MTU 20V4000G Operation Manuel

Operating Instructions
Diesel Engine
20V4000Gx2
M015565/03E
Engine model kW/cyl. Hz Application group
20V4000G22 110.0 kW/cyl. 50 Hz 3B, continuous operation, variable load, ICXN
20V4000G22 110.0 kW/cyl. 50 Hz 3C, restricted operation, ICXN
20V4000G22 121.0 kW/cyl. 50 Hz 3D, emergency power, fuel stop power, IFN
20V4000G62 100.0 kW/cyl. 50 Hz 3A, continuous operation, unrestricted
Table 1: Applicability
© 2016 Copyright MTU Friedrichshafen GmbH

This publication is protected by copyright and may not be used in any way, whether in whole or in part, without the prior writ-
ten consent of MTU Friedrichshafen GmbH. This particularly applies to its reproduction, distribution, editing, translation, micro-
filming and storage or processing in electronic systems including databases and online services.
All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen GmbH
reserves the right to change, delete or supplement the information provided as and when required.
Table of Contents
1 Safety 5.4 Starting the engine in emergency situations
(override mode) 46
1.1 Important provisions for all products 5 5.5 Operational monitoring 47
1.2 Correct use for all products 6 5.6 Engine – Stopping in manual mode (test
1.3 Personnel and organizational requirements 7 run) 48
1.4 Safety regulations for startup and operation 8 5.7 Engine – Emergency stop 49
1.5 Safety precautions when working on the 5.8 After stopping the engine – Putting the
engine 10 engine out of operation 50
1.6 Fire prevention and environmental 5.9 Plant – Cleaning 51
protection, fluids and lubricants, auxiliary
materials 13
6 Maintenance
1.7 Standards for safety notices in the text 15
6.1 Maintenance task reference table [QL1] 52
2 Transport
7 Troubleshooting
2.1 Transportation 16
2.2 Lifting requirements 17 7.1 Troubleshooting 53
2.3 Crankshaft transport locking device 18 7.2 Fault messages on engine governor 56
3 General Information 8 Task Description

3.1 Engine side and cylinder designations 21 8.1 Engine 67
3.2 Engine overview 22 8.1.1 Engine – Barring manually 67
8.1.2 Engine – Cranking on starting system 69
4 Technical Data 8.1.3 Engine – Test run 70
8.2 Cylinder Liner 71

4.1 20V4000 continuous operation, unrestricted
8.2.1 Cylinder liner – Endoscopic examination 71
3A, optimized fuel consumption G62, 8.2.2 Instructions and comments on endoscopic and
emissions-optimized (EPA) G82 23 visual examination of cylinder liners 73
4.2 20V4000 continuous operation, variable 3B,
optimized fuel consumption G22/G62, 8.3 Crankcase Breather 75
8.3.1 Crankcase breather – Oil separator element
emissions-optimized (“TA-Luft”) G22/G62,
replacement 75
emissions-optimized (EPA) G42/G82 27
4.3 20V4000 continuous operation, restricted 8.4 Valve Drive 77
3C, optimized fuel consumption G22/G62, 8.4.1 Cylinder head cover – Removal and
emissions-optimized (“TA-Luft”) G22/G62 32 installation 77
8.4.2 Valve gear – Lubrication 78
4.4 20V4000 standby power 3D, optimized fuel
8.4.3 Valve clearance – Check and adjustment 79
consumption G22/G62, emissions-optimized
(EPA) G42/G82 36 8.5 Injection Pump / HP Pump 84
4.5 Final compression pressure 40 8.5.1 HP fuel pump – Relief bore check 84
4.6 Firing order 41 8.6 Injector 85
4.7 Main engine dimensions 42
DCL-ID: 0000034750 - 001
8.6.1 Injector – Replacement 85

8.6.2 Injector – Removal and installation 86
5 Operation
8.7 Fuel System 91
5.1 Putting the engine into operation after 8.7.1 Fuel system – Venting 91
extended out-of-service periods (>3 months) 43 8.8 Fuel Filter 92
5.2 Putting the engine into operation after 8.8.1 Fuel filter – Replacement 92
scheduled out-of-service-period 44 8.8.2 Fuel prefilter – Cleaning 93
5.3 Engine – Starting in manual mode (test run) 45 8.8.3 Fuel prefilter – Differential pressure gage
check and adjustment of gage 94
M015565/03E 2016-02 | Table of Contents | 3

8.8.4 Fuel prefilter – Draining 95 8.16.2 Charge-air coolant – Change 118
8.8.5 Fuel prefilter – Flushing 96 8.16.3 Charge-air coolant draining 119
8.8.6 Fuel prefilter – Filter element replacement 98 8.16.4 Charge-air coolant – Filling 120
8.16.5 Charge-air coolant pump – Relief bore check 122
8.9 Charge-Air Cooling 100
8.9.1 Intercooler – Check water drain for coolant 8.17 Belt Drive 123
leakage and absence of restrictions 100 8.17.1 Drive belt – Condition check 123
8.10 Air Filter 101 8.18 Battery-Charging Generator 124

8.10.1 Air filter ‒ Replacement 101 8.18.1 Battery-charging generator drive – Drive belt
8.10.2 Air filter – Removal and installation 102 tension adjustment 124
8.18.2 Battery-charging generator drive – Drive belt
8.11 Air Intake 103 condition check 125
8.11.1 Service indicator – Signal ring position check 103
8.18.3 Battery-charging generator drive – Drive belt
8.12 Starting Equipment 104 replacement 126
8.12.1 Air starter – Manual operation 104
8.19 Engine Mounting / Support 127
8.13 Lube Oil System 105 8.19.1 Engine mounting – Resilient mount check 127
8.13.1 Engine oil – Level check 105
8.20 Cabling 128
8.13.2 Engine oil – Change 106
8.20.1 Engine cabling – Check 128
8.14 Oil Filtration / Cooling 108 8.21 Accessories for (Electronic) Engine
8.14.1 Engine oil filter – Replacement 108
Governor / Control System 129
8.14.2 Centrifugal oil filter – Cleaning and filter-
8.21.1 Engine Control Unit and connectors – Cleaning 129
sleeve replacement 109
8.21.2 Engine Control Unit – Plug connection check 130
8.15 Coolant Circuit, General, High-Temperature
Circuit 111
8.15.1 Engine coolant – Level check 111
9 Appendix A
8.15.2 Engine coolant – Change 112
9.1 Abbreviations 131
8.15.3 Engine coolant – Draining 113
9.2 MTU Contact/Service Partners 134
8.15.4 Engine coolant – Filling 114
8.15.5 Engine coolant pump – Relief bore check 116
10 Appendix B
8.16 Low-Temperature Circuit 117
8.16.1 Charge-air coolant – Level check 117 10.1 Special Tools 135
10.2 Index 141
DCL-ID: 0000034750 - 001
4 | Table of Contents | M015565/03E 2016-02

1 Safety
1.1 Important provisions for all products
Nameplate
The product is identified by nameplate, model designation or serial number and must match with the infor-
mation on the title page of this manual.
Nameplate, model designation or serial number can be found on the product.
All EU-certified engines delivered by MTU come with a second nameplate. When operating the machine in the
EU: The second nameplate must be affixed in a prominent position as described in the accompanying specifi-
cations.
General information
This product may pose a risk of injury or damage in the following cases:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Modifications or conversions
• Noncompliance with the safety instructions and warning notices
Emission regulations and emission labels

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

On all MTU engines fitted with emission labels, these labels must remain on the engine throughout its opera-
tional life.
Engines used exclusively in land-based, military applications other than by US government agencies are ex-
cepted from this proviso.
Please note the following when replacing components with emission labels:
• The relevant emission labels must be affixed to the spare part.
• Do not transfer the emission labels from the replaced part to the spare part.
• Remove the emission labels from the replaced part and destroy them.
TIM-ID: 0000040530 - 008
M015565/03E 2016-02 | Safety | 5

1.2 Correct use for all products
Correct use
The product is intended for use in accordance with its contractually-defined purpose as described in the rele-
vant technical documents only.
Intended use entails operation:
• Within the permissible operating parameters in accordance with the (→ Technical data)
• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubricants
Specifications of the manufacturer)
• With preservation approved by the manufacturer in accordance with the (→ Preservation and Represerva-
tion Specifications of the manufacturer)
• With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU con-
tact/Service partner)
• In the original as-delivered configuration or in a configuration approved by the manufacturer in writing (in-
cluding engine control/parameters)
• In compliance with all safety regulations and in adherence with all warning notices in this manual
• In compliance with the maintenance work and intervals specified in the (→ Maintenance Schedule)
throughout the useful life of the product
• In compliance with the maintenance and repair instructions contained in this manual, in particular with
regard to the specified tightening torques
• With the exclusive use of technical personnel trained in commissioning, operation, maintenance and re-
pair
• By contracting only workshops authorized by the manufacturer to carry out repair and overhaul
The product shall not be operated in explosive atmospheres unless the necessary approval has been grant-
ed.
Any other use, particularly misuse, is considered as being contrary to the intended purpose. Such improper
use increases the risk of injury and damage when working with the product. The manufacturer shall not be
held liable for any damage resulting from improper, non-intended use.
The specifications of the manufacturer will be amended or supplemented as necessary. Prior to operation,
make sure that the latest version is used. The latest version can be found on the websites:
• For drive systems: http://www.mtu-online.com
• For power generation: http://www.mtuonsiteenergy.com
Modifications or conversions
Unauthorized changes to the product represent a contravention of its intended use and compromise safety.
Changes or modifications shall only be considered to comply with the intended use when expressly author-
ized by the manufacturer. The manufacturer shall not be held liable for any damage resulting from unauthor-
ized changes or modifications.
TIM-ID: 0000065671 - 001
6 | Safety | M015565/03E 2016-02

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

Always wear appropriate personal protective equipment, e.g. safety shoes, ear protectors, protective gloves,
goggles, breathing mask. Follow the instructions concerning personal protective equipment in the descrip-
tions of the individual activities.
TIM-ID: 0000040531 - 008
M015565/03E 2016-02 | Safety | 7

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

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

Practice emergency procedures, especially emergency stopping, at regular intervals.
The following steps must be taken if a malfunction of the system is detected or reported by the system:
• Inform supervisor(s) in charge.
• Analyze the message.
• Respond by taking any necessary emergency action, e.g. emergency stop.
Operation
Do not remain in the operating room when the product is running for any longer than absolutely necessary.
Keep a safe distance away from the product if possible. Do not touch the product unless expressly instructed
TIM-ID: 0000040533 - 012
to do so following a written procedure.

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

Parts of the electrical equipment are live, i.e. under voltage/high tension, during operation.
8 | Safety | M015565/03E 2016-02

Follow the applicable warning instructions pertaining to such devices.
TIM-ID: 0000040533 - 012
M015565/03E 2016-02 | Safety | 9

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

Take special care when removing ventilation or plug screws from the product.
Release residual pressure before removing or replacing a component in the supply line. To depressurize pres-
surized lines, shut off the lines first, then release the residual pressure.
Use only proper and calibrated tools. Observe the specified tightening torques during assembly or disassem-
bly.
Carry out work only on assemblies or plants which are properly secured.
Make sure components or assemblies are placed on stable surfaces. Adopt suitable measures to avoid that
components/tools fall down. Use the specified lifting equipment for all components.
TIM-ID: 0000040535 - 012
Never use the product as a climbing aid.

When working high on the equipment, always use suitable ladders and work platforms. Never work on en-
gines or components that are held in place by lifting equipment.
Keep fuel injection lines and connections clean.
Carry out appropriate cleaning procedures to clean and inspect components requiring special cleanness (e.g.
components carrying oil, fuel, or air).
Always seal connections with caps or covers if a line is removed or opened.
Fit new seals when re-installing lines.
10 | Safety | M015565/03E 2016-02

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

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

Check satisfactory function and safe operating condition of tools, jigs and fixtures to be used. Use only the
specified jigs and fixtures for hydraulic removal/installation procedures.
TIM-ID: 0000040535 - 012
Observe the max. permissible force-on pressure specified for the jig/fixture.
Do not attempt to bend or exert force on H.P. lines.
Before starting work, pay attention to the following:
• Vent the installation/removal device, the pumps and the pipework at the relevant designated points.
• During the installation procedure, screw on device with pushed-in plunger.
• During the removal procedure, screw on device with retracted plunger.
For a hydraulic installation/removal device with central expansion pressure supply, screw spindle into shaft
end until correct sealing is established.
M015565/03E 2016-02 | Safety | 11

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

Observe the safety instructions of the battery manufacturer when working with batteries.
Gases released from the battery are explosive. Avoid sparks and naked flames.
Do not allow battery acids to come into contact with skin or clothing.
Wear protective clothing, goggles and protective gloves.
Do not place objects on the battery.
Before connecting the cable to the battery, check the battery polarity. Battery pole reversal may lead to in-
jury through the sudden discharge of acid or bursting of the battery body.
Working on electrical and electronic assemblies

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

Work with laser devices shall be carried out by trained and qualified personnel only. Follow the safety in-
structions in the manufacturer's user manual when working with laser equipment.
Wear special laser safety glasses when working with laser equipment (danger of concentrated radiation).
Laser devices must be equipped, in accordance with their class and usage, with protective devices for ensur-
ing safe operation.
TIM-ID: 0000040535 - 012
Measuring component dimensions

Workpieces, components and measuring equipment lie in the specified tolerance range at a reference tem-
perature of 20 °C.
12 | Safety | M015565/03E 2016-02

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

Dispose of used fluids, lubricants and filters in accordance with local regulations.
Within the EU, batteries can be returned free of charge to the manufacturer where they will be properly recy-
cled.
Auxiliary materials
Process materials may also be hazardous or toxic. When using consumables and auxiliary materials as well
as other chemical substances, observe the information contained in the safety data sheet for the product.
The safety data sheet may be obtained from the relevant manufacturer or from MTU.
Take special care when using hot, chilled or caustic materials.
Used oil
Used oil contains combustion residues that are harmful to health.
Wear protective gloves!
Wash relevant areas after contact with used oil.
TIM-ID: 0000040536 - 010
Lead
• Adopt suitable measures to avoid the formation of lead dust.
• Switch on extraction system.
• When working with lead or lead-containing compounds, avoid direct contact to the skin and do not inhale
lead vapors.
• Wash relevant areas after contact with lead or lead-containing substances.
M015565/03E 2016-02 | Safety | 13

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

• When working with acids and alkaline solutions, wear goggles or face mask, gloves and protective cloth-
ing.
• Do not inhale vapors.
• If urea solution is swallowed, rinse out mouth and drink plenty of water.
• Remove any wet clothing immediately.
• After contact skin, wash body areas with plenty of water.
• Rinse eyes immediately with eyedrops or clean tap water. Seek medical attention as soon as possible.
TIM-ID: 0000040536 - 010
14 | Safety | M015565/03E 2016-02

1.7 Standards for safety notices in the text
DANGER
In the event of immediate danger.
Consequences: Death, serious or permanent injury!
• Remedial action.
WARNING
In the event of a situation involving potential danger.
Consequences: Death, serious or permanent injury!
CAUTION
In the event of a situation involving potential danger.
Consequences: Minor or moderate injuries!
NOTICE
In the event of a situation involving potentially adverse effects on the product.
Consequences: Material damage!
• Additional product information.
Warning notices
1. This manual with all safety instructions and safety notices must be issued to all personnel involved in opera-
tion, maintenance, repair, assembly, installation, or transportation.
2. The higher level warning notice is used if several hazards apply at the same time. Warnings related to person-
al injury shall be considered to include a warning of potential damage.
TIM-ID: 0000040578 - 005
M015565/03E 2016-02 | Safety | 15

2 Transport
2.1 Transportation
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Crossbeam T80091826 1
Crossbeam T80092360 1
DANGER
Suspended load.
Danger to life!
• Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.
Transportation
1. Install the engine mounting locking devices and the engine transportation lock prior to transportation
(→ Page 18).
2. Use the lifting eyes provided to transport the engine/generator (→ Page 17).
3. Use suitable transport and lifting gear only.
4. The engine/generator must only be transported in installation position: max. admissible diagonal pull 10°
(→ Page 17).
5. Remove any loose parts on the engine/generator.
6. Raise and lower the engine/generator slowly. Do not allow hoist slings or chains to contact the engine/
generator or any of their component parts. Adjust lifting gear as necessary.
7. For special packaging with aluminum foil: Suspend the engine by the lifting eyes on the bearing pedestal or
transport by means of handling equipment (forklift truck) capable of bearing the load.
8. Secure the engine/generator such as to preclude tipping during transport. Secure such as to preclude slip-
ping and tipping when driving up or down inclines and ramps.
Setting down after transport

1. Set the 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 - 002
16 | Transport | M015565/03E 2016-02

2.2 Lifting requirements
Lifting requirements
DANGER
Suspended load.
Danger to life!
• Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.
1 Max. admissible diagonal 2 Center of gravity

pull 10°
Take note of the engine center of gravity

See Installation/Arrangement drawings for details on engine center of gravity.
TIM-ID: 0000066317 - 001
M015565/03E 2016-02 | Transport | 17

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) om both sides and take
off with washers (3), guard plates (1) and en-
gine mounting brackets (2).
2. Store the removed parts of the transport
locking device carefully for possible reuse.
TIM-ID: 0000004010 - 015
18 | Transport | M015565/03E 2016-02

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 retainer (3) must point downwards. Insert retainer (3) through the openings of plate (6).
Note: Retainer (3) must lock only the flywheel, not the ring gear.
4. Screw in screw (1) in bores of retainer (3) until retainer (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 retainer (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 - 015
locking device carefully together with this

documentation for possible reuse.
M015565/03E 2016-02 | Transport | 19

Installing guard plates and en-
gine mounting brackets (if appli-
cable) on driving end (KS)
Note: Always use the screws supplied with the or
removed from the guard plates and engine
mounting brackets to secure them on the en-
gine.
1. Install engine mounting brackets (2) on both
sides with guard plates (1) washers (3), and
screws (4).
2. Tighten screws (4).
TIM-ID: 0000004010 - 015
20 | Transport | M015565/03E 2016-02

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 - 013
M015565/03E 2016-02 | General Information | 21

3.2 Engine overview
1 Oil cooler 10 Coolant lines 19 HP fuel pump

2 Crankcase breather 11 Flywheel 20 Gear train
3 Coolant lines 12 Starter 21 Lube oil filter
4 Exhaust system 13 Engine mounting 22 Crank drive
5 Exhaust turbocharger 14 Air supply 23 Battery-charging generator
6 Air intake 15 Cylinder 24 Coolant system
7 Engine Control Unit 16 Cylinder head KGS Free end
8 Air pipework before inter- 17 Crankcase and add-on com-
cooler ponents
9 Intercooler 18 Fuel prefilter
Engine model designation

Key to engine model designation 20V4000Gxy/Pxy
20 Number of cylinders
V Cylinder arrangement: V engine
4000 Series
TIM-ID: 0000002070 - 002
G/P Application
x Application segment (2, 4, 6, 8)
y Design status (2,...)
22 | General Information | M015565/03E 2016-02

4 Technical Data
4.1 20V4000 continuous operation, unrestricted 3A, optimized
fuel consumption G62, emissions-optimized (EPA) G82
Explanation
Abbr. Meaning
DL Ref. value: Continuous power
BL Ref. value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power settings).
N Not yet defined value
- Not applicable
X Applicable
Reference conditions
Engine model Unit 20V4000 20V4000
G62 G82
Application group 3A 3A
Intake air temperature °C 25 25
Charge air coolant temperature °C 55 55
Raw water inlet temperature °C - -
Barometric pressure mbar 1000 1000
Site altitude above sea level m 100 100
Power-related data (power ratings are net brake power as per ISO 3046)
G62 G82
Rated engine speed A rpm 1500 1800
Continuous power ISO 3046 (10% overload capability, A kW 2000 2060
design power DIN 6280, ISO 8528)
General conditions (for maximum power)

TIM-ID: 0000002871 - 004

G62 G82
Intake air depression (new filter) (design) A mbar 25 25
Intake air depression (limit value) L mbar 50 50
Exhaust backpressure (design) A mbar 30 30
Exhaust backpressure (limit value) L mbar 50 50
M015565/03E 2016-02 | Technical Data | 23

Model related data (basic design)
G62 G82
Engine with exhaust turbocharging (ETC) and charge-air X X
cooling (CAC)
Uncooled exhaust lines X X
Operating method: Four-stroke cycle, diesel, single-ac- X X
tion
Combustion method: direct fuel injection X X
Cooling method: conditioned water X X
Direction of rotation: c.c.w. (facing driving end) X X
Number of cylinders 20 20
Cylinder arrangement: V-angle degrees 90 90
Bore mm 165 165
Stroke mm 210 210
Displacement, cylinder Liter 4.49 4.49
Displacement, total Liter 89.81 89.81
Compression ratio 15.5 15.5
Cylinder heads: Individual cylinder heads X X
Cylinder liners: wet, replaceable X X
Number of inlet valves per cylinder 2 2
Number of exhaust valves, per cylinder 2 2
Standard housing connecting flange (engine main PTO) SAE 00 00
Flywheel interface DISC 21" 21"
Air / exhaust gas

G62 G82
Charge air pressure before cylinder (abs.), DL R bar abs 2.5 2.5
Coolant system (HT)

G62 G82
Coolant temperature (at engine connection: outlet to A °C 95 95
cooling equipment)
Coolant temperature after engine, warning R °C 97 97
Coolant temperature after engine, shutdown L °C 99 99
TIM-ID: 0000002871 - 004
Coolant antifreeze content, max. permissible L % 50 50

Pressure loss in the external cooling system, max. per- L bar 0.7 0.7
missible
24 | Technical Data | M015565/03E 2016-02

Coolant system (LT)
G62 G82
Coolant temperature before intercooler (at engine inlet A °C 55 55
from cooling equipment)
Coolant antifreeze content, max. permissible L % 50 50
Pressure loss in the external cooling system, max. per- L bar 0.7 0.7
missible
Lube oil system

G62 G82
Lube oil operating temperature before engine, from R °C 85 86
Lube oil operating temperature before engine, to R °C 95 95
Lube-oil temperature before engine, alarm R °C 95 95
Lube-oil temperature before engine, shutdown L °C -- --
Lube oil operating pressure before engine, from R bar 4.8 4.8
Lube oil operating pressure before engine, to R bar 6.0 6.0
Lube oil pressure before engine, alarm R bar 4.5 4.5
Lube oil pressure before engine, shutdown L bar 4.0 4.0
Fuel system
G62 G82
Fuel pressure at engine inlet connection (during engine L bar -0.1 -0.1
start), min. admissible
Fuel pressure at engine inlet connection (during engine L bar 1.5 1.5
start), max. admissible
General operating data

G62 G82
Cold start capability: air temperature (w/o start aid, R °C 5 5
w/o preheating) (case A)
Preheating temperature (min.) R °C 32 32
Firing speed, from R rpm 80 80
Firing speed, to R rpm 120 120
TIM-ID: 0000002871 - 004
Oil and coolant capacity

G62 G82
Engine coolant capacity, engine side (without cooling R Liter 205 205
equipment)
Charge-air coolant, engine side R Liter 55 55
Engine oil capacity, initial filling (standard oil system) R Liter 390 390
(design: max. operating inclinations)

G62 G82
Oil change quantity max. (standard oil system) (design: R Liter 340 340
max. operating inclinations)
Oil pan capacity dipstick mark min. (standard oil sys- L Liter 245 245
tem) (design: max. operating inclinations)
Oil pan capacity dipstick mark max. (standard oil sys- L Liter 340 340
tem) (design: max. operating inclinations)
Weight
G62 G82
Engine weight, dry (basic engine configuration in accord- R kg 9450 9450
ance with scope of delivery specifications)
Sound
G62 G82
Exhaust noise, unsilenced, DL, (sound power level LW, R dB(A) Approx. 127 Approx. 127
ISO 6798)
Engine surface noise with attenuated intake noise (fil- R dB(A) Approx. 125 Approx. 125
ter), DL, (sound power level LW, ISO 6798)
TIM-ID: 0000002871 - 004

4.2 20V4000 continuous operation, variable 3B, optimized fuel
consumption G22/G62, emissions-optimized (“TA-Luft”) G22/
G62, emissions-optimized (EPA) G42/G82
Explanation
Abbr. Meaning
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable
Engine model Unit 20V4000 20V4000 20V4000 20V4000 20V4000 20V4000
G22 G62 G22 G62 G42 G82
Application group 3B 3B 3B 3B 3B 3B
Intake air tempera- °C 25 25 25 25 25 25
ture
Charge air coolant °C 55 55 55 55 55 55
temperature
Raw water inlet tem- °C - - - - - -
perature
Barometric pressure mbar 1000 1000 1000 1000 1000 1000
Site altitude above m 100 100 100 100 100 100
sea level
G22 G62 G22 G62 G42 G82
Rated engine speed A rpm 1500 1500 1500 1500 1800 1800
Continuous power A kW 2200 2420 2200 2420 2490 2740
ISO 3046 (10% over-
load capability, de-
TIM-ID: 0000002920 - 004
sign power DIN

6280, ISO 8528)

G22 G62 G22 G62 G42 G82
Intake air depression A mbar 25 25 25 25 25 25
(new filter) (design)
Intake air depression L mbar 50 50 50 50 50 50
(limit value)
Exhaust backpres- A mbar 30 30 30 30 30 30
sure (design)
Exhaust backpres- L mbar 50 50 50 50 50 50
sure (limit value)

G22 G62 G22 G62 G42 G82
Engine with exhaust X X X X X X
turbocharging (ETC)
and charge-air cool-
ing (CAC)
Uncooled exhaust X X X X X X
lines
Operating method: X X X X X X
Four-stroke cycle,
diesel, single-action
Combustion method: X X X X X X
direct fuel injection
Cooling method: con- X X X X X X
ditioned water
Direction of rotation: X X X X X X
c.c.w. (facing driving
end)
Number of cylinders 20 20 20 20 20 20
Cylinder arrange- degrees 90 90 90 90 90 90
ment: V-angle
Bore mm 165 165 165 165 165 165
Stroke mm 210 210 210 210 210 210
Displacement, cylin- Liter 4.49 4.49 4.49 4.49 4.49 4.49
der
Displacement, total Liter 89.81 89.81 89.81 89.81 89.81 89.81
Compression ratio 15.5 15.5 15.5 15.5 15.5 15.5
TIM-ID: 0000002920 - 004
Cylinder heads: Indi- X X X X X X

vidual cylinder heads
Cylinder liners: wet, X X X X X X
replaceable
Number of inlet 2 2 2 2 2 2
valves per cylinder
Number of exhaust 2 2 2 2 2 2
valves, per cylinder

G22 G62 G22 G62 G42 G82
Standard housing SAE 00 00 00 00 00 00
connecting flange
(engine main PTO)
Flywheel interface DISC 21" 21" 21" 21" 21" 21"
Air / exhaust gas

G22 G62 G22 G62 G42 G82
Charge air pressure R bar abs 2.7 3.0 3.4 3.7 2.9 3.2
before cylinder
(abs.), DL
Coolant system (HT)

G22 G62 G22 G62 G42 G82
Coolant temperature A °C 95 95 95 95 95 95
(at engine connec-
tion: outlet to cooling
equipment)
Coolant temperature R °C 97 97 97 97 97 97
after engine, warning
Coolant temperature L °C 99 99 99 99 99 99
after engine, shut-
down
Coolant antifreeze L % 50 50 50 50 50 50
content, max. per-
missible
Pressure loss in the L bar 0.7 0.7 0.7 0.7 0.7 0.7
external cooling sys-
tem, max. permissi-
ble
Coolant system (LT)

G22 G62 G22 G62 G42 G82
Coolant temperature A °C 55 55 55 55 55 55
before intercooler (at
engine inlet from
cooling equipment)
TIM-ID: 0000002920 - 004
Coolant antifreeze L % 50 50 50 50 50 50
content, max. per-
missible
Pressure loss in the L bar 0.7 0.7 0.7 0.7 0.7 0.7
external cooling sys-
tem, max. permissi-
ble

Lube oil system
G22 G62 G22 G62 G42 G82
Lube oil operating R °C 85 85 85 85 86 86
temperature before
engine, from
Lube oil operating R °C 95 95 95 95 95 95
temperature before
engine, to
Lube-oil temperature R °C 95 95 95 95 95 95
before engine, alarm
Lube-oil temperature L °C -- -- -- -- -- --
before engine, shut-
down
Lube oil operating R bar 4.8 4.8 4.8 4.8 4.8 4.8
pressure before en-
gine, from
Lube oil operating R bar 6.0 6.0 6.0 6.0 6.0 6.0
pressure before en-
gine, to
Lube oil pressure be- R bar 4.5 4.5 4.5 4.5 4.5 4.5
fore engine, alarm
Lube oil pressure be- L bar 4.0 4.0 4.0 4.0 4.0 4.0
fore engine, shut-
down
Fuel system
G22 G62 G22 G62 G42 G82
Fuel pressure at en- L bar -0.1 -0.1 -0.1 -0.1 -0.1 -0.1
gine inlet connection
(during engine start),
min. admissible
Fuel pressure at en- L bar 1.5 1.5 1.5 1.5 1.5 1.5
gine inlet connection
(during engine start),
max. admissible

G22 G62 G22 G62 G42 G82
TIM-ID: 0000002920 - 004
Cold start capability: R °C 5 5 5 5 10 5

air temperature (w/o
start aid, w/o pre-
heating) (case A)
Coolant preheating: R °C 32 32 32 32 32 32
preheating tempera-
ture (min.)
Firing speed, from R rpm 80 80 80 80 80 80
Firing speed, to R rpm 120 120 120 120 120 120

G22 G62 G22 G62 G42 G82
Engine coolant ca- R Liter 205 205 205 205 205 205
pacity, engine side
(without cooling
equipment)
Charge-air coolant, R Liter 55 55 55 55 55 55
engine side
Engine oil capacity, R Liter 390 390 390 390 390 390
initial filling (stand-
ard oil system) (de-
sign: max. operating
inclinations)
Oil change quantity R Liter 340 340 340 340 340 340
max. (standard oil
system) (design:
max. operating incli-
nations)
Oil pan capacity dip- L Liter 245 245 245 245 245 245
stick mark min.
(standard oil system)
(design: max. operat-
ing inclinations)
Oil pan capacity dip- L Liter 340 340 340 340 340 340
stick mark max.
(standard oil system)
(design: max. operat-
ing inclinations)
Weight
G22 G62 G22 G62 G42 G82
Engine weight, dry R kg 9450 9450 9450 9450 9450 9450
(basic engine config-
uration in accord-
ance with scope of
delivery specifica-
tions)
Sound
TIM-ID: 0000002920 - 004
G22 G62 G22 G62 G42 G82

Exhaust noise, unsi- R dB(A) Approx. Approx. Approx. Approx. Approx. Approx.
lenced, DL, (sound 127 128 128 129 129 131
power level LW, ISO
6798)
Engine surface noise R dB(A) Approx. Approx. Approx. Approx. Approx. Approx.
with attenuated in- 125 126 125 125 126 126
take noise (filter),
DL, (sound power
level LW, ISO 6798)

4.3 20V4000 continuous operation, restricted 3C, optimized fuel
consumption G22/G62, emissions-optimized (“TA-Luft”)
G22/G62
Explanation
Abbr. Meaning
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable
Engine model Unit 20V4000 20V4000 20V4000 20V4000
G22 G62 G22 G62
Application group 3C 3C 3C 3C
Intake air temperature °C 25 25 25 25
Charge air coolant temperature °C 55 55 55 55
Raw water inlet temperature °C - - - --
Barometric pressure mbar 1000 1000 1000 1000
Site altitude above sea level m 100 100 100 100
G22 G62 G22 G62
Rated engine speed A rpm 1500 1500 1500 1500
Fuel stop power ISO 3046 A kW 2420 2662 2420 2662

G22 G62 G22 G62
TIM-ID: 0000002953 - 004
Intake air depression (new filter) (de- A mbar 25 25 25 25

sign)
Intake air depression (limit value) L mbar 50 50 50 50
Exhaust backpressure (design) A mbar 30 30 30 30
Exhaust backpressure (limit value) L mbar 50 50 50 50

G22 G62 G22 G62
Engine with exhaust turbocharging X X X X
(ETC) and charge-air cooling (CAC)
Uncooled exhaust lines X X X X
Operating method: Four-stroke cy- X X X X
cle, diesel, single-action
Combustion method: direct fuel in- X X X X
jection
Cooling method: conditioned water X X X X
Direction of rotation: c.c.w. (facing X X X X
driving end)
Number of cylinders 20 20 20 20
Cylinder arrangement: V-angle degrees 90 90 90 90
Bore mm 165 165 165 165
Stroke mm 210 210 210 210
Displacement, cylinder Liter 4.49 4.49 4.49 4.49
Displacement, total Liter 89.81 89.81 89.81 89.81
Compression ratio 15.5 15.5 15.5 15.5
Cylinder heads: Individual cylinder X X X X
heads
Cylinder liners: wet, replaceable X X X X
Number of inlet valves per cylinder 2 2 2 2
Number of exhaust valves, per cylin- 2 2 2 2
der
Standard housing connecting flange SAE 00 00 00 00
(engine main PTO)
Flywheel interface DISC 21" 21" 21" 21"
Air / exhaust gas

G22 G62 G22 G62
Charge air pressure before cylinder, R bar abs 3.0 3.3 3.7 3.8
BL
Coolant system (HT)

TIM-ID: 0000002953 - 004
G22 G62 G22 G62

Coolant temperature (at engine con- A °C 95 95 95 95
nection: outlet to cooling equipment)
Coolant temperature after engine, R °C 97 97 97 97
warning
Coolant temperature after engine, L °C 99 99 99 99
shutdown

G22 G62 G22 G62
Coolant antifreeze content, max. L % 50 50 50 50
permissible
Pressure loss in the external cooling L bar 0.7 0.7 0.7 0.7
system, max. permissible
Coolant system (LT)

G22 G62 G22 G62
Coolant temperature before inter- A °C 55 55 55 55
cooler (at engine inlet from cooling
equipment)
permissible
Lube oil system

G22 G62 G22 G62
Lube oil operating temperature be- R °C 85 85 85 85
fore engine, from
fore engine, to
Lube-oil temperature before engine, R °C 95 95 95 95
alarm
Lube-oil temperature before engine, L °C -- -- -- --
shutdown
Lube oil operating pressure before R bar 4.8 4.8 4.8 4.8
engine, from
engine, to
Lube oil pressure before engine, R bar 4.5 4.5 4.5 4.5
alarm
Lube oil pressure before engine, L bar 4.0 4.0 4.0 4.0
shutdown
Fuel system
TIM-ID: 0000002953 - 004
G22 G62 G22 G62

Fuel pressure at engine inlet connec- L bar -0.1 -0.1 -0.1 -0.1
tion (during engine start), min. ad-
missible
Fuel pressure at engine inlet connec- L bar 1.5 1.5 1.5 1.5
tion (during engine start), max. ad-
missible

G22 G62 G22 G62
Cold start capability: air temperature R °C 5 5 5 5
(w/o start aid, w/o preheating)
(case A)
Coolant preheating: preheating tem- R °C 32 32 32 32
perature (min.)
Firing speed, from R rpm 80 80 80 80
Firing speed, to R rpm 120 120 120 120

G22 G62 G22 G62
Engine coolant capacity, engine side R Liter 205 205 205 205
(without cooling equipment)
Charge-air coolant, engine side R Liter 55 55 55 55
Engine oil capacity, initial filling R Liter 390 390 390 390
(standard oil system) (design: max.
operating inclinations)
Oil change quantity max. (standard R Liter 340 340 340 340
oil system) (design: max. operating
inclinations)
Oil pan capacity dipstick mark min. L Liter 245 245 245 245
Oil pan capacity dipstick mark max. L Liter 340 340 340 340
Weight
G22 G62 G22 G62
Engine weight, dry (basic engine R kg 9450 9450 9450 9450
configuration in accordance with
scope of delivery specifications)
Sound
G22 G62 G22 G62
TIM-ID: 0000002953 - 004
Exhaust noise, unsilenced, BL, R dB(A) Approx. Approx. Approx. Approx.

(sound power level LW, ISO 6798) 127 128 128 129
Engine surface noise with attenuat- R dB(A) Approx. Approx. Approx. Approx.
ed intake noise (filter), BL, (sound 125 126 125 125
power level LW, ISO 6798)

4.4 20V4000 standby power 3D, optimized fuel consumption
G22/G62, emissions-optimized (EPA) G42/G82
Explanation
Abbr. Meaning
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable
G22 G62 G42 G82
Application group 3D 3D 3D 3D
Intake air temperature °C 25 25 25 25
Charge air coolant temperature °C 55 55 55 55
Raw water inlet temperature °C - - - -
Barometric pressure mbar 1000 1000 1000 1000
Site altitude above sea level m 100 100 100 100
G22 G62 G42 G82
Rated engine speed A rpm 1500 1500 1800 1800
Fuel stop power ISO 3046 A kW 2420 2670 2740 3010

G22 G62 G42 G82
Intake air depression (new filter) (de- A mbar 25 25 25 25
sign)
TIM-ID: 0000002979 - 004
Intake air depression (limit value) L mbar 50 50 50 50

Exhaust backpressure (design) A mbar 30 30 30 30
Exhaust backpressure (limit value) L mbar 50 50 50 50

G22 G62 G42 G82
Engine with exhaust turbocharging X X X X
(ETC) and charge-air cooling (CAC)
Uncooled exhaust lines X X X X
Operating method: Four-stroke cy- X X X X
cle, diesel, single-action
Combustion method: direct fuel in- X X X X
jection
Cooling method: conditioned water X X X X
Direction of rotation: c.c.w. (facing X X X X
driving end)
Number of cylinders 20 20 20 20
Cylinder arrangement: V-angle degrees 90 90 90 90
Bore mm 165 165 165 165
Stroke mm 210 210 210 210
Displacement, cylinder Liter 4.49 4.49 4.49 4.49
Displacement, total Liter 89.81 89.81 89.81 89.81
Compression ratio 15.5 15.5 15.5 15.5
Cylinder heads: Individual cylinder X X X X
heads
Cylinder liners: wet, replaceable X X X X
Number of inlet valves per cylinder 2 2 2 2
Number of exhaust valves, per cylin- 2 2 2 2
der
Standard housing connecting flange SAE 00 00 00 00
(engine main PTO)
Flywheel interface DISC 21" 21" 21" 21"
Air / exhaust gas

G22 G62 G42 G82
Charge air pressure before cylinder, R bar abs 3.0 3.3 3.2 3.3
BL
Coolant system (HT)

TIM-ID: 0000002979 - 004
G22 G62 G42 G82

Coolant temperature (at engine con- A °C 95 95 95 95
nection: outlet to cooling equipment)
Coolant temperature after engine, R °C 97 97 97 97
warning
Coolant temperature after engine, L °C 99 99 99 99
shutdown

G22 G62 G42 G82
permissible
Coolant system (LT)

G22 G62 G42 G82
Coolant temperature before inter- A °C 55 55 55 55
cooler (at engine inlet from cooling
equipment)
permissible
Lube oil system

G22 G62 G42 G82
fore engine, from
fore engine, to
Lube-oil temperature before engine, R °C 95 95 95 95
alarm
Lube-oil temperature before engine, L °C -- -- -- --
shutdown
engine, from
engine, to
Lube oil pressure before engine, R bar 4.5 4.5 4.5 4.5
alarm
Lube oil pressure before engine, L bar 4.0 4.0 4.0 4.0
shutdown
Fuel system
TIM-ID: 0000002979 - 004
G22 G62 G42 G82

Fuel pressure at engine inlet connec- L bar -0.1 -0.1 -0.1 -0.1
tion (during engine start), min. ad-
missible
Fuel pressure at engine inlet connec- L bar 1.5 1.5 1.5 1.5
tion (during engine start), max. ad-
missible

G22 G62 G42 G82
Cold start capability: air temperature R °C 5 5 10 5
(w/o start aid, w/o preheating)
(case A)
Coolant preheating: preheating tem- R °C 32 32 32 32
perature (min.)
Firing speed, from R rpm 80 80 80 80
Firing speed, to R rpm 120 120 120 120

G22 G62 G42 G82
Engine coolant capacity, engine side R Liter 205 205 205 205
(without cooling equipment)
Charge-air coolant, engine side R Liter 55 55 55 55
Engine oil capacity, initial filling R Liter 390 390 390 390
Oil change quantity max. (standard R Liter 340 340 340 340
oil system) (design: max. operating
inclinations)
Oil pan capacity dipstick mark min. L Liter 245 245 245 245
Oil pan capacity dipstick mark max. L Liter 340 340 340 340
Weight
G22 G62 G42 G82
Engine weight, dry (basic engine R kg 9450 9450 9450 9450
configuration in accordance with
scope of delivery specifications)
Sound
G22 G62 G42 G82
TIM-ID: 0000002979 - 004
Exhaust noise, unsilenced, BL, R dB(A) Approx. Approx. Approx. approx.

(sound power level LW, ISO 6798) 128 129 131 132
Engine surface noise with attenuat- R dB(A) Approx. Approx. Approx. Approx.
ed intake noise (filter), BL, (sound 126 126 126 127
power level LW, ISO 6798)

4.5 Final compression pressure
Final compression pressure
Final compression pressure at 120 rpm 24 bar to 28 bar
TIM-ID: 0000002820 - 001

4.6 Firing order
Number of Firing order
cylinders
20 V A1-B5-A8-B7-A5-B2-A7-B10-A2-B3-A10-B6-A3-B4-A6-B9-A4-B1-A9-B8
TIM-ID: 0000035068 - 002

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

20V4000G22/42/62/82 Approx. 3520 mm Approx. 1480 mm Approx. 2390 mm
TIM-ID: 0000002131 - 002

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

months)
Item Action
Engine Depreserve (→ MTU Preservation and Represervation Specifications
A001070/..).
Valve gear Lubricate valve gear (→ Page 78).
Lube oil system Check engine oil level (→ Page 105).
Fuel prefilter Fill with fuel (→ Page 98).
Fuel prefilter, pressure gage Align adjustable pointer with position of pressure indicator (→ Page 94).
Fuel system Vent (→ Page 91).
Coolant circuit Change engine coolant if engine has been out of service for more than one
year (→ Page 112).
Change charge-air coolant (→ Page 118).
Coolant circuit Check engine coolant level (→ Page 111).
Check charge-air coolant level (→ Page 117).
Coolant circuit Heat engine coolant with coolant preheating unit.
ECU Check plug connections (→ Page 130).
Monitoring system Carry out lamp test (see manufacturer's documentation).
Engine/generator control Switch on;
system Operating mode, e.g.: MANUAL, AUTOMATIC OPERATION.
TIM-ID: 0000002193 - 002
M015565/03E 2016-02 | Operation | 43

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

Item Task
Lube oil system Check oil level (→ Page 105);
Cooling system Check engine coolant level (→ Page 111);
Check charge-air coolant level (→ Page 117).
Cooling system Preheat coolant with preheating unit.
Fuel prefilter Drain (→ Page 95).
Monitoring equipment Carry out lamp test (see manufacturer's documentation).
Engine/generator control Switch ON;
system Select operating mode, e.g. MANUAL OPERATION, AUTOMATIC OPERATION.
TIM-ID: 0000002677 - 001
44 | Operation | M015565/03E 2016-02

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

Item Action
Control cabinet, control pan- If coolant temperature is
el etc. (depending on manu- • > 40 °C (with preheating system), or
facturer) • > 10 °C (60 Hz generator, without preheater):
• > 5 °C (50 Hz generator, without preheater):
Press start button.
• Automatic starting sequence is performed;
• Engine speed display instrument indicates increasing speed;
• After the starting sequence is completed, engine is running at rated
speed.
Connecting the generator (if fitted) to network, engine warm-up procedure to

reach operating temperature
Item Action
Control cabinet, control pan- Close the generator circuit breaker.
el etc. (depending on manu-
TIM-ID: 0000065392 - 001
facturer)
Engine Apply full load only after engine has reached operating temperature (coolant
temperature approx. 75 °C).
M015565/03E 2016-02 | Operation | 45

5.4 Starting the engine in emergency situations (override mode)
NOTICE
Safety functions and engine shutdown alarms will be disregarded.
Severe material damage!
• Initiate emergency start only in emergency situations.
Preparation
Item Measure
Operating mode switch Change to override mode (manual mode, if applicable).
Starting the engine in emergency situations

Item Measure
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 Measure
Control cabinet If generator is not connected to mains: Close the generator circuit breaker.
Engine Operate engine at rated power.
TIM-ID: 0000010665 - 002
46 | Operation | M015565/03E 2016-02

5.5 Operational monitoring
DANGER
• Only run the engine at low power. Keep away from the engine's danger zone.
WARNING
Operational monitoring
Item Action
Control and display panels Check readings of operational data (speed, temperature, pressures).
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.
HP pump Check relief bore (→ Page 84).
Fuel prefilter Check reading on differential pressure gage to ensure that maximum admis-
sible value is not exceeded (→ Page 94).
Exhaust system Check exhaust color (→ Page 53).
Intercooler Check condensate drain(s) for water discharge and obstruction
(→ Page 100).
Air filter Check signal ring position of service indicator (→ Page 103).
Replace air filter (→ Page 101), if the signal ring is completely visible in the
service indicator control window.
Engine coolant pump Check relief bore (→ Page 116).
Charge-air coolant pump Check relief bore (→ Page 122).
Compressed-air system (if Check operating pressure on pressure gage;
installed) Always fill compressed-air tank to max. pressure;
Drain condensate from compressed-air tank, pressure drop must not exceed
1 bar.
TIM-ID: 0000002257 - 002
M015565/03E 2016-02 | Operation | 47

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

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

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

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

Item Action
Coolant circulation pump Operate pump for a sufficient period of time after the engine is stopped.
TIM-ID: 0000002285 - 004
48 | Operation | M015565/03E 2016-02

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

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

Item Action
Control cabinet, control pan- Press pushbutton for alarm acknowledgment.
el etc. (depending on manu- • Audible and visual alarm signaling stops.
facturer)
TIM-ID: 0000002305 - 004
M015565/03E 2016-02 | Operation | 49

5.8 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 113);
Drain charge-air coolant (→ Page 119) 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
50 | Operation | M015565/03E 2016-02

5.9 Plant – Cleaning
Preconditions
☑ No operating voltage is applied.

High-pressure cleaning unit - 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.
Plant – Cleaning
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 - 032
• The temperature of the cleaning medium must not exceed 80 °C.

4. For external cleaning with high-pressure jet, use a flat-mouth nozzle only.
Note: Never 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 the high-pressure jet to remove the loosened dirt.
e) Dry engine with compressed air.
M015565/03E 2016-02 | Operation | 51

6 Maintenance
6.1 Maintenance task reference table [QL1]
The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Mainte-
nance Schedule is a stand-alone publication.
The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance
Schedule.
Option
Task Maintenance tasks
W0500 Check engine oil level. (→ Page 105)

W0501 Visually inspect engine for leaks and general condition. (→ Page 47)
W0502 X Check intercooler drain(s). (→ Page 100)
W0503 Check maintenance indicator of air filter. (→ Page 103)
W0504 Check HP fuel pump telltale bores. (→ Page 47)
W0505 Check relief bores of water pump(s). (→ Page 116)
W0506 Check engine for abnormal running noises, exhaust color (→ Page 47)
and vibrations.
W0507 X Drain water and contaminants from fuel prefilter. (→ Page 47)
W0508 X Check reading on differential pressure gage of fuel prefilter. (→ Page 47)
W1001 Replace fuel filter or fuel filter element. (→ Page 92)
W1002 Check and adjust valve clearance. (→ Page 79)
W1003 Check belt condition and tension, replace if necessary. (→ Page 123)
W1005 Replace air filter. (→ Page 101)
W1006 Replace fuel injectors. (→ Page 85)
W1008 Replace engine oil filter when changing engine oil, or when (→ Page 108)
the interval (years) is reached, at the latest.
W1009 X Clean centrifugal oil filter, measure thickness of oil residue (→ Page 109)
layer, replace filter sleeve, every time oil is changed at the
latest.
W1011 Perform endoscopic examination. (→ Page 71)
Table 2: Maintenance task reference table [QL1]

TIM-ID: 0000065343 - 001
52 | Maintenance | M015565/03E 2016-02

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 cabling defective u Check (→ Page 128).
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 130).
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 91).
Engine governor defective u Contact Service.
Engine fires unevenly

Injector defective u Check, replace as necessary (→ Page 85).
TIM-ID: 0000065774 - 001

M015565/03E 2016-02 | Troubleshooting | 53

Engine does not reach nominal speed
Fuel prefilter clogged u Replace (→ Page 98).
Fuel filter clogged u Replace (→ Page 92).
Air filter clogged u Check signal ring position of service indicator (→ Page 103).
Injector defective u Replace (→ Page 85).
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

Intercooler dirty u Contact Service.
Exhaust turbocharger defective u Contact Service.
Coolant discharge at intercooler

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

TIM-ID: 0000065774 - 001

Engine: Overload u Contact Service.
54 | Troubleshooting | M015565/03E 2016-02

Blue exhaust gas
Too much engine oil in the engine u Drain engine oil (→ Page 106).
Oil separator of crankcase u Replace filter (→ Page 75).
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 and contaminants from fuel prefilter (→ Page 95).
Intercooler leaky u Contact Service.
TIM-ID: 0000065774 - 001

7.2 Fault messages on engine governor
The engine governor generates alarms which are indicated in different ways depending on the equipment
configuration:
• as four-digit code on a PIM
• as alarm text on a display
• as four-digit code on a dialog PC
The four-digit code consists of one letter and three figures:

• The letter encodes when the fault occurred the last time:
A = currently present
B = within the last operating hour
C = one to four operating hours ago
D = four to twelve operating hours ago
Alarms that occurred more than twelve hours ago are deleted automatically.
• The three figures encode the fault itself as listed in the table below.
Alarms can also be caused by defective sensors / actuators. If troubleshooting in accordance with the fol-
lowing table is not successful, contact Service to have the sensors / actuators checked and, if required, re-
placed.
Fault Alarm text Meaning Task
code
005 L1 T-CHARGE AIR Charge-air temperature too Reduce power. Change over to idle and
high (1st limit value) contact Service.
006 L2 T-CHARGE AIR Charge-air temperature too Reduce power. Change over to idle and
high (2nd limit value) contact Service.
TIM-ID: 0000003158 - 001
009 L1 T-INTERCOOL- Charge-air coolant temperature Reduce power. Change over to idle and
ER too high (1st limit value) contact Service.
015 L1 P-LUBE OIL Lube oil pressure too low (1st Check engine-oil level and top up, if re-
limit value) quired (→ Page 105).
016 L2 P-LUBE OIL Lube oil pressure too low (2nd 1. Check engine-oil level and top up, if re-
limit value) quired (→ Page 105).
automatic engine shutdown 2. Try to re-start the engine (→ Page 45).
3. Contact Service.
023 L1 COOLANT LEV- Engine coolant level too low Check coolant level and top up, if required
EL (→ Page 111).

code
024 L2 COOLANT LEV- Engine coolant level too low Check coolant level and top up, if required
EL (→ Page 111).
030 ENGINE OVER- Engine overspeed; automatic 1. Acknowledge alarm.
SPEED engine shutdown 2. Try to re-start the engine (→ Page 45).
3. Contact Service.
044 L1 LEVEL INTER- Charge-air coolant level too low Check coolant level and top up, if required
COOLER (1st limit value) (→ Page 117).
045 L2 LEVEL INTER- Charge-air coolant level too low 1. Check coolant level and top up, if re-
COOLER (2nd limit value) quired (→ Page 117).
2. If fault occurs repeatedly: Contact
Service.
051 L1 T-LUBE OIL Lube oil temperature too high Reduce power. Change over to idle and
(1st limit value) contact Service.
052 L2 T-LUBE OIL Lube oil temperature too high 1. Reduce power. Change over to idle and
(2nd limit value) contact Service.
Service.
065 L1 P-FUEL Fuel supply pressure too low 1. Check fuel lines for leaks; repair defec-
(1st limit value) tive lines.
2. Clean fuel prefilter (→ Page 93);
3. Flush fuel prefilter (→ Page 96);
4. Replace filter element of fuel prefilter
(→ Page 98);
5. Replace fuel filter (→ Page 92);
6. If fault is not rectified: Contact Service.
066 L2 P-FUEL Fuel supply pressure too low 1. Check fuel lines for leaks; repair defec-
(2nd limit value) tive lines.
2. Clean fuel prefilter (→ Page 93);
3. Flush fuel prefilter (→ Page 96);
4. Replace filter element of fuel prefilter
(→ Page 98);
5. Replace fuel filter (→ Page 92);
6. If fault is not rectified: Contact Service.
067 L1 T-COOLANT Coolant temperature too high Reduce power. Change over to idle and
(1st limit value) warning contact Service.
068 L2 T-COOLANT Coolant temperature too high 1. Allow the engine to cool down.
(2nd limit value) 2. Check coolant cooler (elements etc.)
automatic engine shutdown and clean contaminated parts (see
manufacturer's documentation).
3. Re-start the engine (→ Page 45);
TIM-ID: 0000003158 - 001
Service.
069 L1 T-EXTERN 1 Violation of first limit for exter- (Depending on the corresponding measur-
nal temperature channel 1 ing point, which is read via CAN bus)
070 L2 T-EXTERN 1 Violation of second limit for ex- (Depending on the corresponding measur-
ternal temperature channel 1 ing point, which is read via CAN bus)
071 L1 T-EXTERN 2 Violation of first limit for exter- (Depending on the corresponding measur-
nal temperature channel 2 ing point, which is read via CAN bus)
072 L2 T-EXTERN 2 Violation of second limit for ex- (Depending on the corresponding measur-
ternal temperature channel 2 ing point, which is read via CAN bus)

code
073 L1 P-EXTERN 1 Violation of first limit for exter- (Depending on the corresponding measur-
nal pressure channel 1 ing point, which is read via CAN bus)
074 L2 P-EXTERN 1 Violation of second limit for ex- (Depending on the corresponding measur-
ternal pressure channel 1 ing point, which is read via CAN bus)
075 L1 P-EXTERN 2 Violation of first limit for exter- (Depending on the corresponding measur-
nal pressure channel 2 ing point, which is read via CAN bus)
076 L2 P-EXTERN 2 Violation of second limit for ex- (Depending on the corresponding measur-
ternal pressure channel 2 ing point, which is read via CAN bus)
077 LIM EXT.COOLANT Alarm from external coolant (Depending on the corresponding measur-
LEV. level monitoring ing point, which is read via CAN bus)
078 LIM INTERCOOLER Alarm from external charge-air (Depending on the corresponding measur-
LEV. coolant level monitoring ing point, which is read via CAN bus)
079 L Bin-EXTERN 3 Alarm from external binary (Depending on the corresponding measur-
channel 3 ing point, which is read via CAN bus)
080 L Bin-EXTERN 4 Alarm from external binary (Depending on the corresponding measur-
channel 4 ing point, which is read via CAN bus)
081 RAIL LEAKAGE HP fuel system leaking, system Contact Service.
contains air
082 RAIL PRESSURE Pressure in HP fuel system ex- Contact Service.
HIGH ceeds specified value;
Solenoid valve of HP fuel con-
trol block jamming or wiring to
solenoid valve defective
083 RAIL PRESSURE Pressure in HP fuel system low- Contact Service.
LOW er than the specified value;
HP fuel control block defective
or system leaking
NOTE:
With very large generators hav-
ing a run-out time of more than
> 20 sec this alarm is not a rel-
evant fault.
089 ENGINE SPEED Engine speed lower than 200 Re-start the engine (→ Page 45);
LOW rpm;
automatic engine shutdown
090 IDLE SPEED LOW Idle speed not reached within a Note further alarms.
specified period;
Termination of starting proce-
dure.
091 RUN UP SPEED Run-up speed not reached Note further alarms.
TIM-ID: 0000003158 - 001
LOW within a specified period;

dure.
092 START SPEED Starter speed not reached with- Note further alarms.
LOW in a specified period;
dure.

code
093 PREHEAT TEMP. Coolant preheating tempera- Check preheating pump / preheating sys-
LIMIT2 ture too low during start (2nd tem (see manufacturer's documentation).
limit value);
dure (depending on project de-
sign)
094 PREHEAT TEMP. Coolant preheating tempera- Check preheating pump / preheating sys-
LIMIT1 ture too low during start (1st tem (see manufacturer's documentation).
limit value)
100 EDM NOT VALID Check sum error of measuring- If fault occurs repeatedly: Contact Service.
point data in EDM
101 IDM NOT VALID Check sum error of measuring- If fault occurs repeatedly: Contact Service.
point data in IDM
102 INVALID FUEL Check sum error of accumulat- If fault occurs repeatedly: Contact Service.
CONS. 1 ed fuel consumption data in
EDM (redundant data record 1)
103 INVALID FUEL Check sum error of accumulat- If fault occurs repeatedly: Contact Service.
CONS. 2 ed fuel consumption data in
EDM (redundant data record 2)
104 OP HOURS1 NOT Check sum error of hour meter If fault occurs repeatedly: Contact Service.
VALID data in EDM
105 OP HOURS2 NOT Check sum error of hour meter If fault occurs repeatedly: Contact Service.
VALID data in IDM
106 ERR REC1 NOT Check sum error of fault mem- If fault occurs repeatedly: Contact Service.
VALID ory in EDM (redundant data re-
cord 1)
107 ERR REC2 NOT Check sum error of fault mem- If fault occurs repeatedly: Contact Service.
VALID ory in EDM (redundant data re-
cord 2)
118 L1 SUPPLY VOLT. Supply voltage too low (1st lim- Check engine governor supply voltage.
LOW it value)
119 L2 SUPPLY VOLT. Supply voltage too low (2nd Check engine governor supply voltage.
LOW limit value)
120 L1 SUPPLY VOLT. Supply voltage too high (1st Check engine governor supply voltage.
HIGH limit value)
121 L2 SUPPLY VOLT. Supply voltage too high (2nd Check engine governor supply voltage.
HIGH limit value); If engine was stopped: Start engine
automatic engine shutdown (→ Page 45).
(depending on project design)
TIM-ID: 0000003158 - 001
122 L1 T-ELECTRONIC Temperature in engine gover- 1. Improve engine room ventilation.

nor housing too high (1st limit 2. Reduce engine power. Change over to
value) idle and contact Service.
134 15V POS ECU DE- Electronic equipment defective; Contact Service.
FECT automatic engine shutdown
136 15V NEG ECU DE- Electronic equipment defective; Contact Service.
FECT automatic engine shutdown

code
137 L1 5V BUFFER Power supply for pressure sen- 1. Disconnect connectors X2 and X3 from
TEST sors defective. engine governor. If alarm does not dis-
appear: Contact Service.
2. Check wiring (pressure sensors).
3. Contact Service.
138 SENSORPOWER- Power supply for pressure sen- 1. Disconnect connectors X2 and X3 from
DEFECT sors defective. engine governor. If alarm does not dis-
appear: Contact Service.
2. Check wiring (pressure sensors).
3. Contact Service.
139 L1 TE BUFFER Internal electronic fault (tem- Contact Service.
TEST perature sensors)
140 TE BUF. ECU DE- Internal electronic fault (tem- Contact Service.
FECT perature sensors)
142 BANK1 ECU DE- Internal electronic fault; Contact Service.
FECT Engine does not start
144 BANK2 ECU DE- Internal electronic fault; Contact Service.
FECT Engine does not start
145 15V_GOOD ECU Electronic equipment defective; Contact Service.
DEFECT automatic engine shutdown
146 L1 AD-TEST1 SUP- A/D-converter supply voltage Contact Service.
PLY too low
147 AD-TEST1 ECU Electronic equipment defective; Contact Service.
PLY too low
PLY too low
170 MI MODULE FAIL Module in maintenance predic- Contact Service.
tor either defective or missing
171 MI NOT ACTIVE Maintenance predictor no more Contact Service.
activated
173 MODULE WRITE EEPROM write limit reached Contact Service.
LIMIT
TIM-ID: 0000003158 - 001
180 CAN1 NODE LOST At least one device not detect- 1. Check wiring (CAN bus).
ed on Default CAN bus 2. Contact Service.
181 CAN2 NODE LOST At least one device not detect- 1. Check wiring (CAN bus).
ed on Redundant CAN bus 2. Contact Service.
182 CAN WRONG PA- Consistency error in CAN pa- Contact Service.
RAMETERS rameters
183 CAN NO PU-DATA Error during project design da- Contact Service.
ta download in engine gover-
nor.

code
184 CAN PU-DATA EE- Error during project design da- Contact Service.
FAIL ta download in EEPROMs
185 CAN LESS MAIL- Error during CAN initialization. Contact Service.
BOXES
186 CAN1 BUS OFF Severe fault on Default CAN Contact Service.
bus;
automatic change-over to Re-
dundant CAN bus
187 CAN1 ERROR PAS- Light fault on Default CAN bus (none)
SIVE (e.g. short-time overload)
188 CAN2 BUS OFF Severe fault on Redundant CAN Contact Service.
bus;
automatic change-over to De-
fault CAN bus
189 CAN2 ERROR PAS- Light fault on Redundant CAN (none)
SIVE bus (e.g. short-time overload)
201 SD T-COOLANT Sensor defect (coolant temper- 1. Check wiring.
ature) 2. Contact Service.
202 SD T-FUEL Sensor defect (Fuel tempera- 1. Check wiring.
ture) 2. Contact Service.
203 SD T-CHARGE AIR Sensor defect (charge-air tem- 1. Check wiring.
perature) 2. Contact Service.
205 SD T-COOLANT Sensor defect (charge-air cool- 1. Check wiring.
INTERC. ant temperature) 2. Contact Service.
208 SD P-CHARGE AIR Sensor defect (charge-air pres- 1. Check wiring.
sure) 2. Contact Service.
211 SD P-LUBE OIL Sensor defect (lube oil pres- 1. Check wiring.
sure) 2. Contact Service.
215 SD P-RAIL FUEL Sensor defect (common rail 1. Check wiring.
pressure); 2. Contact Service.
HP controller in emergency
mode
216 SD T-LUBE OIL Sensor defect (lube oil temper- 1. Check wiring.
ature) 2. Contact Service.
220 SD COOLANT LEV- Sensor defect (coolant level) 1. Check wiring.
EL 2. Contact Service.
223 SD LEVEL INTER- Sensor defect (charge-air cool- 1. Check wiring.
COOLER ant level) 2. Contact Service.
TIM-ID: 0000003158 - 001
229 SD ENG.SPEED Sensor defect (crankshaft 1. Check wiring.

SENSORS speed) and sensor defect (cam- 2. Contact Service.
shaft speed)
230 SD CRANKSHAFT Sensor defect (crankshaft 1. Check wiring.
SPEED speed) 2. Contact Service.
231 SD CAMSHAFT Sensor defect (camshaft 1. Check wiring.
SPEED speed) 2. Contact Service.
240 SD P-FUEL Sensor defect (fuel pressure) 1. Check wiring.
2. Contact Service.

code
245 SD POWER SUP- Sensor defect (engine governor Contact Service.
PLY operating voltage)
246 SD T-ELECTRONIC Sensor defect (temperature in Contact Service.
engine governor)
250 SD CAN SPEED Sensor defect (CAN nominal 1. Check speed transmitter.
DEMAND speed demand) 2. Check wiring (CAN bus).
3. Contact Service.
266 SD SPEED DE- Sensor defect (analog nominal 1. Check speed transmitter.
MAND AN. speed demand) 2. Check wiring.
3. Contact Service.
267 SD SP.DEM.TEST Sensor defect (analog speed 1. Check speed transmitter.
BENCH demand); 2. Check wiring.
NOTE: 3. Contact Service.
Only used in test-stand opera-
tion.
270 SD SPEED DE- Sensor defect (frequency input 1. Check speed transmitter.
MAND FI1 for speed demand); 2. Check wiring.
3. Contact Service.
271 SD T-EXTERN 1 External device defective (CAN Contact Service.
T-EXTERN 1)
272 SD T-EXTERN 2 External device defective (CAN Contact Service.
T-EXTERN 2)
273 SD P-EXTERN 1 External device defective (CAN Contact Service.
P-EXTERN 1)
274 SD P-EXTERN 2 External device defective (CAN Contact Service.
P-EXTERN 2)
275 SD EXT.COOLANT External coolant-level monitor- Contact Service.
LEVEL ing defective (CAN)
276 SD INTERCOOLER External charge-air coolant-lev- Contact Service.
LEVEL el monitoring defective (CAN)
277 SD BIN-EXTERN 3 External device defective (CAN Contact Service.
BIN-EXTERN 3)
278 SD BIN-EXTERN 4 External device defective (CAN Contact Service.
BIN-EXTERN 4)
301 TIMING CYLINDER Injection timing fault cylinder If fault occurs repeatedly: Contact Service.
A1 A1
A2 A2
TIM-ID: 0000003158 - 001
A3 A3
A4 A4
A5 A5
A6 A6

code
A7 A7
A8 A8
A9 A9
A10 A10
B1 B1
B2 B2
B3 B3
B4 B4
B5 B5
B6 B6
B7 B7
B8 B8
B9 B9
B10 B10
321 WIRING CYLINDER Faulty wiring to solenoid valve 1. Check wiring.
A1 cylinder A1; 2. Contact Service.
Misfiring
Misfiring
Misfiring
TIM-ID: 0000003158 - 001

Misfiring
Misfiring
Misfiring

code
Misfiring
Misfiring
Misfiring
Misfiring
B1 cylinder B1; 2. Contact Service.
Misfiring
Misfiring
Misfiring
Misfiring
Misfiring
Misfiring
Misfiring
Misfiring
Misfiring
TIM-ID: 0000003158 - 001

Misfiring
341 OPEN_LOAD CYL. Disconnection in wiring to sole- 1. Check wiring.
A1 noid valve cylinder A1; 2. Contact Service.
Misfiring
Misfiring

code
Misfiring
Misfiring
Misfiring
Misfiring
Misfiring
Misfiring
Misfiring
Misfiring
B1 noid valve cylinder B1; 2. Contact Service.
Misfiring
Misfiring
Misfiring
Misfiring
Misfiring
TIM-ID: 0000003158 - 001

Misfiring
Misfiring
Misfiring

code
Misfiring
Misfiring
361 POWER STAGE Defect in engine governor (sol- Contact Service.
FAIL 1 enoid valve power stage)
362 POWER STAGE Defect in engine governor (sol- Contact Service.
FAIL 2 enoid valve power stage)
363 STOP POWER Solenoid valve or wiring or en- 1. Check wiring.
STAGE 1 gine governor defective 2. Try to re-start the engine (→ Page 45).
automatic engine shutdown 3. Contact Service.
364 STOP POWER Solenoid valve or wiring or en- 1. Check wiring.
STAGE 2 gine governor defective 2. Try to re-start the engine (→ Page 45).
automatic engine shutdown 3. Contact Service.
365 STOP MV-WIRING Solenoid-valve wiring faulty; 1. Check wiring.
automatic engine shutdown 2. Try to re-start the engine (→ Page 45).
3. Contact Service.
381 TRAN.OUT1 Binary transistor output plant 1 Contact Service.
PLANT DEF defective
PLANT DEF defective
PLANT DEF defective
PLANT DEF defective
PLANT DEF defective
PLANT DEF defective
TIM-ID: 0000003158 - 001

8 Task Description
8.1 Engine
8.1.1 Engine – Barring manually
Preconditions

Barring device F6555766 1
Ratchet with extension F30006212 1
DANGER
• Before barring the engine, make sure that there are no persons in the engine's danger zone.
• After finishing work on the engine, make sure that all safety devices are put back in place and all
tools are removed from the engine.
Engine – Barring manually

1. Release screws (1) and remove end cover (2)
from flywheel housing.
TIM-ID: 0000000917 - 014
M015565/03E 2016-02 | Task Description | 67

Note: Use barring device F6555766.
2. Engage barring device (2) in ring gear of fly-
wheel and install it on flywheel housing.
3. Fit ratchet (1) onto barring device (2).
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 removal, follow the reverse sequence of
work steps.
TIM-ID: 0000000917 - 014
68 | Engine | M015565/03E 2016-02

8.1.2 Engine – Cranking on starting system
Pipe gripping pliers F30017884 1
DANGER
• Before barring the engine, make sure that there are no persons in the engine's danger zone.
• After finishing work on the engine, make sure that all safety devices are put back in place and all
tools are removed from the engine.
Cranking engine on starting sys-

tem
1. Disengage bayonet union nut (4) of connec-
tor X4 on Engine Control Unit using pipe
gripping pliers (2) and disconnect connec-
tor (3).
2. Crank engine in unloaded state: Press START
button.
3. Crank engine until oil pressure is indicated.
4. Engine start is automatically interrupted
when specified starting period is expired. If
necessary, re-start the engine after approx.
20 seconds.
5. Fit connector X4, turn bayonet union nut (4)
of connector (3) clockwise using pipe grip-
ping pliers (2) until it engages.
TIM-ID: 0000031172 - 008
M015565/03E 2016-02 | Engine | 69

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

1. Start engine (→ Page 45).
2. Perform test run not below 1/3 load and at least until steady-state temperature is reached.
3. Carry out operational checks (→ Page 47).
4. Stop engine (→ Page 48).
TIM-ID: 0000000870 - 008
70 | Engine | M015565/03E 2016-02

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

Barring device F6555766 1
Ratchet with extension F30006212 1
Endoscope Y20097353 1
Preparatory steps
1. Remove cylinder head cover (→ Page 77).
2. Remove injector (→ Page 86).
Positioning crankshaft at BDC

1. Using barring device, 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,
TIM-ID: 0000003304 - 006
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
M015565/03E 2016-02 | Cylinder Liner | 71

1. Compile endoscopic report using the table.
2. Use technical terms to describe the liner surface (→ Page 73).
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 86).
2. Install cylinder head cover (→ Page 77).
TIM-ID: 0000003304 - 006
72 | Cylinder Liner | M015565/03E 2016-02

8.2.2 Instructions and comments on endoscopic and visual examination of cylinder
liners
Terms used for endoscopic examination
Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic examina-
tion report.
Findings Explanations/Action
Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing products,
particles, broken-off burrs). Removed cylinders clearly show such scoring on the
running surface under endoscope magnification. Cannot be felt with the fingernail.
Findings not critical.
Single scores Clearly visible scores caused by hard particles. They usually start in the TDC area
and cross through the hone pattern in the direction of stroke.
Scored area These areas consist of scores of different length and depth next to one another. In
most cases, they are found at the 6-o'clock and 12-o'clock positions (inlet/
exhaust) along the transverse engine axis.
Smoothened area Smoothened areas are on the running surface but almost the whole honing pattern
is still visible. Smoothened areas appear brighter and more brilliant than the sur-
rounding running surface.
Bright area Bright areas are on the running surface and show local removal of the honing pat-
tern. Grooves from honing process are not visible any more.
Discoloration This is caused by oxidation (surface discoloration through oil or fuel) and tempera-
ture differences around the liner. It appears rather darker within the honed struc-
ture in contrast to the bright metallic running surface. The honing pattern is undis-
turbed. Discolorations extend in stroke direction and may be interrupted.
Corrosion fields / Corrosion fields / spots result from water (condensed water) with the valves in the
spots overlap (open) position. They are clearly visible due to the dark color of the honing
groove bottom.
This corrosion is not critical unless there is corrosion pitting.
Black lines Black lines are a step towards heat discoloration. They are visible as a clear discol-
oration from TDC to BDC in the running surface and the start of localized damage
to the honing pattern.
Cylinder liners with a large number of black lines around the running surface have
limited service life and should be replaced.
Burn mark This is caused by a malfunction in the liner / ring tribosystem. Usually they run
over the whole ring-travel area (TDC/BDC), starting at the first TDC-ring and be-
coming more visible from the second TDC-ring 2 onwards and less pronounced
from TDC-ring 1. The honing pattern is usually no longer visible and displays a
TIM-ID: 0000000014 - 015
clearly defined (straight) edge to the undisturbed surface. The damaged surface is
usually discolored. The circumferential length varies.
Liners with burn marks, or heat discoloration, starting in TDC-ring 1 have to be re-
placed.
Seizure marks, scuff- Irregular circumference lengths and depths. Can be caused either by the piston
ing skirt or the piston crown. Material deposits on the liner (smear), heavy discolora-
tion. Severe, visible scoring.
Replace liner.
M015565/03E 2016-02 | Cylinder Liner | 73

Evaluation of findings and further measures
The findings in the start phase of oxidation discoloration and heat discoloration are similar. A thorough inves-
tigation and compliance with the above evaluation criteria allow an unambiguous evaluation. To avoid unnec-
essary disassembly work, it is recommended that another inspection be carried out after further operation of
the engine.
TIM-ID: 0000000014 - 015
74 | Cylinder Liner | M015565/03E 2016-02

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

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

ement
1. Use screwdriver to remove securing
screws (2) for cover (1).
2. Remove cover (1) with O-ring.
TIM-ID: 0000066941 - 001
M015565/03E 2016-02 | Crankcase Breather | 75

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

Screw Tightening torque (Engine oil) 6 Nm + 2 Nm
7. Replace other oil separator elements in the same way.
TIM-ID: 0000066941 - 001
76 | Crankcase Breather | M015565/03E 2016-02

8.4 Valve Drive
8.4.1 Cylinder head cover – Removal and installation
Preconditions

Gasket (→ Spare Parts Catalog)
Removing cylinder head cover

1. Clean very dirty cylinder head covers (3) prior
to removal.
2. Undo screws (1) and remove with wash-
ers (2).
3. Remove cylinder head cover (3) with gas-
ket (4) from cylinder head.
4. Remove other cylinder head covers in the
same way.
Installing cylinder head cover

1. Clean mating faces.
2. Check gasket (4) for damage, replace if necessary.
3. Place gasket (4) and cylinder head cover (3) onto cylinder head.
4. Install cylinder head cover (3) with screws (1) and washers (2).
5. Install other cylinder head covers in the same way.
TIM-ID: 0000000923 - 008
M015565/03E 2016-02 | Valve Drive | 77

8.4.2 Valve gear – Lubrication
Preconditions

Engine oil
Lubricating valve gear (valve

bridge with guide)
1. Remove cylinder head covers (→ Page 77).
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 77).
Lubricating valve gear (flying

valve bridge)
1. Remove cylinder head covers (→ Page 77).
2. Fill oil chambers of rocker arms and adjusting
screws with oil.
3. Install cylinder head covers (→ Page 77).
TIM-ID: 0000004338 - 004
78 | Valve Drive | M015565/03E 2016-02

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

Feeler gage Y20098771 1
Ring socket wrench F30039518 1
Engine oil
Preparatory steps
2. Install barring tool (→ Page 67).
3. Turn crankshaft with barring tool in engine di-
rection of rotation until “OT-A1” mark and
pointer are aligned.
4. Secure crankshaft in this position.
TIM-ID: 0000004352 - 006
M015565/03E 2016-02 | Valve Drive | 79

Checking valve bridge balance
Fig. Component
X Guided valve bridge
Y Flying valve bridge
Note: Not applicable for engines with flying valve

bridge.
1. Prior to adjusting valve clearance, check
valve bridge balance on all valve bridges.
2. Use feeler gage to determine clearance be-
tween valve bridge and rocker arm.
TIM-ID: 0000004352 - 006
80 | Valve Drive | M015565/03E 2016-02

3. Insert feeler gage with determined value be-
tween valve bridge and valve-stem end (A).
4. At the opposite valve-stem end (B), a feeler
gage thicker by 0.05 mm should not fit, oth-
erwise adjust valve bridge balance.
Adjusting valve bridge balance

Note: Not applicable for engines with flying valve
bridge.
1. Hold valve bridge (1) in place with open-end
wrench and release locknut (2).
2. Use feeler gage to determine clearance be-

tween valve bridge and rocker arm.
3. Place one feeler gage (of the determined val-
ue) each between valve bridge and the two
valve-stem ends (A) and (B).
4. Turn adjusting screw such that both feeler
gages can just be pulled through.
5. Hold adjusting screw securely in position with
Allen key and fit locknut by hand on valve
bridge.
TIM-ID: 0000004352 - 006
6. Replace or rectify adjusting screws which do

not move easily.
M015565/03E 2016-02 | Valve Drive | 81

7. Tighten locknut (2) to specified torque using a torque wrench holding valve bridge (1) in place with open-end
wrench in so doing.
Nut M 16 x 1.5 Preload torque (Engine oil) 35 Nm +5 Nm
8. Recheck valve bridge balance.
Checking valve clearance at two crankshaft positions
TIM-ID: 0000004352 - 006
Item Explanation
1 Cylinder A1 is in firing TDC
2 Cylinder A1 is in overlap TDC
82 | Valve Drive | M015565/03E 2016-02

Item Explanation
I Inlet valve
X Exhaust valve
1. Check TDC position of piston in cylinder A1:

• The piston is at firing TDC when the rocker arms at cylinder A1 are unloaded.
• The piston is at overlap TDC when the rocker arms at cylinder A1 are loaded.
2. Check valve clearance with cold engine:
• Inlet valves (long rocker arm) = 0.2 mm
• Exhaust valves (short rocker arm) = 0.5 mm
3. Check all valve clearances in two crankshaft positions (firing TDC and overlap TDC of cylinder A1) as per
diagram.
4. Use feeler gage to determine the clearance between valve bridge and rocker arm.
5. If the deviation from the specified value exceeds 0.1 mm, adjust valve clearance.
Adjusting valve clearance

1. Release locknut (1).
2. Insert feeler gage between valve bridge and
rocker arm.
3. Turn adjusting screw (2) with Allen key until
appropriate valve clearance is set.
4. Feeler gage (3) must just pass through the
gap.
5. Tighten locknut (1) to specified torque using a torque wrench. Secure adjusting screw (2) in so doing.
Nut M 16 x 1.5 Tightening torque (Engine oil) 90 Nm +9 Nm
6. Replace or rectify adjusting screws and/or locknuts which do not move freely.
7. Check valve clearance.
Final steps
1. Remove barring tool (→ Page 67).
TIM-ID: 0000004352 - 006
M015565/03E 2016-02 | Valve Drive | 83

8.5 Injection Pump / HP Pump
8.5.1 HP fuel pump – Relief bore check
DANGER
WARNING
Checking HP fuel pump relief

bore
1. Visually inspect relief bore for escaping fuel.
2. Contact Service in case of escaping fuel.
TIM-ID: 0000004530 - 002
84 | Injection Pump / HP Pump | M015565/03E 2016-02

8.6 Injector
8.6.1 Injector – Replacement
Injector (→ Spare Parts Catalog)
Injector – Replacement
u Remove injector and install new one (→ Page 86).
TIM-ID: 0000042329 - 002
M015565/03E 2016-02 | Injector | 85

8.6.2 Injector – Removal and installation
Preconditions

Installation and removal jig F6794703 1
Milling cutter F30452739 1
Slotted screwdriver F30452578 1
Torque screwdriver, 1–5 Nm F30452774 1
Assembly compound (Optimoly Paste White T) 40477 1
Assembly compound (Kluthe Hakuform 30-15) X00067260 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.
NOTICE
Cable damage during operation.
Fire hazard!
• Twist the cables when attaching.
• Ensure that the cables do not touch any components.
NOTICE
Removing all injectors.
Component damage possible!
• Ensure that the HP accumulator is secured on the engine through two HP lines.
Preparatory steps
1. Close off fuel supply to engine.
TIM-ID: 0000000952 - 013
86 | Injector | M015565/03E 2016-02

Removing injector
Note: Always replace the first and last injectors of
one engine side first. Replace the inner injec-
tors only after the installation of the outer in-
jectors on this engine side is completed.
1. Release the cable terminal threaded connec-
tion (arrowed) on the injector and remove ca-
ble terminals.
2. Remove screw (2) and take off hold-down

clamp (1).
3. Remove HP fuel line (5).
4. Install installation/removal jig on the cylinder

head.
5. Remove injector with installation/removal jig.
6. Remove the installation/removal jig.
TIM-ID: 0000000952 - 013
M015565/03E 2016-02 | Injector | 87

7. Remove sealing ring (1) from injector or use a
self-made hook to take it out of the cylinder
head.
8. Remove O-rings (2) from injector.
9. Cover all connections and bores, or seal with
suitable plugs.
Installing injector
1. Prior to installation, remove all blanking
plugs.
2. Coat injector with assembly paste in the area
of the nozzle retaining nut.
3. Fit new O-rings on injector and apply assem-
bly compound.
4. Fit new sealing ring with assembly compound
on injector, pay attention to installation posi-
tion of sealing ring.
5. Clean sealing face on cylinder head and pro-

tective sleeve with milling cutter.
6. Insert injector into cylinder head, making
sure that the HP line connections are aligned
correctly.
7. Press in injector with installation/removal jig.
8. Remove the installation/removal jig.
TIM-ID: 0000000952 - 013
88 | Injector | M015565/03E 2016-02

9. Use slotted screwdriver to check thrust ring
at both line ends for secure seating.
10. Tighten loose thrust ring to specified tightening torque.

Thrust ring Tightening torque 5 Nm to 10 Nm
11. Coat screw head mating face (2) and thread

with engine oil.
12. Fit hold-down clamp (1) in correct position by hand. Tighten screw (2) to specified initial tightening torque
using a torque wrench.
Screw M12 Preload torque (Engine oil) 5 Nm to 10 Nm
TIM-ID: 0000000952 - 013
13. Fit O-rings (4) and (6) on HP fuel line (5) and coat with assembly compound.
14. Tighten HP fuel line (5) to specified initial tightening torque.
HP line Preload torque (Engine oil) 5 Nm to 10 Nm
15. Tighten screw (2) to specified torque using a torque wrench.

Screw M12 Tightening torque 100 Nm + 10 Nm
M015565/03E 2016-02 | Injector | 89

16. Tighten union nut of adapter (limiting valve) to specified torque using a torque wrench.
Union nut Tightening torque 140 Nm + 10 Nm
17. Tighten union nut of adapter (injector) to specified torque using a torque wrench.
Union nut Tightening torque 120 Nm +10 Nm
18. Twist cable several times.
19. Insert cable lugs (arrowed) underneath the screws on the injector and tighten screws to specified torque us-
ing a torque wrench.
Screw Tightening torque 1.5 Nm
Final steps
2. Open fuel supply to engine.
TIM-ID: 0000000952 - 013
90 | Injector | M015565/03E 2016-02

8.7 Fuel System
8.7.1 Fuel system – Venting
Preconditions

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

1. Loosen flushing/return line of HP pump at
connection (1).
2. Unlock fuel priming pump (2), screw out han-
dle.
3. Operate the fuel priming pump (2) with the
handle until bubble-free fuel comes out of the
connection (1).
4. Lock fuel priming pump (2), screw in handle.
5. Verify that fuel priming pump (2) is locked:
handle must be tightened.
6. Tighten connection (1) of flushing/return
line.
TIM-ID: 0000004707 - 003
M015565/03E 2016-02 | Fuel System | 91

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.
Fuel filter – Replacement

1. Remove easy-change filter using filter
wrench.
2. Clean sealing face on filter head.
3. Apply a thin coat of oil to the seal on the
easy-change filter (arrowed).
4. Screw on the easy-change filter by hand until
the seal is in contact and tighten hand-tight.
5. Replace the other easy-change filters in the
same way.
6. Vent fuel system (→ Page 91).
TIM-ID: 0000000927 - 009
92 | Fuel Filter | M015565/03E 2016-02

8.8.2 Fuel prefilter – Cleaning
Preconditions

Diesel fuel
Sealing ring (→ Spare Parts Catalog)
WARNING
• Do not smoke.
Cleaning fuel prefilter

1. Close fuel supply.
2. Remove nuts from filter head.
3. Unscrew filter bowl and drain fuel into a suit-
able container.
4. Remove securing nut for filter element and
pull off filter element downwards.
5. Use a soft brush to wash filter element in
clean fuel.
6. Wash filter bowl with clean fuel.
7. Insert filter element in filter head and secure
with nut.
8. Insert new sealing ring in groove in filter
head.
9. Fit cover with gasket and tighten nuts cross-
wise.
10. Open fuel inlet.
TIM-ID: 0000004936 - 006
M015565/03E 2016-02 | Fuel Filter | 93

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

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

1. With the engine running at full load or rated power, read off pressure at gage (1).
2. If differential pressure as indicated between position of adjustable pointer (2) and pressure-indicating point-
er (3) of pressure gage is ≥ 0.3 bar, flush filter element of the cut-in filter (→ Page 96).
TIM-ID: 0000004925 - 009
94 | Fuel Filter | M015565/03E 2016-02

8.8.4 Fuel prefilter – Draining
Preconditions

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

1 Left filter cut in
2 Right filter cut in
1. Switch off filter to be drained.

2. Open threaded vent plug (5) of the filter to be
drained.
3. Unlock drain valve (6) by pressing toggle and
open it.
4. Drain water and contaminants from the filter
until pure fuel emerges.
5. Close drain valve (6).
TIM-ID: 0000019514 - 002
6. Remove screws securing the cover and take

off cover (2).
7. Fill filter housing with clean fuel.
8. Place new seal in cover (2).
9. Fit cover with gasket and secure it with
screws.
10. Cut in the cut-out filter again.
11. When fuel emerges from system, close vent
plug (5).
M015565/03E 2016-02 | Fuel Filter | 95

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

Diesel fuel
Seal (→ Spare Parts Catalog)
DANGER
WARNING
• Do not smoke.
WARNING
Liquid or gaseous media, e.g. fuel, are poisonous.
Escaping vapors of highly volatile media, e.g. fuel or ether.
Risk of fatal injury through swallowing; risk of poisoning through inhalation; irritation to eyes
and skin!
• Seek medical attention immediately; do not induce vomiting.
• Do not inhale vapors or mist.
• Wear protective clothing, protective gloves, and safety glasses.
• If contact is made with skin, wash off with water and soap.
WARNING
• Wear ear protectors. TIM-ID: 0000004937 - 023
96 | Fuel Filter | M015565/03E 2016-02

Fuel prefilter – Flushing
Note: Only in the case of double fuel prefilter:
1. Cut out the contaminated filter.
2. Open threaded vent plug (5) of filter to be

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

1. Remove screws securing cover and take off cover (2).
3. Place new seal in cover (2).
4. Fit cover with seal and secure it with screws.
5. Check differential pressure (→ Page 94).
Result: If flushing did not lead to an improvement of the differential pressure, replace filter element (→ Page 98).
TIM-ID: 0000004937 - 023
M015565/03E 2016-02 | Fuel Filter | 97

8.8.6 Fuel prefilter – Filter element replacement
Preconditions

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

1. Switch off filter to be drained.
TIM-ID: 0000004944 - 006
98 | Fuel Filter | M015565/03E 2016-02

2. Open threaded vent plug (5) of contaminated
filter.
3. Unlock drain valve (6) by pressing toggle and
open it.
4. Drain water and contamination from filter.
5. Close drain valve (6).
6. Remove screws securing the cover and take
off cover (2).
7. Remove spring housing (4) and filter ele-
ment (3).
8. Insert new filter element (3) and spring hous-
ing (4).
10. Place new gasket in cover (2).
11. Fit cover with gasket and secure it with
screws.
12. Cut in the cut-out filter again.
13. Close threaded vent plug (5) when fuel
emerges.
14. Set adjustable pointer of differential pressure
display instrument (→ Page 94).
TIM-ID: 0000004944 - 006
M015565/03E 2016-02 | Fuel Filter | 99

8.9 Charge-Air Cooling
8.9.1 Intercooler – Check water drain for coolant leakage and absence of restrictions
DANGER
WARNING
WARNING
Intercooler – Check water drain

for coolant leakage and absence
of restrictions
1. With the engine running check the drain
bore(s) on the right and left of the engine for
emerging air (at driving end). If no air es-
capes:
• Clean 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 the injectors(→ Page 86).
2. Bar engine manually (→ Page 67).
3. Bar engine with starting system to blow out combustion chambers (→ Page 69).
4. Install the injectors(→ Page 86).
TIM-ID: 0000000955 - 005
100 | Charge-Air Cooling | M015565/03E 2016-02

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 102).
2. Reset signal ring of service indicator (→ Page 103).
TIM-ID: 0000000903 - 005
M015565/03E 2016-02 | Air Filter | 101

8.10.2 Air filter – Removal and installation
Preconditions
Air filter – Removal and installa-

tion
1. Loosen clamp (2).
2. Remove air filter (1) and clamp (2) from con-
necting flange of intake housing (3).
3. Verify that there are no objects in the flange
of the intake housing (3) and clean it.
4. Place new air filter (1) with clamp (2) onto in-
take housing (3).
5. Tighten clamp (2).
TIM-ID: 0000000904 - 012
102 | Air Filter | M015565/03E 2016-02

8.11 Air Intake
8.11.1 Service indicator – Signal ring position check
Preconditions
Checking signal ring position

1. If the signal ring is completely visible in the
control window (2), replace air filter
(→ Page 101).
2. After installation of new filter, press reset
button (1).
Result: Engaged piston with signal ring moves back
to initial position.
TIM-ID: 0000005484 - 009
M015565/03E 2016-02 | Air Intake | 103

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
104 | Starting Equipment | M015565/03E 2016-02

8.13 Lube Oil System
8.13.1 Engine oil – Level check
Preconditions
WARNING
Hot oil.
Checking oil level prior to en-

gine start
1. Withdraw oil dipstick from guide tube and
wipe it.
2. Insert oil dipstick into guide tube up to the
stop, withdraw after approx. 10 seconds and
check oil level.
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-
changer flowing back into the oil pan.
3. The oil level must reach mark (1) or exceed
mark (1) by up to 2 cm.
4. Top up with oil to mark (1) as necessary
(→ Page 106).
5. Insert oil dipstick into guide tube up to the
stop.
Checking oil level after engine stop

1. 5 minutes after stopping the engine, withdraw oil dipstick from guide tube and wipe it.
2. Insert oil dipstick into guide tube up to the stop, withdraw after approx. 10 seconds and check oil level.
3. Oil level must be between marks (1) and (2).
4. Top up with oil to mark (1) as necessary (→ Page 106).
5. Insert oil dipstick into guide tube up to the stop.
TIM-ID: 0000000931 - 013
M015565/03E 2016-02 | Lube Oil System | 105

8.13.2 Engine oil – Change
Preconditions
☑ Engine is at operating temperature.
☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.

Ratchet adapter F30027341 1
Engine oil
WARNING
Hot oil.
Oil change without semirotary hand pump: Draining 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: Engine oil extraction

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

1. Check layer thickness of oil residues in the centrifugal oil filter, clean and replace filter sleeve (→ Operating
Instructions).
2. Replace engine oil filter (→ Page 108).
TIM-ID: 0000000930 - 013
106 | Lube Oil System | M015565/03E 2016-02

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. Tighten drain screws (2) and (3) to specified torque using a torque wrench.
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 engine oil through the filler neck up to
the “max.” mark on the oil dipstick.
3. Close cover (1) on filler neck.
4. Check engine oil level (→ Page 105).
5. Crank engine on starting system (→ Page 69).
TIM-ID: 0000000930 - 013
M015565/03E 2016-02 | Lube Oil System | 107

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

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

1. Unscrew engine oil filter with filter wrench.
2. Clean sealing face on connecting piece.
3. Check sealing ring of new engine oil filter and
apply a thin layer of engine oil.
4. Screw on and tighten engine oil filter by
hand.
5. Replace other engine oil filters in the same
way.
6. Bar engine with startingsystem (→ Page 69).
7. Check engine oil level (→ Page 105).
TIM-ID: 0000000933 - 010
108 | Oil Filtration / Cooling | M015565/03E 2016-02

8.14.2 Centrifugal oil filter – Cleaning and filter-sleeve replacement
Preconditions

Cold cleaner (Hakutex 60) X00056750 1
Filter sleeve (→ Spare Parts Catalog)
WARNING
Hot oil.
WARNING
TIM-ID: 0000060251 - 001
M015565/03E 2016-02 | Oil Filtration / Cooling | 109

Centrifugal oil filter, cleaning
and filter-sleeve replacement
1. Remove clamp (14).
2. Release cover nut (2) and take off cover (1).
3. Carefully lift rotor (11), allow oil to drain and
remove from housing.
4. Holding the rotor (11) firmly, release rotor
cover nut (3).
5. Take off rotor cover (4).
6. Remove filter sleeve (6).
7. Measure thickness of oil residues on filter
sleeve (6).
Result: Shorten maintenance interval if the oil resi-
dues exceed the maximum thickness of
45 mm.
8. Disassemble rotor tube (7), conical disk (8)
and rotor base (10).
9. Wash rotor cover (4), rotor tube (7), conical
disk (8) and rotor base (10) with cold cleaner.
10. Blow out with compressed air.
11. Check sealing ring (9), fit new one if necessa-
ry.
12. Assemble rotor tube (7), conical disk (8) and
rotor base (10) with sealing ring (9).
13. Insert new filter sleeve (6) in rotor tube (7)
with the smooth paper surface facing the
wall.
14. Check sealing ring (5), fit new one if necessa-
ry.
15. Mount rotor cover (4) with sealing ring (5).
16. Tighten rotor cover nut (3) with torque wrench to the specified torque.
Nut Tightening torque 80 Nm ±12 Nm
17. Place rotor (11) in housing (12) and check for ease of movement.
18. Check sealing ring (13), fit new one if necessary.
19. Fit sealing ring (13) on housing (12).
20. Fit cover (1).
21. Tighten cover nut (2) by hand.
22. Install clamp (14) and tighten with torque wrench to the specified torque.
Clamp Tightening torque 20 Nm ±3 Nm
23. Tighten cover nut (2) with torque wrench to the specified torque.
TIM-ID: 0000060251 - 001

Screw Tightening torque 7 Nm ±1 Nm
110 | Oil Filtration / Cooling | M015565/03E 2016-02

8.15 Coolant Circuit, General, High-Temperature Circuit
8.15.1 Engine coolant – Level check
Preconditions
WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
Checking engine 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.
3. Check engine coolant level (engine coolant must be visible at bottom edge of cast-in eye of filler neck).
Checking engine coolant level at

remote cooler:
Note: Engine coolant must be visible at marker
plate.
1. Check engine coolant level.
2. Top up engine coolant as necessary
(→ Page 114).
3. Check and clean cap.
4. Place cap on filler neck and close.
Checking engine coolant level via level sensor:

Note: Engine coolant level is automatically monitored by the engine control system.
1. Switch on engine control system and check readings on the display.
2. Top up engine coolant as necessary (→ Page 114).
TIM-ID: 0000000937 - 013
M015565/03E 2016-02 | Coolant Circuit, General, High-Temperature Circuit | 111

8.15.2 Engine coolant – Change
Coolant
Engine coolant change

1. Drain engine coolant (→ Page 113).
2. Fill with engine coolant (→ Page 114).
TIM-ID: 0000000036 - 031
112 | Coolant Circuit, General, High-Temperature Circuit | M015565/03E 2016-02

8.15.3 Engine coolant – Draining
Preconditions
WARNING
Preparatory steps
1. Provide a suitable receptacle to catch the coolant.
2. Switch off preheating unit.
Engine coolant – Draining

1. Turn breather valve of filler neck on coolant expansion tank counterclockwise to first stop and allow pressure
to escape.
2. Continue to turn breather valve counterclockwise 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 HT coolant pump elbow
• on crankcase, left and right sides.
• at preheating unit
5. Close all open drain points.
6. Position breather valve on filler neck and
close.
TIM-ID: 0000000936 - 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 breather valve on coolant expansion
tank counterclockwise to the first stop and
allow pressure to escape.
2. Continue to turn breather valve counterclock-
wise and remove.
TIM-ID: 0000000959 - 009

Filling coolant from below with
pump
1. Connect appropriate pump with hose to drain
valve of engine coolant pump (arrow).
2. Loosen vent line union on distributor piece

(arrowed).
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 overflow edge is
reached.
6. Close drain valve.
7. Check serviceable condition of breather valve
on coolant expansion tank, clean sealing
faces as necessary.
8. Fit breather valve and close it.
9. Start engine (→ Page 45).
10. After 10 seconds of running the engine with-
out load, stop engine (→ Page 48).
11. Turn breather valve on coolant expansion
tank counterclockwise to the first stop and
allow pressure to escape.
wise and remove.
13. Check coolant level (→ Page 111) and top up
coolant as necessary:
a) Top up coolant in expansion tank via filler
neck until coolant level at top edge of fill-
er neck remains constant.
b) Fit breather valve and close it.
14. Repeat the steps from "Start engine"
(→ Step 9) until coolant no longer needs to be
TIM-ID: 0000000959 - 009
topped up.
15. Remove pump and hose.
Final steps
1. Start engine and run it without load for some minutes.
2. Check coolant level (→ Page 111) and top up coolant as necessary.

8.15.5 Engine coolant pump – Relief bore check
DANGER
WARNING
Checking engine coolant pump

relief bore
1. Check relief bore for oil and coolant dis-
charge.
2. Shut down engine (→ Page 48) and disable
engine start, observe general safety instruc-
tions in “Maintenance and Repair”.
3. Clean the relief bore with a wire if it is dirty.
• 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: 0000000939 - 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 120).
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 120).
TIM-ID: 0000000042 - 008
M015565/03E 2016-02 | Low-Temperature Circuit | 117

8.16.2 Charge-air coolant – Change
Coolant
Charge-air coolant – Change

1. Drain charge-air coolant (→ Page 119).
2. Fill with charge-air coolant (→ Page 120).
TIM-ID: 0000000041 - 011
118 | Low-Temperature Circuit | M015565/03E 2016-02

8.16.3 Charge-air coolant draining
Preconditions

WARNING
Charge-air coolant draining

1. Provide an appropriate container to drain the
coolant into.
2. Turn breather valve of filler neck on coolant
expansion tank counterclockwise to first stop
and allow pressure to escape.
wise and remove.
4. Draw off precipitated corrosion inhibitor oil
from the expansion tank through filler neck.
5. Open drain cocks and drain plugs and drain
coolant at the following points:
• at the LT cooling pump
6. Draining of residual coolant:

• at intercooler, left and right side
7. Close all drain valves and install drain plugs
with new sealing rings.
8. Fit breather valve onto filler neck and close it.
TIM-ID: 0000007017 - 001

8.16.4 Charge-air coolant – Filling
Preconditions

Charge-air 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 breather valve of filler neck on coolant
expansion tank counterclockwise to first stop
and allow pressure to escape.
wise and remove.
3. Remove plug screw from filling point on cool-
ant line to intercooler.
TIM-ID: 0000007005 - 002

Filling charge-air coolant
1. Pour in treated coolant via the filling point on
the coolant line to the intercooler and via the
filler neck of the expansion tank until coolant
is visible at the marker plate.
2. Install plug screws of filling points with new
sealing rings.
3. Check proper condition of breather valve,
clean sealing faces if required.
4. Position breather valve on filler neck and
close.
Final steps
1. Start the engine and operate it at idle speed for some minutes.
2. Check coolant level (→ Page 117).
TIM-ID: 0000007005 - 002

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. Shut down engine (→ Page 48) and disable
engine start, observe general safety instruc-
tions “Maintenance and Repair”.
3. Clean the relief bore with a wire if it is dirty.
• 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: 0000000943 - 004

8.17 Belt Drive
8.17.1 Drive belt – Condition check
Preconditions
☑ Guard is removed.
Drive belt – Condition check
Item Findings Action

Drive belt A Singular cracks None
Drive belt B Cracks on entire circumference Replace (→ Page 126)
Drive belt C Chunking
Drive belt Belt is oily, shows signs of over-
heating
TIM-ID: 0000000920 - 011
M015565/03E 2016-02 | Belt Drive | 123

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

1. Loosen locknut (2) and screws (1).
2. Tension drive belt with tensioning nut (3) and
check belt tension (→ Page 125).
3. Tighten locknut (2).
5. Install guard cover.
TIM-ID: 0000000944 - 001
124 | Battery-Charging Generator | M015565/03E 2016-02

8.18.2 Battery-charging generator drive – Drive belt condition check
Preconditions

Belt tension tester Y4345711 1
Preparatory steps
1. Remove protective cover.
2. Check belt condition visually (→ Page 123).
Checking drive belt tension

1. Fit sensor head on belt tension tester and tap drive belt with a suitable tool.
2. Hold belt tension tester over belt drive until the measured value is displayed. For specifications, refer to table
below.
Application Measured value for new drive Measured value for used drive
belt belt
Series 4000 92 Hz to 96 Hz 80 Hz to 84 Hz
3. Adjust drive belt tension if the measured values deviate from the specifications above (→ Page 124).
TIM-ID: 0000000946 - 002
M015565/03E 2016-02 | Battery-Charging Generator | 125

8.18.3 Battery-charging generator drive – Drive belt replacement
Preconditions

Drive belt (→ Spare Parts Catalog)
Note: In the event of drive belt failure during engine operation fit a new drive belt as quickly as possible. Noncom-
pliance with these instructions may lead to severe consequential damage to drive unit and gear train, since
pretension by the drive belt is no longer provided. Therefore, engine operation without drive-belt connection
is not allowed.
Battery-charging generator
drive – Drive belt replacement
1. Remove guard cover.
2. Loosen locknut (2) and screws (1).
3. Release drive belt with tensioning nut (3) and
take off belt.
4. Clean belt pulleys.
5. Fit new drive belt.
6. Tension drive belt with tensioning nut (3) and
check belt tension (→ Page 124).
7. Tighten locknut (2).
9. Install guard cover.
10. Check belt tension after 30 minutes and
again after 8 hours engine runtime.
TIM-ID: 0000000965 - 001
126 | Battery-Charging Generator | M015565/03E 2016-02

8.19 Engine Mounting / Support
8.19.1 Engine mounting – Resilient mount check
Preconditions
☑ Engine filled with coolant and engine oil.
Engine mounting – Checking the

condition of resilient mounts
1. Wipe rubber surface with dry cloth, do not
use organic detergents.
2. Visually inspect resilient mounts for cracks
and deformation.
3. Have cracked mounts replaced, contact Serv-
ice.
Checking settling dimension

1. Measure settling dimension:
• Dimension (a) = 57 mm.
2. Have resilient mounts replaced if dimension (a) is too small, contact Service.
TIM-ID: 0000066404 - 001
M015565/03E 2016-02 | Engine Mounting / Support | 127

8.20 Cabling
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 - 024
128 | Cabling | M015565/03E 2016-02

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

Solvent (isopropyl alcohol) X00058037 1
Cleaning Engine Control Unit

and connectors
1. Remove coarse dirt from housing surface us-
ing a cloth moistened with isopropyl alcohol.
2. Remove dirt on surface of connectors (1),
sockets and shrink pieces (2) using isopropyl
alcohol.
3. Check legibility of cable labels. Clean or re-
place illegible labels.
Cleaning severely contaminated

connectors on Engine Control
Unit
1. Undo bayonet union nut (4) with pipe grip-
ping pliers (2) and disconnect connector (3).
2. Clean connector housings, connector socket
housings (1) and all contacts with isopropyl
alcohol.
3. When connectors, sockets and all contacts
are dry: Fit connectors and check Engine
Control Unit connections (→ Page 130).
TIM-ID: 0000000948 - 012
M015565/03E 2016-02 | Accessories for (Electronic) Engine Governor / Control System | 129
8.21.2 Engine Control Unit – Plug connection check
Preconditions

Checking Engine Control Unit

plug connections
1. Check that all plug connections on the En-
gine Control Unit are properly seated using
pipe gripping pliers (3).
2. Tighten loose bayonet union nuts (2) with
pipe gripping pliers (3) by turning them clock-
wise until they latch into place.
3. Make sure that unassigned sockets are
closed off with cover caps.
4. Contact Service if bayonet union nuts are de-
fective.
TIM-ID: 0000031185 - 005
130 | Accessories for (Electronic) Engine Governor / Control System | M015565/03E 2016-02
9 Appendix A
9.1 Abbreviations
Abbre- Meaning Explanation
viation
A/D Analog/Digital converter Converter: converts sensor voltages into digital val-
ues
ADEC Advanced Diesel Engine Controller Engine management system
AFRS Air Filter Restriction Sensor
AGR Abgasrückführung Exhaust Gas Recirculation
AL Alarm
ANSI American National Standards Institute Association of American standardization organiza-
tions
ATL Abgasturbolader/Abgasturboaufladung Exhaust turbocharger/exhaust turbocharging
ATS Air Temperature Sensor
BR Baureihe Series
BV Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU Publica-
tion No. A01061/..
CAN Controller Area Network Data bus system, bus standard
CDC Calibration Drift Compensation Drift correction setting with DiaSys in engine gover-
nor
CEL Check Engine Lamp 1st function: Warning lamp (rectify fault as soon as
possible)
2nd function: Read out fault codes
CKT Circuit
CLS Coolant Level Sensor Monitors coolant level
CM Current Measurement Current measured value
CPS Coolant Pressure Sensor Monitors coolant pressure
CR Common Rail
CTS Coolant Temperature Sensor Monitors coolant temperature
DDEC Detroit Diesel Electronic Controls Engine control system made by Detroit Diesel
DDL Diagnostic Data Link Diagnostic lines
DDR Diagnostic Data Reader Diagnostic unit
Dia- Electronic dialog system
Sys®
DIN Deutsches Institut für Normung e. V. German national standards institute. At the same
TIM-ID: 0000000858 - 015
time identifier of German standards (DIN = “Deut-

sche Industrie-Norm”)
DL Default Lost Alarm: Default CAN bus failure
DMC Data Matrix Code
DOC Diesel Oxidation Catalyst Oxidation catalyst upstream of the diesel particulate
filter
DPF Diesel Particulate Filter
DT Diagnostic Tool Diagnostic unit
ECM Electronic Control Module Electronic control unit of the DDEC system
M015565/03E 2016-02 | Appendix A | 131

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

value
LOLO Low Low Alarm: Measured value lower than 2nd minimum lim-
it value
LSG Limit Speed Governor Maximum-speed governor
LSU Lambda Sonde Universal Universal Lambda probe
LT Low Temperature
MCR Maximum Continuous Rating Torque limitation curve
132 | Appendix A | M015565/03E 2016-02

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

VSS Vehicle Speed Sensor
WZK Werkzeugkatalog Tool Catalog
ZKP Zuordnung - Kategorie - Parameter Assignment - Category - Parameter. A number allo-
cated to a parameter describing its function and as-
signment
M015565/03E 2016-02 | Appendix A | 133

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
134 | Appendix A | M015565/03E 2016-02

10 Appendix B
10.1 Special Tools
Barring device
Part No.: F6555766
Qty.: 1
Used in: 8.1.1 Engine – Barring manually (→ Page 67)
Qty.: 1
Used in: 8.2.1 Cylinder liner – Endoscopic examination (→ Page 71)
Belt tension tester

Part No.: Y4345711
Qty.: 1
Used in: 8.18.2 Battery-charging generator drive – Drive belt con-
dition check (→ Page 125)
Crossbeam
Part No.: T80091826
Qty.: 1
Used in: 2.1 Transportation (→ Page 16)
DCL-ID: 0000034750 - 001
M015565/03E 2016-02 | Appendix B | 135

Crossbeam
Part No.: T80092360
Qty.: 1
Used in: 2.1 Transportation (→ Page 16)
Endoscope
Part No.: Y20097353
Qty.: 1
Feeler gage
Part No.: Y20098771
Qty.: 1
Used in: 8.4.3 Valve clearance – Check and adjustment
(→ Page 79)
Filter wrench
Part No.: F30379104
Qty.: 1
Used in: 8.8.1 Fuel filter – Replacement (→ Page 92)
Qty.:
Used in: 8.14.1 Engine oil filter – Replacement (→ Page 108)
DCL-ID: 0000034750 - 001
136 | Special Tools | M015565/03E 2016-02

High-pressure cleaning unit
Part No.: -
Qty.: 1
Used in: 5.9 Plant – Cleaning (→ Page 51)
Installation and removal jig

Part No.: F6794703
Qty.: 1
Used in: 8.6.2 Injector – Removal and installation (→ Page 86)
Milling cutter
Part No.: F30452739
Qty.: 1
Pipe gripping pliers

Part No.: F30017884
Qty.: 1
Used in: 8.1.2 Engine – Cranking on starting system (→ Page 69)
Qty.: 1
Used in: 8.21.1 Engine Control Unit and connectors – Cleaning
(→ Page 129)
Qty.: 1
Used in: 8.21.2 Engine Control Unit – Plug connection check
(→ Page 130)
DCL-ID: 0000034750 - 001
M015565/03E 2016-02 | Special Tools | 137

Ratchet adapter
Part No.: F30027340
Qty.: 1
Used in: 8.3.1 Crankcase breather – Oil separator element re-
placement (→ Page 75)
Ratchet adapter
Part No.: F30027341
Qty.: 1
Used in: 8.13.2 Engine oil – Change (→ Page 106)
Ratchet with extension

Part No.: F30006212
Qty.: 1
Used in: 8.1.1 Engine – Barring manually (→ Page 67)
Qty.: 1
Ring socket wrench

Part No.: F30039518
Qty.: 1
(→ Page 79)
DCL-ID: 0000034750 - 001
138 | Special Tools | M015565/03E 2016-02

Slotted screwdriver
Part No.: F30452578
Qty.: 1
Torque screwdriver, 1–5 Nm

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

Part No.: F30452769
Qty.: 1
Used in: 2.3 Crankshaft transport locking device (→ Page 18)
Qty.: 1
(→ Page 79)
Qty.: 1
Qty.: 1
Used in: 8.14.2 Centrifugal oil filter – Cleaning and filter-sleeve re-

Part No.: F30044239
Qty.: 1
Used in: 8.3.1 Crankcase breather – Oil separator element re-
DCL-ID: 0000034750 - 001

Qty.: 1
Used in: 8.14.2 Centrifugal oil filter – Cleaning and filter-sleeve re-
M015565/03E 2016-02 | Special Tools | 139

Part No.: F30452768
Qty.: 1
Used in: 2.3 Crankshaft transport locking device (→ Page 18)
Qty.: 1
(→ Page 79)
Qty.: 1
Qty.: 1
Used in: 8.13.2 Engine oil – Change (→ Page 106)
DCL-ID: 0000034750 - 001
140 | Special Tools | M015565/03E 2016-02

10.2 Index
A D
Abbreviations 131 Differential pressure gage
After stopping the engine – Adjustment
– Putting the engine out of operation 50 – Fuel prefilter 94
Air filter – Check
– Installation 102 – Fuel prefilter 94
– Removal 102 Dimensions
– Replacement 101 – Engine 42
Air starter Drive belt
– Manual operation 104 – Condition check 123
C E
Cabling Emergency start
– Check – Override mode 46
– On engine 128 Engine
Centrifugal oil filter – Barring
– Cleaning 109 – Manually 67
Charge-air coolant – Cranking
– Change 118 – On starting system 69
– Check – Emergency start (override mode) 46
– Level at filler neck 117 – Emergency stop 49
– Level via level sensor 117 – Main dimensions 42
– Filling 120 – Starting in manual mode (test run) 45
Charge-air coolant draining 119 – Stopping in manual mode (test run) 48
Charge-air coolant pump – Test run 70
– Relief bore check 122 Engine cabling
Connectors – Check 128
– Cleaning 129 Engine Control Unit
Contact persons 134 – Cleaning 129
Coolant – Plug connection check 130
– Change 112, 118 Engine coolant
– Filling 114 – Change 112
Coolant pump – Check
– Relief bore check 122 – Level at external cooler 111
Crankcase breather – Level at filler neck 111
– Oil separator element – Level via level sensor 111
– Replacement 75 – Draining 113
Crankshaft – Filling 114
– Transport locking device Engine coolant pump
– Installation/removal 18 – Check
Cylinder – Relief bore 116
– Designation 21 Engine data
Cylinder head cover – 20V4000G22/G42/G62/G82
DCL-ID: 0000034750 - 001
– Installation 77 – 3B 27

– Removal 77 – 3D 36
Cylinder liner – 20V4000G22/G62
– Endoscopic examination 71 – 3C 32
– Instructions and comments on endoscopic and visual – 20V4000G62/G82
examination 73 – 3A 23
Engine driving end
– Definition 21
Engine free end
– Definition 21
Engine mounting
– Check 127
M015565/03E 2016-02 | Index | 141

Engine oil O
– Centrifugal oil filter Oil separator element
– Cleaning 109 – Replacement
– Change 106 – Crankcase breather 75
– Filter sleeve Operational monitoring 47
– Replacement 109 Overview
Engine oil filter – Engine 22
– Replacement 108
Engine oil level P
– Check 105 Plant
Engine overview 22 – Cleaning 51
Engine sides Preparation
– Designation 21 – Putting the engine into operation after extended out-of-
service periods (>3 months) 43
F
Putting the engine into operation after scheduled out-of-
Fault messages on engine governor 56 service-period 44
Filter sleeve
– Replacement 109 R
Final compression pressure 40 Relief bore
Firing order 41 – Check
Fuel filter – Engine coolant pump 116
– Replacement 92 Relief bore check
Fuel prefilter – HP fuel pump 84
– Adjustment Resilient mounts
– Differential pressure gage 94 – Check 127
– Check
– Differential pressure gage 94 S
– Cleaning 93 Safety notices, standards 15
– Filter element Safety regulations
– Replacement 98 – Auxiliary materials 13
– Flushing 96 – Environmental protection 13
Fuel prefilter – Draining 95 – Fire prevention 13
Fuel system – Fluids and lubricants 13
– Venting 91 – Important provisions 5, 6
– Maintenance work 10
H
– Operation 8
Hotline 134 – Organizational requirements 7
HP fuel pump – Personnel requirements 7
– Relief bore check 84 – Repair work 10
– Startup 8
I
Safety requirements
Injector – Safety notices, standards 15
– Installation 86 Service indicator
– Removal 86 – Signal ring position check 103
– Replacement 85 Service partners 134
Intercooler Spare parts service 134
– Check water drain for coolant leakage and absence of Starting valve
DCL-ID: 0000034750 - 001
restrictions 100 – Manual operation 104

L T
Lifting requirements 17 Transport locking device
– Crankshaft
M
– Installation/removal 18
Main dimensions Transportation
– Engine 42 – Description 16
Maintenance schedule – Lifting requirements 17
– Maintenance task reference table [QL1] 52 Troubleshooting 53
MTU contact persons 134
142 | Index | M015565/03E 2016-02

V
Valve clearance
– Adjustment 79
– Check 79
Valve gear
– Lubrication 78
DCL-ID: 0000034750 - 001
M015565/03E 2016-02 | Index | 143

MTU 20V4000G Operation Manuel

Caricato da

Informazioni sul documento

Titolo originale

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

MTU 20V4000G Operation Manuel

Caricato da

Copyright:

Formati disponibili

Operating Instructions

© 2016 Copyright MTU Friedrichshafen GmbH

3 General Information 8 Task Description

8.2 Cylinder Liner 71

8.6.1 Injector – Replacement 85

M015565/03E 2016-02 | Table of Contents | 3

8.10 Air Filter 101 8.18 Battery-Charging Generator 124

DCL-ID: 0000034750 - 001

4 | Table of Contents | M015565/03E 2016-02

Emission regulations and emission labels

Replacing components with emission labels

M015565/03E 2016-02 | Safety | 5

6 | Safety | M015565/03E 2016-02

Clothing and personal protective equipment

M015565/03E 2016-02 | Safety | 7

Safety regulations during operation

Malfunctions and emergency stop

to do so following a written procedure.

Operation of electrical equipment

8 | Safety | M015565/03E 2016-02

M015565/03E 2016-02 | Safety | 9

Safety regulations during maintenance and repair work

Never use the product as a climbing aid.

10 | Safety | M015565/03E 2016-02

Safety regulations following maintenance and repair work

Hydraulic installation and removal

M015565/03E 2016-02 | Safety | 11

Working with batteries

Working on electrical and electronic assemblies

Work with laser devices

Measuring component dimensions

12 | Safety | M015565/03E 2016-02

Environmental protection and disposal

M015565/03E 2016-02 | Safety | 13

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

14 | Safety | M015565/03E 2016-02

M015565/03E 2016-02 | Safety | 15

Setting down after transport

16 | Transport | M015565/03E 2016-02

1 Max. admissible diagonal 2 Center of gravity

Take note of the engine center of gravity

M015565/03E 2016-02 | Transport | 17

Transport locking devices

Removing guard plates and en-

18 | Transport | M015565/03E 2016-02

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

Removing the transport locking

locking device carefully together with this

M015565/03E 2016-02 | Transport | 19

TIM-ID: 0000004010 - 015

20 | Transport | M015565/03E 2016-02

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

M015565/03E 2016-02 | General Information | 21

1 Oil cooler 10 Coolant lines 19 HP fuel pump

Engine model designation

22 | General Information | M015565/03E 2016-02

General conditions (for maximum power)

Engine model Unit 20V4000 20V4000

M015565/03E 2016-02 | Technical Data | 23

Air / exhaust gas

Coolant system (HT)

Coolant antifreeze content, max. permissible L % 50 50

24 | Technical Data | M015565/03E 2016-02