 Hz 1904 bhp TA-Luft-optimized (die-
tion, variable load, sel)
ICXN
ID 1 2 3 4
Intake air temperature °C 25 25 25 25
Charge-air coolant temperature °C 55 45 45 55
Barometric pressure mbar 1000 1000 1000 1000
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Site altitude above sea level m 100 100 100 100

ID 1 2 3 4
Engine without sequential turbocharging - X X X X
(exhaust turbochargers without cut-in /
cut-out control)

ID 1 2 3 4
Rated engine speed A rpm 1500 1500 1500 1500
Continuous power ISO 3046 (10% over- A kW 1420 1420 1420 1420
load capability) (power range DIN 6280,
ISO 8528)
Fuel stop power ISO 3046 A kW 1562 1562 1562 1562

ID 1 2 3 4
Intake depression (new filter) A mbar 15 15 15 15
Intake depression, max. L mbar 50 50 50 50
Exhaust gas overpressure A mbar 30 30 30 30
Exhaust gas overpressure, max. L mbar 85 85 85 85
Fuel temperature at engine inlet connec- R °C 25 25 25 25
tion
Fuel temperature at engine inlet connec- L °C 55 55 55 55
tion, max. (w/o power reduction)
tion, max.
3. Consumption
ID 1 2 3 4
Specific fuel consumption (be) – 100% R g/kWh 189 200 200 218
DL (+5%; EN 590; 42.8 MJ/kg)
Specific fuel consumption (be) – 100% BL R g/kWh - - - -
(+5%; EN 590; 42.8 MJ/kg)
Fuel consumption at zero load R kg/h 21.0 21.0 21.0 21.0

ID 1 2 3 4
Engine with exhaust turbocharging (ETC) - X X X X
and charge-air cooling (intercooler)
Uncooled exhaust lines - X X X X
Operating method: four-stroke cycle, die- - X X X X
sel, single-acting
Combustion method: direct injection - X X X X
Cooling method: treated water - X X X X
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Direction of rotation: c.c.w. (facing driv- - X X X X

ing end)
Number of cylinders - 12 12 12 12
Cylinder arrangement: V angle Degrees 90 90 90 90
(°)
Bore mm 170 170 170 170
Stroke mm 210 210 210 210
Cylinder displacement Liters 4.77 4.77 4.77 4.77

ID 1 2 3 4
Total displacement Liters 57.2 57.2 57.2 57.2
Compression ratio - 16.4 16.4 16.4 16.4

ID 1 2 3 4
Combustion air volumetric flow – DL R m³/s 1.6 1.8 1.8 2.1
Combustion air volumetric flow – BL R m³/s 1.8 1.95 1.95 2.2
Exhaust gas volume (at exhaust gas tem- R m³/s 4.0 4.9 4.9 5.2
perature) – DL
perature) – BL
Exhaust gas temperature after engine – R °C 455 505 505 470
DL
BL

ID 1 2 3 4
Coolant temperature (at engine connec- A °C 100 100 100 100
tion: outlet to cooling system)
Coolant temperature after engine, limit 1 L °C 102 102 102 102
Coolant antifreeze content, max. L % 50 50 50 50

ID 1 2 3 4
Coolant temperature (at engine connec- R °C 62 58 58 70
Coolant temperature before intercooler, L °C 75 75 75 75
limit 1
Coolant temperature before intercooler, L °C - - - -
limit 2
10. Lube oil system

ID 1 2 3 4
Lube oil temperature before engine, limit L °C 99 99 99 99
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1
2

ID 1 2 3 4
High idling speed, max. (static) L rpm 1700 1700 1700 1700
Limit speed for overspeed alarm / emer- L rpm 1950 1950 1950 1950
gency shutdown
Limit speed for overspeed message L rpm 1950 1950 1950 1950
Firing speed, from R rpm 80 80 80 80
Firing speed, to R rpm 120 120 120 120
18. Capacities
ID 1 2 3 4
Engine coolant, engine side (w/o cooling R Liters 160 160 160 160
equipment)
Charge-air coolant, engine side R Liters 40 40 40 40
Fuel, engine side R Liters 7 7 7 7
Total engine oil capacity, initial filling R Liters 260 260 260 260
(standard oil system) (option: max. oper-
ating inclinations)
Oil change quantity, max. (standard oil R Liters 200 200 200 200
system) (option: max. operating inclina-
tions)
Oil pan capacity at dipstick mark “min.” L Liters 160 160 160 160
ating inclinations)
Oil pan capacity at dipstick mark “max.” L Liters 200 200 200 200
ating inclinations)

ID 1 2 3 4
Engine mass, dry (basic engine configura- R kg 6200 * 6200 * 6200 * 6200 *
tion acc. to scope of delivery specifica-
tion)
22. Acoustics
ID 1 2 3 4
Exhaust noise, unsilenced – DL (free-field R dB(A) 111 113 113 113
sound pressure level Lp, 1 m distance,
ISO 6798, +3 dB(A) tolerance)
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Exhaust noise, unsilenced – DL (sound R dB(A) 124 126 126 126

power level LW, ISO 6798, +3 dB(A) tol-
erance)
Exhaust noise, unsilenced – BL (free-field R dB(A) - -
Exhaust noise, unsilenced – BL (sound R dB(A) - -
erance)

ID 1 2 3 4
Engine surface noise with attenuated in- R dB(A) 102 104 104 104
take noise (filter) – DL (free-field sound
power level Lp, 1 m distance, ISO 6798,
+2 dB(A) tolerance)
take noise (filter) – DL (sound power lev-
el LW, ISO 6798, +2 db(A) tolerance)
Engine surface noise with attenuated in- R dB(A) - -
take noise (filter) – BL (free-field sound
pressure level Lp, 1 m distance, ISO
6798, +2 dB(A) tolerance)
take noise (filter) – BL (sound power level
TIM-ID: 0000082069 - 001

4.3 Product data 12V4000G14F, application 3E
Key

er
3E standby power, 50 Hz 1904 bhp Optimized fuel con-
overload capability ac- sumption
cording to ICXN
3E standby power, 50 Hz 1904 bhp TA-Luft-optimized (die-
overload capability ac- sel)
cording to ICXN
3E standby power, 50 Hz 1904 bhp NEA Singapore for
overload capability ac- ORDE
cording to ICXN
ID 1 2 3

ID 1 2 3
TIM-ID: 0000082070 - 001


ID 1 2 3

ID 1 2 3
3. Consumption
ID 1 2 3
590; 42.8 MJ/kg)
590; 42.8 MJ/kg)

ID 1 2 3
acting
TIM-ID: 0000082070 - 001

(°)
Bore mm 170 170 170
Stroke mm 210 210 210

ID 1 2 3
DL
BL
Exhaust gas temperature after engine – DL R °C 455 470 505
Exhaust gas temperature after engine – BL R °C 475 490 520

ID 1 2 3
cooling system)

ID 1 2 3
cooling system)
10. Lube oil system

ID 1 2 3

ID 1 2 3
down
TIM-ID: 0000082070 - 001

18. Capacities
ID 1 2 3

ID 1 2 3

ID 1 2 3
22. Acoustics
ID 1 2 3
ance)
Exhaust noise, unsilenced – BL (free-field sound pres- R dB(A) - -
ance)
Exhaust noise, unsilenced – BL (sound power level R dB(A) - -
tolerance)
Engine surface noise with attenuated intake noise (fil- R dB(A) - -
ter) – BL (free-field sound pressure level Lp, 1 m dis-
ter) – BL (sound power level LW, ISO 6798, +2 dB(A)
tolerance)
TIM-ID: 0000082070 - 001

4.4 Product data 12V4000G14F, application 3F
Key

er
3F mains backup 50 Hz 1904 bhp Optimized fuel con-
mode, unlimited, ICXN sumption
3F mains backup 50 Hz 1904 bhp TA-Luft-optimized (die-
mode, unlimited, ICXN sel)
3F mains backup 50 Hz 1904 bhp NEA Singapore for
mode, unlimited, ICXN ORDE
ID 1 2 3

ID 1 2 3
TIM-ID: 0000082071 - 001
ID 1 2 3

ID 1 2 3
3. Consumption
ID 1 2 3
590; 42.8 MJ/kg)
590; 42.8 MJ/kg)

ID 1 2 3
acting
(°)
Bore mm 170 170 170
Stroke mm 210 210 210
TIM-ID: 0000082071 - 001

ID 1 2 3
DL

ID 1 2 3
BL

ID 1 2 3
cooling system)

ID 1 2 3
cooling system)
10. Lube oil system

ID 1 2 3

ID 1 2 3
down
18. Capacities
TIM-ID: 0000082071 - 001
ID 1 2 3

ID 1 2 3

ID 1 2 3
22. Acoustics
ID 1 2 3
ance)
ance)
tolerance)
tolerance)
TIM-ID: 0000082071 - 001

4.5 Product data 12V4000G14F, application 3G
Key

er
3G continuous opera- 50 Hz 1904 bhp Optimized fuel con-
tion, time-limited, sumption
ICXN
3G continuous opera- 50 Hz 1904 bhp TA-Luft-optimized (die-
tion, time-limited, sel)
ICXN
3G continuous opera- 50 Hz 1904 bhp NEA Singapore for
tion, time-limited, ORDE
ICXN
ID 1 2 3

ID 1 2 3
TIM-ID: 0000082072 - 001


ID 1 2 3

ID 1 2 3
3. Consumption
ID 1 2 3
590; 42.8 MJ/kg)
590; 42.8 MJ/kg)

ID 1 2 3
acting
TIM-ID: 0000082072 - 001

(°)
Bore mm 170 170 170
Stroke mm 210 210 210

ID 1 2 3
DL
BL

ID 1 2 3
cooling system)

ID 1 2 3
cooling system)
10. Lube oil system

ID 1 2 3

ID 1 2 3
down
TIM-ID: 0000082072 - 001

18. Capacities
ID 1 2 3

ID 1 2 3

ID 1 2 3
22. Acoustics
ID 1 2 3
ance)
ance)
tolerance)
tolerance)
TIM-ID: 0000082072 - 001

4.6 Product data 12V4000G14RF, application 3B
Key
DL Reference value: Continuous power. Continuously attainable power at standard conditions.

er
1 12V4000G14R Power generation 1500 rpm 1205 kW Ref. 25 °C/55 °C
F 3B continuous opera- 50 Hz 1616 bhp Optimized fuel con-
ICXN
F 3B continuous opera- 50 Hz 1616 bhp TA-Luft-optimized (die-
ICXN
F 3B continuous opera- 50 Hz 1616 bhp NEA Singapore for
ICXN
F 3B continuous opera- 50 Hz 1616 bhp China NRMM Stage III
ICXN
ID 1 2 3 4
TIM-ID: 0000082073 - 001

ID 1 2 3 4
cut-out control)

ID 1 2 3 4
ISO 8528)

ID 1 2 3 4
tion
tion, max.
3. Consumption
ID 1 2 3 4
DL (+5%; EN 590; 42.8 MJ/kg)
(+5%; EN 590; 42.8 MJ/kg)

ID 1 2 3 4
sel, single-acting
TIM-ID: 0000082073 - 001

ing end)
(°)
Bore mm 170 170 170 170
Stroke mm 210 210 210 210

ID 1 2 3 4

ID 1 2 3 4
perature) – DL
perature) – BL
DL
BL

ID 1 2 3 4

ID 1 2 3 4
limit 1
limit 2
10. Lube oil system

ID 1 2 3 4
TIM-ID: 0000082073 - 001
1
2

ID 1 2 3 4
gency shutdown
18. Capacities
ID 1 2 3 4
equipment)
ating inclinations)
tions)
ating inclinations)
ating inclinations)

ID 1 2 3 4
tion)
22. Acoustics
ID 1 2 3 4
TIM-ID: 0000082073 - 001

erance)
erance)

ID 1 2 3 4
+2 dB(A) tolerance)
TIM-ID: 0000082073 - 001

4.7 Product data 12V4000G14S, applications 3B, 3F, 3G
Key

er
1 12V4000G14S Power generation 1800 rpm 1520 kW Ref. 25 °C/45 °C
3B continuous opera- 60 Hz 2038 bhp EPA Stationary EMERG
tion, variable load, T2 (40CFR60)
ICXN EPA Nonroad T2 Comp
(40CFR89)
ICXN
3F mains backup 60 Hz 2038 bhp EPA Stationary EMERG
mode, unlimited, ICXN T2 (40CFR60)
EPA Nonroad T2 Comp
(40CFR89)
ICXN
3G continuous opera- 60 Hz 2038 bhp EPA Stationary EMERG
tion, time-limited, T2 (40CFR60)
TIM-ID: 0000082074 - 001

(40CFR89)
ID 1 2 3 4 5 6
Intake air temperature °C 25 25 25 25 25 25
Charge-air coolant tem- °C 45 55 55 45 55 45
perature

ID 1 2 3 4 5 6
Barometric pressure mbar 1000 1000 1000 1000 1000 1000
Site altitude above sea m 100 100 100 100 100 100
level

ID 1 2 3 4 5 6
Engine without sequential - X X X X X X
turbocharging (exhaust
turbochargers without
cut-in / cut-out control)
ID 1 2 3 4 5 6
Rated engine speed A rpm 1800 1800 1800 1800 1800 1800
Continuous power ISO A kW 1520 1520 1520 1520 1520 1520
3046 (10% overload capa-
bility) (power range DIN
6280, ISO 8528)
Fuel stop power ISO A kW 1672 1672 1672 1672 1672 1672
3046

ID 1 2 3 4 5 6
Intake depression (new A mbar 15 15 15 15 15 15
filter)
Intake depression, max. L mbar 50 50 50 50 50 50
Exhaust gas overpressure A mbar 30 30 30 30 30 30
Exhaust gas overpres- L mbar 85 85 85 85 85 85
sure, max.
Fuel temperature at en- R °C 25 25 25 25 25 25
gine inlet connection
Fuel temperature at en- L °C 55 55 55 55 55 55
gine inlet connection,
max. (w/o power reduc-
tion)
max.
TIM-ID: 0000082074 - 001

3. Consumption
ID 1 2 3 4 5 6
Specific fuel consumption R g/kWh 203 196 196 203 196 203
(be) – 100% DL (+5%; EN
590; 42.8 MJ/kg)
Specific fuel consumption R g/kWh - - - - - -
(be) – 100% BL (+5%; EN
590; 42.8 MJ/kg)
Fuel consumption at zero R kg/h 29.0 29.0 29.0 29.0 29.0 29.0
load

ID 1 2 3 4 5 6
Engine with exhaust tur- - X X X X X X
bocharging (ETC) and
charge-air cooling (inter-
cooler)
Uncooled exhaust lines - X X X X X X
Operating method: four- - X X X X X X
stroke cycle, diesel, sin-
gle-acting
Combustion method: di- - X X X X X X
rect injection
Cooling method: treated - X X X X X X
water
Direction of rotation: - X X X X X X
c.c.w. (facing driving end)
Number of cylinders - 12 12 12 12 12 12
Cylinder arrangement: V Degrees 90 90 90 90 90 90
angle (°)
Bore mm 170 170 170 170 170 170
Stroke mm 210 210 210 210 210 210
Cylinder displacement Liters 4.77 4.77 4.77 4.77 4.77 4.77
Total displacement Liters 57.2 57.2 57.2 57.2 57.2 57.2
Compression ratio - 16.4 16.4 16.4 16.4 16.4 16.4

ID 1 2 3 4 5 6
Combustion air volumet- R m³/s 2.2 2.1 2.1 2.2 2.1 2.2
TIM-ID: 0000082074 - 001
ric flow – DL
ric flow – BL
Exhaust gas volume (at R m³/s 5.2 4.8 4.8 5.2 4.8 5.2
exhaust gas temperature)
– DL
– BL

ID 1 2 3 4 5 6
Exhaust gas temperature R °C 405 420 420 405 420 405
after engine – DL
after engine – BL

ID 1 2 3 4 5 6
Coolant temperature (at A °C 100 100 100 100 100 100
engine connection: outlet
to cooling system)
Coolant temperature after L °C 102 102 102 102 102 102
engine, limit 1
engine, limit 2
Coolant antifreeze con- L % 50 50 50 50 50 50
tent, max.

ID 1 2 3 4 5 6
Coolant temperature (at R °C 57 65 65 57 65 57
to cooling system)
Coolant temperature be- L °C 75 75 75 75 75 75
fore intercooler, limit 1
Coolant temperature be- L °C - - - - - -
tent, max.
10. Lube oil system

ID 1 2 3 4 5 6
Lube oil temperature be- L °C 99 99 99 99 99 99
fore engine, limit 1

ID 1 2 3 4 5 6
TIM-ID: 0000082074 - 001
High idling speed, max. L rpm 1900 1900 1900 1900 1900 1900
(static)
Limit speed for overspeed L rpm 1950 1950 1950 1950 1950 1950
alarm / emergency shut-
down
message
Firing speed, from R rpm 80 80 80 80 80 80
Firing speed, to R rpm 120 120 120 120 120 120

18. Capacities
ID 1 2 3 4 5 6
Engine coolant, engine R Liters 160 160 160 160 160 160
side (w/o cooling equip-
ment)
Charge-air coolant, en- R Liters 40 40 40 40 40 40
gine side
Fuel, engine side R Liters 7 7 7 7 7 7
Total engine oil capacity, R Liters 260 260 260 260 260 260
initial filling (standard oil
system) (option: max. op-
erating inclinations)
Oil change quantity, max. R Liters 200 200 200 200 200 200
(standard oil system) (op-
tion: max. operating incli-
nations)
Oil pan capacity at dip- L Liters 160 160 160 160 160 160
stick mark “min.” (stand-
ard oil system) (option:
max. operating inclina-
tions)
stick mark “max.” (stand-
tions)

ID 1 2 3 4 5 6
Engine mass, dry (basic R kg 6200 * 6200 * 6200 * 6200 * 6200 * 6200 *
engine configuration acc.
to scope of delivery spec-
ification)
22. Acoustics
ID 1 2 3 4 5 6
Exhaust noise, unsilenced R dB(A) 113 112 112 113 112 113
– DL (free-field sound
pressure level Lp, 1 m
distance, ISO 6798,
+3 dB(A) tolerance)
TIM-ID: 0000082074 - 001
– DL (sound power level
LW, ISO 6798, +3 dB(A)
tolerance)
Exhaust noise, unsilenced R dB(A) - - - - - -
– BL (free-field sound
distance, ISO 6798,
+3 dB(A) tolerance)

ID 1 2 3 4 5 6
– BL (sound power level
LW, ISO 6798, +3 dB(A)
tolerance)
Engine surface noise with R dB(A) 104 104 104 104 104 104
attenuated intake noise
(filter) – DL (free-field
sound power level Lp,
1 m distance, ISO 6798,
+2 dB(A) tolerance)
(filter) – DL (sound power
level LW, ISO 6798,
+2 db(A) tolerance)
Engine surface noise with R dB(A) - - - - - -
(filter) – BL (free-field
sound pressure level Lp,
+2 dB(A) tolerance)
(filter) – BL (sound power
level LW, ISO 6798,
+2 dB(A) tolerance)
TIM-ID: 0000082074 - 001

Key

er
ICXN
ICXN
ICXN
ICXN
ID 1 2 3 4
TIM-ID: 0000082075 - 001

ID 1 2 3 4
cut-out control)

ID 1 2 3 4
ISO 8528)

ID 1 2 3 4
tion
tion, max.
3. Consumption
ID 1 2 3 4
DL (+5%; EN 590; 42.8 MJ/kg)
(+5%; EN 590; 42.8 MJ/kg)
Fuel consumption at zero load R kg/h 21.0 21.0 39 39

ID 1 2 3 4
sel, single-acting
TIM-ID: 0000082075 - 001

ing end)
(°)
Bore mm 170 170 170 170
Stroke mm 210 210 210 210

ID 1 2 3 4

ID 1 2 3 4
perature) – DL
perature) – BL
DL
BL

ID 1 2 3 4

ID 1 2 3 4
limit 1
limit 2
10. Lube oil system

ID 1 2 3 4
TIM-ID: 0000082075 - 001
1
2

ID 1 2 3 4
gency shutdown
18. Capacities
ID 1 2 3 4
equipment)
ating inclinations)
tions)
ating inclinations)
ating inclinations)

ID 1 2 3 4
tion)
22. Acoustics
ID 1 2 3 4
TIM-ID: 0000082075 - 001

erance)
erance)

ID 1 2 3 4
+2 dB(A) tolerance)
TIM-ID: 0000082075 - 001

Key

er
cording to ICXN
cording to ICXN
cording to ICXN
3E standby power, 50 Hz 2112 bhp China NRMM Stage III
overload capability ac- (GB20891-2014)
cording to ICXN
ID 1 2 3 4
TIM-ID: 0000082076 - 001

ID 1 2 3 4
cut-out control)

ID 1 2 3 4
ISO 8528)

ID 1 2 3 4
tion
tion, max.
3. Consumption
ID 1 2 3 4
DL (+5%; EN 590; 42.8 MJ/kg)
(+5%; EN 590; 42.8 MJ/kg)

ID 1 2 3 4
sel, single-acting
TIM-ID: 0000082076 - 001

ing end)
(°)
Bore mm 170 170 170 170
Stroke mm 210 210 210 210

ID 1 2 3 4

ID 1 2 3 4
perature) – DL
perature) – BL
DL
BL

ID 1 2 3 4

ID 1 2 3 4
limit 1
limit 2
10. Lube oil system

ID 1 2 3 4
TIM-ID: 0000082076 - 001
1
2

ID 1 2 3 4
gency shutdown
18. Capacities
ID 1 2 3 4
equipment)
ating inclinations)
tions)
ating inclinations)
ating inclinations)

ID 1 2 3 4
tion)
22. Acoustics
ID 1 2 3 4
TIM-ID: 0000082076 - 001

erance)
erance)

ID 1 2 3 4
+2 dB(A) tolerance)
TIM-ID: 0000082076 - 001

Key

er
3F mains backup 50 Hz 2112 bhp China NRMM Stage III
mode, unlimited, ICXN (GB20891-2014)
ID 1 2 3 4

TIM-ID: 0000082077 - 001
ID 1 2 3 4
cut-out control)

ID 1 2 3 4
ISO 8528)

ID 1 2 3 4
tion
tion, max.
3. Consumption
ID 1 2 3 4
DL (+5%; EN 590; 42.8 MJ/kg)
(+5%; EN 590; 42.8 MJ/kg)

ID 1 2 3 4
sel, single-acting
TIM-ID: 0000082077 - 001

ing end)
(°)
Bore mm 170 170 170 170
Stroke mm 210 210 210 210

ID 1 2 3 4

ID 1 2 3 4
perature) – DL
perature) – BL
DL
BL

ID 1 2 3 4

ID 1 2 3 4
limit 1
limit 2
10. Lube oil system

ID 1 2 3 4
TIM-ID: 0000082077 - 001
1
2

ID 1 2 3 4
gency shutdown
18. Capacities
ID 1 2 3 4
equipment)
Engine oil capacity, initial filling (standard R Liters 260 260 260 260
oil system) (option: max. operating incli-
nations)
tions)
ating inclinations)
ating inclinations)

ID 1 2 3 4
tion)
22. Acoustics
ID 1 2 3 4
TIM-ID: 0000082077 - 001

erance)
erance)

ID 1 2 3 4
+2 dB(A) tolerance)
TIM-ID: 0000082077 - 001

Key

er
ICXN
ICXN
ICXN
3G continuous opera- 50 Hz 2112 bhp China NRMM Stage III
tion, time-limited, (GB20891-2014)
ICXN
ID 1 2 3 4
TIM-ID: 0000082078 - 001

ID 1 2 3 4
cut-out control)

ID 1 2 3 4
ISO 8528)

ID 1 2 3 4
tion
tion, max.
3. Consumption
ID 1 2 3 4
DL (+5%; EN 590; 42.8 MJ/kg)
(+5%; EN 590; 42.8 MJ/kg)

ID 1 2 3 4
sel, single-acting
TIM-ID: 0000082078 - 001

ing end)
(°)
Bore mm 170 170 170 170
Stroke mm 210 210 210 210

ID 1 2 3 4

ID 1 2 3 4
perature) – DL
perature) – BL
DL
BL

ID 1 2 3 4

ID 1 2 3 4
limit 1
limit 2
10. Lube oil system

ID 1 2 3 4
TIM-ID: 0000082078 - 001
1
2

ID 1 2 3 4
gency shutdown
18. Capacities
ID 1 2 3 4
equipment)
ating inclinations)
tions)
ating inclinations)
ating inclinations)

ID 1 2 3 4
tion)
22. Acoustics
ID 1 2 3 4
TIM-ID: 0000082078 - 001

erance)
erance)

ID 1 2 3 4
+2 dB(A) tolerance)
TIM-ID: 0000082078 - 001

Key

er
(40CFR89)
ICXN
EPA Nonroad T2 Comp
(40CFR89)
ICXN
TIM-ID: 0000082079 - 001

(40CFR89)
ID 1 2 3 4 5 6
perature

ID 1 2 3 4 5 6
level

ID 1 2 3 4 5 6
ID 1 2 3 4 5 6
6280, ISO 8528)
3046

ID 1 2 3 4 5 6
filter)
sure, max.
tion)
max.
TIM-ID: 0000082079 - 001

3. Consumption
ID 1 2 3 4 5 6
(be) – 100% DL (+5%; EN
590; 42.8 MJ/kg)
(be) – 100% BL (+5%; EN
590; 42.8 MJ/kg)
load

ID 1 2 3 4 5 6
cooler)
gle-acting
rect injection
water
angle (°)
Bore mm 170 170 170 170 170 170
Stroke mm 210 210 210 210 210 210

ID 1 2 3 4 5 6
TIM-ID: 0000082079 - 001
ric flow – DL
ric flow – BL
– DL
– BL

ID 1 2 3 4 5 6
after engine – DL
after engine – BL

ID 1 2 3 4 5 6
to cooling system)
engine, limit 1
engine, limit 2
tent, max.

ID 1 2 3 4 5 6
to cooling system)
tent, max.
10. Lube oil system

ID 1 2 3 4 5 6

ID 1 2 3 4 5 6
TIM-ID: 0000082079 - 001
(static)
down
message

18. Capacities
ID 1 2 3 4 5 6
ment)
gine side
nations)
tions)
tions)

ID 1 2 3 4 5 6
Engine mass, dry (basic R kg 6200 * 6200 * 6200 * 6200 * 6200 * 6200 *
ification)
22. Acoustics
ID 1 2 3 4 5 6
distance, ISO 6798,
+3 dB(A) tolerance)
TIM-ID: 0000082079 - 001
LW, ISO 6798, +3 dB(A)
tolerance)
distance, ISO 6798,
+3 dB(A) tolerance)

ID 1 2 3 4 5 6
LW, ISO 6798, +3 dB(A)
tolerance)
+2 dB(A) tolerance)
level LW, ISO 6798,
+2 db(A) tolerance)
+2 dB(A) tolerance)
level LW, ISO 6798,
+2 dB(A) tolerance)
TIM-ID: 0000082079 - 001

4.13 Product data 12V4000G74F, application 3D; 12V4000G74S,
application 3D
Key

er
3D standby power, 50 Hz 2112 bhp Optimized fuel con-
fuel stop power, IFN sumption
3D standby power, 50 Hz 2112 bhp NEA Singapore for
fuel stop power, IFN ORDE
3D standby power, 50 Hz 2112 bhp China NRMM Stage III
fuel stop power, IFN (GB20891-2014)
3D standby power, 60 Hz 2328 bhp EPA Stationary EMERG
fuel stop power, IFN T2 (40CFR60)
EPA Nonroad T2 Comp
(40CFR89)
ID 1 2 3 4 5
Intake air temperature °C 25 25 25 25 25
TIM-ID: 0000082085 - 001
Charge-air coolant tempera- °C 55 45 45 45 55

ture
Barometric pressure mbar 1000 1000 1000 1000 1000
Site altitude above sea level m 100 100 100 100 100

ID 1 2 3 4 5
Engine without sequential - X X X X X
turbocharging (exhaust tur-
bochargers without cut-in /
cut-out control)
ID 1 2 3 4 5
Rated engine speed A rpm 1500 1500 1500 1800 1800
Fuel stop power ISO 3046 A kW 1575 1575 1575 1736 1736

ID 1 2 3 4 5
Intake depression (new filter) A mbar 15 15 15 15 15
Intake depression, max. L mbar 50 50 50 50 50
Exhaust gas overpressure A mbar 30 30 30 30 30
Exhaust gas overpressure, L mbar 85 85 85 85 85
max.
Fuel temperature at engine R °C 25 25 25 25 25
inlet connection
Fuel temperature at engine L °C 55 55 55 55 55
inlet connection, max. (w/o
power reduction)
inlet connection, max.
3. Consumption
ID 1 2 3 4 5
Specific fuel consumption R g/kWh - - - - -
(be) – 100% DL (+5%; EN
590; 42.8 MJ/kg)
Specific fuel consumption R g/kWh 189 199 199 206 201
(be) – 100% BL (+5%; EN
590; 42.8 MJ/kg)
Fuel consumption at zero R kg/h 21.0 30.0 30.0 29.0 29.0
load

TIM-ID: 0000082085 - 001
ID 1 2 3 4 5
Engine with exhaust turbo- - X X X X X
charging (ETC) and charge-
Uncooled exhaust lines - X X X X X
Operating method: four- - X X X X X
stroke cycle, diesel, single-
acting

ID 1 2 3 4 5
Combustion method: direct - X X X X X
injection
Cooling method: treated wa- - X X X X X
ter
Direction of rotation: c.c.w. - X X X X X
(facing driving end)
Number of cylinders - 12 12 12 12 12
Cylinder arrangement: V an- Degrees 90 90 90 90 90
gle (°)
Bore mm 170 170 170 170 170
Stroke mm 210 210 210 210 210
Cylinder displacement Liters 4.77 4.77 4.77 4.77 4.77
Total displacement Liters 57.2 57.2 57.2 57.2 57.2
Compression ratio - 16.4 16.4 16.4 16.4 16.4

ID 1 2 3 4 5
Combustion air volumetric R m³/s - - - - -
flow – DL
Combustion air volumetric R m³/s 1.8 2.0 2.0 2.4 2.3
flow – BL
Exhaust gas volume (at ex- R m³/s - - - - -
haust gas temperature) – DL
Exhaust gas volume (at ex- R m³/s 4.5 5.3 5.3 5.7 5.4
haust gas temperature) – BL
Exhaust gas temperature af- R °C - - - - -
ter engine – DL
Exhaust gas temperature af- R °C 460 510 510 435 430
ter engine – BL

ID 1 2 3 4 5
Coolant temperature (at en- A °C 100 100 100 100 100
gine connection: outlet to
cooling system)
Coolant temperature after L °C 102 102 102 102 102
engine, limit 1
TIM-ID: 0000082085 - 001
engine, limit 2
Coolant antifreeze content, L % 50 50 50 50 50
max.

ID 1 2 3 4 5
Coolant temperature (at en- R °C 65 58 58 57 67
cooling system)
Coolant temperature before L °C 75 75 75 75 75
intercooler, limit 1
Coolant temperature before L °C - - - - -
max.
10. Lube oil system

ID 1 2 3 4 5
Lube oil temperature before L °C 99 99 99 99 99
engine, limit 1
engine, limit 2

ID 1 2 3 4 5
High idling speed, max. (stat- L rpm 1700 1700 1700 1900 1900
ic)
Limit speed for overspeed L rpm 1950 1950 1950 1950 1950
down
message
Firing speed, from R rpm 80 80 80 80 80
Firing speed, to R rpm 120 120 120 120 120
18. Capacities
ID 1 2 3 4 5
Engine coolant, engine side R Liters 160 160 160 160 160
(w/o cooling equipment)
Charge-air coolant, engine R Liters 40 40 40 40 40
side
Fuel, engine side R Liters 7 7 7 7 7
Total engine oil capacity, ini- R Liters 260 260 260 260 260
TIM-ID: 0000082085 - 001
tial filling (standard oil sys-

tem) (option: max. operating
inclinations)
Oil change quantity, max. R Liters 200 200 200 200 200
tion: max. operating inclina-
tions)

ID 1 2 3 4 5
Oil pan capacity at dipstick L Liters 160 160 160 160 160
mark “min.” (standard oil
system) (option: max. oper-
ating inclinations)
mark “max.” (standard oil
ating inclinations)

ID 1 2 3 4 5
Engine mass, dry (basic en- R kg 6200 * 6200 * 6200 * 6200 * 6200 *
gine configuration acc. to
scope of delivery specifica-
tion)
22. Acoustics
ID 1 2 3 4 5
Exhaust noise, unsilenced – R dB(A) - - - - -
DL (free-field sound pressure
level Lp, 1 m distance, ISO
DL (sound power level LW,
ISO 6798, +3 dB(A) toler-
ance)
Exhaust noise, unsilenced – R dB(A) 113 113 113 115 114
BL (free-field sound pressure
BL (sound power level LW,
ance)
Engine surface noise with at- R dB(A) - - - - -
tenuated intake noise (filter)
– DL (free-field sound power
TIM-ID: 0000082085 - 001
– DL (sound power level LW,

ISO 6798, +2 db(A) toler-
ance)

ID 1 2 3 4 5
Engine surface noise with at- R dB(A) 103 103 103 105 105
– BL (free-field sound pres-
sure level Lp, 1 m distance,
ance)
– BL (sound power level LW,
ance)
TIM-ID: 0000082085 - 001

application 3D
Key

er
EPA Nonroad T2 Comp
(40CFR89)
ID 1 2 3 4 5
TIM-ID: 0000082086 - 001

ture

ID 1 2 3 4 5
cut-out control)
ID 1 2 3 4 5

ID 1 2 3 4 5
max.
inlet connection
power reduction)
3. Consumption
ID 1 2 3 4 5
(be) – 100% DL (+5%; EN
590; 42.8 MJ/kg)
(be) – 100% BL (+5%; EN
590; 42.8 MJ/kg)
load

TIM-ID: 0000082086 - 001
ID 1 2 3 4 5
acting

ID 1 2 3 4 5
injection
ter
gle (°)
Bore mm 170 170 170 170 170
Stroke mm 210 210 210 210 210

ID 1 2 3 4 5
flow – DL
flow – BL
ter engine – DL
ter engine – BL

ID 1 2 3 4 5
cooling system)
engine, limit 1
TIM-ID: 0000082086 - 001
engine, limit 2
max.

ID 1 2 3 4 5
cooling system)
max.
10. Lube oil system

ID 1 2 3 4 5
engine, limit 1
engine, limit 2

ID 1 2 3 4 5
ic)
down
message
18. Capacities
ID 1 2 3 4 5
side
TIM-ID: 0000082086 - 001

inclinations)
tions)

ID 1 2 3 4 5
ating inclinations)
ating inclinations)

ID 1 2 3 4 5
Engine mass, dry (basic en- R kg 6200 * 6200 * 6200 * 6200 * 6200 *
tion)
22. Acoustics
ID 1 2 3 4 5
ance)
ance)
TIM-ID: 0000082086 - 001

ance)

ID 1 2 3 4 5
ance)
ance)
TIM-ID: 0000082086 - 001

4.15 Product data 16V4000B24F, application 3A; 16V4000B14S,
application 3A; 16V4000B24S, application 3A
Key

er
1 16V4000B24F Power generation 1500 rpm 1635 kW Ref. 25 °C/55 °C
ID 1 2 3

ID 1 2 3
TIM-ID: 0000082067 - 001
ID 1 2 3

ID 1 2 3
3. Consumption
ID 1 2 3
590; 42.8 MJ/kg)
590; 42.8 MJ/kg)

ID 1 2 3
acting
(°)
Bore mm 170 170 170
Stroke mm 210 210 210
TIM-ID: 0000082067 - 001

ID 1 2 3

ID 1 2 3
Exhaust gas volume (at exhaust gas temperature) – R m³/s 4.9 * 6.3 7.1
DL
Exhaust gas volume (at exhaust gas temperature) – R m³/s 5.4 * 6.7 7.6
BL

ID 1 2 3
cooling system)

ID 1 2 3
cooling system)
10. Lube oil system

ID 1 2 3

ID 1 2 3
down
18. Capacities
TIM-ID: 0000082067 - 001
ID 1 2 3

ID 1 2 3

ID 1 2 3
Engine mass, dry (basic engine configuration acc. to R kg 7700 7700 7700
22. Acoustics
ID 1 2 3
ance)
Exhaust noise, unsilenced – BL (free-field sound pres- R dB(A) -
ance)
Exhaust noise, unsilenced – BL (sound power level R dB(A) -
tolerance)
Engine surface noise with attenuated intake noise (fil- R dB(A) -
Engine surface noise with attenuated intake noise (fil- R dB(A) -
tolerance)
TIM-ID: 0000082067 - 001

Key

er
ICXN
ICXN
ICXN
ICXN
ID 1 2 3 4
TIM-ID: 0000082081 - 001

ID 1 2 3 4
cut-out control)

ID 1 2 3 4
ISO 8528)

ID 1 2 3 4
tion
tion, max.
3. Consumption
ID 1 2 3 4
DL (+5%; EN 590; 42.8 MJ/kg)
(+5%; EN 590; 42.8 MJ/kg)

ID 1 2 3 4
sel, single-acting
TIM-ID: 0000082081 - 001

ing end)
(°)
Bore mm 170 170 170 170
Stroke mm 210 210 210 210

ID 1 2 3 4

ID 1 2 3 4
perature) – DL
perature) – BL
DL
BL

ID 1 2 3 4

ID 1 2 3 4
limit 1
limit 2
10. Lube oil system

ID 1 2 3 4
TIM-ID: 0000082081 - 001
1
2

ID 1 2 3 4
gency shutdown
18. Capacities
ID 1 2 3 4
equipment)
ating inclinations)
tions)
ating inclinations)
ating inclinations)

ID 1 2 3 4
Engine mass, dry (basic engine configura- R kg 7700 7700 7700 7700
tion)
22. Acoustics
ID 1 2 3 4
TIM-ID: 0000082081 - 001

erance)
Exhaust noise, unsilenced – BL (free-field R dB(A) - - - -
Exhaust noise, unsilenced – BL (sound R dB(A) - - - -
erance)

ID 1 2 3 4
+2 dB(A) tolerance)
Engine surface noise with attenuated in- R dB(A) - - - -
TIM-ID: 0000082081 - 001

Key

er
cording to ICXN
cording to ICXN
cording to ICXN
cording to ICXN
ID 1 2 3 4
TIM-ID: 0000082082 - 001

ID 1 2 3 4
cut-out control)

ID 1 2 3 4
ISO 8528)

ID 1 2 3 4
tion
tion, max.
3. Consumption
ID 1 2 3 4
DL (+5%; EN 590; 42.8 MJ/kg)
(+5%; EN 590; 42.8 MJ/kg)

ID 1 2 3 4
sel, single-acting
TIM-ID: 0000082082 - 001

ing end)
(°)
Bore mm 170 170 170 170
Stroke mm 210 210 210 210

ID 1 2 3 4

ID 1 2 3 4
perature) – DL
perature) – BL
DL
BL

ID 1 2 3 4

ID 1 2 3 4
limit 1
limit 2
10. Lube oil system

ID 1 2 3 4
TIM-ID: 0000082082 - 001
1
2

ID 1 2 3 4
gency shutdown
18. Capacities
ID 1 2 3 4
equipment)
ating inclinations)
tions)
ating inclinations)
ating inclinations)

ID 1 2 3 4
tion)
22. Acoustics
ID 1 2 3 4
TIM-ID: 0000082082 - 001

erance)
erance)

ID 1 2 3 4
+2 dB(A) tolerance)
el LW, ISO 6798, +2 dB(A) tolerance)
TIM-ID: 0000082082 - 001

Key

er
ID 1 2 3 4

TIM-ID: 0000082083 - 001
ID 1 2 3 4
cut-out control)

ID 1 2 3 4
ISO 8528)

ID 1 2 3 4
tion
tion, max.
3. Consumption
ID 1 2 3 4
DL (+5%; EN 590; 42.8 MJ/kg)
(+5%; EN 590; 42.8 MJ/kg)

ID 1 2 3 4
sel, single-acting
TIM-ID: 0000082083 - 001

ing end)
(°)
Bore mm 170 170 170 170
Stroke mm 210 210 210 210

ID 1 2 3 4

ID 1 2 3 4
perature) – DL
perature) – BL
DL
BL

ID 1 2 3 4

ID 1 2 3 4
limit 1
limit 2
10. Lube oil system

ID 1 2 3 4
TIM-ID: 0000082083 - 001
1
2

ID 1 2 3 4
gency shutdown
18. Capacities
ID 1 2 3 4
equipment)
ating inclinations)
tions)
ating inclinations)
ating inclinations)

ID 1 2 3 4
tion)
22. Acoustics
ID 1 2 3 4
TIM-ID: 0000082083 - 001

erance)
erance)

ID 1 2 3 4
+2 dB(A) tolerance)
TIM-ID: 0000082083 - 001

Key

er
ICXN
ICXN
ICXN
ICXN
ID 1 2 3 4
TIM-ID: 0000082084 - 001

ID 1 2 3 4
cut-out control)

ID 1 2 3 4
ISO 8528)

ID 1 2 3 4
tion
tion, max.
3. Consumption
ID 1 2 3 4
DL (+5%; EN 590; 42.8 MJ/kg)
(+5%; EN 590; 42.8 MJ/kg)

ID 1 2 3 4
sel, single-acting
TIM-ID: 0000082084 - 001

ing end)
(°)
Bore mm 170 170 170 170
Stroke mm 210 210 210 210

ID 1 2 3 4

ID 1 2 3 4
perature) – DL
perature) – BL
DL
BL

ID 1 2 3 4

ID 1 2 3 4
limit 1
limit 2
10. Lube oil system

ID 1 2 3 4
TIM-ID: 0000082084 - 001
1
2

ID 1 2 3 4
gency shutdown
18. Capacities
ID 1 2 3 4
equipment)
ating inclinations)
tions)
ating inclinations)
ating inclinations)

ID 1 2 3 4
tion)
22. Acoustics
ID 1 2 3 4
TIM-ID: 0000082084 - 001

erance)
erance)

ID 1 2 3 4
+2 dB(A) tolerance)
TIM-ID: 0000082084 - 001

Key

er
(40CFR89)
ICXN
EPA Nonroad T2 Comp
(40CFR89)
ICXN
TIM-ID: 0000082080 - 001

(40CFR89)
ID 1 2 3 4 5 6
perature

ID 1 2 3 4 5 6
level

ID 1 2 3 4 5 6
ID 1 2 3 4 5 6
6280, ISO 8528)
3046

ID 1 2 3 4 5 6
filter)
sure, max.
tion)
max.
TIM-ID: 0000082080 - 001

3. Consumption
ID 1 2 3 4 5 6
(be) – 100% DL (+5%; EN
590; 42.8 MJ/kg)
(be) – 100% BL (+5%; EN
590; 42.8 MJ/kg)
load

ID 1 2 3 4 5 6
cooler)
gle-acting
rect injection
water
angle (°)
Bore mm 170 170 170 170 170 170
Stroke mm 210 210 210 210 210 210

ID 1 2 3 4 5 6
TIM-ID: 0000082080 - 001
ric flow – DL
ric flow – BL
– DL
– BL

ID 1 2 3 4 5 6
after engine – DL
after engine – BL

ID 1 2 3 4 5 6
to cooling system)
engine, limit 1
engine, limit 2
tent, max.

ID 1 2 3 4 5 6
to cooling system)
tent, max.
10. Lube oil system

ID 1 2 3 4 5 6

ID 1 2 3 4 5 6
TIM-ID: 0000082080 - 001
(static)
down
message

18. Capacities
ID 1 2 3 4 5 6
ment)
gine side
nations)
tions)
tions)

ID 1 2 3 4 5 6
Engine mass, dry (basic R kg 7700 7700 7700 7700 7700 7700
ification)
22. Acoustics
ID 1 2 3 4 5 6
distance, ISO 6798,
+3 dB(A) tolerance)
TIM-ID: 0000082080 - 001
LW, ISO 6798, +3 dB(A)
tolerance)
distance, ISO 6798,
+3 dB(A) tolerance)

ID 1 2 3 4 5 6
LW, ISO 6798, +3 dB(A)
tolerance)
+2 dB(A) tolerance)
level LW, ISO 6798,
+2 db(A) tolerance)
+2 dB(A) tolerance)
level LW, ISO 6798,
+2 dB(A) tolerance)
TIM-ID: 0000082080 - 001

Key

er
ICXN
ICXN
ICXN
ICXN
ID 1 2 3 4
TIM-ID: 0000082087 - 001

ID 1 2 3 4
cut-out control)

ID 1 2 3 4
ISO 8528)

ID 1 2 3 4
tion
tion, max.
3. Consumption
ID 1 2 3 4
DL (+5%; EN 590; 42.8 MJ/kg)
(+5%; EN 590; 42.8 MJ/kg)

ID 1 2 3 4
sel, single-acting
TIM-ID: 0000082087 - 001

ing end)
(°)
Bore mm 170 170 170 170
Stroke mm 210 210 210 210

ID 1 2 3 4

ID 1 2 3 4
perature) – DL
perature) – BL
DL
BL

ID 1 2 3 4

ID 1 2 3 4
limit 1
limit 2
10. Lube oil system

ID 1 2 3 4
TIM-ID: 0000082087 - 001
1
2

ID 1 2 3 4
gency shutdown
18. Capacities
ID 1 2 3 4
equipment)
ating inclinations)
tions)
ating inclinations)
ating inclinations)

ID 1 2 3 4
tion)
22. Acoustics
ID 1 2 3 4
TIM-ID: 0000082087 - 001

erance)
erance)

ID 1 2 3 4
+2 dB(A) tolerance)
TIM-ID: 0000082087 - 001

Key

er
cording to ICXN
cording to ICXN
cording to ICXN
cording to ICXN
ID 1 2 3 4
TIM-ID: 0000082100 - 001

ID 1 2 3 4
cut-out control)

ID 1 2 3 4
ISO 8528)

ID 1 2 3 4
tion
tion, max.
3. Consumption
ID 1 2 3 4
DL (+5%; EN 590; 42.8 MJ/kg)
(+5%; EN 590; 42.8 MJ/kg)

ID 1 2 3 4
sel, single-acting
TIM-ID: 0000082100 - 001

ing end)
(°)
Bore mm 170 170 170 170
Stroke mm 210 210 210 210

ID 1 2 3 4

ID 1 2 3 4
perature) – DL
perature) – BL
DL
BL

ID 1 2 3 4

ID 1 2 3 4
limit 1
limit 2
10. Lube oil system

ID 1 2 3 4
TIM-ID: 0000082100 - 001
1
2

ID 1 2 3 4
gency shutdown
18. Capacities
ID 1 2 3 4
equipment)
ating inclinations)
tions)
ating inclinations)
ating inclinations)

ID 1 2 3 4
tion)
22. Acoustics
ID 1 2 3 4
TIM-ID: 0000082100 - 001

erance)
erance)

ID 1 2 3 4
+2 dB(A) tolerance)
TIM-ID: 0000082100 - 001

Key

er
ID 1 2 3 4

TIM-ID: 0000082102 - 001
ID 1 2 3 4
cut-out control)

ID 1 2 3 4
ISO 8528)

ID 1 2 3 4
tion
tion, max.
3. Consumption
ID 1 2 3 4
DL (+5%; EN 590; 42.8 MJ/kg)
(+5%; EN 590; 42.8 MJ/kg)

ID 1 2 3 4
sel, single-acting
TIM-ID: 0000082102 - 001

ing end)
(°)
Bore mm 170 170 170 170
Stroke mm 210 210 210 210

ID 1 2 3 4

ID 1 2 3 4
perature) – DL
perature) – BL
DL
BL

ID 1 2 3 4

ID 1 2 3 4
limit 1
limit 2
10. Lube oil system

ID 1 2 3 4
TIM-ID: 0000082102 - 001
1
2

ID 1 2 3 4
gency shutdown
18. Capacities
ID 1 2 3 4
equipment)
ating inclinations)
tions)
ating inclinations)
ating inclinations)

ID 1 2 3 4
tion)
22. Acoustics
ID 1 2 3 4
TIM-ID: 0000082102 - 001

erance)
erance)

ID 1 2 3 4
+2 dB(A) tolerance)
TIM-ID: 0000082102 - 001

Key

er
ICXN
ICXN
ICXN
ICXN
ID 1 2 3 4
TIM-ID: 0000082101 - 001

ID 1 2 3 4
cut-out control)

ID 1 2 3 4
ISO 8528)

ID 1 2 3 4
tion
tion, max.
3. Consumption
ID 1 2 3 4
DL (+5%; EN 590; 42.8 MJ/kg)
(+5%; EN 590; 42.8 MJ/kg)

ID 1 2 3 4
sel, single-acting
TIM-ID: 0000082101 - 001

ing end)
(°)
Bore mm 170 170 170 170
Stroke mm 210 210 210 210

ID 1 2 3 4

ID 1 2 3 4
perature) – DL
perature) – BL
DL
BL

ID 1 2 3 4

ID 1 2 3 4
limit 1
limit 2
10. Lube oil system

ID 1 2 3 4
TIM-ID: 0000082101 - 001
1
2

ID 1 2 3 4
gency shutdown
18. Capacities
ID 1 2 3 4
equipment)
ating inclinations)
tions)
ating inclinations)
ating inclinations)

ID 1 2 3 4
tion)
22. Acoustics
ID 1 2 3 4
TIM-ID: 0000082101 - 001

erance)
sound pressure level Lp, 1 m dis-
erance)

ID 1 2 3 4
+2 dB(A) tolerance)
TIM-ID: 0000082101 - 001

Key

er
(40CFR89)
ICXN
EPA Nonroad T2 Comp
(40CFR89)
ICXN
TIM-ID: 0000082103 - 001

(40CFR89)
ID 1 2 3 4 5 6
perature

ID 1 2 3 4 5 6
level

ID 1 2 3 4 5 6
ID 1 2 3 4 5 6
6280, ISO 8528)
3046

ID 1 2 3 4 5 6
filter)
sure, max.
tion)
max.
TIM-ID: 0000082103 - 001

3. Consumption
ID 1 2 3 4 5 6
(be) – 100% DL (+5%; EN
590; 42.8 MJ/kg)
(be) – 100% BL (+5%; EN
590; 42.8 MJ/kg)
load

ID 1 2 3 4 5 6
cooler)
gle-acting
rect injection
water
angle (°)
Bore mm 170 170 170 170 170 170
Stroke mm 210 210 210 210 210 210

ID 1 2 3 4 5 6
TIM-ID: 0000082103 - 001
ric flow – DL
ric flow – BL
– DL
– BL

ID 1 2 3 4 5 6
after engine – DL
after engine – BL

ID 1 2 3 4 5 6
to cooling system)
engine, limit 1
engine, limit 2
tent, max.

ID 1 2 3 4 5 6
to cooling system)
tent, max.
10. Lube oil system

ID 1 2 3 4 5 6

ID 1 2 3 4 5 6
TIM-ID: 0000082103 - 001
(static)
down
message

18. Capacities
ID 1 2 3 4 5 6
ment)
gine side
nations)
tions)
tions)

ID 1 2 3 4 5 6
Engine mass, dry (basic R kg 7700 7700 7700 7700 7700 7700
ification)
22. Acoustics
ID 1 2 3 4 5 6
distance, ISO 6798,
+3 dB(A) tolerance)
TIM-ID: 0000082103 - 001
LW, ISO 6798, +3 dB(A)
tolerance)
distance, ISO 6798,
+3 dB(A) tolerance)

ID 1 2 3 4 5 6
LW, ISO 6798, +3 dB(A)
tolerance)
+2 dB(A) tolerance)
level LW, ISO 6798,
+2 db(A) tolerance)
+2 dB(A) tolerance)
level LW, ISO 6798,
+2 dB(A) tolerance)
TIM-ID: 0000082103 - 001

application 3D
Key

er
EPA Nonroad T2 Comp
(40CFR89)
ID 1 2 3 4 5
TIM-ID: 0000082104 - 001

ture

ID 1 2 3 4 5
cut-out control)
ID 1 2 3 4 5

ID 1 2 3 4 5
max.
inlet connection
power reduction)
3. Consumption
ID 1 2 3 4 5
(be) – 100% DL (+5%; EN
590; 42.8 MJ/kg)
(be) – 100% BL (+5%; EN
590; 42.8 MJ/kg)
load

TIM-ID: 0000082104 - 001
ID 1 2 3 4 5
acting

ID 1 2 3 4 5
injection
ter
gle (°)
Bore mm 170 170 170 170 170
Stroke mm 210 210 210 210 210

ID 1 2 3 4 5
flow – DL
flow – BL
ter engine – DL
ter engine – BL

ID 1 2 3 4 5
cooling system)
engine, limit 1
TIM-ID: 0000082104 - 001
engine, limit 2
max.

ID 1 2 3 4 5
cooling system)
max.
10. Lube oil system

ID 1 2 3 4 5
engine, limit 1
engine, limit 2

ID 1 2 3 4 5
ic)
down
message
18. Capacities
ID 1 2 3 4 5
side
TIM-ID: 0000082104 - 001

inclinations)
tions)

ID 1 2 3 4 5
ating inclinations)
ating inclinations)

ID 1 2 3 4 5
Engine mass, dry (basic en- R kg 7700 7700 7700 7700 7700
tion)
22. Acoustics
ID 1 2 3 4 5
ance)
ance)
TIM-ID: 0000082104 - 001

ance)

ID 1 2 3 4 5
ance)
ance)
TIM-ID: 0000082104 - 001

application 3D
Key

er
EPA Nonroad T2 Comp
(40CFR89)
ID 1 2 3 4 5
TIM-ID: 0000082105 - 001

ture

ID 1 2 3 4 5
cut-out control)
ID 1 2 3 4 5

ID 1 2 3 4 5
max.
inlet connection
power reduction)
3. Consumption
ID 1 2 3 4 5
(be) – 100% DL (+5%; EN
590; 42.8 MJ/kg)
(be) – 100% BL (+5%; EN
590; 42.8 MJ/kg)
load

TIM-ID: 0000082105 - 001
ID 1 2 3 4 5
acting

ID 1 2 3 4 5
injection
ter
gle (°)
Bore mm 170 170 170 170 170
Stroke mm 210 210 210 210 210

ID 1 2 3 4 5
flow – DL
flow – BL
ter engine – DL
ter engine – BL

ID 1 2 3 4 5
cooling system)
engine, limit 1
TIM-ID: 0000082105 - 001
engine, limit 2
max.

ID 1 2 3 4 5
cooling system)
max.
10. Lube oil system

ID 1 2 3 4 5
engine, limit 1
engine, limit 2

ID 1 2 3 4 5
ic)
down
message
18. Capacities
ID 1 2 3 4 5
side
Engine oil capacity, initial fill- R Liters 300 300 300 300 300
TIM-ID: 0000082105 - 001
ing (standard oil system) (op-

tions)
tions)

ID 1 2 3 4 5
ating inclinations)
ating inclinations)

ID 1 2 3 4 5
Engine mass, dry (basic en- R kg 7700 7700 7700 7700 7700
tion)
22. Acoustics
ID 1 2 3 4 5
D (free-field sound pressure
ance)
ance)
TIM-ID: 0000082105 - 001

ance)

ID 1 2 3 4 5
ance)
ance)
TIM-ID: 0000082105 - 001

4.28 Product data 16V4000G94S, application 3D
Key
value), not suitable for design purposes
N Not yet defined value. Value has not yet been defined or will not be defined

er
EPA Nonroad T2 Comp
(40CFR89)
ID 1 2
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

ID 1 2
Engine without sequential turbocharging (exhaust turbochargers - X X
without cut-in / cut-out control)
TIM-ID: 0000082106 - 001
ID 1 2
Rated engine speed A rpm 1800 1800
Fuel stop power ISO 3046 A kW 2740 2740

ID 1 2
Intake depression (new filter) A mbar 15 15
Intake depression, max. L mbar 30 30
Exhaust gas overpressure A mbar 30 30
Exhaust gas overpressure, max. L mbar 85 85
Fuel temperature at engine inlet connection R °C 25 25
Fuel temperature at engine inlet connection, max. (w/o power re- L °C 55 55
duction)
Fuel temperature at engine inlet connection, max. L °C 55 55
3. Consumption
ID 1 2
Specific fuel consumption (be) – 100% DL (+5%; EN 590; 42.8 R g/kWh - -
MJ/kg)
Specific fuel consumption (be) – 100% BL (+5%; EN 590; 42.8 R g/kWh 215 215
MJ/kg)
Fuel consumption at zero load R kg/h 39.0 39.0

ID 1 2
Engine with exhaust turbocharging (ETC) and charge-air cooling - X X
(intercooler)
Uncooled exhaust lines - X X
Operating method: four-stroke cycle, diesel, single-acting - X X
Combustion method: direct injection - X X
Cooling method: treated water - X X
Direction of rotation: c.c.w. (facing driving end) - X X
Number of cylinders - 16 16
Cylinder arrangement: V angle Degrees 90 90
(°)
Bore mm 170 170
Stroke mm 210 210
Cylinder displacement Liters 4.77 4.77
Total displacement Liters 76.3 76.3
Compression ratio - 16.4 16.4
TIM-ID: 0000082106 - 001

ID 1 2
Combustion air volumetric flow – DL R m³/s - -
Combustion air volumetric flow – BL R m³/s 3.7 3.7
Exhaust gas volume (at exhaust gas temperature) – DL R m³/s - -
Exhaust gas volume (at exhaust gas temperature) – BL R m³/s 10,0 10,0
Exhaust gas temperature after engine – DL R °C - -
Exhaust gas temperature after engine – BL R °C 515 515

ID 1 2
Coolant temperature (at engine connection: outlet to cooling sys- A °C 100 100
tem)
Coolant temperature after engine, limit 1 L °C 102 102
Coolant temperature after engine, limit 2 L °C 104 104
Coolant antifreeze content, max. L % 50 50

ID 1 2
Coolant temperature (at engine connection: outlet to cooling sys- R °C 64 64
tem)
Coolant temperature before intercooler, limit 1 L °C 75 75
Coolant temperature before intercooler, limit 2 L °C - -
Coolant antifreeze content, max. L % 50 50
10. Lube oil system

ID 1 2
Lube oil temperature before engine, limit 1 L °C 99 99
Lube oil temperature before engine, limit 2 L °C 101 101

ID 1 2
High idling speed, max. (static) L rpm 1900 1900
Limit speed for overspeed alarm / emergency shutdown L rpm 1950 1950
Limit speed for overspeed message L rpm 1950 1950
Firing speed, from R rpm 80 80
Firing speed, to R rpm 120 120
18. Capacities
ID 1 2
Engine coolant, engine side (without cooling equipment) R Liters 175 175
Charge-air coolant, engine side R Liters 50 50
Fuel, engine side R Liters 8 8
Total engine oil capacity, initial filling (standard oil system) (op- R Liters 300 300
TIM-ID: 0000082106 - 001
Oil change quantity, max. (standard oil system) (option: max. op- R Liters 240 240
Oil pan capacity at dipstick mark “min.” (standard oil system) (op- L Liters 210 210
Oil pan capacity at dipstick mark “max.” (standard oil system) L Liters 240 240
(option: max. operating inclinations)

ID 1 2
Engine mass, dry (basic engine configuration acc. to scope of de- R kg 7700 7700
livery specification)
22. Acoustics
ID 1 2
Exhaust noise, unsilenced – DL (free-field sound pressure level R dB(A) - -
Lp, 1 m distance, ISO 6798, +3 dB(A) tolerance)
Exhaust noise, unsilenced – DL (sound power level LW, ISO 6798, R dB(A) - -
+3 dB(A) tolerance)
Exhaust noise, unsilenced – BL (free-field sound pressure level Lp, R dB(A) 118 118
1 m distance, ISO 6798, +3 dB(A) tolerance)
Exhaust noise, unsilenced – BL (sound power level LW, ISO 6798, R dB(A) 131 131
+3 dB(A) tolerance)
Engine surface noise with attenuated intake noise (filter) – DL R dB(A) - -
(free-field sound power level Lp, 1 m distance, ISO 6798,
+2 dB(A) tolerance)
Engine surface noise with attenuated intake noise (filter) – DL R dB(A) - -
(sound power level LW, ISO 6798, +2 db(A) tolerance)
Engine surface noise with attenuated intake noise (filter) – BL R dB(A) 107 107
(free-field sound pressure level Lp, 1 m distance, ISO 6798,
+2 dB(A) tolerance)
Engine surface noise with attenuated intake noise (filter) – BL R dB(A) 126 126
(sound power level LW, ISO 6798, +2 dB(A) tolerance)
TIM-ID: 0000082106 - 001

4.29 Product data 12V4000B24X, application 3A; 12V4000G14X,
application 3B; 12V4000G24X, application 3B; 12V4000G74X,
application 3D; 12V4000G84X, application 3D
Product type Application Speed Optimization
12V4000B24X 3A continuous op- 50 Hz Optimized fuel con- (→ Page 32), see Product data
eration sumption 12V400B24F, 3A continuous op-
eration, optimized fuel consump-
tion
60 Hz Optimized fuel con- (→ Page 32), see Product data
sumption 12V4000B24S, 3A continuous
operation, optimized fuel con-
sumption
12V4000G14X 3B continuous op- 50 Hz Optimized fuel con- (→ Page 36), see Product data
eration sumption 12V4000G14F, 3B continuous
sumption
sumption 12V4000G14S, 3B continuous
sumption
12V4000G14X 3B continuous op- 50 Hz TA-Luft-optimized (→ Page 36), see Product data
eration 12V4000G14F, 3B continuous
operation, TA-Luft-optimized
sumption
sumption
12V4000G74X 3D standby power 50 Hz Optimized fuel con- (→ Page 90), see Product data
sumption 12V4000G74F, 3D standby pow-
er, optimized fuel consumption
sumption 12V4000G74S, 3D standby pow-
TIM-ID: 0000082107 - 001

4.30 Product data 16V4000B24X, application 3A; 16V4000G14X,
application 3B; 16V4000G24X, application 3B; 16V4000G74X,
application 3D; 16V4000G84X, application 3D
Product type Application Speed Optimization
16V4000B24X 3A continuous op- 50 Hz Optimized fuel con- (→ Page 102), see Product data
eration sumption 16V400B24F, 3A continuous op-
eration, optimized fuel consump-
tion
sumption 16V4000B24S, 3A continuous
sumption
sumption
sumption
sumption
sumption
TIM-ID: 0000082108 - 001

4.31 Firing order
Cylinders Firing order
12V A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1
16V A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B7
TIM-ID: 0000023263 - 003

4.32 Main engine dimensions
Engine model Length (A) Width (B) Height (C)

12V4000Gx3 with 2-barrel HP fuel pump 2433.5 mm 1660.5 mm 2181.5 mm
12V4000Gx3 with 4-barrel HP fuel pump 2495 mm 1660.5 mm 2181.5 mm
16V4000Gx3 2981.3 mm 1660.5 mm 2181.5 mm
TIM-ID: 0000002133 - 003

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

months)
Item Action
Engine Depreserve (→ MTU Preservation and Represervation Specifications
A001070/.)
Valve drive Lubricate valve drive every ≥ 6 months (→ Page 235).
HP fuel pump Only for engines without oil priming pump:
Fill HP fuel pump with fresh engine oil (→ Page 241).
Lube oil system Check engine oil level (→ Page 284).
Engines with lube oil priming pump: Prime the engine for 20 seconds at a
pressure of at least 0.3 bar.
Only for engines without oil priming pump: Crank engine on starting system
without injecting fuel (→ Page 220).
Fuel prefilter Fill with fuel (→ Page 269), (→ Page 271).
Fuel prefilter, pressure Check low pressure indicator on switchable fuel prefilter (→ Page 268).
gauge
Coolant circuit If engine is out of service for more than one year, change engine coolant
(→ Page 293).
Change charge-air coolant (→ Page 314).
Coolant circuit Check engine coolant level (→ Page 292);
Check charge-air coolant level (→ Page 313).
Coolant circuit Heat engine coolant with coolant preheater.
Engine Control Unit Check plug-in connections (→ Page 331).
Monitoring system Carry out lamp test (see manufacturer's documentation).
Engine/generator control Switch on;
system Select operating mode, e.g. MANUAL OPERATION, AUTOMATIC OPERATION.
TIM-ID: 0000082294 - 001
178 | Operation | MS15038/00E 2018-06

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

Item Action
Lube oil system Check engine oil level (→ Page 284);
Coolant circuit Check engine coolant level (→ Page 292).
Check charge-air coolant level (→ Page 313).
Coolant circuit Heat engine coolant with coolant preheater.
Fuel prefilter Drain water (→ Page 263), (→ Page 265).
Monitoring system Carry out lamp test (see manufacturer's documentation).
Engine/generator control Switch ON;
system Select operating mode, e.g.: MANUAL, AUTOMATIC OPERATION.
TIM-ID: 0000074303 - 001
MS15038/00E 2018-06 | Operation | 179

5.3 Starting the engine in manual mode (test run)
Preconditions
☑ Generator (if fitted) is not connected to network
☑ External start interlock is not activated.
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Before cranking the engine with starter system, make sure that there are no persons in the engine's
danger zone.
WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
NOTICE
Re-starting the engine following an automatic safety shutdown.
Risk of severe engine damage!
• Before starting the engine, make sure the root cause of the safety shutdown was eliminated.
• If the root cause cannot be identified or eliminated, contact Service.
Preparation
Item Action
Operating mode switch (if Change to manual mode.
fitted)
Preheating pump (if fitted) Switch on.
Starting the engine

Item Action
Control cabinet, operator If coolant temperature is
station etc. (depending on • with preheater: min. 32 °C, max. 55 °C, recommended > 40 °C, or
manufacturer) • without preheater: > 10 °C:
Press start button.
• Automatic starting sequence is performed;
• Engine speed display instrument indicates increasing speed;
• After the starting sequence is completed, engine is running at rated
speed.
Connecting the generator (if fitted) to network, engine warm-up procedure to

TIM-ID: 0000077768 - 002
reach operating temperature

Item Action
Control cabinet, operator Close the generator circuit breaker.
station etc. (depending on
manufacturer)
Engine Do not connect to full load until the engine is at operating temperature (en-
gine coolant temperature, min. 60 °C, recommended 75 °C).
180 | Operation | MS15038/00E 2018-06

5.4 Re-starting the engine following an automatic safety
shutdown
NOTICE
Re-starting the engine following an automatic safety shutdown.
Risk of severe engine damage!
• Before starting the engine, make sure the root cause of the safety shutdown was eliminated.
• If the root cause cannot be identified or eliminated, contact Service.
Note: • If an engine has been shutdown by a fault (red alarm), the engine may only be re-started when the fault
has been identified and eliminated.
Procedure following an automatic safety shutdown

1. Eliminate fault.
2. If the root cause cannot be identified or eliminated, contact Service.
Important
The function "Overdrive safety system" (if fitted), which is only used in emergency situations, is not affect-
ed.
TIM-ID: 0000081383 - 001
MS15038/00E 2018-06 | Operation | 181

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

Item Action
Switchgear cabinet, control Activate pushbutton for Override input of the ECU.
panel etc. (depending on • Certain shutdown criteria and/or starting prerequisites are ignored.
manufacturer)
Switchgear cabinet, control Actuate start button, for further starting sequence, refer to engine start
panel etc. (depending on (→ Page 180).
manufacturer)
Control and display panels During operation, check the displayed operational data (speed, temperature,
pressures).
Constantly monitor plant limit values.
TIM-ID: 0000000984 - 003
182 | Operation | MS15038/00E 2018-06

5.6 Engine – Emergency start (Override mode)
DANGER
danger zone.
WARNING
WARNING
Exhaust gases are harmful to health and may cause cancer.
Risk of poisoning and suffocation!
• Keep the engine room well-ventilated at all times.
• Repair leaking exhaust pipework immediately.
NOTICE
Safety functions and engine shutdown alarms will be disregarded.
Severe material damage!
• Initiate emergency start only in emergency situations.
Preparation
Item Action
Operating mode selector Change to Override mode (Manual mode, if applicable).
switch
Starting the engine in emergency situations

Item Action
Control cabinet Actuate switch/button for ECU override input.
Control cabinet • Automatic starting procedure is performed; any safety functions and
alarms leading to engine shutdown are disregarded;
• Engine speed display instrument indicates increasing speed;
• After the starting sequence is completed, engine is running at rated
speed.
Connecting the generator (if fitted) to mains

Item Action
Control cabinet If generator is not connected to mains: Close the generator circuit breaker.
TIM-ID: 0000010665 - 003
Engine Operate engine at rated power.
MS15038/00E 2018-06 | Operation | 183

5.7 Operational monitoring
DANGER
Components are moving or rotating.
• Operate the engine at low load only. Keep clear of the danger zone of the engine.
WARNING
Operational monitoring
Item Action
Control and display panels Check readings of operating data (speed, temperature, pressures).
Plate Check for presence of emissions label and check readability and content (on-
ly for EPA area) (→ Page 185).
Engine oil Engine oil level – Check (→ Page 284)
Engine under load Check engine/plant and piping for leaks, repair leaky pipes with the engine
Engine at nominal speed stopped (exhaust lines and turbocharger turbine housings may be red-hot. If
the maximum exhaust temperatures are not exceeded, no restrictions in en-
gine operation are required).
Check for abnormal running noises and vibration.
Fuel prefilter Check fuel prefilter service indicator (if applicable) (→ Page 268).
Drain water and contaminants from fuel prefilter (if applicable) (→ Page 263),
(→ Page 265).
Exhaust system Check exhaust color (→ Page 194).
Intercooler Check condensate drain(s) for water discharge and obstruction
(→ Page 276).
Air filter Check signal ring position of contamination indicator (→ Page 280).
Replace air filter (→ Page 277), if the signal ring is completely visible in the
service indicator window.
Engine coolant pump Check relief bore (→ Page 298).
Charge-air coolant pump Check relief bore (→ Page 320).
Compressed-air system (if Check operating pressure on pressure gauge;
applicable) Always fill compressed-air tank to max. pressure;
Drain condensate from compressed-air tank, pressure drop must not exceed
1 bar.
TIM-ID: 0000081757 - 001
184 | Operation | MS15038/00E 2018-06

5.8 Emission label – Check
Emission label – Check

Note: If there are any irregularities, notify your MTU contact person/service partner without delay.
1. Check that emission labels are present (there can be more than one).
2. Check emission label for intactness.
3. Check that emission label is fully legible.
4. Check content of emission label:
• Does the label on the engine match the label document in the Business Portal/Equipment?
• Does the engine number on the emission label match the engine identification plate?
• Does the Manufacturing Date match the year of manufacture on the identification plate?
TIM-ID: 0000063752 - 002
MS15038/00E 2018-06 | Operation | 185

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

Item Action
Engine After opening the generator breaker (if applicable), allow to cool down off-
load for approx. 5 minutes.
Preparing the pump drive (diesel-mechanical / diesel-electric)

Item Action
Engine Allow to cool down for approx. 5 minutes at reduced engine speed. Observe
natural resonance of engine (installation-dependent)!
Engine shutdown
TIM-ID: 0000002285 - 005
Item Action
Control cabinet, operator Note: The engine may only be shut down using the Stop button in normal op-
station etc. (depending on eration.
manufacturer) Press Stop button.
• Automatic stopping sequence is performed;
• Engine is at standstill.
186 | Operation | MS15038/00E 2018-06

After engine shutdown
Item Action
Coolant circulating pump Allow to run on for sufficient time after stopping.
TIM-ID: 0000002285 - 005
MS15038/00E 2018-06 | Operation | 187

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

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

Item Action
Control cabinet, control pan- Press pushbutton for alarm acknowledgment.
el etc. (depending on manu- • Audible and visual alarm signaling stops.
facturer)
TIM-ID: 0000002305 - 004
188 | Operation | MS15038/00E 2018-06

5.11 After stopping the engine – Engine remains ready for
operation
After stopping the engine

Item Action
Engine/generator/pump Select operating mode, e.g. MANUAL, AUTOMATIC OPERATION.
control
TIM-ID: 0000000983 - 003
MS15038/00E 2018-06 | Operation | 189

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

Item Action
Coolant circuit Drain engine coolant (→ Page 294);
Drain charge-air coolant (→ Page 315) if:
• freezing temperatures are to be expected and the engine is to remain out
of service for an extended period and if no antifreeze has been added to
the coolant;
• the engine room is not heated;
• the coolant is not kept at a suitable temperature;
• the antifreeze concentration is insufficient for the engine-room tempera-
ture;
• antifreeze concentration is 50 % and engine-room temperature is below
-40 °C.
Engine/generator/pump Switch off.
control
Air intake and exhaust sys- If the engine is to remain out of service for more than 1 week, seal the en-
tem gine's air and exhaust sides. If the engine is to remain out of service for more
than 1 month, carry out preservation (→ Preservation and Represervation
Specifications A001070/..).
TIM-ID: 0000002706 - 003
190 | Operation | MS15038/00E 2018-06

5.13 Plant – Cleaning
Preconditions
☑ No operating voltage applied.

High-pressure cleaner (→ Tools Catalog) 1
Cleaner (Hakupur 50/136) X00056700 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
Water jet from high-pressure cleaning unit.
Risk of eye injury, risk of scalding!
• Do not direct water jet at persons.
• Wear protective clothing, protective gloves, and goggles/safety 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.
Cleaning the plant

1. Carry out plant cleaning only in areas where an appropriate oil separator is provided (environmental protec-
tion).
2. Prior to putting the cleaning unit into operation, read the operating instructions of the high-pressure cleaning
units carefully and observe the safety precautions.
3. The following requirements apply for cleaning the plant outside with a high-pressure cleaning unit:
• 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 - 034
• The temperature of the cleaning medium must not exceed 80 °C.

4. For external cleaning with high-pressure jet, use a fan jet nozzle only.
Note: Never direct 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 high-pressure jet to remove loosened dirt.
e) Dry engine with compressed air.
MS15038/00E 2018-06 | Operation | 191

6 Maintenance
6.1 Maintenance task reference table [QL1]
The required maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The
Maintenance Schedule is a separate publication.
The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance
Schedule.
Task Item Maintenance tasks
Option
WM00296 ENGINE GENERAL Carry out test run, minimum duration: until steady-state temperature is (→ Page 221)
reached, no less than 1/3 load (monthly)
WM00174 EMERGENCY AIR-SHUTOFF Check function of emergency air shut-off flaps X Not installed
FLAPS
WM00222 PREHEATER Check function of preheater and inspect for leaks X (→ Page 302)
WM00067 OIL CONDITIONING Replace oil filter at each oil change or when the time limit (years) is reached, at X (→ Page 288)
the latest
WM00148 PREHEATER Replace thermostat of preheater (electric) X (→ Page 309)
WM00297 FUEL INJECTOR Replace rings (→ Page 250)
WM00285 ENGINE GENERAL Check engine oil level (→ Page 284)
WM00286 ENGINE GENERAL Visually inspect engine for leaks and general condition (→ Page 184)
WM00289 ENGINE GENERAL Check engine for abnormal running noises, exhaust color and vibrations (→ Page 184)
WM00112 LABELS AND MISCELLANEOUS Check if emission label is present, check readability and content X (→ Page 185)
MATERIALS
WM00291 ENGINE GENERAL Check reading on differential pressure gauge of fuel prefilter X (→ Page 184)
WM00290 ENGINE GENERAL Drain water and contaminants from fuel prefilter X (→ Page 184)
WM00287 ENGINE GENERAL Check maintenance indicator on air filter X (→ Page 280)
WM00288 ENGINE GENERAL Check relief bore of coolant pump (→ Page 298),
(→ Page 320)
WM00063 OIL CONDITIONING Automatic centrifugal oil filter, automatic: Measure thickness of oil residue lay- X (→ Page 289)
er, clean, replace paper element at each engine oil change at the latest
WM00228 FUEL PIPEWORK FROM PUMP Check cooler elements for external contamination and leak-tightness X (→ Page 258)
TO FILTER
WM00069 LUBE OIL PUMP WITH DRIVE Inspect pump visually X (→ Page 287)
WM00050 ENGINE MOUNTING Check general condition of rubber mount (visual inspection) X (→ Page 324)
WM00136 ENGINE MOUNTING Check firm seating of securing screws X (→ Page 325)
WM00189 ENGINE MOUNTING Check general condition of resilient genset mounts (visual inspection) X (→ Page 327)
WM00188 ENGINE MOUNTING Check genset mount securing screws for firm seating X (→ Page 328)
WM00084 FUEL PREFILTER Fuel prefilter, replace filter X (→ Page 269)
(→ Page 271)
WM00086 FUEL FILTER Replace easy-change fuel filter (→ Page 261)
WM00245 EMERGENCY AIR-SHUTOFF Lubricate emergency air-shutoff flap lubrication points X Not installed
FLAPS
TIM-ID: 0000081881 - 001
WM00066 OIL CONDITIONING Automatic oil filter, check and clean filtering screen X Not installed
WM00170 BATTERY-CHARGING GENERA- Check condition of belt and replace as necessary. Adjust belt tension X (→ Page 321),
TOR (→ Page 322)
WM00664 COOLANT EXPANSION TANK Replace valve cover (→ Page 312)
WM00076 AIR FILTER Replace air filter X (→ Page 277)
WM00692 CRANKCASE BREATHER Replace filter or filter element X (→ Page 229)
WM00098 CYLINDER HEAD Measure valve protrusion (→ Page 231)
WM00094 VALVE DRIVE Check valve clearance, adjust as necessary. IMPORTANT! Initial setting after (→ Page 236)
1,000 operating hours and every overhaul of cylinder heads after 1,000 operat-
ing hours
192 | Maintenance | MS15038/00E 2018-06

Task Item Maintenance tasks
Option
WM00106 CRANKCASE BREATHER Replace oil separator X (→ Page 226)
WM00119 CRANKCASE BREATHER Replace filter or filter element X (→ Page 229)
WM00110 CRANKCASE Perform endoscopic examination of cylinder liner (→ Page 222)
WM00090 FUEL INJECTOR Replace fuel injection valve/injector (→ Page 244)
WM00089 FUEL INJECTOR Reset drift compensation (CDC) parameter (→ Page 333)
WM00040 PREHEATER Overhaul preheating unit X (→ Page 303)
Table 2: Maintenance task reference table [QL1]

TIM-ID: 0000081881 - 001
MS15038/00E 2018-06 | Maintenance | 193

7 Troubleshooting
7.1 Troubleshooting
Engine does not turn when starter is actuated
Cause Corrective action
Battery low or faulty u Charge or replace (→ manufacturer's documentation).
Cable connections faulty u Check cable connections for secure seating (→ manufacturer's
documentation).
Starter (electric): Engine cabling u Check whether cable connections are properly secured.
or starter faulty Contact Service.
Starter (compressed air): Cabling u Check whether cable connections are properly secured.
on starting valve or starter Contact Service.
defective
Engine wiring faulty u Check (→ Page 329).
Engine / generator control: u Perform visual inspection (→ manufacturer's documentation).
Assemblies or connectors
possibly loose
Engine governor: Plug-in u Check plug-in connections (→ Page 331).
connections loose
Running gear blocked (engine u Contact Service.
cannot be barred manually)
Engine turns on starting but does not fire

Poor rotation by (electric) starter: u Charge or replace (→ manufacturer's documentation).
Battery low or faulty
Poor rotation by (air) starter: u Check compressed air system.
Pressure too low.
Air in fuel system u Vent fuel system (→ Page 256).
Engine governor defective u Contact Service.
Engine fires unevenly

Injector defective u Check, replace as necessary (→ Page 244).
TIM-ID: 0000074300 - 001

194 | Troubleshooting | MS15038/00E 2018-06

Engine does not reach nominal speed
Fuel prefilter (not switchable) u Replace (→ Page 269).
clogged
Fuel prefilter (switchable) clogged. u Replace (→ Page 271).
Fuel filter clogged u Replace (→ Page 261).
Air filter clogged u Check signal ring position of service indicator (→ Page 280).
Injector defective u Replace (→ Page 244).
Engine: Overload u Contact Service.
Engine speed not steady

Speed transmitter defective u Contact Service.
Charge-air temperature too high

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

Air pipework leaking u Check air pipework for leakage.
Intercooler dirty u Contact Service.
Exhaust turbocharger defective u Contact Service.
Coolant discharge at intercooler

TIM-ID: 0000074300 - 001
Leaking, major coolant discharge u Contact Service.
Black exhaust gas

Engine: Overload u Contact Service.
MS15038/00E 2018-06 | Troubleshooting | 195

Blue exhaust gas
Too much engine oil in the engine u Drain engine oil (→ Page 282).
Oil separator of crankcase u Replace filter (→ Page 226).
breather contaminated
Exhaust turbocharger, cylinder u Contact Service.
head, piston rings or cylinder liner
defective
White exhaust gas

Engine is not at operating u Run engine to reach operating temperature.
temperature
Water in fuel u Check fuel system on fuel prefilter;
Drain water from fuel prefilter (not switchable) (→ Page 263).
Drain fuel prefilter (switchable) (→ Page 265).
Intercooler leaky u Contact Service.
TIM-ID: 0000074300 - 001

7.2 Fault messages
Possible engine responses to yellow alarm:
Warning, power limitation/reduction, speed limitation, engine shutdown
Possible engine responses to red alarm:

Engine shutdown, power limitation/reduction, speed limitation, warning
Procedure following an automatic safety shutdown (→ Page 181)
3 – HI T-Fuel
The fuel temperature at sensor 1. Reduce power.
B33 has violated limit value 1. 2. Check fuel cooling system (if applicable).
Fuel temperature is too high. 3. Contact Service.
4 – SS T-Fuel
The fuel temperature at sensor 1. Reduce power.
B33 has violated limit value 2. 2. Check fuel cooling system (if applicable).
Fuel temperature is too high. 3. Contact Service.
5 – HI T-Charge Air
The charge-air temperature at 1. Reduce power.
sensor B9 has violated limit value 2. Check whether alarms 9 and 10 are signaled.
1. Charge-air temperature is too 3. Contact Service.
high.
6 – SS T-Charge Air
The charge-air temperature at 1. Reduce power.
sensor B9 has violated limit value 2. Check whether alarms 9 and 10 are signaled.
2. Charge-air temperature is too 3. Contact Service.
high.
9 – HI T-Coolant Intercooler
TIM-ID: 0000082405 - 001

The intercooler coolant 1. Reduce power.
temperature measured at sensor 2. Check whether alarm 23 is signaled.
B26.has violated limit value 1. The 3. Check cooler (plant) for contamination.
intercooler coolant temperature is 4. Check fan operation (plant).
too high. 5. Contact Service.

10 – SS T-Coolant Intercooler
The intercooler coolant 1. Reduce power.
temperature measured at sensor 2. Check whether alarm 23 is signaled.
B26 has violated limit value 2. The 3. Check cooler (plant) for contamination.
intercooler coolant temperature is 4. Check fan operation (plant).
too high. 5. Contact Service.
15 – LO P-Lube Oil
The lube oil pressure at sensor 1. Check engine oil level (→ Page 284).
B5.1 has violated lower limit value 2. Contact Service.
1. Lube oil pressure is too low.
16 – SS P-Lube Oil
The lube oil pressure at sensor 1. Check engine oil level (→ Page 284).
B5.1 has violated lower limit value 2. Contact Service.
2. Lube oil pressure is too low.
23 – LO Coolant Level
Coolant level at level switch B533 1. Check engine coolant level (→ Page 292).
in HT circuit is too low. 2. Check relief bore of engine coolant pump (→ Page 298).
3. Check cooling circuit visually for leaks.
4. Contact Service.
25 – HI P-Diff-Lube Oil
The differential oil pressure at 1. Replace engine oil filter (→ Page 288).
sensors B5.1 and B5.3 has 2. Contact Service.
violated upper limit value 1. The
differential oil pressure is too
high.
26 – SS P-Diff-Lube Oil
The differential oil pressure at 1. Replace engine oil filter (→ Page 288).
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sensors B5.1 and B5.3 has 2. Contact Service.

violated limit value 2. The
differential oil pressure is too
high.

27 – HI Level Leakage Fuel
Switch F46 in the collecting tank u Contact Service.
has been tripped. The HP fuel
system is leaking.
30 – SS Engine Overspeed
Engine speed has violated the 1. Restart the engine if the emergency stop was tripped by the engine
limit value or the engine overspeed test.
overspeed test has been tripped. 2. Contact Service if the emergency stop was tripped by the engine.
An emergency engine shutdown
has been initiated.
31 – HI ETC1 Overspeed
The speed of the LP turbocharger, 1. Reduce power.
A side, at sensor B44.1 has 2. Contact Service.
violated limit value 1. The exhaust
turbocharger speed is too high.
Cause: Fault or malfunction of
another exhaust turbocharger.
32 – SS ETC1 Overspeed
The speed of the A side LP 1. Reduce power.
turbocharger at sensor B44.1 has 2. Contact Service.
violated limit value 2. The exhaust
turbocharger speed is too high.
Cause: Fault or malfunction of
another exhaust turbocharger.
44 – LO Coolant Level Intercooler

Coolant level in LT circuit at 1. Check charge-air coolant level (→ Page 313).
switch B557 is too low. 2. Check relief bore of charge-air coolant pump (→ Page 320).
3. Check cooling circuit visually for leaks.
4. Contact Service.
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51 – HI T-Lube Oil
The lube oil temperature at sensor 1. Reduce power.
B7 has violated limit value 1. Lube 2. Check operation of cooler and fan (plant).
oil temperature is too high. 3. Check engine coolant level (→ Page 292).
4. Contact Service.

52 – SS T-Lube Oil
The lube oil temperature at sensor 1. Check operation of cooler and fan (plant).
B7 has violated limit value 2. Lube 2. Check engine coolant level (→ Page 292).
oil temperature is too high. 3. Contact Service.
59 – SS T-Coolant L3
The coolant temperature at 1. Check operation of cooler and fan (plant).
sensor B6 has violated upper limit 2. Check engine coolant level (→ Page 292).
value 3. Coolant temperature is 3. Contact Service.
too high.
60 – SS T-Coolant L4
sensor B6 has violated upper limit 2. Check engine coolant level (→ Page 292).
value 4. Coolant temperature is 3. Contact Service.
too high.
63 – HI P-Crank Case
The crankcase pressure at sensor 1. Stop engine.
B50 has violated upper limit value 2. Contact Service.
1. The crankcase pressure is too
high.
64 – SS P-Crank Case
The crankcase pressure at sensor 1. Stop engine.
2. The crankcase pressure is too
high.
65 – LO P-Fuel
The fuel pressure at sensor B34.1 1. Replace fuel prefilter (→ Page 269) (→ Page 271).
has violated limit value 1. Fuel 2. Replace fuel filter (→ Page 261).
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pressure is too low. 3. Contact Service.
66 – SS P-Fuel
The fuel pressure at sensor B34.1 1. Replace fuel prefilter (→ Page 269) (→ Page 271).
has violated limit value 2. Fuel 2. Replace fuel filter (→ Page 261).
pressure is too low. 3. Contact Service.

67 – HI T-Coolant
The coolant temperature at 1. Reduce power.
sensor B6 has violated limit value 2. Check operation of cooler and fan (plant).
1. Coolant temperature is too 3. Check engine coolant level (→ Page 292).
high. 4. Contact Service.
68 – SS T-Coolant
sensor B6 has violated limit value 2. Check engine coolant level (→ Page 292).
2. Coolant temperature is too 3. Contact Service.
high.
82 – HI P-Fuel (Common Rail)

The HP fuel pressure at sensor u Contact Service.
B48 has violated the limit value.
Fuel pressure is too high.
83 – LO P-Fuel (Common Rail)

B48 has violated the limit value.
Fuel pressure is too low.
89 – SS Engine Speed too low

The engine speed has violated the 1. Acknowledge alarm.
limit value. An emergency engine 2. Observe any other messages.
shutdown has been initiated. 3. Contact Service.
90 – SS Idle Speed Not Reached

The engine has failed to reach idle 1. Check pressure supply (plant) of starter.
speed within the defined time 2. Check fuel filter, replace as necessary (→ Page 261).
after reaching starter 3. Check fuel prefilter, replace as necessary.
disengagement speed. 4. Observe any other messages.
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5. Contact Service.
91 – SS Release Speed Not Reached

The engine has failed to reach 1. Check pressure supply (plant) of starter.
starter disengagement speed 2. Observe any other messages.
within the defined time after 3. Contact Service.
reaching starter speed.

92 – SS Starter Speed Not Reached
The engine has failed to reach the 1. Check pressure supply (plant) of starter.
defined speed threshold within 2. Observe any other messages.
the defined time. 3. Contact Service.
93 – SS T-Preheat
The engine coolant temperature u Contact Service.
has failed to reach the defined
limit value 2. Preheater is out of
order. Start interlock.
94 – LO T-Preheat
The engine coolant temperature u Contact Service.
has failed to reach the defined
limit value 1. Preheater is out of
order.
95 – AL Prelubrication Fault
The oil pressure at sensor B5.1 1. Check engine cabling (→ Page 329).
has violated the specified value. 2. Contact Service.
The specified oil pressure was not
reached. The starting sequence
was terminated.
118 – LO ECU Power Supply Voltage

The ECU supply voltage has 1. Check condition of batteries (plant).
violated lower limit value 1. 2. Check plug connections to Engine Control Unit (→ Page 331).
3. Check battery charging-generator.
4. Contact Service.
119 – LOLO ECU Power Supply Voltage

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violated lower limit value 2. 2. Check plug connections to Engine Control Unit (→ Page 331).
4. Contact Service.

120 – HI ECU Power Supply Voltage
violated upper limit value 1. 2. Check plug connections to Engine Control Unit (→ Page 331).
4. Contact Service.
321 – AL Wiring Cylinder A1

Short circuit fault in the injector 1. Check wiring of affected injector (→ Page 329).
wiring for cylinder A1 or injector 2. Replace injector (→ Page 244).
defective. 3. Contact Service.




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Short circuit fault in injector 1. Check wiring of affected injector (→ Page 329).
wiring cylinder A9 or injector 2. Replace injector (→ Page 244).

wiring cylinder A10 or injector 2. Replace injector (→ Page 244).
331 – AL Wiring Cylinder B1

wiring for cylinder B1 or injector 2. Replace injector (→ Page 244).


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wiring cylinder B9 or injector 2. Replace injector (→ Page 244).

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341 – AL Open Load Cylinder A1
Disruption fault in injector wiring 1. Check wiring of affected injector (→ Page 329).
to cylinder A1. 2. Contact Service.

for cylinder A2. 2. Contact Service.






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351 – AL Open Load Cylinder B1

to cylinder B1. 2. Contact Service.





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365 – AL Stop MV-Wiring Ground

Short circuit of injector positive 1. Check wiring (→ Page 329).
connection to ground of one or 2. Restart engine.
more injectors. Short circuit of 3. Contact Service.
injector negative connection to
ground of one or more injectors.
448 – HI P-Charge Air

The charge-air pressure at sensor 1. Power reduction.
B10 has violated upper limit value 2. Check sensor B10 and replace as necessary.
1. The charge-air pressure is too 3. Contact Service.
high.
449 – SS P-Charge Air

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The charge-air pressure at sensor 1. Power reduction.
B10 has violated limit value 2. The 2. Check sensor B10 and replace as necessary.
charge-air pressure is too high. 3. Contact Service.

454 – SS Power Reduction Active
Power reduction activated. A main 1. Observe any other messages.
alarm activating power reduction 2. Contact Service.
has been tripped.
510 – AL Override applied

The Override function was u No action required.
activated. Override suppresses
other alarms.
536 – AL Wiring PWM_CM1

HP fuel control block M8 of the 1. Check engine cabling (→ Page 329).
HP fuel pump cannot be activated. 2. Contact Service.
745 – AL Emission Fault

Summary emission fault alarm 1. Observe any other messages.
2. Contact Service.
759 – AL L1 T-Fuel b.Engine

The charge-air pressure at sensor 1. Check sensor B33, replace as necessary.
1. The fuel temperature before the
engine is too high.
760 – AL L2 T-Fuel b.Engine

The charge-air pressure at sensor 1. Check sensor B33, replace as necessary.
2. The fuel temperature has
violated the critical upper limit
value.
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833 – AL Emission Warning

2. Contact Service.

834 – AL Gas Path Warning
2. Contact Service.
835 – AL Gas Path Fault

2. Contact Service.
1024 – LOLO P-Fuel (Common RailA)

B48.1 has violated lower limit
value 2. Fuel pressure is too low.
1032 – AL Inj. Drift Limit 1 Cyl. A1

The drift correction for u Schedule an injector replacement.
energization (start and duration)
of injector A1 has violated limit 1.
The injector will soon reach its
maximum drift limit.


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of injector A10 has violated limit
1. The injector will soon reach its

1042 – AL Inj. Drift Limit 1 Cyl. B1
of injector B1 has violated limit 1.




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of injector B10 has violated limit
1. The injector will soon reach its

The drift correction for u Replace injector (→ Page 244).
The injector has reached its
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of injector A10 has violated limit
2. The injector has reached its



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of injector B10 has violated limit
2. The injector has reached its

1170 – AL Permanent Injection
The ECU has detected continuous u Contact Service.
injection at one or more injectors
based on the pressure gradient in
the HP fuel system (B48).
1174 – HI T-Fuel f(T0)

The charge-air pressure at sensor 1. Reduce power.
B33 has violated upper limit value 2. Check fuel cooling system (if applicable).
1. Fuel temperature is too high. 3. Contact Service.
1175 – SS T-Fuel f(T0)

The charge-air pressure at sensor 1. Reduce power.
B33 has violated upper limit value 2. Check fuel cooling system (if applicable).
1. The fuel temperature has 3. Contact Service.
violated the critical upper limit
value.
1376 – AL Refdrive Impossibl Ubat Low

The ECU supply voltage is two low 1. Check condition of batteries (plant).
for successful homing of all flaps 2. Check plug connections to Engine Control Unit (→ Page 331).
even when the engine is running. 3. Contact Service.
1377 – AL Refdrive Impossibl Eng Op Point

Homing of one or more flaps 1. Run engine up to idling speed. Result: Homing is executed.
before engine start was not 2. Contact Service.
completed successfully. Homing
the affected flaps is no longer
possible.
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8 Task Description
8.1 Engine
8.1.1 Engine – Barring manually
Preconditions

Barring tool F6555766 1
Ratchet with extension F30006212 1
DANGER
danger zone.
Barring engine manually

1. Loosen screws (1) and remove end cover (2)
from flywheel housing.
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218 | Task Description | MS15038/00E 2018-06

2. Engage barring tool (2) in ring gear of fly-
wheel and mount on flywheel housing.
3. Fit ratchet (1) on barring tool.
Note: No resistance other than compression resist-
ance must be encountered.
4. Rotate crankshaft in engine direction of rota-
tion.
Result: If the resistance exceeds the normal com-
pression resistance, contact Service.
5. For barring tool removal follow reverse se-
quence of working steps.
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MS15038/00E 2018-06 | Engine | 219

8.1.2 Engine – Cranking on starting system
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.
Note: Crank the engine on the starting system in the following cases only:
• To prime the engine: Procedure for engines without lube oil priming pump only. Use the lube oil priming
pump to prime engines equipped with such (→ Page 178).
• Before starting the engine in a contingency situation to maintain operation of a leaking intercooler
(→ Page 276).
.
Cranking engine on starting system

Note: • The engine must not start and no fuel may be injected when cranking.
• The ECU must by energized in order to crank the engine.
1. Choose one of the following procedures:
a) External starting sequence: The Stop signal is applied at the ECU. The starters are energized by the plant
controller.
b) Internal starting sequence: The engine can be cranked on the starter without injecting fuel via CAN-
J1939, SPN 1206.
Note: Leave intervals between cranking operations to avoid overheating the starter.
2. Perform the following steps three times in a row:
a) Crank the engine for 15 seconds.
b) Wait 60 seconds.
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220 | Engine | MS15038/00E 2018-06

8.1.3 Engine – Test run
DANGER
WARNING
WARNING
Engine – Test run

1. Start engine (→ Page 180).
2. Perform test run not below 1/3 load and at least until steady-state temperature is reached.
3. Carry out operational checks (→ Page 184).
4. Stop engine (→ Page 186).
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MS15038/00E 2018-06 | Engine | 221

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

Barring tool F6555766 1
Ratchet with extension F30006212 1
Endoscope Y20097353 1
Preparatory steps
1. Remove cylinder head cover (→ Page 240).
2. Remove injector (→ Page 245).
Positioning crankshaft at BDC

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

Findings Measure
• Thin carbon coating around carbon scraper ring No actions required.
• Slight localized additive deposits at top edge
• Localized smooth areas at bottom edge
• Carbon deposits on entire circumference between top piston ring and
bottom edge of carbon scraper ring
• First signs of marks left by top piston ring
• Bright mark on entire circumference
• Faultless, even honing pattern
• First signs of marks left by lower cooling bores
• Running pattern seems darker
• Dark areas with even or varying degrees of discoloration Further endoscopic examina-
• Beginning and end of the discoloration are not sharply defined and do tion required as part of mainte-
not cover the entire stroke area nance work.
• Dark areas in the upper section of the cooling bore, remaining circum-
ference are faultless
• Piston rings are faultless
• On the entire circumference, apart from light areas of discoloration (do Cylinder liner must be replaced,
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not impair operation) clearly darker stripes that start at the top piston contact Service.
ring
• Heat discoloration in the direction of stroke and honing pattern dam-
age
• Heat discoloration of piston rings
222 | Cylinder Liner | MS15038/00E 2018-06

1. Compile endoscopic report using the table.
2. Use technical terms to describe the liner surface (→ Page 224).
3. Depending on findings:
• Do not take any action or
• carry out a further endoscopic examination as part of maintenance work or
• contact Service; cylinder liner must be replaced.
Final steps
1. Install injector (→ Page 245).
2. Install cylinder head cover (→ Page 240).
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8.2.2 Cylinder liner – Instructions and comments on endoscopic and visual
examination
Terms used for endoscopic examination
Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic examina-
tion report.
Findings Explanations/Action
Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing products,
particles, broken-off burrs). Removed cylinders clearly show such scoring on the
running surface under endoscope magnification. Cannot be felt with the fingernail.
Findings not critical
Single scores Clearly visible scores caused by hard particles. They usually start in the TDC area
and cross through the honing pattern in the direction of stroke.
Scored area These areas consist of scores of different length and depth next to one another. In
most cases, they are found at the 6-o'clock and 12-o'clock positions (inlet/
exhaust) along the transverse engine axis.
Polished area Polished areas are on the running surface but almost the whole honing pattern is
still visible. Polished areas appear brighter and more shiny than the surrounding
running surface.
Bright area Bright areas are on the running surface and show local removal of the honing pat-
tern. Grooves from the honing process are not visible any more.
Discoloration This is caused by oxidation (surface discoloration through oil or fuel) and tempera-
ture differences around the liner. It appears rather darker within the honed struc-
ture in contrast to the bright metallic running surface. The honing pattern is undis-
turbed. Discolorations extend in stroke direction and may be interrupted.
Corrosion fields / Corrosion fields / spots result from moisture (condensate) with the valves in the
spots overlap (open) position. They are clearly visible due to the dark color of the honing
groove bottom.
This corrosion is not critical unless there is corrosion pitting.
Black lines Black lines are a preliminary stage of burn marks. They are visible as a clear discol-
oration from TDC to BDC in the running surface and the start of localized damage
to the honing pattern.
Cylinder liners with a large number of black lines around the running surface have
limited service life and should be replaced.
Burn mark These are caused by a disturbance in the liner / ring tribo system. Usually they run
over the whole ring-travel area (TDC/BDC), starting at the first TDC-ring and be-
coming more visible from the second TDC-ring 2 onwards and less pronounced
from TDC-ring 1. The honing pattern is usually no longer visible and displays a
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clearly defined (straight) edge to the undisturbed surface. The damaged surface is
usually discolored. The circumferential length varies.
Liners with burn marks starting in TDC ring 1 have to be replaced.
Seizure marks, scuff- Irregular circumference lengths and depths. Can be caused either by the piston
ing skirt or the piston crown. Material deposits on the liner (smear), heavy discolora-
tion. Severe, visible scoring.
Replace liner.
Table 3: Endoscopic examination – Terms used
224 | Cylinder Liner | MS15038/00E 2018-06

Evaluation of findings and further measures
The findings in the start phase of oxidation discoloration and burn marks are similar. A thorough investigation
and compliance with the above evaluation criteria allow an unambiguous evaluation. To avoid unnecessary
disassembly work, it is recommended that another inspection be carried out after further operation of the
engine.
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MS15038/00E 2018-06 | Cylinder Liner | 225

8.3 Crankcase Breather
8.3.1 Crankcase breather – Oil separator element replacement
Preconditions

Ratchet bit F30027340 1
Engine oil
Filter element (→ Spare Parts Catalog)
O-ring (→ Spare Parts Catalog)
WARNING
Oil is hot.
Oil can contain residue/substances which are harmful to health.
Risk of injury and poisoning!
• Allow the product to cool to below 50 °C before beginning work.
• Wear protective clothing, protective gloves and goggles/safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.
Replacing oil separator element

– Variant A
1. Remove securing screws (2) for cover (1)
with screwdriver.
2. Remove cover (1) with O-ring.
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226 | Crankcase Breather | MS15038/00E 2018-06

3. Remove filter element (1) from housing (2).
4. Insert new filter element in housing.
5. Install cover with new O-ring.
6. Tighten cover screws to specified torque using a torque wrench.

Screw Tightening torque (Engine oil) 6 Nm +2 Nm
7. Replace further oil separator filter elements in the same way.
Replacing oil separator element

– Variant B
1. Remove securing screws (2) for cover (1)
with screwdriver.
2. Remove cover (1) and O-ring.
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3. Remove filter element (1) from oil separator
housing (2).
4. Insert new filter element in housing.
5. Install cover with new O-ring.
6. Tighten cover screws tighten to specified torque using a torque wrench.

Screw Tightening torque (Engine oil) 8 Nm +1 Nm
7. Replace further oil separator filter elements in the same way.
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8.3.2 Crankcase breather – Filter element replacement
Preconditions

Assembly compound (Kluthe Hakuform 30-10) X00067260 1
Engine oil
Filter insert (→ Spare Parts Catalog) 3
O-ring (→ Spare Parts Catalog) 3
WARNING
Oil is hot.
Filter element – Replacement

1. Release clamp (2) and remove hose (3) from
cover (1).
2. Undo clamp (6) and remove cover (1).
3. Remove air filter (5) with filter mounts (4).
4. Remove O-ring (9) from adapter (8).
5. Coat new O-ring (9) with assembly compound
and insert in groove on adapter (8).
6. Insert filter holder (4) in correct position in
adapter (8).
7. Place new air filter (5) in correct position on
filter holder (4).
Note: Angular position of air filter cover
(→ Step 13).
8. Insert filter holder (4) in correct position in
cover (1) and mount cover (1).
9. Coat thread and nut mating face on clamp (6)
with engine oil.
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10. Tighten clamp (6) to specified tightening torque.

Clamp Tightening torque (Engine oil) 9 Nm +1 Nm
11. Install hose (3) and tighten clamp (2) with torque wrench to the specified torque.
Clamp Tightening torque 5 Nm +1 Nm
12. Replace other oil separator filter elements in the same way.
MS15038/00E 2018-06 | Crankcase Breather | 229

13. Observe angular position of air filter covers.
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8.4 Valve Drive
8.4.1 Valve protrusion – Measurement
Preconditions

Measuring jig 1 Y4350009 1
Depth gage, 200 mm Y20000918 1
Measuring jig 2, optional Y4350010 1
Preparatory steps
1. Remove cylinder head covers (→ Page 240).
2. Install barring tool (→ Page 218).
3. Turn crankshaft in direction of rotation using
barring tool until TDC mark (1) and pointer (2)
are aligned.
Calibrating measuring jigs 1 and

2
1. Place measuring unit (2) on calibration
plate (3).
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MS15038/00E 2018-06 | Valve Drive | 231

2. Turn measuring unit screws (1) into the threads and tighten to specified torque using a torque wrench.
Screw M10 Tightening torque 20 Nm
3. Set all dial gages to 0.

4. Unscrew measuring unit (2) from calibration plate (3).
Step 1: Measure valve protrusion at the valve head with measuring jig 1
1. Check TDC position of piston in cylinder A1:
• If rocker arms on cylinder A1 are unloaded, the piston is in firing TDC.
• If rocker arms on cylinder A1 are loaded, the piston is in overlap TDC.
2. Measure valve stem end to cylinder head top distance for each valve in two crankshaft positions (firing TDC
and overlap TDC) according to the diagram. Diagram (→ Page 236).
3. Place measuring unit 1 (2) on the cylinder
head (3).
4. Turn measuring unit screws (1) into the threads provided for the cylinder head cover and tighten to specified
torque using a torque wrench.
5. Determine the values with all dial gages.

• The valve protrusion value must be ≤ 1.5 mm.
• If the value is > 1.5 mm, measure with a depth gage or optionally with measuring jig 2.
6. Unscrew measuring unit (2) from cylinder head (3).
Step 2: Measure valve protrusion at the valve stem with a depth gage
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232 | Valve Drive | MS15038/00E 2018-06

3. Release adjusting screw (1) and remove valve
bridge. Do not remove rocker arm (2).
4. Measure distance (A) between valve stem

end and cylinder head top at the injector
bore with depth gage.
• The specified value for a new cylinder
head: 93.8 mm.
• Admissible wear: 2 mm.
• Have the affected cylinder head replaced
by expert personnel ahead of schedule if
the measured value is > 95.8 mm.
5. Install valve bridge.
6. Adjusting valve clearance (→ Page 236)
Step 2 optional: Measure valve protrusion at the valve stem with measuring
jig 2
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MS15038/00E 2018-06 | Valve Drive | 233

Note: Do not remove rocker arm (2).
3. Release adjusting screw (1) and remove valve
bridge.
4. Place measuring unit 2 (2) on the cylinder

head (3).
5. Turn measuring unit screws (1) into the threads provided for the cylinder head cover and tighten to specified
torque using a torque wrench.
6. Determine the values with all dial gages.

• The valve protrusion value must be ≤ 2 mm.
• Have the affected cylinder head replaced by expert personnel if the value is > 2 mm.
7. Unscrew measuring unit (2) from cylinder head (3).
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8. Install valve bridge.

9. Adjusting valve clearance (→ Page 236)
Final steps
1. Remove barring tool (→ Page 218).
234 | Valve Drive | MS15038/00E 2018-06

8.4.2 Valve gear – Lubrication
Preconditions

Engine oil
Valve gear – Lubrication

2. Fill oil chambers of valve bridges with oil.
3. Fill oil chambers of rocker arms and adjusting
screws with oil.
4. Install cylinder head covers (→ Page 240).
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MS15038/00E 2018-06 | Valve Drive | 235

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

Feeler gauge Y20098771 1
Valve setting gauge Y4349603 1
Angular screw driver F30002815 1
Socket wrench, 24 mm F30039526 1
Engine oil
Preparatory steps
2. Install barring tool (→ Page 218).
Note: Pointer (1) is located in the lower opening of
the flywheel housing (arrow).
3. Use barring tool to turn crankshaft in direc-
tion of rotation until marking OT/A1 on the
rear side of the flywheel housing and point-
er (1) are aligned.
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236 | Valve Drive | MS15038/00E 2018-06

Note: Danger of confusion: There might be an addi-
tional OT/A1 mark (1) on the outer perimeter
of the flywheel.
4. The additional OT/A1 mark (1) (if applicable)
on the outer perimeter of the flywheel must
not be used for reference.
Diagram for 8V engines – Two

crankshaft positions

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MS15038/00E 2018-06 | Valve Drive | 237


Checking valve clearance at two crankshaft positions

• If the rocker arms are unloaded on cylinder A1, the piston is in firing TDC.
• If the rocker arms are under load on cylinder A1, the piston is in overlap TDC.
2. Check valve clearance adjustment with cold engine:
• Inlet valves (long rocker arm) = 0.2 mm ±0.05 mm
• Exhaust valves (short rocker arm) = 0.5 mm ±0.05 mm
3. Check all valve clearances in two crankshaft positions (firing TDC and overlap TDC of cylinder A1) as per
diagram:
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1 Cylinder A1 is in firing TDC

2 Cylinder A1 is in overlap TDC
I Inlet valve
X Exhaust valve
4. Use valve setting gauge or feeler gauge to determine the distance between valve bridge and rocker arm.
5. If the deviation from the set value exceeds 0.1 mm, adjust valve clearance.
238 | Valve Drive | MS15038/00E 2018-06

Adjusting valve clearance
1. Release locknut (1).
2. Insert valve setting gauge (3) between valve
bridge and rocker arm.
Note: Replace or rectify adjusting screws and/or
locknuts which do not move freely.
3. Using angular screw driver, set adjusting
screw (2) so that the specified valve clear-
ance is provided.
Note: Valve setting gauge must just pass through
the gap.
4. Pass valve setting gauge (3) between valve
bridge and rocker arm.
5. Tighten locknut (1) to specified torque using a torque wrench, holding the adjusting screw (2) in place to
prevent it from turning.
Locknut M16x1.5 Tightening torque (Engine oil) 90 Nm +9 Nm
6. Check valve clearance, adjust as necessary.
Final steps
1. Remove barring tool (→ Page 218).
2. Install cylinder head covers (→ Page 240).
TIM-ID: 0000000922 - 016
MS15038/00E 2018-06 | Valve Drive | 239

8.4.4 Cylinder head cover – Removal and installation
Preconditions

Profile gasket (→ Spare Parts Catalog)
Removing cylinder head cover

1. Clean very dirty cylinder head covers (1) prior
to removal.
2. Remove screws (2) together with wash-
ers (3).
3. Remove cylinder head cover together with
profile gasket (4) from cylinder head.
Installing cylinder head cover

1. Clean installation surface.
2. Check profile gasket (4) for damage and replace as necessary.
3. Coat profile gasket with assembly compound.
4. Insert profile gasket in groove on cylinder head cover (1).
5. Fit cylinder head cover (1) on cylinder head.
6. Install cylinder head cover with screws (2) and washers (3).
TIM-ID: 0000081659 - 001
240 | Valve Drive | MS15038/00E 2018-06

8.5 Injection Pump / HP Pump
8.5.1 HP fuel pump – Filling with engine oil
Preconditions

Fuel suction pipe F30378207 1
Engine oil
WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.
WARNING
Liquid or gaseous media, e.g. fuel, are poisonous.
Escaping vapors of highly volatile media, e.g. fuel or ether.
Risk of fatal injury through swallowing; risk of poisoning through inhalation; irritation to eyes
and skin!
• Seek medical attention immediately; do not induce vomiting.
• Do not inhale vapors or mist.
• Wear protective clothing, protective gloves, and safety glasses.
• If contact is made with skin, wash off with water and soap.
WARNING
Oils/oil vapors are combustible/explosive.
• Avoid open flames, electric sparks and ignition sources.
• Do not smoke.
NOTICE
HP fuel pump not filled with engine oil.
Damage to components, major material damage!
• Ensure that th HP fuel pump is filled with engine oil before it is installed or put into operation.
NOTICE
Contaminated components.
Risk of damage to component!
TIM-ID: 0000082191 - 001
• Check components for special cleanliness and clean if necessary.
MS15038/00E 2018-06 | Injection Pump / HP Pump | 241

Preparatory steps (two-cylinder
HP pump)
u Undo nut (2) and remove oil line (1) from HP
pump.
Preparatory steps (four-cylinder

HP pump)
u Undo nut (2) and remove oil line (1) from HP
pump.
Filling HP pump (two-cylinder

HP pump)
1. Remove union (1).
Note: Excess engine oil runs into gear box.
2. Use fuel suction pipe to fill HP pump with
2 liters of clean engine oil.
TIM-ID: 0000082191 - 001
242 | Injection Pump / HP Pump | MS15038/00E 2018-06

3. Screw in union (1) and use a torque wrench to tighten to specified tightening torque.
Union M16x1.5 Tightening torque 40 Nm
Filling HP pump (four-cylinder

HP pump)
1. Remove union (1).
Note: Excess engine oil runs into gear box.
2. Use fuel suction pipe to fill HP pump with
2 liters of clean engine oil.
3. Screw in union (1) and use a torque wrench to tighten to specified tightening torque.
Union M16x1.5 Tightening torque 40 Nm
Final steps
u Install oil line.
TIM-ID: 0000082191 - 001
MS15038/00E 2018-06 | Injection Pump / HP Pump | 243

8.6 Injector
8.6.1 Injector – Replacement
Injector (→ Spare Parts Catalog)
Injector – Replacement
u Remove injector and install new one (→ Page 245).
TIM-ID: 0000042329 - 002
244 | Injector | MS15038/00E 2018-06

8.6.2 Injector – Removal and installation
Preconditions

Installation/removal jig F6789889 1
Milling cutter F30452739 1
Torque screwdriver, 1–5 Nm F30452774 1
Assembly compound (Molykote P 37) 50564 1
Multi-purpose grease 40320 1
Engine oil
Injector (→ Spare Parts Catalog)
WARNING
• Do not smoke.
WARNING
and skin!
WARNING
Hot components/surfaces.
Risk of burns!
• Allow the engine to cool down to below 50 °C before beginning work.
• Wear suitable protective equipment/thermal gloves.
TIM-ID: 0000081645 - 001
• Avoid unprotected contact with hot surfaces.
WARNING
Internal tension and residual pressure in the HP fuel system.Parts can be ejected when loosening them.
Risk of injury by ejected parts!
• Only use specified tools and devices.
• Wear goggles/facial protection.
MS15038/00E 2018-06 | Injector | 245

NOTICE
Contamination of components.
Damage to component!
• Check components for special cleanliness.
Preparatory steps
1. Allow HP system to cool down.
2. Shut off fuel supply to engine.
Removing injector
1. Disconnect cable connector on injector.
Note: Observe system pressure.

2. Slowly undo nuts (4, 6) and remove HP fuel
line (5).
Note: When the adapter is unscrewed, the stored
volume of the injector is drained.
3. Remove adapter (3).
4. Remove screw (2) and take off hold-down
clamp (1). TIM-ID: 0000081645 - 001
246 | Injector | MS15038/00E 2018-06

5. Install installation/removal jig on the cylinder
head.
6. Remove injector with installation/removal jig.
7. Remove the installation/removal jig.
Note: The sealing ring (2) for sealing the combus-

tion chamber must only be used once.
8. If the sealing ring (2) did not remain on the
injector (1) when removed, use a self-made
wire hook or magnet to extract it from the
cylinder head and dispose accordingly.
9. Dispose of injector (1) with O-rings in place.
10. Clean all mating and sealing surfaces.
11. Cover all connections and bores, or seal with
suitable plugs.
Installing injector
Note: • The new sealing ring is included in the
scope of supply of the injector (new part).
• A multi-purpose grease without solids con-
tent must be used.
1. Install new sealing ring (1) abutted to (Multi-
purpose grease) and ensure that the installa-
tion position is correct.
TIM-ID: 0000081645 - 001
MS15038/00E 2018-06 | Injector | 247

Note: Remove plugs on HP line only before installa-
tion of the adapter.
2. Remove plug.
3. Use milling cutter to remove oil carbon from
sealing face on cylinder head and protective
sleeve.
4. Coat damper ring (2) with (Assembly com-
pound (Molykote P 37)).
5. Coat O-rings (3) and (5) with (Assembly com-
pound (Kluthe Hakuform 30-15)).
Note: Make sure that the sealing ring does not fall
into the water sleeve.
6. Ensure that the sealing ring (4) is correctly
seated.
7. Insert injector (1) in the cylinder head, ensur-
ing that it is correctly aligned with the HP line
connection.
8. Press in injector with installation/removal jig.

10. Coat screw head mating face and thread of

hold-down clamp (2) with engine oil.
11. Fit hold-down clamp (1) in correct position, fit
screw (2) and tighten by hand.
Note: Make sure parts are perfectly clean.
12. Apply engine oil to thread, sealing taper and
thrust ring of adapter (3).
13. Apply (Assembly compound (Kluthe Haku-
form 30-15)) to O-rings on adapter (3).
14. Install adapter (3) and tighten hand-tight.
TIM-ID: 0000081645 - 001
248 | Injector | MS15038/00E 2018-06

15. Use a torque wrench to tighten hold-down clamp screw (2) to specified tightening torque.
Screw M12 Tightening torque (Engine oil) 100 Nm+10 Nm
16. Use a torque wrench and long socket to tighten adapter (3) to specified tightening torque.
Adapter Tightening torque (Engine oil) 100 Nm+10 Nm

17. Coat thread and sealing cone of HP line (5) with engine oil.
18. Thread in HP line (5), ensuring that the sealing areas are not damage.
19. Tighten nuts (4, 6) by hand as far as possible.
20. Use a torque wrench to tighten nuts (4, 6) to specified tightening torque in the following order. Tightening
sequence:
1 Nut on adapter (4)
2 Nut on rail (6)
Nut Tightening torque (Engine oil) 45 Nm +3 Nm
21. Fit cable connector on injector.
Reset CDC parameters after installing new injectors

Note: Failure to reset drift compensation (CDC) will void the emissions certification of the engine.
u Reset drift compensation (CDC) with DiaSys® (→ Dialog system DiaSys® E531920/.) If DiaSys® is not avail-
able, contact Service.
TIM-ID: 0000081645 - 001
Final steps
2. Open fuel supply to engine.
MS15038/00E 2018-06 | Injector | 249

8.6.3 Injector rings – Replacement
Preconditions

Installation/removal jig F6789889 1
Milling cutter F30452739 1
Torque screwdriver, 1–5 Nm F30452774 1
Assembly compound (Molykote P 37) 50564 1
Multi-purpose grease 40320 1
Engine oil
Damping ring (→ Spare Parts Catalog)
O-ring (→ Spare Parts Catalog)
Sealing ring (→ Spare Parts Catalog)
WARNING
• Do not smoke.
WARNING
and skin!
WARNING
TIM-ID: 0000081752 - 001
Risk of burns!
WARNING
Internal tension and residual pressure in the HP fuel system.Parts can be ejected when loosening them.
Risk of injury by ejected parts!
• Wear goggles/facial protection.
250 | Injector | MS15038/00E 2018-06

NOTICE
Contamination of components.
Damage to component!
• Check components for special cleanliness.
Preparatory steps
1. Allow HP system to cool down.
2. Shut off fuel supply to engine.
Removing injector, removing

rings
1. Disconnect cable connector at injector (ar-
rowed).
Note: Observe system pressure.

2. Slowly undo nuts (4, 6) and remove HP fuel
line (5).
Note: When the adapter is unscrewed, the stored
volume of the injector is drained.
3. Remove adapter (3).
4. Remove screw (2) and take off hold-down
clamp (1).
TIM-ID: 0000081752 - 001
MS15038/00E 2018-06 | Injector | 251

5. Install installation/removal jig on the cylinder
head.
6. Remove injector with installation/removal jig.
8. Remove sealing ring (4) from injector or use a

self-made wire hook or magnet to take it out
of the cylinder head and dispose properly.
9. Remove O-rings (5), O-ring (3) and damper
ring (2) from injector (1) and dispose accord-
ingly.
10. Clean all mating and sealing surfaces.
11. Cover all connections and bores, or seal with
suitable plugs.
TIM-ID: 0000081752 - 001
252 | Injector | MS15038/00E 2018-06

Replacing rings, installing injec-
tor
Note: Remove plugs on HP line only before installa-
tion of the adapter.
1. Remove plug.
2. Use milling cutter to remove oil carbon from
sealing face on cylinder head and protective
sleeve.
Note: • Replace sealing ring (1) between injector
and water sleeve whenever the injector is
disassembled.
• Make sure the ring assembly is correctly
positioned: The closed side of the CE ring
must abut on the injector, while the pro-
truding (open) side of the CE ring must
face the combustion chamber.
• A multi-purpose grease without solids con-
tent must be used.
3. Install new sealing ring (1) abutted to (Multi-
purpose grease) and ensure that the installa-
tion position is correct.
4. Fit damper ring (2) on injector and apply (As-
sembly compound (Molykote P 37)).
5. Fit new O-rings (5) on injector (3) and apply
(Assembly compound (Kluthe Hakuform
30-15)).
Note: Make sure that the sealing ring (4) does not
fall into the coolant sleeve.
6. Ensure that the sealing ring (4) is correctly
seated.
7. Insert injector (1) in the cylinder head, ensur-
ing that it is correctly aligned with the HP line
connection.
TIM-ID: 0000081752 - 001
MS15038/00E 2018-06 | Injector | 253

8. Press in injector with installation/removal jig.
9. Remove installation/removal jig.
10. Coat screw head mating face and thread of

hold-down clamp (2) with engine oil.
11. Fit hold-down clamp (1) in correct position, fit
screw (2) and tighten by hand.
12. Apply engine oil to thread, sealing taper and
thrust ring of adapter (3).
13. Apply (Assembly compound (Kluthe Haku-
form 30-15)) to O-rings on adapter (3).
14. Install adapter (3) and tighten hand-tight.
15. Use a torque wrench to tighten hold-down clamp screw (2) to specified tightening torque.
Screw M12 Tightening torque (Engine oil) 100 Nm+10 Nm
16. Use a torque wrench and long socket to tighten adapter (3) to specified tightening torque.
Adapter Tightening torque (Engine oil) 100 Nm+10 Nm
TIM-ID: 0000081752 - 001

17. Coat thread and sealing cone of HP line (5) with engine oil.
18. Thread in HP line (5), ensuring that the sealing areas are not damage.
19. Tighten nuts (4, 6) by hand as far as possible.
20. Use a torque wrench to tighten nuts (4, 6) to specified tightening torque in the following order. Tightening
sequence:
1 Nut on adapter (4)
2 Nut on rail (6)
Nut Tightening torque (Engine oil) 45 Nm +3 Nm
254 | Injector | MS15038/00E 2018-06

21. Fit cable connector on injector (arrowed).
Note: Do not reset drift correction (CDC) after re-in-
stalling a used injector.
22. After fitting new injectors (→ Page 245).
Final steps
2. Open fuel supply to engine.
TIM-ID: 0000081752 - 001
MS15038/00E 2018-06 | Injector | 255

8.7 Fuel System
8.7.1 Fuel system – Venting
Preconditions

Diesel fuel
WARNING
• Do not smoke.
Venting LP fuel system

1. Remove cap from vent valve (2).
2. Open vent valve (2) and connect suitable
hose (inner diameter 6 mm).
3. Provide suitable container to collect escaping
fuel.
TIM-ID: 0000081668 - 001
256 | Fuel System | MS15038/00E 2018-06

Note: See figure (a).
4. Unlock hand pump: Hold sleeve (2). Turn han-
dle (1) counterclockwise until sleeve can be
moved back (arrowed).
Note: • See figure (b).
• After pulling the handle, wait briefly until
the chamber is optimally filled.
5. Operate pump with handle (1) until bubble-
free fuel emerges from threaded vent plug.
6. Close threaded vent plug.
7. Continue to operate the pump until resist-
ance is noticeable (at least 50 times), to ach-
ieve full filling height.
Note: See figure (c).
8. Lock hand pump: Slide sleeve (2) forwards
and hold. Turn handle (1) clockwise until both
parts are firmly screwed together by hand.
9. Remove hose from vent valve and fit cap.
10. Verify that fuel hand pump is properly locked:
Handle (1) must be tightened finger-tight.
TIM-ID: 0000081668 - 001
MS15038/00E 2018-06 | Fuel System | 257

8.7.2 Fuel cooler – External contamination and leak-tightness check
Preconditions
☑ All fuel cooler power sources are disconnected.
WARNING
• Do not smoke.
WARNING
Risk of burns!
WARNING
and skin!
Fuel cooler – External contamination and leak-tightness check

Element Findings Action
Check fuel cooler and connections Leakage Contact Service.
for leakage.
Check housing and fuel cooler Dust and/or foreign objects Clean fan guard with a soft brush.
electric motor for dust and foreign Clean surface of fuel cooler with a
objects. damp rag.
Clean fuel cooler if heavily conta-
minated (→ Page 259).
TIM-ID: 0000081753 - 001
258 | Fuel System | MS15038/00E 2018-06

8.7.3 Fuel cooler – Cleaning
Preconditions
☑ All fuel cooler power sources are disconnected.
WARNING
• Do not smoke.
WARNING
and skin!
WARNING
WARNING
Chemical substances in cleaners.
Risk of irritation and chemical burns!
• Always obey manufacturer's instructions for use.
NOTICE
Cleaning agents should not be left to take effect for too long.
Damage to components is possible!
NOTICE
Inappropriate cleaning tool.
Risk of damage to component!
• Use appropriate cleaning tool.
TIM-ID: 0000081754 - 001
Cleaning with a compressed-air pistol

1. Blow out cooler elements with a jet of compressed air working against the direction of the cooling air parallel
to the cooling fins.
2. Remove and dispose of dirt before putting engine into operation.
3. Use industrial high-pressure cleaner to clean fuel cooler in case of stubborn contamination.
MS15038/00E 2018-06 | Fuel System | 259

Cleaning with industrial high-pressure cleaner
Note: • To avoid damage to cooling elements, only aim water jet parallel to the cooling fins applying moderate
pressure.
• To improve the cleaning effect, add a suitable degreasing agent to the water (in accordance with the rec-
ommendations of the high-pressure cleaner manufacturer). The degreasing agent must be approved for
light metal containing coolers.
1. Use high-pressure cleaner to clean cooling elements working against the direction of the cooling air.
2. Thoroughly dry cooler and surrounding areas before putting engine into operation.
TIM-ID: 0000081754 - 001
260 | Fuel System | MS15038/00E 2018-06

8.8 Fuel Filter
8.8.1 Fuel filter – Replacement
Preconditions

Filter wrench F30379104 1
Engine oil
Easy-change filter (→ Spare Parts Catalog)
WARNING
• Do not smoke.
WARNING
and skin!
Replacing fuel filter

1. Provide suitable container to collect escaping
fuel.
2. Remove easy-change filter (2) with filter
wrench.
3. Clean sealing surface on filter head (1).
4. Coat seal on easy-change filter lightly with oil
(arrowed).
5. Screw on easy-change filter (2) by hand until
the seal makes contact with the filter head
and tighten manually.
6. Replace further easy-change filters in the
same way.
TIM-ID: 0000081674 - 001
7. Vent fuel system (→ Page 256).
MS15038/00E 2018-06 | Fuel Filter | 261

8.8.2 Fuel prefilter – Pressure ratios
WARNING
and skin!
Pressure ratios
Note: • If the fuel prefilter is above the full level of the fuel tank, during engine operation the fuel pressure in the
filter is lower than ambient pressure (vacuum).
• If the fuel prefilter is below the empty level of the fuel tank, during engine operation the fuel pressure in
the filter is higher than ambient pressure (overpressure).
In the case of overpressure, fuel can escape under pressure.
u The pressure ratios shown be known from commissioning. Pressure ratios can be checked with the engine
shut down.
Checking pressure ratios

1. Stop engine and disable engine start.
2. Carefully open threaded vent plug (1) slightly:
Result: • If no fuel emerges, this is an indication of
vacuum or pressure balance.
• If fuel emerges, this is a sign of overpres-
sure.
3. Collect fuel as it emerges.
TIM-ID: 0000066726 - 002
262 | Fuel Filter | MS15038/00E 2018-06

8.8.3 Fuel prefilter (non-switchable) – Draining
DANGER
WARNING
• Do not smoke.
WARNING
and skin!
WARNING
WARNING
Fuel in the prefilter can be pressurized.
Risk of injury through spraying fuel!
• Wear protective gloves and eye protectors/safety mask.
• Open screw-coupling slowly.
Preparatory steps
u Pressure ratios in the fuel prefilter, see (→ Page 262).
• In case of low pressure, drain fuel prefilter according to version A, see (→ Page 263).
• In case of high pressure, drain fuel prefilter according to version B, see (→ Page 264).
Draining fuel prefilter with low pressure, version A

Note: The fuel prefilter must only be drained with the engine at a standstill!
1. Provide a suitable container to collect the water.
TIM-ID: 0000066428 - 004
3. Close fuel supply if a shutoff valve is available.
MS15038/00E 2018-06 | Fuel Filter | 263

4. Open threaded vent plug (1) of filter to be
serviced.
5. Open drain plug (1).

6. Allow water to drain until fuel emerges.
7. Close drain plug (2) again.
8. Drain second filter on module, from
(→ Step 4).
9. Close threaded vent plug again.
10. Open fuel supply.
11. Vent fuel prefilter (→ Page 274).
Draining fuel prefilter with high

pressure, version B
Note: The fuel prefilter can be drained during
engine operation or with the engine at a
standstill!
1. Provide a suitable container to collect the wa-
ter.
2. Take care when opening drain plug (1) be-
cause fuel or water can spurt out.
TIM-ID: 0000066428 - 004

264 | Fuel Filter | MS15038/00E 2018-06

8.8.4 Fuel prefilter (switchable) – Draining
DANGER
WARNING
• Do not smoke.
WARNING
and skin!
WARNING
WARNING
Preparatory steps
• In case of low pressure, drain fuel prefilter according to version A, see (→ Page 265).
• In case of high pressure, drain fuel prefilter according to version B, see (→ Page 267).
Draining fuel prefilter with low pressure, version A

Note: • During engine operation, only the cut-out filter module must be drained!
• At engine standstill, both filter modules can be drained!
TIM-ID: 0000066393 - 004
MS15038/00E 2018-06 | Fuel Filter | 265

2. During engine operation, turn the switchover
level as far as the stop (arrowed) to cut out
the filter module to be serviced.
Result: • Filter module (1) is cut in
• Filter module (2) is cut out
3. Open threaded vent plug (1) of filter to be

serviced.
4. Open drain plug (1).

7. Drain the second filter on the module to be
serviced, from (→ Step 3).
TIM-ID: 0000066393 - 004
266 | Fuel Filter | MS15038/00E 2018-06

Draining fuel prefilter with high pressure, version B
Note: The filter modules can be drained without switchover during engine operation and at engine stand-
still!
2. Take care when opening drain plug (1) be-
cause fuel or water can spurt out.
TIM-ID: 0000066393 - 004
MS15038/00E 2018-06 | Fuel Filter | 267

8.8.5 Fuel prefilter (switchable) – Low pressure indicator check
Low pressure indicator on

switchable fuel prefilter
1. Check low pressure indicator reading at low
pressure gauge (3):
• Red zone (1): -1.0 bar to -0.4 bar (low
pressure)
• Green zone (2): -0.4 bar to +0.5 bar (nor-
mal operation)
2. Switch over the fuel prefilter or replace a fil-
ter element (→ Page 271) when the low pres-
sure gauge (3) indicates minimum admissible
fuel pressure during operation (1) .
TIM-ID: 0000074064 - 002
268 | Fuel Filter | MS15038/00E 2018-06

8.8.6 Fuel prefilter (non-switchable) – Filter element replacement
Diesel fuel
Filter parts kit (→ Spare Parts Catalog)
WARNING
• Do not smoke.
WARNING
and skin!
WARNING
Preparatory steps
Replacing filter element

Note: The filter element on the fuel prefilter must only be changed with the engine at a standstill!
1. Provide a suitable container in which to collect the fuel.
3. Close fuel supply if a shutoff valve is available.
TIM-ID: 0000066395 - 005
MS15038/00E 2018-06 | Fuel Filter | 269

4. Open threaded vent plug and ensure that fuel
does not emerge continuously.
Result: The filter can now be changed!
5. If fuel emerges continuously, check shutoff
valve in fuel supply, notify Service.
Note: • As soon as the filter housing is opened,
absolute cleanness is imperative!
• Carefully extract the filter element straight
up avoiding contact with the upper edge of
the cylinder if at all possible to prevent
contamination of the fuel remaining in the
filter housing.
6. Unscrew filter cover (1) and withdraw with fil-
ter element (3) from filter housing (4).
7. Unclip filter element (3) from filter cover (1).
8. Install new O-ring (2) on filter cover (1).
9. Coat new O-rings on filter cover and filter ele-
ment with fuel.
10. Clip new filter element (3) into filter cover (1).
11. Screw filter cover (1) into filter housing.
Result: Filter cover (1) must lie flat on the housing
(4).
12. Use a torque wrench to tighten filter cover (1) to specified tightening torque.
Filter cover Tightening torque 40 Nm
13. Replace other filter elements in the same way.

17. Check fuel prefilter for leaks.
TIM-ID: 0000066395 - 005
270 | Fuel Filter | MS15038/00E 2018-06

8.8.7 Fuel prefilter (switchable) – Filter element replacement
Diesel fuel
Filter parts kit (→ Spare Parts Catalog)
DANGER
WARNING
• Do not smoke.
WARNING
and skin!
WARNING
WARNING
Preparatory steps
TIM-ID: 0000066431 - 004

• In case of low pressure, replace fuel prefilter according to version A, see (→ Page 271).
• In case of high pressure, replace fuel prefilter according to version B, see (→ Page 273).
Replacing fuel prefilter with low pressure, version A

Note: • During engine operation, the filter elements must only be replaced on the cut-out filter module!
• At engine standstill, the filter elements on both filter modules can be replaced!
MS15038/00E 2018-06 | Fuel Filter | 271

2. During engine operation, turn the switchover
level as far as the stop (arrowed) to cut out
the filter module to be serviced.
Result: • Filter module (1) is cut in
• Filter module (2) is cut out
3. Check fuel level in filter.

Result: If the fuel level is stable, the filter can be
changed!
4. If the fuel level falls, the switchover point is
leaking. Screw on the filter cover again imme-
diately and vent the filter (→ Page 274).
Check the switchover point, contact Service.
filter housing.
ment with fuel.
(4).
11. Tighten filter cover (1) to specified torque using a torque wrench.
TIM-ID: 0000066431 - 004

272 | Fuel Filter | MS15038/00E 2018-06

Replacing fuel prefilter with high pressure, version B
Note: The filter modules must only be replaced with the engine at a standstill!
3. Close fuel inlet.
4. Open threaded vent plug and ensure that fuel
does not emerge continuously.
Result: The filter can now be changed!
5. If fuel emerges continuously, check shutoff
valve in fuel supply, notify Service.
filter housing.
ment with fuel.
(4).
12. Tighten filter cover (1) to specified torque using a torque wrench.

TIM-ID: 0000066431 - 004
MS15038/00E 2018-06 | Fuel Filter | 273

8.8.8 Fuel prefilter – Venting
DANGER
WARNING
• Do not smoke.
WARNING
and skin!
WARNING
WARNING
Preparatory steps
1. Pressure ratios in the fuel prefilter, see (→ Page 262).
• In case of underpressure, replace fuel prefilter according to version A, see (→ Page 274).
• In case of overpressure, replace fuel prefilter according to version B, see (→ Page 275).
2. With the non-switchable fuel prefilter, the engine must be shut down and secured against starting.
3. With the switchable fuel prefilter, the cut-out filter module can be vented during engine operation.
Venting fuel prefilter with low pressure, version A

1. Open fuel supply as necessary.
TIM-ID: 0000058279 - 006
274 | Fuel Filter | MS15038/00E 2018-06

2. Release threaded vent plugs (2, 3) and un-
screw at least one rotation.
Note: • Only operate the fuel priming pump man-
ually!
• Only hold the pump plunger vertically to
avoid damaging the pump!
3. Unlock fuel priming pump, screw out han-
dle (1).
Note: Catch escaping fuel with a suitable rag.
4. Operate fuel priming pump handle (1) until
bubble-free fuel emerges from the threaded
vent plugs (2, 3).
Note: Never actuate the handle with the threaded
vent plugs closed!
5. Move handle (1) of fuel priming pump back
and screw in.
6. Close threaded vent plugs (2, 3) and tighten
by hand.
Venting fuel prefilter with high

pressure, version B
1. Open fuel supply as necessary.
2. Carefully release threaded vent plugs (1) and
unscrew at least one rotation.
3. Leave threaded vent plugs (1) opened until
bubble-free fuel emerges at the vent plugs.
4. Close threaded vent plugs (1) and tighten by
hand.
TIM-ID: 0000058279 - 006
MS15038/00E 2018-06 | Fuel Filter | 275

8.9 Charge-Air Cooling
8.9.1 Intercooler – Checking condensate drain for coolant leakage and obstruction
DANGER
WARNING
WARNING
Intercooler – Checking conden-

sate drain for coolant leakage
and obstruction
1. With the engine running, check if air escapes
from the condensate drain bore(s) on the
right and left of the engine (driving end). If no
air escapes:
• Clean condensate drain bore(s)
• Blow out with compressed air
2. If a large amount of coolant is continuously
discharged, the intercooler is leaking. Con-
tact Service.
Emergency measures prior to engine start with a leaking intercooler

1. Remove injectors (→ Page 245).
2. Bar engine manually (→ Page 218).
3. Bar engine with starting system to blow out combustion chambers (→ Page 220).
4. Install injectors (→ Page 245).
TIM-ID: 0000000929 - 009
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8.10 Air Filter
8.10.1 Air filter ‒ Replacement
Air filter (→ Spare Parts Catalog)
Air filter ‒ Replacement

1. Remove air filter and install new one (→ Page 279).
2. Reset signal ring of service indicator (→ Page 280).
TIM-ID: 0000000903 - 005
MS15038/00E 2018-06 | Air Filter | 277

8.10.2 Air filter – Check
Air filter (→ Spare Parts Catalog)
Checking air filter

1. Check entire circumference of air filter for damage.
2. Fit new air filter if damaged (→ Page 277).
TIM-ID: 0000005430 - 005
278 | Air Filter | MS15038/00E 2018-06

8.10.3 Air filter – Removal and installation
Preconditions
DANGER
Falling from great heights.
Risk of serious injury – danger to life!
• When working high on the equipment, always use suitable ladders or work platforms.
• Use personal protective equipment.
WARNING
For all described tasks at the genset:
Risk of injury!
• For all tasks, the respective required personal protective equipment (safety shoes, ear protection,
protective gloves, safety goggles, respiratory protection, etc.) is to be used.
NOTICE
Stepping or climbing on the genset to perform installation tasks is to be avoided.
Otherwise, there is a risk of component damage or leakage!
• Use suitable and approved climbing aids or work platforms.
Removing and installing air fil-

ter
1. Release clamp (2).
2. Remove air filter (1) and clamp (2) from con-
necting flange of intake housing (3).
3. Verify that there are no objects in the con-
necting flange of the intake housing (3) and
clean it.
4. Place new air filter (1) with clamp (2) onto in-
take housing (3).
5. Tighten clamps (2).
TIM-ID: 0000005457 - 013
MS15038/00E 2018-06 | Air Filter | 279

8.11 Air Intake
8.11.1 Contamination indicator – Signal ring position check
Preconditions
WARNING
The engine draws in large volumes of ambient air for combustion. This air intake results in a strong vac-
uum.
Risk of injury if body parts are drawn in! There is also a danger if opening of the entrance door
can be prevented!
• Only operate the engine with installed air filters.
• Never open air-carrying components during operation.
• Ensure that the engine room is well-ventilated.
Checking signal ring position

1. If the signal ring is completely visible in the
viewing window (2), replace air filter
(→ Page 277).
2. After installation of new filter, press reset
button (1).
Result: Engaged plunger with signal ring returns to
initial position.
TIM-ID: 0000005484 - 010
280 | Air Intake | MS15038/00E 2018-06

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

1. Press pushbutton for manual start (arrow)
and hold.
2. Allow compressed air to enter the starter un-
til the engine fires evenly.
3. Release pushbutton.
TIM-ID: 0000006076 - 006
MS15038/00E 2018-06 | Starting Equipment | 281

8.13 Lube Oil System, Lube Oil Circuit
8.13.1 Engine oil – Change
Preconditions
☑ Engine is at operating temperature.
☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.

Engine oil
WARNING
Oil is hot.
Oil change without semirotary hand pump: Draining engine oil at drain
plug(s) on oil pan
1. Provide a suitable container in which to collect the engine oil.
2. Remove drain plug(s) and drain engine oil.
3. Install drain plug(s) with new sealing ring.
Oil change with semirotary hand pump: Extracting engine oil

1. Provide a suitable container in which to collect the engine oil.
2. Use semirotary hand pump to extract all engine oil from oil pan.
Engine oil treatment

1. Check layer thickness of oil residues in the centrifugal oil filter, clean centrifugal oil filter and replace filter
sleeve (→ Page 289).
2. Replace engine oil filter (→ Page 288).
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Draining residual oil from equip-
ment carrier (only with un-
scheduled engine oil change)
1. Provide a suitable container in which to col-
lect the engine oil.
2. Remove drain plug (1) and drain engine oil
from engine oil heat exchanger and from en-
gine oil filter.
3. Remove drain plugs (2) and (3) and drain en-
gine oil.
4. Install drain plug(s) with new sealing ring.
5. Use torque wrench to tighten drain plugs (2) and (3) to specified tightening torque.
Screw M26 x 1.5 Tightening torque (Engine oil) 100 Nm +10 Nm
Filling with new engine oil

1. Open cover (1) on filler neck.
2. Pour oil in at filler neck up to 'max.' mark at
oil dipstick.
3. Close cover (1) on filler neck.
4. Check engine oil level (→ Page 284).
5. Bar engine with starting system
(→ Page 220).
TIM-ID: 0000000930 - 015
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8.13.2 Engine oil level – Check
Preconditions
WARNING
Oil is hot.
Checking engine oil level after

extended standstill
1. Pull out dipstick from guide tube and wipe it.
2. Insert oil dipstick into guide tube up to the
stop, pull it out after approx. 10 seconds and
check oil level.
Note: After extended standstill, the oil level may be
up to 2 cm above mark (1). This may be
caused e.g. by oil from oil filters and heat ex-
changers flowing back into the oil pan. After
extended standstill, the oil level "2 cm above
mark (2)" is the minimum oil level.
3. Oil level must be at least 2 cm above
mark (2).
4. If necessary, top up with oil, maximum to
mark (1) (→ Page 282).
5. Insert oil dipstick into guide tube up to the
stop.
Checking oil level immediately after engine stop

1. 5 minutes after stopping the engine, pull out oil dipstick from guide tube and wipe it.
2. Insert oil dipstick into guide tube up to the stop, pull it out after approx. 10 seconds and check oil level.
3. Oil level must be between marks (1) and (2).
4. If necessary, top up with oil, maximum to mark (1) (→ Page 282).
5. Insert oil dipstick into guide tube up to the stop.
TIM-ID: 0000000931 - 017

8.13.3 Engine oil – Sample extraction and analysis
Preconditions

MTU test kit F6798833 1
Engine oil
DANGER
WARNING
Oil is hot.
WARNING
Engine oil sample extraction

and analysis (engine without
centrifugal oil filter)
Note: Only take the engine oil sample by opening
an oil drain screw with the engine stationary.
1. With the engine shut down, open the screw,
e.g. at the oil filter.
2. Drain approx. 1 liter engine oil into a clean
container.
3. Seal oil drain screw (arrow) again with a new
sealing ring.
4. Use equipment and chemicals in MTU test kit
TIM-ID: 0000074951 - 001
to analyze engine oil for:

• Dispersing capacity (spot test)
• Proportion of water
• Dilution by fuel

Engine oil, sample extraction
and analysis
1. With the engine running at operating temper-
ature, open screw (1) on carrier of centrifugal
oil filter support by 1 to 2 rotations.
2. Drain approx. 2 liters engine oil to flush out
the oil sludge.
3. Drain approx. 1 liter engine oil into a clean
container.
4. Close screw (1) and tighten to specified tightening torque.

Screw - Tightening torque (Engine oil) 20 Nm +2 Nm
5. Use equipment and chemicals in MTU test kit to analyze engine oil for:
• Dispersing capacity (spot test)
• Proportion of water
• Dilution by fuel
TIM-ID: 0000074951 - 001

8.13.4 Oil priming pump – Visual inspection
Preconditions
Visually inspecting oil priming

pump
1. Inspect oil priming pump and connections for
firm seating and leaks. Retighten loose
threaded connections as necessary.
2. Check leak telltale bore (2) for oil discharge.
Result: If oil emerges, the gear pump (1) usually has
to be replaced (→ see manufacturer's docu-
mentation).
TIM-ID: 0000064765 - 003

8.14 Oil Filtration / Cooling
8.14.1 Engine oil filter – Replacement
Preconditions

Filter wrench F30379104
Engine oil
Oil filter (→ Spare Parts Catalog)
WARNING
Oil is hot.
Replacing engine oil filter

1. Remove engine oil filter using the filter
wrench.
2. Clean the sealing surface on the connecting
piece.
3. Check sealing ring (1) of new engine oil filter
and apply a thin coat of engine oil.
4. Check inscription on filter: must be “Oil Fil-
ter”.
5. Screw on and tighten engine oil filter by
hand.
6. Replace other engine oil filters in the same
way.
Note: See label (2) on filter housing.
7. Crank engine on starting system without in-
jecting fuel (→ Page 220).
8. Check engine oil level (→ Page 284).
TIM-ID: 0000000933 - 014
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8.14.2 Centrifugal oil filter – Cleaning and filter sleeve replacement
Preconditions

Oil filter wrench F30455924 1
Cold cleaner (Hakutex 60) X00056750 1
Filter sleeve (→ Spare Parts Catalog)
WARNING
Oil is hot.
WARNING
TIM-ID: 0000060251 - 007
MS15038/00E 2018-06 | Oil Filtration / Cooling | 289

Cleaning centrifugal oil filter
and replacing filter sleeve
1. Remove clamp (17).
2. Undo cover nut (2) and take off cover (1).
3. Carefully lift rotor (14), allow oil to drain and
remove from housing.
Note: Do not clamp the rotor unit in a bench vise.
4. Holding the rotor (14) firmly with an oil filter
wrench, Undo rotor cover nut (3).
5. Take off rotor cover (3).
6. Measure thickness of oil residues on filter
sleeve (6).
Result: Shorten maintenance interval if the oil resi-
dues exceed the maximum thickness of
45 mm.
7. Remove filter sleeve (6).
8. Disassemble rotor tube (7), conical disk (8)
and rotor base (13).
9. Wash rotor cover (3), rotor tube (7), conical
disk (8) and rotor base (13) with cold cleaner.
10. Blow out with compressed air.
11. Replace sealing rings (9, 10, 12).
12. Apply assembly compound to sealing
rings (9, 10) and insert them in grooves of
bearing axle (11).
13. Assemble rotor tube (7), conical disk (8) and
rotor base (13) with sealing ring (12).
Note: Observe marks and notices on the paper
sleeve!
14. Insert new filter sleeve (6) in rotor tube (7)
with the smooth paper surface facing the out-
er wall.
15. Check sealing rings (4, 5), fit new ones as
necessary.
16. Fit sealing ring (5) in rotor tube (7) and seal-
ing ring (4) in rotor cover (3).
TIM-ID: 0000060251 - 007
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Note: Do not clamp the rotor unit in a bench vise. Use an oil filter wrench.
17. Install rotor cover (3) and use a torque wrench to tighten nut of rotor cover (3) to specified tightening torque.
Nut Tightening torque 80 Nm ±12 Nm
18. Place rotor (14) in housing (15) and check for ease of movement.
19. Check sealing ring (16), fit new one as necessary.
20. Fit sealing ring (16) on housing (15).
21. Fit cover (1).
22. Tighten cover nut (2) by hand.
23. Install clamp (17) and use a torque wrench to tighten to tighten to specified torque.
Clamp Tightening torque 20 Nm ±3 Nm
24. Use a torque wrench to tighten cover nut (2) to specified tightening torque.
Screw Tightening torque 7 Nm ±1 Nm
TIM-ID: 0000060251 - 007
MS15038/00E 2018-06 | Oil Filtration / Cooling | 291

8.15 Coolant Circuit, General, High-Temperature Circuit
8.15.1 Engine coolant – Level check
Preconditions
WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.
Checking coolant level at re-

mote cooler:
1. Check coolant level (coolant must be visible
at marking plate).
2. Top up with treated coolant as necessary
(→ Page 296).
3. Check and clean breather valve.
4. Position breather valve on filler neck and
close.
Checking engine coolant level 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 296). TIM-ID: 0000018677 - 002
292 | Coolant Circuit, General, High-Temperature Circuit | MS15038/00E 2018-06

8.15.2 Engine coolant – Change
Coolant
Engine coolant change

1. Drain engine coolant (→ Page 294).
2. Fill with engine coolant (→ Page 296).
TIM-ID: 0000000036 - 031
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8.15.3 Engine coolant – Draining
Preconditions
DANGER
Falling from great heights.
Risk of serious injury – danger to life!
• When working high on the equipment, always use suitable ladders or work platforms.
• Use personal protective equipment.
WARNING
WARNING
Coolant contains antifreeze and is toxic.
Risk of poisoning and slipping!
• Avoid contact with eyes and skin.
• Do not inhale vapors or mist, wear breathing protection.
• Do not eat, drink, smoke when working with antifreeze.
• Wipe up escaped/spilled coolant immediately.
Preparatory steps
1. Provide a suitable container to catch the coolant.
2. Switch off preheater.
Draining engine coolant

1. Turn valve cover of coolant expansion tank
counterclockwise until the first stop and al-
low pressure to escape.
2. Continue to turn valve cover counterclock-
wise and remove.
3. Draw off separated corrosion inhibitor oil in
expansion tank through the filler neck.
4. Open drain valves and/or drain plugs and
drain coolant at the following points:
• At preheater
• Thermostat housing (1)
• Twin elbow (2)
• At elbow (4) of HT coolant pump
• Crankcase (3), left and right side
TIM-ID: 0000000960 - 005
Final steps
1. Tighten shutoff cocks (3) and (4) with torque wrench to specified tightening torque.
Spindle 11 A/F Tightening torque 12 Nm

2. Close all other open drain points.
3. Position valve cover on filler neck and close.
TIM-ID: 0000000960 - 005

8.15.4 Engine coolant – Filling
Preconditions

Coolant
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 valve cover on coolant expansion tank
counterclockwise to first stop and release
pressure.
2. Continue to turn valve cover counter-clock-
wise and remove.
TIM-ID: 0000000959 - 011

Filling with coolant from below
using a pump
1. Connect appropriate pump with hose to drain
valve of engine coolant pump (arrowed).
2. Loosen the vent line union at the distributor

piece (arrow).
3. Open drain valve and pump coolant into en-
gine at 0.5 bar minimum.
4. Tighten union (arrow) if coolant leaks out at
loose union.
5. Fill expansion tank until coolant level reaches
overflow edge.
6. Close drain valve and tighten with torque wrench to specified tightening torque.
Spindle 11A/F Tightening torque 12 Nm
7. Check satisfactory condition of valve cover on coolant expansion tank, clean sealing faces if required.
8. Fit valve cover and close it.
10. After 10 seconds of running the engine without load, stop engine (→ Page 186).
11. Turn valve cover on coolant expansion tank counterclockwise to first stop and release pressure.
TIM-ID: 0000000959 - 011
12. Continue to turn valve cover counter-clockwise and remove.

13. Check coolant level (→ Page 292) and top up coolant as necessary:
a) Fill in coolant in expansion tank until coolant level at top edge of filler neck remains constant.
b) Fit valve cover and close it.
14. Repeat the steps from "Start engine" (→ Step 9) until coolant no longer needs to be topped up.
15. Disconnect pump and hose.
Final steps
1. Start engine and run it without load for some minutes.
2. Check coolant level (→ Page 292) and top up coolant as necessary.

8.15.5 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
• If discharge exceeds the specified limits:
Contact Service.
2. If the relief bore is dirty, stop the engine
(→ Page 186) and disable engine start, ob-
serve general safety instructions for mainte-
nance and repair.
3. Clean relief bore with a wire.
TIM-ID: 0000000961 - 014

8.15.6 Engine coolant – Sample extraction and analysis
Preconditions

MTU test kit 5605892099/00 1
DANGER
WARNING
WARNING
Coolant contains antifreeze and is toxic.
Risk of poisoning and slipping!
• Avoid contact with eyes and skin.
• Do not inhale vapors or mist, wear breathing protection.
• Do not eat, drink, smoke when working with antifreeze.
• Wipe up escaped/spilled coolant immediately.
WARNING
Engine coolant – Sample extrac-

tion and analysis
1. With the engine running, open drain valve (1).
2. Flush sample-extraction point by draining ap-
prox. 1 liter coolant.
3. Drain approx. 1 liter coolant into a clean con-
tainer.
TIM-ID: 0000000938 - 013

4. Tighten shut-off cock (2) to specified torque using a torque wrench.
Spindle A/F11 Tightening torque 12 Nm
5. Using the equipment and chemicals from the MTU test kit, examine coolant for:
• antifreeze concentration
• Amount of corrosion protection oil
• pH value
6. For engine coolant change intervals, refer to (→ MTU Fluids and Lubricants Specifications (A001061/..)).
TIM-ID: 0000000938 - 013

8.15.7 Preheater – Overview
1 Outlet 5 Control thermostat 9 Pump

2 24 VDC input 6 Intake Arrow Flow direction
3 Main power supply input 7 Safety thermostat
4 Control box 8 Housing cover
Variant Heating output Rated voltage Frequency Phases
1 9 kW 400 V 50 Hz 3
2 9 kW 480 V 60 Hz 3
3 12 kW 400 V 50 Hz 3
4 12 kW 480 V 60 Hz 3
TIM-ID: 0000081760 - 001

8.15.8 Preheater – Function and leak check
Preconditions
☑ Preheater is switched on.
WARNING
Coolant is hot and highly pressurized.
Risk of injury! Risk of scalding!
• Allow engine to cool down.
Function check
Note: The preheater operates properly if the measured value of the coolant temperature is within the control range
of the thermostat.
1. Check coolant preheating temperature.
2. Contact Service if the temperatures are out of normal range.
Leak check
1. Check unit for leaks at coolant inlet and coolant outlet.
2. Tighten leaking connections.
TIM-ID: 0000082043 - 001

8.15.9 Preheater – Overhaul
Preconditions
☑ All preheater power sources are disconnected.
Replacing solenoid switch

u Replace solenoid switch (→ Page 304).
Cleaning heating element and replacing gasket

u Clean heating element and housing and check (→ Page 306).
Replacing thermostat
u Replace thermostat (→ Page 309).
TIM-ID: 0000081923 - 001

8.15.10 Preheater – Solenoid switch replacement
Preconditions

Solenoid switch (→ Spare Parts Catalog) 1
DANGER
Electric voltage supply for operation.
Danger of burns and fatal electric shock!
• Make certain that the power supply to the product is switched off before starting work. Secure
against unintentional switching on!
WARNING
WARNING
Risk of burns!
Preparatory steps
2. Disconnect all preheater power sources.
3. Allow heating elements to cool down.
4. Close shutoff valves in the supply and return line to/from preheater.
Replacing solenoid switch

1. Undo screws on control box (1) and open
control box.
TIM-ID: 0000081912 - 001

2. Mark all cables (4) prior to disconnection.
3. Disconnect all cables (4) from solenoid
switch (1).
Note: The solenoid switch is secured to the rail (2)
by a spring clip (3).
4. Pull out the spring clip with a screwdriver and
slide the solenoid switch off the rail.
5. Fit a new solenoid switch on the rail and fully
engage the spring clip.
6. Connect up all wires as marked previously.
7. Close the control box and tighten the screws.
Final steps
1. Open shutoff valves in the supply and return line to/from preheater.
2. Disconnect preheater power sources.
3. Switch on preheater.
TIM-ID: 0000081912 - 001

8.15.11 Preheater – Heating element and housing check
Preconditions

Screw locking compound (Loctite 586) 40033 1
O-ring (→ Spare Parts Catalog) 1
DANGER
WARNING
Risk of burns!
WARNING
NOTICE
Preparatory steps
Removing coolant lines

1. Close shutoff valves in coolant return line and coolant supply line.
TIM-ID: 0000081913 - 001

2. Open drain plug at coolant inlet (arrowed)
and drain coolant.
3. Undo clamps on both lines on preheater side.
Checking heating element and

housing for contamination
1. Undo screws (1) between electrical part (2)
and housing.
2. Pull electrical part (1) with heating element
out of housing.
3. Check inside of housing for dirt. Clean with a
wire brush and/or moist rag as necessary.
4. Check heating element for contamination.
Clean with a wire brush as necessary.
5. Fit new O-ring ensuring it is correctly posi-
tioned.
6. Insert cleaned or new heating element into
housing.
7. Install electrical part (2) and tighten
screws (1).
Installing coolant lines

1. Clean drain plug and screw-in thread (ar-
rowed) at preheater.
2. Coat drain plug with screw locking compound
Loctite 586 and screw in.
3. Connect coolant return and supply lines to
preheater and tighten clamps.
4. Vent coolant preheating circuit:
a) Open return line valve.
TIM-ID: 0000081913 - 001
b) Undo the clamp of the coolant supply

line near the valve.
c) Wait until coolant has reached the end of
the coolant supply line.
d) Tighten the clamp of the coolant supply
line.
5. Fill in engine coolant until the required level
is reached (→ Page 296).

Final steps
1. Connect preheater power sources.
TIM-ID: 0000081913 - 001

8.15.12 Preheater thermostats – Replacement
Preconditions

Thermostat (→ Spare Parts Catalog)
DANGER
WARNING
Risk of burns!
WARNING
Preparatory steps
Replacing safety thermostat

1. Undo screws (1) on cover of electrical
part (2) and remove cover.
TIM-ID: 0000081762 - 001

2. Mark cables prior to disconnection.
3. Disconnect terminals from blade terminals of
measuring unit (2).
4. Undo thermostat clip (1) and remove safety
thermostat.
5. Insert new safety thermostat in recess.
6. Secure thermostat clip.
7. Connect cable.
8. Fit cover and tighten screws.
Replacing control thermostat

1. Undo screws (1) on housing cover (2) of con-
trol thermostat and remove cover.
2. Mark cables prior to disconnection.

3. Disconnect wires.
4. Remove screws (2) and control thermo-
stat (1).
5. Install new control thermostat (1) with
screws (2).
6. Connect cable.
7. Fit housing cover and tighten screws.
TIM-ID: 0000081762 - 001

Final steps
1. Connect preheater to power supply.
TIM-ID: 0000081762 - 001

8.15.13 Coolant expansion tank valve cover – Replacement
Preconditions

Valve cover (→ Spare Parts Catalog) 1
WARNING
Preparatory steps
u Switch off preheater.
Replacing valve cover

Note: Schematic diagram. Design may deviate.
1. Turn valve cover (1) on coolant expansion
tank counterclockwise until the first stop and
release pressure.
2. Continue to turn valve cover counterclock-
wise and remove.
3. Remove chain with screw (4) and washer (3).
4. Draw off separated corrosion inhibitor oil in
expansion tank via filler neck (2).
5. Fit new valve cover and close it.
6. Install chain.
TIM-ID: 0000065495 - 005

8.16 Low-Temperature Circuit
8.16.1 Charge-air coolant – Level check
Preconditions
WARNING
Checking charge-air coolant level at filler neck:

1. Turn cap on coolant expansion tank counterclockwise to the first stop and allow pressure to escape.
2. Continue to turn cap counterclockwise and remove.
Note: Charge-air coolant must be visible at marker
plate.
3. Check charge-air coolant level.
4. Top up charge-air coolant as necessary
(→ Page 317).
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 317).
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8.16.2 Charge-air coolant – Change
Coolant
Charge-air coolant – Change

1. Drain charge-air coolant (→ Page 315).
2. Fill with charge-air coolant (→ Page 317).
TIM-ID: 0000000041 - 011
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8.16.3 Charge-air coolant – Draining
Preconditions

WARNING
Draining charge-air coolant

1. Provide a suitable container to catch coolant.
4. Draw off separated corrosion inhibitor oil in expansion tank through filler neck.
5. Unscrew drain screw (1) and drain charge-air
coolant at thermostat housing.
6. Open drain valve (2) and drain charge-air
coolant at charge-air coolant pump.
TIM-ID: 0000079645 - 001

7. Drain remaining coolant at intercooler (ar-
rowed).
8. Use a torque wrench to tighten drain valve on charge-air coolant pump to specified tightening torque.
Spindle A/F11 Tightening torque 12 Nm
9. Screw in drain screws on thermostat housing and intercooler with new sealing rings.
10. Position valve cover on filler neck at coolant expansion tank and close.
TIM-ID: 0000079645 - 001

8.16.4 Charge-air coolant – Filling
Preconditions

Coolant
WARNING
NOTICE
Preparatory steps
pressure.
2. Continue to turn valve cover counter-clock-
wise and remove.
TIM-ID: 0000000940 - 010

Filling coolant using a pump
1. Connect appropriate pump with hose to drain
valve (1).

piece (arrow).
3. Open drain valve and pump coolant into en-
gine at 0.5 bar minimum.
loose union.
5. Fill expansion tank until overflow edge is
reached.
6. Close drain valve and tighten with torque wrench to specified tightening torque.
Spindle 11A/F Tightening torque 12 Nm
7. Check satisfactory condition of valve cover and clean sealing faces if required.
8. Position valve cover on filler neck and close.
10. After 10 seconds of running the engine without load, stop the engine (→ Page 186).
TIM-ID: 0000000940 - 010

13. Check coolant level (→ Page 313) and top up coolant as necessary:
a) Top up coolant via expansion tank until coolant level at top edge of filler neck remains constant.
b) Position valve cover on filler neck and close.
14. Repeat the steps from “Start engine” (→ Step 9) until coolant no longer needs to be topped up.
15. Disconnect pump and hose.

Alternatively: Filling coolant
through filler neck
piece (arrow).
2. Fill in coolant in expansion tank via filler neck
until coolant level at top edge of filler neck
remains constant.
loose union.
4. Check satisfactory condition of valve cover
on coolant expansion tank, clean sealing
faces if required.
5. Fit valve cover and close it.
7. After 10 seconds of running the engine with-
out load, stop the engine (→ Page 186).
pressure.
9. Turn valve cover counterclockwise and re-
move.
10. Check coolant level (→ Page 313) and top up
with coolant via filler neck as necessary:
a) Fill in coolant in expansion tank until
coolant level at top edge of filler neck re-
mains constant.
b) Fit valve cover and close it.
11. Repeat the steps from “Start engine”
(→ Step 6) until coolant no longer needs to be
topped up.
Final steps
1. Start engine and run it without load for some minutes.
2. Check coolant level (→ Page 313) and top up coolant as necessary.
TIM-ID: 0000000940 - 010

8.16.5 Charge-air coolant pump – Relief bore check
DANGER
WARNING
Charge-air coolant pump – Re-

lief bore check
1. Check relief bore for oil and coolant dis-
charge.
2. Stop engine (→ Page 186) and disable engine
start, observe general safety instructions for
maintenance and repair.
3. Clean the relief bore with a wire if it is conta-
minated.
• Permissible coolant discharge: up to 10
drops per hour.
• Permissible oil discharge: up to 5 drops
per hour.
4. If discharge exceeds the specified limits:
Contact Service.
TIM-ID: 0000000964 - 008

8.17 Belt Drive
8.17.1 Drive belt – Condition check
Preconditions
WARNING
Exposed rotating parts can eject drawn-in components or draw in body parts.
Risk of crushing, limbs or extremities may be pinched, trapped or entangled!
Risk of injury due to flying parts!
• Install rotating components at a suitable distance from other components.
• Never operate the engine without protective covers or safety guards which meet applicable accident
prevention regulations.
• Ensure that the safety guards can prevent body parts from being drawn in by rotating components.
Drive belt – Condition check

1. Remove cover.
2. Checking drive belt condition:

Item Findings Action
Drive belt A Singular cracks None
Drive belt B Cracks on entire circumference Replace (→ Page 323)
Drive belt C Chunking
Drive belt Belt is oily, shows signs of over-
heating
3. Install cover.
TIM-ID: 0000000920 - 014
MS15038/00E 2018-06 | Belt Drive | 321

8.18 Battery-Charging Generator
8.18.1 Battery-charging generator – Drive belt tension adjustment
Preconditions

WARNING
Belt tensioner spring is pretensioned.
Risk of hands being crushed!
• Lock belt tensioner in position.
Adjusting belt tension

1. Slacken screws (1) and (2) by half a turn.
Result: Belt tensioner moves against the drive belt
and tensions it.
2. Tighten screw (2) to specified torque using a torque wrench.

Screw M10 Tightening torque 60 Nm +5 Nm
TIM-ID: 0000071474 - 002
3. Tighten screw (1) with a torque wrench.
322 | Battery-Charging Generator | MS15038/00E 2018-06

8.18.2 Battery-charging generator drive – Drive belt replacement
Preconditions

Drive belt (→ Spare Parts Catalog)
WARNING
Belt tensioner spring is pretensioned.
Risk of hands being crushed!
• Lock belt tensioner in position.
Battery-charging generator drive – Drive belt replacement

1. Remove protective cover.
2. Loosen screws (2) and (3) by half a turn.
3. Mount socket or box wrench on screw (1)
and press belt tensioner in direction of arrow
as far as the stop.
4. Tighten screw (3).
5. Remove the used drive belt.
6. Fit new drive belt.
7. Loosen screw (3) by half a turn.
Result: Belt tensioner moves against the drive belt
and tensions it.
8. Tighten screw (3) with torque wrench to specified tightening torque.

TIM-ID: 0000022970 - 007
Screw M10 Tightening torque 60 Nm +5 Nm
9. Tighten screw (2).

10. Install protective cover.
11. Readjust drive belt tension after 30 minutes and after 8 hours engine runtime (→ Page 322).
MS15038/00E 2018-06 | Battery-Charging Generator | 323

8.19 Engine Mounting / Support
8.19.1 Engine mounting – Checking resilient element
NOTICE
Contamination of engine mounts made of natural rubber with fuel or oil.
Engine mounts swell. Risk of shorter service life or destruction of the mounts!
• Cover engine mounts when working with fuel or oil.
• Remove contaminations on the rubber mounts immediately with a dry cloth and degrease them.
Engine mounting – Check

Visually inspect resilient elements. • Damage Replace (contact Service).
• Brittleness
• Deformation
• Crack formation
• Swelling
TIM-ID: 0000015370 - 007
324 | Engine Mounting / Support | MS15038/00E 2018-06

8.19.2 Engine mounting – Checking securing screws for firm seating
Preconditions
☑ Engine is stopped and starting disabled

Engine oil
Version A – resilient engine

mounting
1. Check that securing screws (1, 2) and base
frame screw connections (3) are tight.
2. Use a torque wrench to tighten loose screw connections (1) to specified tightening torque.
Screw M20 Control torque (Engine oil) 500 Nm +50 Nm
4. Use a torque wrench to tighten loose base frame screw connections (3) to specified tightening torque.
TIM-ID: 0000080368 - 001
MS15038/00E 2018-06 | Engine Mounting / Support | 325

Version B – rigid engine mount-
ing with standalone generator
1. Check that securing screws (1, 2, 3) and base
frame screw connections (arrowed) are tight.
2. Use a torque wrench to tighten loose screw connections (1, 2) to specified tightening torque.
4. Tighten loose base frame screw connections (arrowed).
TIM-ID: 0000080368 - 001

8.19.3 Generator mounting – Check
Resilient element (→ Spare Parts Catalog)
NOTICE
Contamination of engine mounts made of natural rubber with fuel or oil.
Engine mounts swell. Risk of shorter service life or destruction of the mounts!
• Cover engine mounts when working with fuel or oil.
• Remove contaminations on the rubber mounts immediately with a dry cloth and degrease them.
Generator mounting – Check

Visually inspect damping mounts. • Damage Replace (→ contact Service.)
• Brittleness
• Deformation
• Crack formation
• Swelling
TIM-ID: 0000081033 - 001
MS15038/00E 2018-06 | Engine Mounting / Support | 327

8.19.4 Generator mounting – Securing screw firm seating check
Preconditions
Generator mounting, securing screw firm seating check

1. Check securing screws for firm seating.
2. Tighten loose screws.
TIM-ID: 0000078761 - 001

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

Solvent (isopropyl alcohol) X00058037 1
Engine cabling – Check

1. Check securing screws of cable clamps on engine and tighten loose screw connections.
2. Ensure that cables are securely seated in clamps and cannot move freely.
3. Check if all cable clips are closed and intact.
4. Replace faulty cable clips.
5. Check cable clamps for secure fit, tighten loose clamps.
6. Replace faulty cable clamps.
7. Visually inspect the following electrical components for damage:
• Connector housings
• Contacts
• Plug connectors
• Cables and terminals
• Plug-in contacts
Result: If cable conductors are damaged, contact Service.
Note: Close connectors that are not plugged in with the protective cap supplied.
8. Use isopropyl alcohol to clean dirty connector housings, plug connectors and contacts.
9. Ensure that all connecting plugs of the sensors are correctly engaged.
TIM-ID: 0000000029 - 025
MS15038/00E 2018-06 | Wiring (General) for Engine/Gearbox/Unit | 329

8.21 Accessories for (Electronic) Engine Governor / Control System
8.21.1 Engine governor and connector – Cleaning
Preconditions

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

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

Note: Close connectors that are not plugged in with the protective cap supplied.
1. Release latches of connectors and withdraw connectors.
2. Clean connector housings, connector socket housings and all contacts with isopropyl alcohol.
3. When connectors, sockets and all contacts are dry: Fit connectors and latch them.
TIM-ID: 0000000047 - 014
330 | Accessories for (Electronic) Engine Governor / Control System | MS15038/00E 2018-06
8.21.2 Engine Control Unit plug connections – Check
Preconditions
☑ Electronic engine management system is de-energized.
Checking plug connections at Engine Control Unit

1. Check all plug connections for firm seating.
2. Lock loose connectors.
3. Check dust cap on ECU connectors for damage and correct seating.
TIM-ID: 0000082594 - 001
MS15038/00E 2018-06 | Accessories for (Electronic) Engine Governor / Control System | 331
8.21.3 Engine governor ECU 9 – Removal and installation
Preconditions
☑ Protective cover over connectors on Heavy-Duty version removed.
NOTICE
Wrong engine governor installed.
Engine damage!
• When reassembling an engine, make sure that the governor with the data record for the given engine
is installed.
Removing engine governor from

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

1. For installation follow reverse sequence of working steps. Ensure that connectors are plugged in the correct
socket.
2. Check resilient mounts before installing.
Result: Replace the resilient mounts if the rubber is perished, or the mounts are otherwise defective.
TIM-ID: 0000063846 - 001
332 | Accessories for (Electronic) Engine Governor / Control System | MS15038/00E 2018-06
8.21.4 Parameters for drift correction (CDC) – Resetting with DiaSys®
Preconditions
Parameters for drift correction (CDC) – Resetting with DiaSys®

Note: The engine will lose its emissions certification of the drift correction parameters (CDC) if not reset.
1. Use DiaSys® to reset the CDC parameters (→ Dialog system DiaSys® E531920/..).
2. If no DiaSys® is available, contact Service.
TIM-ID: 0000079409 - 001
MS15038/00E 2018-06 | Accessories for (Electronic) Engine Governor / Control System | 333
9 Appendix A
9.1 Abbreviations
Abbre- Meaning Explanation
viation
A/D Analog/Digital converter Converter: converts sensor voltages into digital val-
ues
ADEC Advanced Diesel Engine Controller Engine management system
AFRS Air Filter Restriction Sensor
AL alarm
ANSI American National Standards Institute Association of American standardization organiza-
tions
ATS Air Temperature Sensor
BR Series
BV Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU Publica-
tion No. A001061/..
CAN Controller Area Network Data bus system, bus standard
CDC Calibration Drift Compensation Drift correction setting with DiaSys in engine gover-
nor
CEL Check Engine Lamp 1st function: Warning lamp (rectify fault as soon as
possible)
2nd function: Read out fault codes
CKT Circuit
CLS Coolant level sensor Monitors coolant level
CM Current Measurement Current measured value
CPS Coolant pressure sensor Monitors coolant pressure
CR Common Rail
CTS Coolant temperature sensor Monitors coolant temperature
DDEC Detroit Diesel Electronic Controls Engine control system made by Detroit Diesel
DDL Diagnostic Data Link Diagnostic lines
DDR Diagnostic Data Reader Diagnostic unit
Dia- Electronic dialog system
Sys®
DIN Deutsches Institut für Normung e. V. At the same time identifier of German standards
(DIN = “Deutsche Industrie-Norm”)
DL Default Lost Alarm: Default CAN bus failure
TIM-ID: 0000000858 - 016
DMC Data Matrix Code

DOC Diesel Oxidation Catalyst Oxidation catalyst upstream of the diesel particulate
filter
DPF Diesel Particulate Filter
DT Diagnostic Tool Diagnostic unit
ECM Electronic Control Module Electronic control unit of the DDEC system
ECU Engine Control Unit Engine governor
EDM Engine Data Module Memory module for engine data
334 | Appendix A | MS15038/00E 2018-06

viation
EE- Electrically Erasable Programmable Read
PROM Only Memory
EFPA Electronic Foot Pedal Assembly Electronic accelerator pedal
EGR Exhaust Gas Recirculation
EIL Engine Ident Label
EIM-ID Emission Identification Number
EMU Engine Monitoring Unit
ESCM Extreme Site Condition Management Power reduction for operation in extreme conditions
ESD Einzelspeicherdruck Injector accumulator pressure
ETC Exhaust turbocharger/exhaust turbocharg-
ing
EUI Electronic Unit Injector Electronic injection nozzle unit
FO Frequency Output
FPS Fuel Pressure Sensor Monitors fuel pressure
FRS Fuel Restriction Sensor Monitors differential fuel pressure
FTS Fuel Temperature Sensor Monitors fuel temperature
FWCP Fire Water Control Panel Control cabinet
GND Ground
HP High Pressure
HI High Alarm: Measured value exceeds 1st maximum limit
HIHI High High Alarm: Measured value exceeds 2nd maximum limit
HT High Temperature
IDM Interface Data Module Memory module for interface data
IIG Initial injector equalization Initial input of injector code in Engine Control Unit
with DiaSys
INJ Injector
ISO International Organization for Standardiza- International umbrella organization for all national
tion standardization institutes
KGS Kupplungsgegenseite Engine free end in accordance with DIN ISO 1204
KS Kupplungsseite Engine driving end in accordance with DIN ISO 1204
L1 Limit 1 Limit value, limit 1
L2 Limit 2 Limit value, limit 2
Reference surface for heights above sea
level
LED Light Emitting Diode Light emitting diode
TIM-ID: 0000000858 - 016
LLK Ladeluftkühlung Charge-air cooling

LO Low Alarm: Measured value lower than 1st minimum limit
value
LOLO Low Low Alarm: Measured value lower than 2nd minimum lim-
it value
LP Low Pressure
LSG Limit Speed Governor Maximum-speed governor
LSU Lambda Sonde Universal Universal Lambda probe
LT Low Temperature
MS15038/00E 2018-06 | Appendix A | 335

viation
MCR Maximum Continuous Rating Torque limitation curve
N/A Not Applicable
NN Normal Null Reference surface for heights above sea level
OEM Original Equipment Manufacturer
OI Optimized Idle
OLS Oil Level Sensor Monitors oil level
OPS Oil pressure sensor Monitors oil pressure
OTS Oil Temperature Sensor Monitors oil temperature
OT Oberer Totpunkt Top Dead Center (TDC)
PAN Panel Control panel
PIM Peripheral Interface Module
PWM Pulse Width Modulation Modulated signal
P-xyz Pressure-xyz Pressure measuring point xyz
RL Redundancy Lost Alarm: Redundant CAN bus failure
rpm Revolutions per minute
SAE Society of Automotive Engineers U.S. standardization organization
SD Sensor Defect Alarm: Sensor failure
SEL Stop Engine Lamp 1st function: Warning lamp (stop engine and rectify
fault); 2nd function: Read out fault codes
SID System Identifier
SPC Spare Parts Catalog
SRS Synchronous Reference Sensor TDC cylinder 1
SS Safety System / Security Shutdown Safety system alarm
TBS Turbocharger Boost Sensor Monitors charge-air pressure
TC Tool Catalog
TCI Turbo Compressor Inlet
TCO Turbo Compressor Outlet
TD Transmitter Deviation Alarm: Sensor comparison fault
TPS Throttle Position Sensor
TRS Timing Reference Sensor
T-xyz Temperature-xyz Temperature measuring point xyz
U_PDU Voltage Power Driver Unit Distribution voltage for solenoid valve output stages
UDV Überdruckventil Pressure relief valve
UT Unterer Totpunkt Bottom Dead Center (BDC)
TIM-ID: 0000000858 - 016
VNT Variable nozzle turbine

VSG Variable-speed governor
VSS Vehicle Speed Sensor
ZKP Zuordnung - Kategorie - Parameter A number allocated to a parameter describing its
function and assignment
336 | Appendix A | MS15038/00E 2018-06

9.2 MTU Contact/Service Partners
The worldwide network of the sales organization with subsidiaries, sales offices, representatives and custom-
er service centers ensure fast and direct support on site and ensure the high availability of our products.
Local Support
Experienced and qualified specialists place their knowledge and expertise at your disposal.
For locally available support, go to the MTU Internet site: http://www.mtu-online.com
24h Hotline
With our 24h hotline and high flexibility, we're your contact around the clock: during each operating phase,
preventive maintenance and corrective operations in case of a malfunction, for information on changes in
conditions of use and for supplying spare parts.
Your contact person in our Customer Assistance Center:
E-mail: 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 9077777
Fax.: +49 7541 9077778
TIM-ID: 0000000873 - 016
MS15038/00E 2018-06 | Appendix A | 337

10 Appendix B
10.1 Special Tools
Angular screw driver
Part No.: F30002815
Qty.: 1
Used in: 8.4.3 Valve clearance – Check and adjustment
(→ Page 236)
Barring tool
Part No.: F6555766
Qty.: 1
Used in: 8.1.1 Engine – Barring manually (→ Page 218)
Qty.: 1
Used in: 8.2.1 Cylinder liner – Endoscopic examination
(→ Page 222)
Crossbeam
Part No.: T80091826
Qty.: 1
Used in: 2.1 Transport (→ Page 19) DCL-ID: 0000049199 - 001
338 | Appendix B | MS15038/00E 2018-06

Crossbeam
Part No.: T80092360
Qty.: 1
Used in: 2.1 Transport (→ Page 19)
Depth gage, 200 mm

Part No.: Y20000918
Qty.: 1
Used in: 8.4.1 Valve protrusion – Measurement (→ Page 231)
Endoscope
Part No.: Y20097353
Qty.: 1
(→ Page 222)
Feeler gauge
Part No.: Y20098771
Qty.: 1
(→ Page 236)
DCL-ID: 0000049199 - 001
MS15038/00E 2018-06 | Special Tools | 339

Filter wrench
Part No.: F30379104
Qty.: 1
Used in: 8.8.1 Fuel filter – Replacement (→ Page 261)
Qty.:
Used in: 8.14.1 Engine oil filter – Replacement (→ Page 288)
Fuel suction pipe

Part No.: F30378207
Qty.: 1
Used in: 8.5.1 HP fuel pump – Filling with engine oil (→ Page 241)
High-pressure cleaner
Part No.:
Qty.: 1
Used in: 5.13 Plant – Cleaning (→ Page 191)
Installation/removal jig
Part No.: F6789889
Qty.: 1
Used in: 8.6.2 Injector – Removal and installation (→ Page 245)
Qty.: 1
Used in: 8.6.3 Injector rings – Replacement (→ Page 250)
DCL-ID: 0000049199 - 001
340 | Special Tools | MS15038/00E 2018-06

Measuring jig 1
Part No.: Y4350009
Qty.: 1
Measuring jig 2, optional

Part No.: Y4350010
Qty.: 1
Milling cutter
Part No.: F30452739
Qty.: 1
Qty.: 1
MTU test kit

Part No.: F6798833
Qty.: 1
Used in: 8.13.3 Engine oil – Sample extraction and analysis
(→ Page 285)
DCL-ID: 0000049199 - 001

MTU test kit
Part No.: 5605892099/00
Qty.: 1
Used in: 8.15.6 Engine coolant – Sample extraction and analysis
(→ Page 299)
Oil filter wrench

Part No.: F30455924
Qty.: 1
Used in: 8.14.2 Centrifugal oil filter – Cleaning and filter sleeve re-
placement (→ Page 289)
Ratchet bit
Part No.: F30027340
Qty.: 1
Used in: 8.3.1 Crankcase breather – Oil separator element re-
Qty.: 1
Used in: 8.3.2 Crankcase breather – Filter element replacement
(→ Page 229)
Qty.: 1
Qty.: 1
Qty.: 1
Used in: 8.8.6 Fuel prefilter (non-switchable) – Filter element re-
Qty.: 1
Used in: 8.8.7 Fuel prefilter (switchable) – Filter element replace-
ment (→ Page 271)
DCL-ID: 0000049199 - 001
Qty.: 1
Qty.: 1
Used in: 8.18.1 Battery-charging generator – Drive belt tension ad-
justment (→ Page 322)
Qty.: 1
Used in: 8.18.2 Battery-charging generator drive – Drive belt re-

Ratchet bit
Part No.: F30027341
Qty.: 1
Qty.: 1
Qty.: 1
Used in: 8.13.1 Engine oil – Change (→ Page 282)
Qty.: 1
Qty.: 1
Qty.: 1
Used in: 8.19.2 Engine mounting – Checking securing screws for
firm seating (→ Page 325)
Ratchet with extension

Part No.: F30006212
Qty.: 1
Used in: 8.1.1 Engine – Barring manually (→ Page 218)
Qty.: 1
(→ Page 222)
Socket wrench, 24 mm
Part No.: F30039526
Qty.: 1
(→ Page 236)
DCL-ID: 0000049199 - 001

Torque screwdriver, 1–5 Nm
Part No.: F30452774
Qty.: 1
Qty.: 1
Torque wrench, 10–60 Nm

Part No.: F30452769
Qty.: 1
Used in: 2.3 Crankshaft transport locking device (→ Page 21)
Qty.: 1
Used in: 8.5.1 HP fuel pump – Filling with engine oil (→ Page 241)
Qty.: 1
Qty.: 1
Qty.: 1
Qty.: 1
Qty.: 1

Part No.: F30047798
Qty.: 1
DCL-ID: 0000049199 - 001

Part No.: F30044239
Qty.: 1
Used in: 8.3.1 Crankcase breather – Oil separator element re-
Qty.: 1
Used in: 8.3.2 Crankcase breather – Filter element replacement
(→ Page 229)
Qty.: 1

Part No.: F30452768
Qty.: 1
Used in: 2.3 Crankshaft transport locking device (→ Page 21)
Qty.: 1
(→ Page 236)
Qty.: 1
Qty.: 1
Qty.: 1
Used in: 8.13.1 Engine oil – Change (→ Page 282)
Qty.: 1
Qty.: 1
Qty.: 1
Qty.: 1

Part No.: F30027336
DCL-ID: 0000049199 - 001
Qty.: 1
Used in: 8.8.6 Fuel prefilter (non-switchable) – Filter element re-
Qty.: 1
Used in: 8.8.7 Fuel prefilter (switchable) – Filter element replace-
ment (→ Page 271)

Valve setting gauge
Part No.: Y4349603
Qty.: 1
(→ Page 236)
DCL-ID: 0000049199 - 001

10.2 Index
A Cylinder head cover
Abbreviations 334 – Installation 240
Actuators – Removal 240
– Overview 27 Cylinder liner
After stopping the engine – Endoscopic examination 222
– Engine remains ready for operation 189 – Endoscopic inspection
– Putting the engine out of operation 190 – Instructions and comments on endoscopic and visu-
Air filter al examination 224
– Check 278
D
– Installation 279
– Removal 279 Drive belt
– Replacement 277 – Condition check 321
Air starter
E
– Manual operation 281
ECS
B – Fault messages 197
Battery-charging generator ECU 9
– Drive belt replacement 323 – Installation 332
– Drive belt tension adjustment 322 – Removal 332
ECU9
C – Fault messages 197
Cabling Emergency start
– Check – Override mode 183
– On engine 329 Emission label
CDC parameters – Check 185
– Resetting 333 Endoscopic inspection
Centrifugal oil filter – Cylinder liner
– Cleaning 289 – Instructions and comments 224
Charge-air coolant Engine
– Change 314 – Barring
– Check – Manually 218
– Level at filler neck 313 – Cranking
– Level via level sensor 313 – On starting system 220
– Draining 315 – Emergency start (Override mode) 183
– Filling 317 – Emergency stop 188
Charge-air coolant pump – Main dimensions 177
– Relief bore check 320 – Overview 25
Connector – Starting in manual mode (test run) 180
– Cleaning 330 – Stopping in Manual mode (test run) 186
Contact persons 337 – Test run 221
Contamination indicator Engine cabling
– Signal ring position check 280 – Check 329
Coolant Engine Control Unit
– Plug connections
DCL-ID: 0000049199 - 001
– Change 293, 314

– Filling 296 – Check 331
Coolant expansion tank Engine coolant
– Valve cover replacement 312 – Analysis
Crankcase breather – Sample 299
– Filter element replacement 229 – Change 293
– Oil separator element replacement 226 – Draining 294
Crankshaft – Extraction
– Transport locking device – Sample 299
– Installation/removal 21 – Filling 296
Cylinder Engine coolant level
– Designation 24 – Check 292
MS15038/00E 2018-06 | Index | 347

Engine coolant pump G
– Relief bore check 298 Generator mounting
Engine driving end – Check 327
– Definition 24 – Securing screw firm seating check 328
Engine free end
– Definition 24 H
Engine governor Heating element
– Cleaning 330 – Check
Engine governor ECU 9 – Preheater 306
– Installation 332 Hotline 337
– Removal 332 Housing
Engine mounting – Check
– Check 324 – Preheater 306
– Checking securing screws for firm seating 325 HP pump
Engine oil – Filling with engine oil 241
– Centrifugal oil filter
– Cleaning 289 I
– Change 282 Injector
– Filter sleeve – Installation 245
– Replacement 289 – Removal 245
– Sample extraction and analysis 285 – Replacement 244
Engine oil filter Injector rings
– Replacement 288 – Replacement 250
Engine oil level Intercooler
– Check 284 – Checking condensate drain for coolant leakage 276
Engine overview 25 – Checking condensate drain for obstructions 276
Engine sides
– Designation 24 L
Lifting specifications 20
F
Fault messages M
– ECS with ECU9 197 Main dimensions 177
Filter sleeve Maintenance Schedule
– Replacement 289 – Maintenance task reference table [QL1] 192
Firing order 176 MTU contact persons 337
Fuel cooler
– Check O
– External contamination 258 Oil priming pump
– Leak-tightness 258 – Visual inspection 287
– Cleaning 259 Oil separator
Fuel filter – Replacement 226
– Replacement 261 Operational monitoring 184
Fuel prefilter Overview
– Draining – Engine 25
– Non-switchable 263 – Preheater 301
– Switchable 265
– Filter element replacement P
DCL-ID: 0000049199 - 001
– Non-switchable 269 Parameters for drift correction (CDC)

– Switchable 271 – Resetting 333
– Low pressure indicator check Plant
– Switchable 268 – Cleaning 191
– Pressure ratios 262
– Venting 274
Fuel system
– Venting 256
348 | Index | MS15038/00E 2018-06

Preheater Product data 12V4000G14S
– Check – 3B continuous operation
– Heating element 306 – Optimized fuel consumption 58
– Housing 306 – 3F mains backup mode
– Function check 302 – EPA Nonroad T2 Comp (40CFR89) 58
– Leak check 302 – EPA Stationary EMERG T2 (40CFR60) 58
– Overhaul 303 – Optimized fuel consumption 58
– Overview 301 – 3G continuous operation
– Replacement – EPA Nonroad T2 Comp (40CFR89) 58
– Solenoid switch 304 – EPA Stationary EMERG T2 (40CFR60) 58
– Thermostat 309 – Optimized fuel consumption 58
Product data 12V4000B14S Product data 12V4000G14X
– 3A continuous operation – 3B continuous operation
– Optimized fuel consumption 32 – Optimized fuel consumption 174
Product data 12V4000B24F – TA-Luft-optimized 174
– 3A continuous operation Product data 12V4000G24F
– Optimized fuel consumption 32 – 3B continuous operation
Product data 12V4000B24S – China NRMM Stage III (GB20891-2014) 64
– 3A continuous operation – NEA Singapore for ORDE 64
– Optimized fuel consumption 32 – Optimized fuel consumption 36, 64
Product data 12V4000B24X – TA-Luft-optimized 64
– 3A continuous operation – 3E standby power
– Optimized fuel consumption 174 – China NRMM Stage III (GB20891-2014) 69
Product data 12V4000G14F – NEA Singapore for ORDE 69
– 3B continuous operation – Optimized fuel consumption 69
– China NRMM Stage III (GB20891-2014) 36 – TA-Luft-optimized 69
– NEA Singapore for ORDE 36 – 3F mains backup mode
– TA-Luft-optimized 36 – China NRMM Stage III (GB20891-2014) 74
– 3E standby power – NEA Singapore for ORDE 74
– NEA Singapore for ORDE 41 – Optimized fuel consumption 74
– Optimized fuel consumption 41 – TA-Luft-optimized 74
– TA-Luft-optimized (diesel) 41 – 3G continuous operation
– 3F mains backup mode – China NRMM Stage III (GB20891-2014) 79
– NEA Singapore for ORDE 45 – NEA Singapore for ORDE 79
– TA-Luft-optimized (diesel) 45 – TA-Luft-optimized 79
– 3G continuous operation Product data 12V4000G24S
– NEA Singapore for ORDE 49 – 3B continuous operation
– Optimized fuel consumption 49 – EPA Nonroad T2 Comp (40CFR89) 84, 152
– TA-Luft-optimized (diesel) 49 – EPA Stationary EMERG T2 (40CFR60) 84
Product data 12V4000G14RF – Optimized fuel consumption 84
– 3B continuous operation – 3F mains backup mode
– China NRMM Stage III (GB20891-2014) 53 – EPA Nonroad T2 Comp (40CFR89) 84
– NEA Singapore for ORDE 53 – EPA Stationary EMERG T2 (40CFR60) 84
– TA-Luft-optimized (diesel) 53 – 3G continuous operation
Product data 12V4000G14RS – EPA Nonroad T2 Comp (40CFR89) 84
DCL-ID: 0000049199 - 001
– 3B continuous operation – EPA Stationary EMERG T2 (40CFR60) 84

– EPA Nonroad T2 Comp (40CFR89) 58 – Optimized fuel consumption 84
– EPA Stationary EMERG T2 (40CFR60) 58 Product data 12V4000G24X
– 3B continuous operation
– Optimized fuel consumption 174
– TA-Luft-optimized 174
Product data 12V4000G74F
– 3D standby power
– China NRMM Stage III (GB20891-2014) 90
– NEA Singapore for ORDE 90
MS15038/00E 2018-06 | Index | 349

Product data 12V4000G74S Product data 16V4000G14S
– 3D standby power – 3B continuous operation
– EPA Stationary EMERG T2 (40CFR60) 90 – 3F mains backup mode
– Optimized fuel consumption 90 – EPA Nonroad T2 Comp (40CFR89) 126
Product data 12V4000G74X – EPA Stationary EMERG T2 (40CFR60) 126
– 3D standby power – Optimized fuel consumption 126
– Optimized fuel consumption 174 – 3G continuous operation
Product data 12V4000G84F – EPA Nonroad T2 Comp (40CFR89) 126
– 3D standby power – EPA Stationary EMERG T2 (40CFR60) 126
– China NRMM Stage III (GB20891-2014) 96 – Optimized fuel consumption 126
– NEA Singapore for ORDE 96 Product data 16V4000G14X
Product data 12V4000G84S – Optimized fuel consumption 175
– 3D standby power – TA-Luft-optimized 175
– EPA Nonroad T2 Comp (40CFR89) 96 Product data 16V4000G24F
– EPA Stationary EMERG T2 (40CFR60) 96 – 3B continuous operation
Product data 12V4000G84X – NEA Singapore for ORDE 132
– 3D standby power – Optimized fuel consumption 132
– Optimized fuel consumption 174 – TA-Luft-optimized 132
Product data 16V4000B14S – 3E standby power
– 3A continuous operation – China NRMM Stage III (GB20891-2014) 137
– Optimized fuel consumption 102 – NEA Singapore for ORDE 137
Product data 16V4000B24F – Optimized fuel consumption 137
– 3A continuous operation – TA-Luft-optimized 137
– Optimized fuel consumption 102 – 3F mains backup mode
Product data 16V4000B24S – China NRMM Stage III (GB20891-2014) 142
– 3A continuous operation – NEA Singapore for ORDE 142
Product data 16V4000B24X – TA-Luft-optimized 142
– 3A continuous operation – 3G continuous operation
Product data 16V4000G14F – NEA Singapore for ORDE 147
– 3B continuous operation – Optimized fuel consumption 147
– China NRMM Stage III (GB20891-2014) 106 – TA-Luft-optimized 147
– NEA Singapore for ORDE 106 Product data 16V4000G24S
– TA-Luft-optimized (diesel) 106 – EPA Stationary EMERG T2 (40CFR60) 152
– 3E standby power – Optimized fuel consumption 152
– China NRMM Stage III (GB20891-2014) 111 – 3F mains backup mode
– NEA Singapore for ORDE 111 – EPA Nonroad T2 Comp (40CFR89) 152
– Optimized fuel consumption 111 – EPA Stationary EMERG T2 (40CFR60) 152
– TA-Luft-optimized (diesel) 111 – Optimized fuel consumption 152
– 3F mains backup mode – 3G continuous operation
– China NRMM Stage III (GB20891-2014) 116 – EPA Nonroad T2 Comp (40CFR89) 152
– NEA Singapore for ORDE 116 – EPA Stationary EMERG T2 (40CFR60) 152
DCL-ID: 0000049199 - 001

– TA-Luft-optimized (diesel) 116 Product data 16V4000G24X
– 3G continuous operation – 3B continuous operation
– China NRMM Stage III (GB20891-2014) 121 – Optimized fuel consumption 175
– NEA Singapore for ORDE 121 – TA-Luft-optimized 175
– Optimized fuel consumption 121 Product data 16V4000G74F
– TA-Luft-optimized (diesel) 121 – 3D standby power
Product data 16V4000G14RS – China NRMM Stage III (GB20891-2014) 158
– 3B continuous operation – NEA Singapore for ORDE 158
– EPA Stationary EMERG T2 (40CFR60) 126
350 | Index | MS15038/00E 2018-06

Product data 16V4000G74S Starting valve
– 3D standby power – Manual operation 281
– EPA Nonroad T2 Comp (40CFR89) 158
– EPA Stationary EMERG T2 (40CFR60) 158 T
– Optimized fuel consumption 158 Thermostat
Product data 16V4000G74X – Replacement
– 3D standby power – Preheater 309
– Optimized fuel consumption 175 Transport
Product data 16V4000G84F – Description 19
– 3D standby power – Lifting specifications 20
– China NRMM Stage III (GB20891-2014) 164 Transport locking device
– NEA Singapore for ORDE 164 – Crankshaft
– Optimized fuel consumption 164 – Installation/removal 21
Product data 16V4000G84S Troubleshooting 194
– 3D standby power
– EPA Nonroad T2 Comp (40CFR89) 164 V
– EPA Stationary EMERG T2 (40CFR60) 164 Valve clearance
– Optimized fuel consumption 164 – Adjustment 236
Product data 16V4000G84X – Check 236
– 3D standby power Valve cover
– Optimized fuel consumption 175 – Replacement 312
Product data 16V4000G94S Valve gear
– 3D standby power – Lubrication 235
– EPA Nonroad T2 Comp (40CFR89) 170 Valve protrusion
– EPA Stationary EMERG T2 (40CFR60) 170 – Measurement 231
W
Pump
– Engine coolant Warning notices, standards 18
– Relief bore check 298
Putting the engine-generator set into operation after ex-
tended out-of-service-periods (>3 months) 178
Putting the engine-generator set into operation after
scheduled out-of-service-period 179
S
Safety regulations
– Assembly work 12
– Auxiliary materials 16
– Environmental protection 16
– Fire prevention 16
– Fluids and lubricants 16
– Important provisions 6, 8
– Initial start-up 10
– Maintenance work 12
– Operation 10
– Organizational requirements 9
– Personnel requirements 9
DCL-ID: 0000049199 - 001
– Repair work 12

Safety requirements
– Warning notices, standards 18
Safety system
– Override 182
Sensors
– Overview 27
Service partners 337
Solenoid switch
– Replacement
– Preheater 304
Spare parts service 337
MS15038/00E 2018-06 | Index | 351

Operating Instructions: Diesel Engine 12V4000Bx4 12V4000Gx4 16V4000Bx4 16V4000Gx4

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Operating Instructions

© 2018 Copyright MTU Friedrichshafen GmbH

MS15038/00E 2018-06 | Table of Contents | 3

8 Task Description 8.11 Air Intake 280

4 | Table of Contents | MS15038/00E 2018-06

MS15038/00E 2018-06 | Table of Contents | 5

Emission regulations and emission labels

Emission certification applicable to engines with EPA Nonroad Tier 4 emission

Replacing components with emission labels

6 | Safety | MS15038/00E 2018-06

MS15038/00E 2018-06 | Safety | 7

8 | Safety | MS15038/00E 2018-06

Clothing and personal protective equipment

MS15038/00E 2018-06 | Safety | 9

Safety regulations during operation

Malfunctions and emergency stop

10 | Safety | MS15038/00E 2018-06

Operation of electrical equipment

MS15038/00E 2018-06 | Safety | 11

Safety regulations when performing assembly, maintenance, and repair work

Setting down, lifting and climbing

12 | Safety | MS15038/00E 2018-06

Removing, installing and cleanliness

Safety regulations after performing assembly, maintenance, and repair work

MS15038/00E 2018-06 | Safety | 13

Hydraulic installation and removal

Working with batteries

Working on electrical and electronic assemblies

14 | Safety | MS15038/00E 2018-06

Working with laser equipment

Measuring component dimensions

MS15038/00E 2018-06 | Safety | 15

Environmental protection and disposal

Fluids and lubricants/auxiliary materials (process materials)

16 | Safety | MS15038/00E 2018-06

Acids/alkalines/reducing agents (e.g. AdBlue®, DEF)

MS15038/00E 2018-06 | Safety | 17

18 | Safety | MS15038/00E 2018-06

Setting down after transport

MS15038/00E 2018-06 | Transport | 19

1 Max. permissible diagonal 2 Center of gravity

Taking note of the engine center of gravity

20 | Transport | MS15038/00E 2018-06

Transport locking devices

Removing guard plates and en-

MS15038/00E 2018-06 | Transport | 21

6. Install locknut (2) of screw (1) on plate (6) and tighten.

Removing the transport locking

locking device carefully together with this

22 | Transport | MS15038/00E 2018-06

MS15038/00E 2018-06 | Transport | 23

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

24 | General Information | MS15038/00E 2018-06

1 Cylinder head cover 6 Fuel filter 11 Coolant distribution housing

MS15038/00E 2018-06 | General Information | 25

1 Intercooler 6 LT thermostat housing 11 Starter

Engine model designation

26 | General Information | MS15038/00E 2018-06