Operating Instructions

Diesel engine
8V4000Gx1
12V4000Gx1
16V4000Gx1

M015570/05E
Engine model Power Application group
8V4000G61 91.9/93.8 kW/cyl. (3A) 3A, continuous operation, unrestricted
111.9/119.4 kW/cyl. (3B, 3C) 3B, continuous operation at variable load
123.1/131.3 kW/cyl. (3D) 3C, continuous operation, time-limited
3D standby power, fuel stop power, IFN
8V4000G81 93.8 kW/cyl. (3A) 3A, continuous operation, unrestricted
125 kW/cyl. (3B) 3B, continuous operation at variable load
137.5 kW/cyl. (3D) 3D standby power, fuel stop power, IFN
12V4000G21 100.4/109.2 kW/cyl. (3B, 3C) 3B, continuous operation at variable load
110.8/120.4 kW/cyl. (3D) 3C, continuous operation, time-limited
3D standby power, fuel stop power, IFN
12V4000G41 85 kW/cyl. (3A) 3A, continuous operation, unrestricted
112.9 kW/cyl. (3B) 3B, continuous operation at variable load
124.2 kW/cyl. (3D) 3D standby power, fuel stop power, IFN
12V4000G61 91.3/93.3 kW/cyl. (3A) 3A, continuous operation, unrestricted
110.8/120.4 kW/cyl. (3B, 3C) 3B, continuous operation at variable load
122.1/132.5 kW/cyl. (3D) 3C, continuous operation, time-limited
3D standby power, fuel stop power, IFN
12V4000G81 93.3 kW/cyl. (3A) 3A, continuous operation, unrestricted
124.2 kW/cyl. (3B) 3B, continuous operation at variable load
136.7 kW/cyl. (3D) 3D standby power, fuel stop power, IFN
16V4000G21 100/108.4 kW/cyl. (3B, 3C) 3B, continuous operation at variable load
110/119.4 kW/cyl. (3D) 3C, continuous operation, time-limited
3D standby power, fuel stop power, IFN
16V4000G41 85 kW/cyl. (3A) 3A, continuous operation, unrestricted
113.1 kW/cyl. (3B) 3B, continuous operation at variable load
124.4 kW/cyl. (3D) 3D standby power, fuel stop power, IFN
16V4000G61 90.6/93.4 kW/cyl. (3A) 3A, continuous operation, unrestricted
110/119.4 kW/cyl. (3B, 3C) 3B, continuous operation at variable load
121.3/131.3 kW/cyl. (3D) 3C, continuous operation, time-limited
3D standby power, fuel stop power, IFN
16V4000G81 93.4 kW/cyl. (3A) 3A, continuous operation, unrestricted
124.4 kW/cyl. (3B) 3B, continuous operation at variable load
136.9 kW/cyl. (3D) 3D standby power, fuel stop power, IFN

Table 1: Applicability

© 2019 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 4.9 8/12/16V 4000G engine data: Continuous
operation, unlimited 3A, optimized exhaust
1.1 Important provisions for all products 5 emission (EPA) 63
1.2 Gendrive engines – Intended use 7 4.10 Firing order 67
1.3 Personnel and organizational requirements 8 4.11 Engine – Main dimensions 68
1.4 Safety regulations for initial start-up and
operation 9
5 Operation
1.5 Safety regulations for assembly,
maintenance, and repair work 11 5.1 Preparations for putting operation after
1.6 Fire and environmental protection, fluids extended out-of-service periods (>3 months) 69
and lubricants 15 5.2 Preparations for putting into operation after
1.7 Standards for warning notices in the text scheduled out-of-service-period 70
and highlighted information 18 5.3 Starting the engine in manual mode (test
run) 71
2 Transport 5.4 Re-starting the engine following an
automatic safety shutdown 72
2.1 Transport 19 5.5 Safety system – Override 73
2.2 Lifting specifications 21 5.6 Emergency engine start (Override mode) 74
2.3 Crankshaft transport locking device 22 5.7 Operational checks 75
5.8 Engine – Stopping in Manual mode (test
3 General Information run) 76
3.1 Engine side and cylinder designations 25 5.9 Engine – Emergency stop 78
3.2 Engine layout 26 5.10 After stopping the engine – Engine remains
3.3 Sensors and actuators – Overview 27 ready for operation 79
5.11 After stopping the engine – Putting the
engine out of operation 80
4 Technical Data
5.12 Plant – Cleaning 81
4.1 8/12/16V 4000 engine data: Standby
operation 3D, optimized fuel consumption 31 6 Maintenance
4.2 8/12/16V 4000 engine data: Standby
operation 3D, optimized exhaust emission 6.1 Maintenance task reference table [QL1] 82
(EPA) 35
4.3 8/12/16V 4000 engine data: Continuous 7 Troubleshooting
operation, limited 3C, optimized fuel 7.1 Troubleshooting 84
consumption 39 7.2 Fault messages on engine governor 87
4.4 8/12/16V 4000 engine data: Continuous
operation, limited, 3C, optimized exhaust
8 Task Description
emission ("TA-Luft") 43
4.5 8/12/16V 4000 engine data: Continuous 8.1 Engine 98
operation, variable 3B, optimized fuel 8.1.1 Engine – Barring manually 98
consumption 47 8.1.2 Engine – Cranking on starting system 99
DCL-ID: 0000053939 - 001

4.6 8/12/16V 4000 engine data: Continuous 8.1.3 Engine – Test run 100
operation, variable 3B, optimized exhaust 8.2 Cylinder Liner 101
emission ("TA-Luft") 51 8.2.1 Cylinder liner – Endoscopic inspection 101
4.7 8/12/16V 4000 engine data: Continuous 8.2.2 Cylinder liner – Instructions and comments on
operation, variable 3B, optimized exhaust endoscopic and visual examination 103
emission (EPA) 55 8.3 Crankcase Breather 105
4.8 8/12/16V 4000 engine data: Continuous 8.3.1 Crankcase breather – Filter element
operation, unlimited 3A, optimized fuel replacement 105
consumption 59

M015570/05E 2019-07 | Table of Contents | 3

8.3.2 Crankcase breather – Oil separator
replacement, diaphragm check and
8.15 Coolant Circuit, General, High-Temperature
replacement 106 Circuit 146
8.15.1 Engine coolant – Level check 146
8.4 Valve Drive 108 8.15.2 Engine coolant – Change 148
8.4.1 Valve gear – Lubrication 108 8.15.3 Engine coolant – Draining 149
8.4.2 Valve clearance – Check and adjustment 109 8.15.4 Engine coolant – Filling 150
8.4.3 Cylinder head cover – Removal and 8.15.5 Engine coolant pump – Relief bore check 153
installation 114 8.15.6 Engine coolant – Sample extraction and
analysis 154
8.5 Injection Pump / HP Pump 115
8.5.1 HP fuel pump – Relief bore check 115 8.16 Low-Temperature Circuit 156
8.16.1 Charge-air coolant level – Check 156
8.6 Injection Valve / Injector 116
8.16.2 Charge-air coolant – Change 158
8.6.1 Injector – Replacement 116
8.16.3 Charge-air coolant – Draining 159
8.6.2 Injector – Removal and installation 117
8.16.4 Charge-air coolant – Filling 161
8.7 Fuel System 122 8.16.5 Charge-air coolant pump – Relief bore check 165
8.7.1 Fuel system – Venting 122 8.16.6 Charge-air coolant – Sample extraction and
analysis 166
8.8 Fuel Filter 123
8.8.1 Fuel filter – Replacement 123 8.17 Belt Drive 168
8.8.2 Fuel prefilter – Cleaning 124 8.17.1 Drive belt – Condition check 168
8.8.3 Fuel prefilter – Differential pressure gauge
8.18 Battery-Charging Generator 169
check and adjustment 125
8.18.1 Battery-charging generator drive – Drive belt
8.8.4 Fuel prefilter – Draining 126
tension adjustment 169
8.8.5 Fuel prefilter – Flushing 128
8.18.2 Battery-charging generator drive – Drive belt
8.8.6 Fuel prefilter – Filter element replacement 131
condition check 170
8.9 Charge-Air Cooling 133 8.18.3 Battery-charging generator drive – Drive belt
8.9.1 Intercooler – Checking condensate drain for replacement 171
coolant leakage and obstruction 133
8.19 Cabling 172
8.10 Air Filter 134 8.19.1 Engine cabling – Check 172
8.10.1 Air filter ‒ Replacement 134
8.20 Accessories for (Electronic) Engine
8.10.2 Air filter – Removal and installation 135
Governor / Control System 173
8.11 Air Intake 136 8.20.1 Engine governor and connectors – Cleaning 173
8.11.1 Contamination indicator – Signal ring position 8.20.2 Engine Control Unit – Plug connection check 174
check 136

8.12 Starting Equipment 137 9 Appendix A

8.12.1 Air starter – Manual operation 137
9.1 Abbreviations 175
8.13 Lube Oil System, Lube Oil Circuit 138
8.13.1 Engine oil level – Check 138
9.2 Conversion tables 179
8.13.2 Engine oil – Change 139 9.3 MTU Contact/Service Partners 183
8.13.3 Engine oil – Sample extraction and analysis 141
10 Appendix B
8.14 Oil Filtration / Cooling 143
8.14.1 Engine oil filter – Replacement 143 10.1 Special Tools 184
8.14.2 Centrifugal oil filter – Cleaning and filter 10.2 Index 190
DCL-ID: 0000053939 - 001

sleeve replacement 144

4 | Table of Contents | M015570/05E 2019-07

1 Safety
1.1 Important provisions for all products
General
This product may pose a risk of injury or damage in the following cases:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Changes or modifications which are neither made nor authorized by the manufacturer
• Noncompliance with the safety instructions and warning notices

Nameplates
The product is identified by nameplate, model designation or serial number. This data must match the speci-
fications in these instructions.
Nameplates, model designation or serial number can be found on the product.
All EU-certified engines delivered by MTU come with a second nameplate. This second nameplate is deliv-
ered "loosely" with the engine. If the nameplate secured to the engine after installation in the vehicle/system
is not visible without the removal of components, the system integrator must install the second nameplate in
a clearly visible area on the vehicle/system.

Emission specifications and emission label

Responsibility for compliance with emission regulations
Modification or removal of any mechanical/electronic components or the installation of additional compo-
nents including the execution of calibration processes that might affect the emission characteristics of the
product are prohibited by emission regulations. Emission-related components must only be serviced, ex-
changed or repaired if the components used for this purpose are approved by the manufacturer.
Noncompliance with these specifications will invalidate the design type approval or certification issued by
the emissions regulation authorities. The manufacturer does not accept any liability for violations of the
emission regulations.
The product must be operated over its entire life cycle according to the conditions defined as "Intended use"
(→ Page 7).

Emission certification applicable to engines with EPA Nonroad Tier 4 emission

certification in accordance with 40 CFR 1039 and with EPA Locomotive emission
certification in accordance with 40 CFR 1033
Extract from the standard:
Failing to follow these instructions when installing a certified engine in a piece of nonroad equipment violates
federal law (40 CFR 1068.105(b)), subject to fines or other penalties as described in the Clean Air Act.
TIM-ID: 0000040530 - 014

Extract from the standard:

If you install the engine in a way that makes the engine's emission control information label hard to read
during normal engine maintenance, you must place a duplicate label on the equipment, as described in 40
CFR 1068.105.
When fitting the second label, the requirements of 40 CFR 1068.105(c) must be followed and observed. This
paragraph describes the process for requesting and fitting the label, the documentation obligations and stor-
age obligations for the required documents.

M015570/05E 2019-07 | Safety | 5

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

TIM-ID: 0000040530 - 014

6 | Safety | M015570/05E 2019-07

1.2 Gendrive engines – Intended use
Intended 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 admissible operating parameters in accordance with the (→ technical sales documents – prod-
uct data – TVU data)
• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubricants
Specifications of the manufacturer)
• With preservation approved by the manufacturer in accordance with the (→ Preservation and Represerva-
tion Specifications of the manufacturer)
• With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU con-
tact/Service partner)
• In the original as-delivered configuration or in a configuration approved by the manufacturer in writing (al-
so applies to engine control/parameters)
• In compliance with all safety regulations and observance of all safety and 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
The product shall not be operated in explosive atmospheres unless it fulfills the conditions for such use and
approval has been granted.
The section below applies to applications deployed in regions under the jurisdiction of the EPA.
• Use of EPA Tier 2 and Tier 3 certified genset engines.
• EPA Tier 2 and Tier 3 certified genset engines may only be used in generator sets for stationary emergen-
cy applications. Non-emergency operation is limited to 100 hrs per year.
The engines may be used in fixed speed gensets only. Permanent limitation to a max. engine power of less
than 560 kW (e.g. by means of correspondingly low generator power) is not admissible.
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 use.
The specifications of the manufacturer will be amended or supplemented as necessary. Prior to use, ensure
that the most recent version is available. The latest version can be found at:
• For drive systems: http://www.mtu-online.com
• For power generation: http://www.mtuonsiteenergy.com

Modifications or conversions
Unauthorized changes to the product breach the conditions concerning its intended use and compromise
safety.
Only modifications or conversions expressly authorized by the manufacturer are regarded as compliant in
this sense. The manufacturer shall not be held liable for any damage resulting from unauthorized modifica-
TIM-ID: 0000078341 - 003

tions or conversions.

M015570/05E 2019-07 | Safety | 7

1.3 Personnel and organizational requirements
Organizational measures of the user/manufacturer
This manual must be issued to all personnel involved in operation, maintenance, repair, assembly, installa-
tion, or transportation.
Keep this manual handy in the vicinity of the product such that it is accessible to operating, maintenance,
repair, assembly, installation, and transport personnel at all times.
Personnel must receive instruction on product handling and repair based on this manual. In particular, per-
sonnel must have read and understood the safety requirements and warnings before starting work.
This is important in the case of personnel who only occasionally perform work on or around the product.
Such personnel must be instructed repeatedly.

Personnel requirements
All work on the product must be carried out by trained, instructed and qualified personnel only:
• Training at the Training Center of the manufacturer
• Qualified personnel from the areas mechanical engineering, plant construction, and electrical engineering
and also for work with live parts
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 respective
descriptions of the individual activities or the manufacturer's documentation included in the delivery.
When working on live components, in particular on electrical switchgear or on high-voltage component, wear
special protective clothing according to IEC 61482.
Safe handling of Substances of Very High Concern pursuant to the REACH regulation (Registration, Evalua-
tion, Authorization and restriction of CHemicals): We recommend wearing protective gloves at all times in
order to reduce risk when working.

TIM-ID: 0000040531 - 013

8 | Safety | M015570/05E 2019-07

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

Safety regulations during operation

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

Malfunctions and emergency stop

Practice emergency procedures, especially emergency stopping, at regular intervals.
Take the following steps if any system malfunctions are detected or signaled by the system:
• Inform supervisor(s) in charge.
• Analyze the message.
• Respond by taking any necessary emergency action, e.g. emergency stop.
TIM-ID: 0000040533 - 021

After a safety shutdown, the engine must only be started after the cause of the shutdown has been eliminat-
ed.
Contact Service if the root cause of the malfunction cannot be clearly identified.

Operation
Do not remain in the operating room when the product is running unless absolutely necessary. Keep your
stay as short as possible.
Keep a safe distance away from the product if possible. Do not touch the product unless expressly instructed
to do so following a written procedure.

M015570/05E 2019-07 | Safety | 9

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

Operation of electrical equipment

When electrical equipment is in operation, certain components of these appliances are electrically live.
Follow the applicable operating and safety instructions when operating the devices and heed warnings at all
times.

TIM-ID: 0000040533 - 021

10 | Safety | M015570/05E 2019-07

1.5 Safety regulations for assembly, maintenance, and repair
work
Safety regulations for work prior to assembly, maintenance, and repair
Have assembly, maintenance, or repair work carried out by qualified and authorized personnel only.
Allow the product to cool down to less than 50 °C (risk of explosion from oil vapors, fluids and lubricants,
risk of burning).
Relieve pressure in fluid and lubricant systems and compressed-air lines which are to be opened. Use suita-
ble containers of adequate capacity to catch fluids and lubricants.
Release residual pressure before removing or replacing a component in the supply line. To depressurize pres-
surized lines, shut off the lines first, then release the residual pressure.
Work must only be carried out on lines when they are free of fluids and lubricants.
Ensure adequate ventilation of the operating room when conducting an oil change, working on the gaseous/
liquid fuel system or working with consumables (e.g. adhesive, cleaner).
Never carry out assembly, maintenance, or repair work with the product in operation, unless:
• It is expressly permitted to do so following a written procedure.
Lock-out the product to preclude undesired starting, e.g.
• Start interlock
• Key switch
• Close supply line for hydraulic starting.
• Close the main valve on the compressed-air system and vent the compressed-air line when air starters are
fitted.
Attach “Do not operate” sign in the operating area or to control equipment.
Disconnect the battery cables or actuate the battery isolating switch, if fitted. Lock circuit breakers.
Before starting work on CaPoS, if used:
• Switch off the charging system (DC/DC converter).
• Discharge the UltraCap modules using the appropriate discharger.
• Short-circuit the UltraCap modules with a suitable wire jumper.
Before working on the exhaust gas aftertreatment system, close the shutoff valve on the reducing agent
tank. Note that the reducing agent pumps continue to run for a certain period when the engine is stopped.
Disconnect the control equipment from the product.
Use the recommended special tools or suitable equivalents when instructed to do so.

Safety regulations when performing assembly, maintenance, and repair work

Special tools and lifting equipment
Use only proper and calibrated tools. Observe the specified tightening torques during assembly or disassem-
bly.
TIM-ID: 0000040535 - 023

Setting down, lifting and climbing

Carry out work only on assemblies or plants which are properly secured.
Use appropriate lifting equipment for all components. Use all specified attachment points and observe the
center of gravity.
Never stand beneath a suspended load.
Never work on engines or components when they are held in place by lifting equipment.
Make sure components or assemblies are placed on stable surfaces and secured against tilting over or roll-
ing away. Adopt suitable measures to prevent components/tools from falling down.

M015570/05E 2019-07 | Safety | 11

Assume a safe standing position when performing assembly work.
Never use the product as a climbing aid.
When working high on the equipment, always use suitable ladders and work platforms. Special instructions
for outdoor areas: There must be no risk of slipping e.g. due to icing.

Removing, installing and cleanliness

Pay particular attention to cleanliness at all times.
Completely wipe up escaped fluids and lubricants due to the risk of slipping.
Take special care when removing ventilation or plug screws from the product.
Ensure that O-rings are not installed in a slanted/twisted condition.
Carry out appropriate cleaning procedures to clean and inspect components requiring special cleanness
(e.g. components carrying oil, fuel, or air).
Note cooling time for components which are heated for installation or removal (risk of burning).
Ensure that all mounts and dampers are installed correctly.
Remove any accumulation of condensate after assembling chilled components. Coat the components with a
suitable corrosion inhibitor as necessary.

Lines
Ensure that lines for all fluids and lubricants and their connections are clean.
Always seal connections with caps or covers if a line is removed or opened.
Fit new seals when re-installing lines.
Never bend lines and avoid damaging lines, particularly the fuel lines.
Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent contact
with other components. Do not place fuel or oil lines near hot components.

Miscellaneous
Sufficient ventilation must be guaranteed during the work.
Wear a breathing mask offering protection against soot, dust, and mineral fibers (filter class P3) when work-
ing on exhaust components. Clean the work area with a dust extraction machine of class H. Wear protective
gloves and goggles for protection against acidic condensate.
Do not touch elastomeric seals (e.g. Viton sealing rings) with your bare hands if they have a carbonized or
resinous appearance.
Elastomer components (e.g. engine mounts, damping elements, couplings and V-belts) must not be painted.
Only install them after painting the engine or mask them prior to painting.
The following applies to starters with copper-beryllium alloy pinions:
• Wear a respirator mask (filter class P3). Do not blow out the interior of the flywheel housing or the starter
with compressed air. Clean the flywheel housing inside with a class H dust extraction device.
• Observe the safety data sheet.
TIM-ID: 0000040535 - 023

Safety regulations after performing assembly, maintenance, and repair work

Before barring the engine, make sure no one is in the danger zone of the engine.
Check that all access ports/apertures which have been opened to facilitate working are closed again.
All safety devices must be installed and all tools and loose parts must be removed (especially the barring
tool).
Ensure that no unattached parts have been left in/on the product (e.g. including rags and cable straps).
Ensure that the grounding system is properly connected.

12 | Safety | M015570/05E 2019-07

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

Hydraulic installation and removal

Check the function and safe operating condition of tools and fixtures to be used. Use only the specified devi-
ces for hydraulic removal/installation procedures.
Observe the max. permissible push-on pressure specified for the equipment.
Do not attempt to bend or apply force to lines which are under pressure.
Before starting work, pay attention to the following:
• Vent the installation/removal jig, the pumps and the pipework at the relevant designated points.
• For hydraulic installation, screw on the jig with the piston retracted.
• For hydraulic removal, screw on the jig with the piston extended.
For a hydraulic installation/removal jig with central expansion pressure supply, screw spindle into shaft end
until correct sealing is established.
During hydraulic installation and removal of components, ensure that nobody is standing in the immediate
vicinity of the component to be installed/removed.

Working with batteries

Observe the safety instructions of the manufacturer when working on batteries.
Gases released from the battery are explosive. Avoid sparks and naked flames.
Do not allow battery acids to come into contact with skin or clothing.
Wear protective clothing, goggles and protective gloves.
Do not place objects on the battery.
Before connecting the cable to the battery, check the battery polarity. The battery may explode and spray
acid if the battery terminals are connected incorrectly.
TIM-ID: 0000040535 - 023

Working on electrical and electronic assemblies

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

M015570/05E 2019-07 | Safety | 13

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

Working with laser equipment

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

Measuring component dimensions

Workpieces, components and measuring equipment lie in the specified tolerance range at a reference tem-
perature of 20 °C.

TIM-ID: 0000040535 - 023

14 | Safety | M015570/05E 2019-07

1.6 Fire and environmental protection, fluids and lubricants
Fire prevention and fire
Flames, naked light and smoking are prohibited.
In the event of a fire, stop the fuel supply if this is possible without endangering personnel.
The product has hot surfaces that can ignite combustible gases and other substances in the surrounding
area. The operating company must ensure that the product is installed and operated a sufficient distance
away from danger sources and any existing safety instructions or recommendations must be observed. Prod-
ucts that comply with the SOLAS convention do not constitute such a danger.
Depending on the operating and ambient conditions, fuel temperatures above the flash point temperature
are possible in the tank. This can lead to the creation of a dangerous potentially explosive atmosphere in the
tank and makes suitable explosion protection measures necessary.
After working with combustible indirect materials (e.g. cleaning agents), ensure that the area is well ventilat-
ed. The resultant steam/air mixture must be sufficiently diluted to prevent a potentially explosive atmos-
phere.
Immediately eliminate any leaks of indirect materials. Splashes of indirect materials on hot components can
cause fires, therefore keep the product clean at all times. Do not leave rags saturated with fluids and lubri-
cants on the product. Do not store combustible materials near the product.
Incorrect refueling of the reducing agent system with fuel can lead to fires.
Before welding, clean the areas to be welded with a nonflammable fluid. Do not carry out welding work on
pipes and components carrying oil or fuel.
When starting the engine with an external power source, connect the ground lead last and remove it first. To
avoid sparks in the vicinity of the battery, connect the ground lead from the external power source to the
ground lead of the engine or to the ground terminal of the starter.
A risk of fire due to human error or a technical defect can not be completely excluded. Always have suitable
extinguishing agents (fire extinguishers) on hand and familiarize yourself fully with their handling.
For safety-critical environments, check whether further fire prevention measures are necessary.
Toxic substances may be created during a fire. Always wear protective gloves and any other personal protec-
tive equipment that may be necessary when touching any components.

Noise
Wear ear protectors in workplaces with a sound pressure level in excess of 85 dB (A).
Noise can lead to an increased risk of accidents if acoustic signals, warning shouts or sounds indicating dan-
ger are compromised.

Environmental protection and disposal

Dispose of used fluids, lubricants and components in accordance with local regulations.
Within the EU, batteries can be returned free of charge to the manufacturer where they will be properly recy-
TIM-ID: 0000040536 - 020

cled.

Indirect materials, fluids and lubricants

Process materials may also be hazardous or toxic. When handling process materials as well as other chemi-
cal substances, observe the information contained in the associated safety data sheet. The safety data sheet
may be obtained from the relevant manufacturer or from MTU.
Only operating materials approved by the manufacturer must be used in accordance with the Fluids and Lu-
bricants Specifications. Request the most recent edition from the manufacturer.

M015570/05E 2019-07 | Safety | 15

Contamination of indirect materials with reducing agent (e.g. AdBlue®, DEF): Store indirect materials in sepa-
rate containers and use separate drip trays. Even very slight contamination with reducing agent can lead to
malfunctions in sensors and other components.
Used oil contains combustion residues that are harmful to health.
When handling used oil, protective gloves must be worn.
Wash relevant areas after contact with used oil.

Registration, evaluation, approval and limitation of chemicals (REACH

ordinance)
Particularly hazardous substances in our products are compiled in a list:
• For drive systems: www.mtu-online.com/mtu/technische-info → SVHC in acc. with REACH in MTU prod-
ucts
• For power generation: www.mtuonsiteenergy.com/technische-infos → Tools and Downloads → SVHC ACC.
REACH IN MTU PRODUCTS

Compressed air
• Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII and B) out of con-
tainers, risks causing an explosion.
• Wear goggles when blowing dirt off workpieces or blowing away 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 a compressed air device from the supply line. To depressurize
compressed-air lines, shut off the lines first, then release the residual pressure.
• Carrying out a leakage test as specified.

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
• Observe the relevant safety data sheet for all materials.
• 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.
TIM-ID: 0000040536 - 020

• Avoid body contact (eyes, hands).

• Wear protective clothing, protective gloves, closed shoes and safety goggles.
• Make sure that the working area is well ventilated.
• Avoid knocking or jolting the containers, valves and fittings or workpieces in any way.

16 | Safety | M015570/05E 2019-07

Acids/alkaline solutions/reducing agents (e.g. AdBlue®, DEF)
• Observe the relevant safety data sheet for all materials.
• When working with acids and alkaline solutions, wear goggles or face mask, gloves and protective cloth-
ing.
• Do not inhale vapors.
• If reducing agent 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. Consult a doctor as soon as possible.
Contamination of reducing agent with other indirect materials: Store reducing agent in separate contain-
ers and use separate drip trays. Even very slight contamination can result in malfunctions to the exhaust
aftertreatment system.
Incorrect refueling of the reducing agent system with fuel can cause leakages at the gaskets and in the
hoses.
TIM-ID: 0000040536 - 020

M015570/05E 2019-07 | Safety | 17

1.7 Standards for warning notices in the text and highlighted
information
DANGER
In the event of immediate danger.
Consequences: Death, serious or permanent injury!
• Remedial action.

WARNING
In the event of a situation involving potential danger.
Consequences: Death, serious or permanent injury!
• Remedial action.

CAUTION
In the event of a situation involving potential danger.
Consequences: Minor or moderate injuries!
• Remedial action.

NOTICE
In the event of a situation involving potentially adverse effects on the product.
Consequences: Material damage!
• Remedial action.
• Additional product information.

Warning notices
1. This manual with all safety instructions and warning notices must be issued to all personnel involved in oper-
ation, maintenance, repair, assembly, installation, or transportation.
2. The highest level warning notice is used if several hazards apply at the same time. Warnings related to per-
sonal injury shall be considered to include a warning of potential damage.

Highlighted information
Important
This field contains product information which is important or useful for the user.
This information must not refer to hazards related to personal injury or material damage.
TIM-ID: 0000040578 - 006

18 | Safety | M015570/05E 2019-07

2 Transport
2.1 Transport
Transport

Attach the engine at the lifting eyes provided only.

Only use transport and lifting gear approved by MTU.
Take the engine's center of gravity into account.
If the engine is supplied with special aluminum foil packing, lift the engine at the lifting eyes of the bearing
TIM-ID: 0000002613 - 002

pedestal or use a means of transportation which is appropriate for the given weight (forklift truck).
Install the crankshaft locking device and the locking screws for the engine mounts prior to engine transporta-
tion.
Secure the engine against tilting during transport. In particular when going down inclines or ramps, the en-
gine must be secured against moving and tilting.

Setting down the engine following transport

Only set down engine on a firm, level surface.
Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate.

M015570/05E 2019-07 | Transport | 19

Never set down engines onto the oil pan unless expressly permitted by MTU on an engine-specific basis.

TIM-ID: 0000002613 - 002

20 | Transport | M015570/05E 2019-07

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

1 Max. admissible diagonal 2 Center of gravity

pull 10°

Take note of the engine center of gravity

Refer to the installation/arrangement drawings for details of the center of gravity of the system or the center
of gravity of the engine/generator.
TIM-ID: 0000065481 - 003

M015570/05E 2019-07 | Transport | 21

2.3 Crankshaft transport locking device
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Torque wrench, 10–60 Nm F30452769 1
Torque wrench, 60–320 Nm F30452768 1
Ratchet bit F30027340 1
Engine oil

Transport locking device

Note: The locking device on both ends protects the crankshaft bearings from shocks and vibration damage during
engine transport.

Observe the following instructions for removal and installation of the trans-
port locking device:
1. When installing the engine on site, leave the transport locking device installed on both sides of the engine as
long as possible.
2. Never start or bar the engine with the crankshaft transport locking device installed. If the generator is al-
ready mounted on the engine, ensure that the transport locking device of the generator is removed.
3. Prior to every engine transport, reinstall the transport locking device on both sides according to the instruc-
tions. If the engine is to be moved together with the generator, install the transport locking device of the
generator.
4. Always use the screws supplied with or installed in the transport locking device to secure it.

Installing the transport locking

device on driving end (KS)
1. Remove screws (2) and washers (2).
2. Remove guard plate (3) from flywheel hous-
ing (4).

TIM-ID: 0000035999 - 005

22 | Transport | M015570/05E 2019-07

Note: Attach plate (6) only to the upper part of the openings.
3. 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

4. Screw locknut (2) onto screws (1) up to the end of the thread.
5. The long end of retainer (3) must face downwards. Insert retainer (3) through the openings of plate (6).
Note: Retainer (3) must lock only the flywheel, not the ring gear.
6. Install screw (1) into the bore of retainer (3) until the retainer (3) is locked in position.
Note: The screw (1) must be tightened alternately on both sides of the flywheel housing.
7. Tighten screw (1) to specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw M10 Tightening torque (Engine oil) 30 Nm +3 Nm

8. Fit locknut (2) of screw (1) on plate (6) and secure.

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 plate (6).
3. Store the removed parts of the transport
TIM-ID: 0000035999 - 005

locking device carefully for possible reuse.

M015570/05E 2019-07 | Transport | 23

4. Install guard plate (3) on flywheel housing (4).
5. Install screws (2) with washers (1) and tight-
en.

TIM-ID: 0000035999 - 005

24 | Transport | M015570/05E 2019-07

3 General Information
3.1 Engine side and cylinder designations

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

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

M015570/05E 2019-07 | General Information | 25

3.2 Engine layout
Illustration valid for 8/12/16V 4000 Gxy engines

1 Coolant line 9 Starting equipment 17 Lube oil filter

2 Exhaust system 10 Oil filler neck 18 Fuel pump (high pressure)
3 Exhaust turbocharger 11 Mounting / support 19 Gear train
4 Air intake 12 Oil pan 20 Running gear
5 Intercooler 13 Fuel line (high pressure) 21 Coolant system
6 Engine governor 14 Inspection port cover 22 Lube oil system
7 PTO systems, driving end 15 Cylinder head
and free end (coupling) 16 Fuel line (low pressure)
8 Air supply

Engine model designation

Key to the engine model designations 8/12/16V 4000 Gxy
Designation Meaning
8/12/16 Number of cylinders
V Cylinder arrangement: V engine
TIM-ID: 0000009976 - 003

4000 Series
G Application
x Application segment (2, 4, 6, 8)
y Design index (1, 2,...)

26 | General Information | M015570/05E 2019-07

3.3 Sensors and actuators – Overview
Illustrations apply similarly to 8/12/16 V 4000 Gx1.

Item Designation Monitors

1 B6 Engine coolant temperature
2 B9 Charge-air temperature
3 B10 Charge-air pressure
TIM-ID: 0000000966 - 003

M015570/05E 2019-07 | General Information | 27

Item Designation Monitors
1 B13 Crankshaft speed

TIM-ID: 0000000966 - 003

28 | General Information | M015570/05E 2019-07

Item Designation Monitors
1 B26 Charge-air coolant temperature
2 B5 Lube oil pressure
3 B7 Lube oil temperature
TIM-ID: 0000000966 - 003

M015570/05E 2019-07 | General Information | 29

Item Designation Monitors
1 B1 Camshaft speed
2 B34 Fuel pressure in LP fuel system
3 B33 Fuel temperature in HP fuel system
4 B48 Fuel pressure in HP fuel system

The injectors are located underneath the cylinder head covers of the cylinder. Injector replacement and re-
quired tasks (→ Page 116).
TIM-ID: 0000000966 - 003

30 | General Information | M015570/05E 2019-07

4 Technical Data
4.1 8/12/16V 4000 engine data: Standby operation 3D, optimized
fuel consumption
Explanation:
CP Ref. value: Continuous power (CP)
FSP Ref. value: Fuel stop power (FSP)
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power setting)
N Not yet defined value
- Not applicable
X Applicable

REFERENCE CONDITIONS
Engine model 8V 12V 12V 16 V 16 V
4000 G61 4000 G21 4000 G61 4000 G21 4000 G61
Application group 3D 3D 3D 3D 3D
Intake air temperature °C 25 25 25 25 25
Charge-air coolant tempera- °C 55 55 55 55 55
ture
Barometric pressure mbar 1000 1000 1000 1000 1000
Site altitude above sea level m 100 100 100 100 100

POWER-RELATED DATA (power ratings are net brake power to ISO 3046)
Number of cylinders 8 12 12 16 16
Engine rated speed A rpm 1500 1500 1500 1500 1500
Fuel stop power ISO 3046 A kW 985 1330 1465 1760 1940

GENERAL CONDITIONS (for maximum power)

Number of cylinders 8 12 12 16 16
Intake depression (new filter) A mbar 30 30 30 30 30
Intake depression, max. L mbar 50 50 50 50 50
Exhaust gas overpressure A mbar 30 30 30 30 30
Exhaust gas overpressure, L mbar 51 51 51 51 51
TIM-ID: 0000002870 - 001

max.

CONSUMPTION
Number of cylinders 8 12 12 16 16
Lube oil consumption in run-in R % of B 0.5 0.5 0.5 0.5 0.5
state (B = hourly fuel con-
sumption)

M015570/05E 2019-07 | Technical Data | 31

MODEL-RELATED DATA (basic design)
Number of cylinders 8 12 12 16 16
Engine with exhaust turbo- X X X X X
charging (ETC) and charge-air
cooling (CAC)
Exhaust piping, non-cooled X X X X X
Operating method: four-stroke X X X X X
cycle, diesel, single-acting
Combustion method: direct X X X X X
injection
Cooling method: conditioned X X X X X
water
Direction of rotation: c.c.w. X X X X X
(facing driving end)
Number of cylinders 8 12 12 16 16
Cylinder configuration: V an- Degrees 90 90 90 90 90
gle (°)
Bore mm 165 165 165 165 165
Stroke mm 190 190 190 190 190
Cylinder displacement liter 4.06 4.06 4.06 4.06 4.06
Total displacement liter 32.5 48.7 48.7 65.0 65.0
Compression ratio 15.5 15.5 15.5 15.5 15.5
Cylinder heads: single-cylin- X X X X X
der
Cylinder liners: wet, replacea- X X X X X
ble
Number of inlet valves, per 2 2 2 2 2
cylinder
Number of exhaust valves, per 2 2 2 2 2
cylinder
Standard flywheel housing SAE 00 00 00 00 00
connecting flange (engine
main PTO)
Flywheel interface DISC 21" 21" 21" 21" 21"

COMBUSTION AIR / EXHAUST GAS

Number of cylinders 8 12 12 16 16
Charge-air pressure before R bar abs 3.4 3.0 3.2 2.9 3.1
TIM-ID: 0000002870 - 001

cylinder, FSP

COOLING SYSTEM (HT circuit)

Number of cylinders 8 12 12 16 16
Coolant temperature (at en- A °C 95 95 95 95 95
gine outlet to cooling equip-
ment)
Coolant temperature after en- R °C 97 97 97 97 97
gine, alarm

32 | Technical Data | M015570/05E 2019-07

Number of cylinders 8 12 12 16 16
Coolant temperature after en- L °C 99 99 99 99 99
gine, shutdown
Coolant antifreeze content, L % 50 50 50 50 50
max.
Pressure loss in off-engine L bar 0.7 0.7 0.7 0.7 0.7
cooling system, max.

COOLING SYSTEM (LT circuit)

Number of cylinders 8 12 12 16 16
Coolant temperature before A °C 55 55 55 55 55
intercooler (at engine inlet
from cooling equipment)
Coolant antifreeze content, L % 50 50 50 50 50
max.
Pressure loss in off-engine L bar 0.7 0.7 0.7 0.7 0.7
cooling system, max.

LUBE OIL SYSTEM

Number of cylinders 8 12 12 16 16
Lube oil operating tempera- R °C 85 85 85 85 85
ture upstream of engine, from
Lube oil operating tempera- R °C 95 95 95 95 95
ture upstream of engine, to
Lube oil temperature before R °C 95 95 95 95 95
engine, alarm
Lube oil operating pressure R bar 5.0 5.0 5.0 5.0 5.0
upstream of engine, from
Lube oil operating pressure R bar 6.0 6.0 6.0 6.0 6.0
upstream of engine, to
Lube oil pressure before en- R bar 4.5 4.5 4.5 4.5 4.5
gine, alarm
Lube oil pressure before en- L bar 4.0 4.0 4.0 4.0 4.0
gine, shutdown

FUEL SYSTEM
Number of cylinders 8 12 12 16 16
Fuel pressure at engine inlet L bar -0.1 -0.1 -0.1 -0.1 -0.1
connection, min. (when en-
TIM-ID: 0000002870 - 001

gine is starting)
Fuel pressure at engine inlet L bar 1.5 1.5 1.5 1.5 1.5
connection, max. (when en-
gine is starting)

M015570/05E 2019-07 | Technical Data | 33

GENERAL OPERATING DATA
Number of cylinders 8 12 12 16 16
Cold start capability: air tem- R °C 5 5 5 5 5
perature (w/o start aid, w/o
preheating) - (case A)
Coolant preheating, preheat- R °C 32 32 32 32 32
ing temperature (min.)
Firing speed, from R rpm 80 80 80 80 80
Firing speed, to R rpm 120 120 120 120 120

CAPACITIES
Number of cylinders 8 12 12 16 16
Engine coolant capacity (with- R liter 145 160 160 175 175
out cooling equipment)
Charge-air coolant capacity R liter 35 40 40 40 40
Engine oil capacity, initial fill- R liter 145 260 260 290 290
ing (standard oil system) (Op-
tion: max. operating inclina-
tions)
Oil pan capacity, dipstick L liter 85 160 160 160 160
mark min. (standard oil sys-
tem) (Option: max. operating
inclinations)
Oil pan capacity, dipstick L liter 115 200 200 230 230
mark max. (standard oil sys-
tem) (Option: max. operating
inclinations)

WEIGHTS / MAIN DIMENSIONS

Number of cylinders 8 12 12 16 16
Dry engine weight (basic en- R kg 4450 5650 5650 6950 6950
gine as per specified scope of
delivery)

ACOUSTICS
Number of cylinders 8 12 12 16 16
Exhaust noise, unsilenced - R db(A) approx. approx. approx. approx. approx.
FSP, (sound power level LW, 127 127 129 128 129
ISO 6798)
TIM-ID: 0000002870 - 001

Engine surface noise with at- R db(A) approx. approx. approx. approx. approx.
tenuated intake noise (filter) - 122 126 127 126 127
FSP (sound power level LW,
ISO 6798)

34 | Technical Data | M015570/05E 2019-07

4.2 8/12/16V 4000 engine data: Standby operation 3D, optimized
exhaust emission (EPA)
Explanation:
CP Ref. value: Continuous power (CP)
FSP Ref. value: Fuel stop power (FSP)
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power setting)
N Not yet defined value
- Not applicable
X Applicable

REFERENCE CONDITIONS
Engine model 8V 12V 12V 16 V 16 V
4000 G81 4000 G41 4000 G81 4000 G41 4000 G81
Application group 3D 3D 3D 3D 3D
Intake air temperature °C 25 25 25 25 25
Charge-air coolant tempera- °C 55 55 55 55 55
ture
Barometric pressure mbar 1000 1000 1000 1000 1000
Site altitude above sea level m 100 100 100 100 100

POWER-RELATED DATA (power ratings are net brake power to ISO 3046)
Number of cylinders 8 12 12 16 16
Engine rated speed A rpm 1800 1800 1800 1800 1800
Fuel stop power ISO 3046 A kW 1100 1490 1640 1990 2190

GENERAL CONDITIONS (for maximum power)

Number of cylinders 8 12 12 16 16
Intake depression (new filter) A mbar 30 30 30 30 30
Intake depression, max. L mbar 50 50 50 50 50
Exhaust gas overpressure A mbar 30 30 30 30 30
Exhaust gas overpressure, L mbar 51 51 51 51 51
max.

CONSUMPTION
TIM-ID: 0000002919 - 001

Number of cylinders 8 12 12 16 16
Lube oil consumption in run-in R % of B 0.5 0.5 0.5 0.5 0.5
state (B = hourly fuel con-
sumption)

M015570/05E 2019-07 | Technical Data | 35

MODEL-RELATED DATA (basic design)
Number of cylinders 8 12 12 16 16
Engine with exhaust turbo- X X X X X
charging (ETC) and charge-air
cooling (CAC)
Exhaust piping, non-cooled X X X X X
Operating method: four-stroke X X X X X
cycle, diesel, single-acting
Combustion method: direct X X X X X
injection
Cooling method: conditioned X X X X X
water
Direction of rotation: c.c.w. X X X X X
(facing driving end)
Number of cylinders 8 12 12 16 16
Cylinder configuration: V an- Degrees 90 90 90 90 90
gle (°)
Bore mm 165 165 165 165 165
Stroke mm 190 190 190 190 190
Cylinder displacement liter 4.06 4.06 4.06 4.06 4.06
Total displacement liter 32.5 48.7 48.7 65.0 65.0
Compression ratio 15.5 15.5 15.5 15.5 15.5
Cylinder heads: single-cylin- X X X X X
der
Cylinder liners: wet, replacea- X X X X X
ble
Number of inlet valves, per 2 2 2 2 2
cylinder
Number of exhaust valves, per 2 2 2 2 2
cylinder
Standard flywheel housing SAE 00 00 00 00 00
connecting flange (engine
main PTO)
Flywheel interface DISC 21" 21" 21" 21" 21"

COMBUSTION AIR / EXHAUST GAS

Number of cylinders 8 12 12 16 16
Charge-air pressure before R bar abs 3.5 3.1 3.4 3.2 3.4
TIM-ID: 0000002919 - 001

cylinder, FSP

COOLING SYSTEM (HT circuit)

Number of cylinders 8 12 12 16 16
Coolant temperature (at en- A °C 95 95 95 95 95
gine outlet to cooling equip-
ment)
Coolant temperature after en- R °C 97 97 97 97 97
gine, alarm

36 | Technical Data | M015570/05E 2019-07

Number of cylinders 8 12 12 16 16
Coolant temperature after en- L °C 99 99 99 99 99
gine, shutdown
Coolant antifreeze content, L % 50 50 50 50 50
max.
Pressure loss in off-engine L bar 0.7 0.7 0.7 0.7 0.7
cooling system, max.

COOLING SYSTEM (LT circuit)

Number of cylinders 8 12 12 16 16
Coolant temperature before A °C 55 55 55 55 55
intercooler (at engine inlet
from cooling equipment)
Coolant antifreeze content, L % 50 50 50 50 50
max.
Pressure loss in off-engine L bar 0.7 0.7 0.7 0.7 0.7
cooling system, max.

LUBE OIL SYSTEM

Number of cylinders 8 12 12 16 16
Lube oil operating tempera- R °C 85 85 85 85 85
ture upstream of engine, from
Lube oil operating tempera- R °C 95 95 95 95 95
ture upstream of engine, to
Lube oil temperature before R °C 95 95 95 95 95
engine, alarm
Lube oil operating pressure R bar 5.0 5.0 5.0 5.0 5.0
upstream of engine, from
Lube oil operating pressure R bar 6.0 6.0 6.0 6.0 6.0
upstream of engine, to
Lube oil pressure before en- R bar 4.5 4.5 4.5 4.5 4.5
gine, alarm
Lube oil pressure before en- L bar 4.0 4.0 4.0 4.0 4.0
gine, shutdown

FUEL SYSTEM
Number of cylinders 8 12 12 16 16
Fuel pressure at engine inlet L bar -0.1 -0.1 -0.1 -0.1 -0.1
connection, min. (when en-
TIM-ID: 0000002919 - 001

gine is starting)
Fuel pressure at engine inlet L bar 1.5 1.5 1.5 1.5 1.5
connection, max. (when en-
gine is starting)

M015570/05E 2019-07 | Technical Data | 37

GENERAL OPERATING DATA
Number of cylinders 8 12 12 16 16
Cold start capability: air tem- R °C 10 10 10 10 10
perature (w/o start aid, w/o
preheating) - (case A)
Coolant preheating, preheat- R °C 32 32 32 32 32
ing temperature (min.)
Firing speed, from R rpm 80 80 80 80 80
Firing speed, to R rpm 120 120 120 120 120

CAPACITIES
Number of cylinders 8 12 12 16 16
Engine coolant capacity (with- R liter 145 160 160 175 175
out cooling equipment)
Charge-air coolant capacity R liter 35 40 40 40 40
Engine oil capacity, initial fill- R liter 145 260 260 290 290
ing (standard oil system) (Op-
tion: max. operating inclina-
tions)
Oil pan capacity, dipstick L liter 85 160 160 160 160
mark min. (standard oil sys-
tem) (Option: max. operating
inclinations)
Oil pan capacity, dipstick L liter 115 200 200 230 230
mark max. (standard oil sys-
tem) (Option: max. operating
inclinations)

WEIGHTS / MAIN DIMENSIONS

Number of cylinders 8 12 12 16 16
Dry engine weight (basic en- R kg 4450 5650 5650 6950 6950
gine as per specified scope of
delivery)

ACOUSTICS
Number of cylinders 8 12 12 16 16
Exhaust noise, unsilenced - R db(A) approx. approx. approx. approx. approx.
FSP, (sound power level LW, 129 128 130 129 129
ISO 6798)
TIM-ID: 0000002919 - 001

Engine surface noise with at- R db(A) approx. approx. approx. approx. approx.
tenuated intake noise (filter) - 125 128 127 127 129
FSP (sound power level LW,
ISO 6798)

38 | Technical Data | M015570/05E 2019-07

4.3 8/12/16V 4000 engine data: Continuous operation, limited 3C,
optimized fuel consumption
Explanation:
CP Ref. value: Continuous power (CP)
FSP Ref. value: Fuel stop power (FSP)
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power setting)
N Not yet defined value
- Not applicable
X Applicable

REFERENCE CONDITIONS
Engine model 8V 12V 12V 16 V 16 V
4000 G61 4000 G21 4000 G61 4000 G21 4000 G61
Application group 3C 3C 3C 3C 3C
Intake air temperature °C 25 25 25 25 25
Charge-air coolant tempera- °C 55 55 55 55 55
ture
Barometric pressure mbar 1000 1000 1000 1000 1000
Site altitude above sea level m 100 100 100 100 100

POWER-RELATED DATA (power ratings are net brake power to ISO 3046)
Number of cylinders 8 12 12 16 16
Engine rated speed A rpm 1500 1500 1500 1500 1500
Fuel stop power ISO 3046 A kW 985 1326 1463 1760 1936

GENERAL CONDITIONS (for maximum power)

Number of cylinders 8 12 12 16 16
Intake depression (new filter) A mbar 30 30 30 30 30
Intake depression, max. L mbar 50 50 50 50 50
Exhaust gas overpressure A mbar 30 30 30 30 30
Exhaust gas overpressure, L mbar 51 51 51 51 51
max.

MODEL-RELATED DATA (basic design)

TIM-ID: 0000002952 - 001

Number of cylinders 8 12 12 16 16
Engine with exhaust turbo- X X X X X
charging (ETC) and charge-air
cooling (CAC)
Number of cylinders 8 12 12 16 16
Cylinder configuration: V an- Degrees 90 90 90 90 90
gle (°)
Bore mm 165 165 165 165 165

M015570/05E 2019-07 | Technical Data | 39

Number of cylinders 8 12 12 16 16
Stroke mm 190 190 190 190 190
Cylinder displacement liter 4.06 4.06 4.06 4.06 4.06
Total displacement liter 32.5 48.7 48.7 65.0 65.0
Compression ratio 15.5 15.5 15.5 15.5 15.5
Number of inlet valves, per 2 2 2 2 2
cylinder
Number of exhaust valves, per 2 2 2 2 2
cylinder
Standard flywheel housing SAE 00 00 00 00 00
connecting flange (engine
main PTO)

COOLING SYSTEM (HT circuit)

Number of cylinders 8 12 12 16 16
Coolant temperature (at en- A °C 95 95 95 95 95
gine outlet to cooling equip-
ment)
Coolant temperature after en- R °C 97 97 97 97 97
gine, alarm
Coolant temperature after en- L °C 99 99 99 99 99
gine, shutdown
Coolant antifreeze content, L % 50 50 50 50 50
max.
Pressure loss in off-engine L bar 0.7 0.7 0.7 0.7 0.7
cooling system, max.

COOLING SYSTEM (LT circuit)

Number of cylinders 8 12 12 16 16
Coolant temperature before A °C 55 55 55 55 55
intercooler (at engine inlet
from cooling equipment)
Coolant antifreeze content, L % 50 50 50 50 50
max.
Pressure loss in off-engine L bar 0.7 0.7 0.7 0.7 0.7
cooling system, max.

LUBE OIL SYSTEM

TIM-ID: 0000002952 - 001

Number of cylinders 8 12 12 16 16
Lube oil operating tempera- R °C 85 85 85 85 85
ture upstream of engine, from
Lube oil operating tempera- R °C 95 95 95 95 95
ture upstream of engine, to
Lube oil temperature before R °C 95 95 95 95 95
engine, alarm
Lube oil operating pressure R bar 5.0 5.0 5.0 5.0 5.0
upstream of engine, from

40 | Technical Data | M015570/05E 2019-07

Number of cylinders 8 12 12 16 16
Lube oil operating pressure R bar 6.0 6.0 6.0 6.0 6.0
upstream of engine, to
Lube oil pressure before en- R bar 4.5 4.5 4.5 4.5 4.5
gine, alarm
Lube oil pressure before en- L bar 4.0 4.0 4.0 4.0 4.0
gine, shutdown

FUEL SYSTEM
Number of cylinders 8 12 12 16 16
Fuel pressure at engine inlet L bar -0.1 -0.1 -0.1 -0.1 -0.1
connection, min. (when en-
gine is starting)
Fuel pressure at engine inlet L bar 1.5 1.5 1.5 1.5 1.5
connection, max. (when en-
gine is starting)

GENERAL OPERATING DATA

Number of cylinders 8 12 12 16 16
Cold start capability: air tem- R °C 5 5 5 5 5
perature (w/o start aid, w/o
preheating) - (case A)
Coolant preheating, preheat- R °C 32 32 32 32 32
ing temperature (min.)
Firing speed, from R rpm 80 80 80 80 80
Firing speed, to R rpm 120 120 120 120 120

CAPACITIES
Number of cylinders 8 12 12 16 16
Engine coolant capacity (with- R liter 145 160 160 175 175
out cooling equipment)
Charge-air coolant capacity R liter 35 40 40 40 40
Engine oil capacity, initial fill- R liter 145 260 260 290 290
ing (standard oil system) (Op-
tion: max. operating inclina-
tions)
Oil pan capacity, dipstick L liter 85 160 160 160 160
mark min. (standard oil sys-
tem) (Option: max. operating
TIM-ID: 0000002952 - 001

inclinations)
Oil pan capacity, dipstick L liter 115 200 200 230 230
mark max. (standard oil sys-
tem) (Option: max. operating
inclinations)

M015570/05E 2019-07 | Technical Data | 41

ACOUSTICS
Number of cylinders 8 12 12 16 16
Exhaust noise, unsilenced - R db(A) approx. approx. approx. approx. approx.
CP (sound power level LW, 126 126 129 127 128
ISO 6798)
Engine surface noise with at- R db(A) approx. approx. approx. approx. approx.
tenuated intake noise (filter) - 124 123 127 126 126
CP (sound power level LW,
ISO 6798)

TIM-ID: 0000002952 - 001

42 | Technical Data | M015570/05E 2019-07

4.4 8/12/16V 4000 engine data: Continuous operation, limited,
3C, optimized exhaust emission ("TA-Luft")
Explanation:
CP Ref. value: Continuous power (CP)
FSP Ref. value: Fuel stop power (FSP)
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power setting)
N Not yet defined value
- Not applicable
X Applicable

REFERENCE CONDITIONS
Engine model 8V 12V 12V 16 V 16 V
4000 G61 4000 G21 4000 G61 4000 G21 4000 G61
Application group 3C 3C 3C 3C 3C
Intake air temperature °C 25 25 25 25 25
Charge-air coolant tempera- °C 55 55 55 55 55
ture
Barometric pressure mbar 1000 1000 1000 1000 1000
Site altitude above sea level m 100 100 100 100 100

POWER-RELATED DATA (power ratings are net brake power to ISO 3046)
Number of cylinders 8 12 12 16 16
Engine rated speed A rpm 1500 1500 1500 1500 1500
Fuel stop power ISO 3046 A kW 985 1326 1463 1760 1936

GENERAL CONDITIONS (for maximum power)

Number of cylinders 8 12 12 16 16
Intake depression (new filter) A mbar 30 30 30 30 30
Intake depression, max. L mbar 50 50 50 50 50
Exhaust gas overpressure A mbar 30 30 30 30 30
Exhaust gas overpressure, L mbar 51 51 51 51 51
max.

MODEL-RELATED DATA (basic design)

TIM-ID: 0000002978 - 001

Number of cylinders 8 12 12 16 16
Engine with exhaust turbo- X X X X X
charging (ETC) and charge-air
cooling (CAC)
Number of cylinders 8 12 12 16 16
Cylinder configuration: V an- Degrees 90 90 90 90 90
gle (°)
Bore mm 165 165 165 165 165

M015570/05E 2019-07 | Technical Data | 43

Number of cylinders 8 12 12 16 16
Stroke mm 190 190 190 190 190
Cylinder displacement liter 4.06 4.06 4.06 4.06 4.06
Total displacement liter 32.5 48.7 48.7 65.0 65.0
Compression ratio 15.5 15.5 15.5 15.5 15.5
Number of inlet valves, per 2 2 2 2 2
cylinder
Number of exhaust valves, per 2 2 2 2 2
cylinder
Standard flywheel housing SAE 00 00 00 00 00
connecting flange (engine
main PTO)

COOLING SYSTEM (HT circuit)

Number of cylinders 8 12 12 16 16
Coolant temperature (at en- A °C 95 95 95 95 95
gine outlet to cooling equip-
ment)
Coolant temperature after en- R °C 97 97 97 97 97
gine, alarm
Coolant temperature after en- L °C 99 99 99 99 99
gine, shutdown
Coolant antifreeze content, L % 50 50 50 50 50
max.
Pressure loss in off-engine L bar 0.7 0.7 0.7 0.7 0.7
cooling system, max.

COOLING SYSTEM (LT circuit)

Number of cylinders 8 12 12 16 16
Coolant temperature before A °C 55 55 55 55 55
intercooler (at engine inlet
from cooling equipment)
Coolant antifreeze content, L % 50 50 50 50 50
max.
Pressure loss in off-engine L bar 0.7 0.7 0.7 0.7 0.7
cooling system, max.

LUBE OIL SYSTEM

TIM-ID: 0000002978 - 001

Number of cylinders 8 12 12 16 16
Lube oil operating tempera- R °C 85 85 85 85 85
ture upstream of engine, from
Lube oil operating tempera- R °C 95 95 95 95 95
ture upstream of engine, to
Lube oil temperature before R °C 95 95 95 95 95
engine, alarm
Lube oil operating pressure R bar 5.0 5.0 5.0 5.0 5.0
upstream of engine, from

44 | Technical Data | M015570/05E 2019-07

Number of cylinders 8 12 12 16 16
Lube oil operating pressure R bar 6.0 6.0 6.0 6.0 6.0
upstream of engine, to
Lube oil pressure before en- R bar 4.5 4.5 4.5 4.5 4.5
gine, alarm
Lube oil pressure before en- L bar 4.0 4.0 4.0 4.0 4.0
gine, shutdown

FUEL SYSTEM
Number of cylinders 8 12 12 16 16
Fuel pressure at engine inlet L bar -0.1 -0.1 -0.1 -0.1 -0.1
connection, min. (when en-
gine is starting)
Fuel pressure at engine inlet L bar 1.5 1.5 1.5 1.5 1.5
connection, max. (when en-
gine is starting)

GENERAL OPERATING DATA

Number of cylinders 8 12 12 16 16
Cold start capability: air tem- R °C 5 5 5 5 5
perature (w/o start aid, w/o
preheating) - (case A)
Coolant preheating, preheat- R °C 32 32 32 32 32
ing temperature (min.)
Firing speed, from R rpm 80 80 80 80 80
Firing speed, to R rpm 120 120 120 120 120

CAPACITIES
Number of cylinders 8 12 12 16 16
Engine coolant capacity (with- R liter 145 160 160 175 175
out cooling equipment)
Charge-air coolant capacity R liter 35 40 40 40 40
Engine oil capacity, initial fill- R liter 145 260 260 290 290
ing (standard oil system) (Op-
tion: max. operating inclina-
tions)
Oil pan capacity, dipstick L liter 85 160 160 160 160
mark min. (standard oil sys-
tem) (Option: max. operating
TIM-ID: 0000002978 - 001

inclinations)
Oil pan capacity, dipstick L liter 115 200 200 230 230
mark max. (standard oil sys-
tem) (Option: max. operating
inclinations)

M015570/05E 2019-07 | Technical Data | 45

ACOUSTICS
Number of cylinders 8 12 12 16 16
Exhaust noise, unsilenced - R db(A) approx. approx. approx. approx. approx.
CP (sound power level LW, 128 127 127 128 129
ISO 6798)
Engine surface noise with at- R db(A) approx. approx. approx. approx. approx.
tenuated intake noise (filter) - 123 126 126 126 127
CP (sound power level LW,
ISO 6798)

TIM-ID: 0000002978 - 001

46 | Technical Data | M015570/05E 2019-07

4.5 8/12/16V 4000 engine data: Continuous operation, variable
3B, optimized fuel consumption
Explanation:
CP Ref. value: Continuous power (CP)
FSP Ref. value: Fuel stop power (FSP)
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power setting)
N Not yet defined value
- Not applicable
X Applicable

REFERENCE CONDITIONS
Engine model 8V 12V 12V 16 V 16 V
4000 G61 4000 G21 4000 G61 4000 G21 4000 G61
Application group 3B 3B 3B 3B 3B
Intake air temperature °C 25 25 25 25 25
Charge-air coolant tempera- °C 55 55 55 55 55
ture
Barometric pressure mbar 1000 1000 1000 1000 1000
Site altitude above sea level m 100 100 100 100 100

POWER-RELATED DATA (power ratings are net brake power to ISO 3046)
Number of cylinders 8 12 12 16 16
Engine rated speed A rpm 1500 1500 1500 1500 1500
Continuous power ISO 3046 A kW 895 1205 1330 1600 1760
(10% overload capability) (de-
sign power DIN 6280, ISO
8528)

GENERAL CONDITIONS (for maximum power)

Number of cylinders 8 12 12 16 16
Intake depression (new filter) A mbar 30 30 30 30 30
Intake depression, max. L mbar 50 50 50 50 50
Exhaust gas overpressure A mbar 30 30 30 30 30
Exhaust gas overpressure, L mbar 51 51 51 51 51
TIM-ID: 0000003001 - 001

max.

CONSUMPTION
Number of cylinders 8 12 12 16 16
Lube oil consumption in run-in R % of B 0.5 0.5 0.5 0.5 0.5
state (B = hourly fuel con-
sumption)

M015570/05E 2019-07 | Technical Data | 47

MODEL-RELATED DATA (basic design)
Number of cylinders 8 12 12 16 16
Engine with exhaust turbo- X X X X X
charging (ETC) and charge-air
cooling (CAC)
Exhaust piping, non-cooled X X X X X
Operating method: four-stroke X X X X X
cycle, diesel, single-acting
Combustion method: direct X X X X X
injection
Cooling system: conditioned X X X X X
water
Direction of rotation: c.c.w. X X X X X
(facing driving end)
Number of cylinders 8 12 12 16 16
Cylinder configuration: V an- Degrees 90 90 90 90 90
gle (°)
Bore mm 165 165 165 165 165
Stroke mm 190 190 190 190 190
Cylinder displacement liter 4.06 4.06 4.06 4.06 4.06
Total displacement liter 32.5 48.7 48.7 65.0 65.0
Compression ratio 15.5 15.5 15.5 15.5 15.5
Cylinder heads: single-cylin- X X X X X
der
Cylinder liners: wet, replacea- X X X X X
ble
Number of inlet valves, per 2 2 2 2 2
cylinder
Number of exhaust valves, per 2 2 2 2 2
cylinder
Standard flywheel housing SAE 00 00 00 00 00
connecting flange (engine
main PTO)
Flywheel interface DISC 21" 21" 21" 21" 21"

COMBUSTION AIR / EXHAUST GAS

Number of cylinders 8 12 12 16 16
Charge-air pressure before R bar abs 3.1 2.8 3.0 2.7 2.9
TIM-ID: 0000003001 - 001

cylinder - CP

COOLING SYSTEM (HT circuit)

Number of cylinders 8 12 12 16 16
Coolant temperature (at en- A °C 95 95 95 95 95
gine outlet to cooling equip-
ment)
Coolant temperature after en- R °C 97 97 97 97 97
gine, alarm

48 | Technical Data | M015570/05E 2019-07

Number of cylinders 8 12 12 16 16
Coolant temperature after en- L °C 99 99 99 99 99
gine, shutdown
Coolant antifreeze content, L % 50 50 50 50 50
max.
Pressure loss in off-engine L bar 0.7 0.7 0.7 0.7 0.7
cooling system, max.

COOLING SYSTEM (LT circuit)

Number of cylinders 8 12 12 16 16
Coolant temperature before A °C 55 55 55 55 55
intercooler (at engine inlet
from cooling equipment)
Coolant antifreeze content, L % 50 50 50 50 50
max.
Pressure loss in off-engine L bar 0.7 0.7 0.7 0.7 0.7
cooling system, max.

LUBE OIL SYSTEM

Number of cylinders 8 12 12 16 16
Lube oil operating tempera- R °C 85 85 85 85 85
ture upstream of engine, from
Lube oil operating tempera- R °C 95 95 95 95 95
ture upstream of engine, to
Lube oil temperature before R °C 95 95 95 95 95
engine, alarm
Lube oil operating pressure R bar 5.0 5.0 5.0 5.0 5.0
upstream of engine, from
Lube oil operating pressure R bar 6.0 6.0 6.0 6.0 6.0
upstream of engine, to
Lube oil pressure before en- R bar 4.5 4.5 4.5 4.5 4.5
gine, alarm
Lube oil pressure before en- L bar 4.0 4.0 4.0 4.0 4.0
gine, shutdown

FUEL SYSTEM
Number of cylinders 8 12 12 16 16
Fuel pressure at engine inlet L bar -0.1 -0.1 -0.1 -0.1 -0.1
connection, min. (when en-
TIM-ID: 0000003001 - 001

gine is starting)
Fuel pressure at engine inlet L bar 1.5 1.5 1.5 1.5 1.5
connection, max. (when en-
gine is starting)

M015570/05E 2019-07 | Technical Data | 49

GENERAL OPERATING DATA
Number of cylinders 8 12 12 16 16
Cold start capability: air tem- R °C 5 5 5 5 5
perature (w/o start aid, w/o
preheating) - (case A)
Coolant preheating, preheat- R °C 32 32 32 32 32
ing temperature (min.)
Firing speed, from R rpm 80 80 80 80 80
Firing speed, to R rpm 120 120 120 120 120

CAPACITIES
Number of cylinders 8 12 12 16 16
Engine coolant capacity (with- R liter 145 160 160 175 175
out cooling equipment)
Charge-air coolant capacity R liter 35 40 40 40 40
Engine oil capacity, initial fill- R liter 145 260 260 290 290
ing (standard oil system) (Op-
tion: max. operating inclina-
tions)
Oil pan capacity, dipstick L liter 85 160 160 160 160
mark min. (standard oil sys-
tem) (Option: max. operating
inclinations)
Oil pan capacity, dipstick L liter 115 200 200 230 230
mark max. (standard oil sys-
tem) (Option: max. operating
inclinations)

WEIGHTS / MAIN DIMENSIONS

Number of cylinders 8 12 12 16 16
Dry engine weight (basic en- R kg 4450 5650 5650 6950 6950
gine as per specified scope of
delivery)

ACOUSTICS
Number of cylinders 8 12 12 16 16
Exhaust noise, unsilenced - R db(A) approx. approx. approx. approx. approx.
CP (sound power level LW, 126 126 127 127 128
ISO 6798)
TIM-ID: 0000003001 - 001

Engine surface noise with at- R db(A) approx. approx. approx. approx. approx.
tenuated intake noise (filter) - 124 123 126 126 126
CP (sound power level LW,
ISO 6798)

50 | Technical Data | M015570/05E 2019-07

4.6 8/12/16V 4000 engine data: Continuous operation, variable
3B, optimized exhaust emission ("TA-Luft")
Explanation:
CP Ref. value: Continuous power (CP)
FSP Ref. value: Fuel stop power (FSP)
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power setting)
N Not yet defined value
- Not applicable
X Applicable

REFERENCE CONDITIONS
Engine model 8V 12V 12V 16 V 16 V
4000 G61 4000 G21 4000 G61 4000 G21 4000 G61
Application group 3B 3B 3B 3B 3B
Intake air temperature °C 25 25 25 25 25
Charge-air coolant tempera- °C 55 55 55 55 55
ture
Barometric pressure mbar 1000 1000 1000 1000 1000
Site altitude above sea level m 100 100 100 100 100

POWER-RELATED DATA (power ratings are net brake power to ISO 3046)
Number of cylinders 8 12 12 16 16
Engine rated speed A rpm 1500 1500 1500 1500 1500
Continuous power ISO 3046 A kW 895 1205 1330 1600 1760
(10% overload capability) (de-
sign power DIN 6280, ISO
8528)

GENERAL CONDITIONS (for maximum power)

Number of cylinders 8 12 12 16 16
Intake depression (new filter) A mbar 30 30 30 30 30
Intake depression, max. L mbar 50 50 50 50 50
Exhaust gas overpressure A mbar 30 30 30 30 30
Exhaust gas overpressure, L mbar 51 51 51 51 51
TIM-ID: 0000003017 - 001

max.

CONSUMPTION
Number of cylinders 8 12 12 16 16
Lube oil consumption in run-in R % of B 0.5 0.5 0.5 0.5 0.5
state (B = hourly fuel con-
sumption)

M015570/05E 2019-07 | Technical Data | 51

MODEL-RELATED DATA (basic design)
Number of cylinders 8 12 12 16 16
Engine with exhaust turbo- X X X X X
charging (ETC) and charge-air
cooling (CAC)
Exhaust piping, non-cooled X X X X X
Operating method: four-stroke X X X X X
cycle, diesel, single-acting
Combustion method: direct X X X X X
injection
Cooling system: conditioned X X X X X
water
Direction of rotation: c.c.w. X X X X X
(facing driving end)
Number of cylinders 8 12 12 16 16
Cylinder configuration: V an- Degrees 90 90 90 90 90
gle (°)
Bore mm 165 165 165 165 165
Stroke mm 190 190 190 190 190
Cylinder displacement liter 4.06 4.06 4.06 4.06 4.06
Total displacement liter 32.5 48.7 48.7 65.0 65.0
Compression ratio 15.5 15.5 15.5 15.5 15.5
Cylinder heads: single-cylin- X X X X X
der
Cylinder liners: wet, replacea- X X X X X
ble
Number of inlet valves, per 2 2 2 2 2
cylinder
Number of exhaust valves, per 2 2 2 2 2
cylinder
Standard flywheel housing SAE 00 00 00 00 00
connecting flange (engine
main PTO)
Flywheel interface DISC 21" 21" 21" 21" 21"

COMBUSTION AIR / EXHAUST GAS

Number of cylinders 8 12 12 16 16
Charge-air pressure before R bar abs 3.5 3.3 3.5 3.1 3.3
TIM-ID: 0000003017 - 001

cylinder - CP

COOLING SYSTEM (HT circuit)

Number of cylinders 8 12 12 16 16
Coolant temperature (at en- A °C 95 95 95 95 95
gine outlet to cooling equip-
ment)
Coolant temperature after en- R °C 97 97 97 97 97
gine, alarm

52 | Technical Data | M015570/05E 2019-07

Number of cylinders 8 12 12 16 16
Coolant temperature after en- L °C 99 99 99 99 99
gine, shutdown
Coolant antifreeze content, L % 50 50 50 50 50
max.
Pressure loss in off-engine L bar 0.7 0.7 0.7 0.7 0.7
cooling system, max.

COOLING SYSTEM (LT circuit)

Number of cylinders 8 12 12 16 16
Coolant temperature before A °C 55 55 55 55 55
intercooler (at engine inlet
from cooling equipment)
Coolant antifreeze content, L % 50 50 50 50 50
max.
Pressure loss in off-engine L bar 0.7 0.7 0.7 0.7 0.7
cooling system, max.

LUBE OIL SYSTEM

Number of cylinders 8 12 12 16 16
Lube oil operating tempera- R °C 85 85 85 85 85
ture upstream of engine, from
Lube oil operating tempera- R °C 95 95 95 95 95
ture upstream of engine, to
Lube oil temperature before R °C 95 95 95 95 95
engine, alarm
Lube oil operating pressure R bar 5.0 5.0 5.0 5.0 5.0
upstream of engine, from
Lube oil operating pressure R bar 6.0 6.0 6.0 6.0 6.0
upstream of engine, to
Lube oil pressure before en- R bar 4.5 4.5 4.5 4.5 4.5
gine, alarm
Lube oil pressure before en- L bar 4.0 4.0 4.0 4.0 4.0
gine, shutdown

FUEL SYSTEM
Number of cylinders 8 12 12 16 16
Fuel pressure at engine inlet L bar -0.1 -0.1 -0.1 -0.1 -0.1
connection, min. (when en-
TIM-ID: 0000003017 - 001

gine is starting)
Fuel pressure at engine inlet L bar 1.5 1.5 1.5 1.5 1.5
connection, max. (when en-
gine is starting)

M015570/05E 2019-07 | Technical Data | 53

GENERAL OPERATING DATA
Number of cylinders 8 12 12 16 16
Cold start capability: air tem- R °C 5 5 5 5 5
perature (w/o start aid, w/o
preheating) - (case A)
Coolant preheating, preheat- R °C 32 32 32 32 32
ing temperature (min.)
Firing speed, from R rpm 80 80 80 80 80
Firing speed, to R rpm 120 120 120 120 120

CAPACITIES
Number of cylinders 8 12 12 16 16
Engine coolant capacity (with- R liter 145 160 160 175 175
out cooling equipment)
Charge-air coolant capacity R liter 35 40 40 40 40
Engine oil capacity, initial fill- R liter 145 260 260 290 290
ing (standard oil system) (Op-
tion: max. operating inclina-
tions)
Oil pan capacity, dipstick L liter 85 160 160 160 160
mark min. (standard oil sys-
tem) (Option: max. operating
inclinations)
Oil pan capacity, dipstick L liter 115 200 200 230 230
mark max. (standard oil sys-
tem) (Option: max. operating
inclinations)

WEIGHTS / MAIN DIMENSIONS

Number of cylinders 8 12 12 16 16
Dry engine weight (basic en- R kg 4450 5650 5650 6950 6950
gine as per specified scope of
delivery)

ACOUSTICS
Number of cylinders 8 12 12 16 16
Exhaust noise, unsilenced - R db(A) approx. approx. approx. approx. approx.
CP (sound power level LW, 128 126 127 127 128
ISO 6798)
TIM-ID: 0000003017 - 001

Engine surface noise with at- R db(A) approx. approx. approx. approx. approx.
tenuated intake noise (filter) - 123 123 126 126 126
CP (sound power level LW,
ISO 6798)

54 | Technical Data | M015570/05E 2019-07

4.7 8/12/16V 4000 engine data: Continuous operation, variable
3B, optimized exhaust emission (EPA)
Explanation:
CP Ref. value: Continuous power (CP)
FSP Ref. value: Fuel stop power (FSP)
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power setting)
N Not yet defined value
- Not applicable
X Applicable

REFERENCE CONDITIONS
Engine model 8V 12V 12V 16 V 16 V
4000 G81 4000 G41 4000 G81 4000 G41 4000 G81
Application group 3B 3B 3B 3B 3B
Intake air temperature °C 25 25 25 25 25
Charge-air coolant tempera- °C 55 55 55 55 55
ture
Barometric pressure mbar 1000 1000 1000 1000 1000
Site altitude above sea level m 100 100 100 100 100

POWER-RELATED DATA (power ratings are net brake power to ISO 3046)
Number of cylinders 8 12 12 16 16
Engine rated speed A rpm 1800 1800 1800 1800 1800
Continuous power ISO 3046 A kW 1000 1355 1490 1810 1990
(10% overload capability) (de-
sign power DIN 6280, ISO
8528)

GENERAL CONDITIONS (for maximum power)

Number of cylinders 8 12 12 16 16
Intake depression (new filter) A mbar 30 30 30 30 30
Intake depression, max. L mbar 50 50 50 50 50
Exhaust gas overpressure A mbar 30 30 30 30 30
Exhaust gas overpressure, L mbar 51 51 51 51 51
TIM-ID: 0000003031 - 001

max.

CONSUMPTION
Number of cylinders 8 12 12 16 16
Lube oil consumption in run-in R % of B 0.5 0.5 0.5 0.5 0.5
state (B = hourly fuel con-
sumption)

M015570/05E 2019-07 | Technical Data | 55

MODEL-RELATED DATA (basic design)
Number of cylinders 8 12 12 16 16
Engine with exhaust turbo- X X X X X
charging (ETC) and charge-air
cooling (CAC)
Exhaust piping, non-cooled X X X X X
Operating method: four-stroke X X X X X
cycle, diesel, single-acting
Combustion method: direct X X X X X
injection
Cooling method: conditioned X X X X X
water
Direction of rotation: c.c.w. X X X X X
(facing driving end)
Number of cylinders 8 12 12 16 16
Cylinder configuration: V an- Degrees 90 90 90 90 90
gle (°)
Bore mm 165 165 165 165 165
Stroke mm 190 190 190 190 190
Cylinder displacement liter 4.06 4.06 4.06 4.06 4.06
Total displacement liter 32.5 48.7 48.7 65.0 65.0
Compression ratio 15.5 15.5 15.5 15.5 15.5
Cylinder heads: single-cylin- X X X X X
der
Cylinder liners: wet, replacea- X X X X X
ble
Number of inlet valves, per 2 2 2 2 2
cylinder
Number of exhaust valves, per 2 2 2 2 2
cylinder
Standard flywheel housing SAE 00 00 00 00 00
connecting flange (engine
main PTO)
Flywheel interface DISC 21" 21" 21" 21" 21"

COMBUSTION AIR / EXHAUST GAS

Number of cylinders 8 12 12 16 16
Charge-air pressure before R bar abs 2.9 2.9 3.1 3.0 3.2
TIM-ID: 0000003031 - 001

cylinder - CP

COOLING SYSTEM (HT circuit)

Number of cylinders 8 12 12 16 16
Coolant temperature (at en- A °C 95 95 95 95 95
gine outlet to cooling equip-
ment)
Coolant temperature after en- R °C 97 97 97 97 97
gine, alarm

56 | Technical Data | M015570/05E 2019-07

Number of cylinders 8 12 12 16 16
Coolant temperature after en- L °C 99 99 99 99 99
gine, shutdown
Coolant antifreeze content, L % 50 50 50 50 50
max.
Pressure loss in off-engine L bar 0.7 0.7 0.7 0.7 0.7
cooling system, max.

COOLING SYSTEM (LT circuit)

Number of cylinders 8 12 12 16 16
Coolant temperature before A °C 55 55 55 55 55
intercooler (at engine inlet
from cooling equipment)
Coolant antifreeze content, L % 50 50 50 50 50
max.
Pressure loss in off-engine L bar 0.7 0.7 0.7 0.7 0.7
cooling system, max.

LUBE OIL SYSTEM

Number of cylinders 8 12 12 16 16
Lube oil operating tempera- R °C 85 85 85 85 85
ture upstream of engine, from
Lube oil operating tempera- R °C 95 95 95 95 95
ture upstream of engine, to
Lube oil temperature before R °C 95 95 95 95 95
engine, alarm
Lube oil operating pressure R bar 5.0 5.0 5.0 5.0 5.0
upstream of engine, from
Lube oil operating pressure R bar 6.0 6.0 6.0 6.0 6.0
upstream of engine, to
Lube oil pressure before en- R bar 4.5 4.5 4.5 4.5 4.5
gine, alarm
Lube oil pressure before en- L bar 4.0 4.0 4.0 4.0 4.0
gine, shutdown

FUEL SYSTEM
Number of cylinders 8 12 12 16 16
Fuel pressure at engine inlet L bar -0.1 -0.1 -0.1 -0.1 -0.1
connection, min. (when en-
TIM-ID: 0000003031 - 001

gine is starting)
Fuel pressure at engine inlet L bar 1.5 1.5 1.5 1.5 1.5
connection, max. (when en-
gine is starting)

M015570/05E 2019-07 | Technical Data | 57

GENERAL OPERATING DATA
Number of cylinders 8 12 12 16 16
Cold start capability: air tem- R °C 10 10 10 10 10
perature (w/o start aid, w/o
preheating) - (case A)
Coolant preheating, preheat- R °C 32 32 32 32 32
ing temperature (min.)
Firing speed, from R rpm 80 80 80 80 80
Firing speed, to R rpm 120 120 120 120 120

CAPACITIES
Number of cylinders 8 12 12 16 16
Engine coolant capacity (with- R liter 145 160 160 175 175
out cooling equipment)
Charge-air coolant capacity R liter 35 40 40 40 40
Engine oil capacity, initial fill- R liter 145 260 260 290 290
ing (standard oil system) (Op-
tion: max. operating inclina-
tions)
Oil pan capacity, dipstick L liter 85 160 160 160 160
mark min. (standard oil sys-
tem) (Option: max. operating
inclinations)
Oil pan capacity, dipstick L liter 115 200 200 230 230
mark max. (standard oil sys-
tem) (Option: max. operating
inclinations)

WEIGHTS / MAIN DIMENSIONS

Number of cylinders 8 12 12 16 16
Dry engine weight (basic en- R kg 4450 5650 5650 6950 6950
gine as per specified scope of
delivery)

ACOUSTICS
Number of cylinders 8 12 12 16 16
Exhaust noise, unsilenced - R db(A) approx. approx. approx. approx. approx.
CP (sound power level LW, 127 127 128 128 129
ISO 6798)
TIM-ID: 0000003031 - 001

Engine surface noise with at- R db(A) approx. approx. approx. approx. approx.
tenuated intake noise (filter) - 123 126 128 126 127
CP (sound power level LW,
ISO 6798)

58 | Technical Data | M015570/05E 2019-07

4.8 8/12/16V 4000 engine data: Continuous operation, unlimited
3A, optimized fuel consumption
Explanation:
CP Ref. value: Continuous power (CP)
FSP Ref. value: Fuel stop power (FSP)
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power setting)
N Not yet defined value
- Not applicable
X Applicable

REFERENCE CONDITIONS
Engine model 8V 12V 16 V
4000 G61 4000 G61 4000 G61
Application group 3A 3A 3A
Intake air temperature °C 25 25 25
Charge-air coolant temperature °C 55 55 55
Barometric pressure mbar 1000 1000 1000
Site altitude above sea level m 100 100 100

POWER-RELATED DATA (power ratings are net brake power to ISO 3046)
Number of cylinders 8 12 16
Engine rated speed A rpm 1500 1500 1500
Continuous power ISO 3046 (10% overload capability) A kW 735 1095 1450
(design power DIN 6280, ISO 8528)

GENERAL CONDITIONS (for maximum power)

Number of cylinders 8 12 16
Intake depression (new filter) A mbar 30 30 30
Intake depression, max. L mbar 50 50 50
Exhaust gas overpressure A mbar 30 30 30
Exhaust gas overpressure, max. L mbar 51 51 51

CONSUMPTION
TIM-ID: 0000003040 - 001

Number of cylinders 8 12 16
Lube oil consumption in run-in state (B = hourly fuel R % of B 0.5 0.5 0.5
consumption)

MODEL-RELATED DATA (basic design)

Number of cylinders 8 12 16
Engine with exhaust turbocharging (ETC) and charge- X X X
air cooling (CAC)
Exhaust piping, non-cooled X X X

M015570/05E 2019-07 | Technical Data | 59

Number of cylinders 8 12 16
Operating method: four-stroke cycle, diesel, single- X X X
acting
Combustion method: direct injection X X X
Cooling method: conditioned water X X X
Direction of rotation: c.c.w. (facing driving end) X X X
Number of cylinders 8 12 16
Cylinder configuration: V angle Degrees 90 90 90
(°)
Bore mm 165 165 165
Stroke mm 190 190 190
Cylinder displacement liter 4.06 4.06 4.06
Total displacement liter 32.5 48.7 65.0
Compression ratio 15.5 15.5 15.5
Cylinder heads: single-cylinder X X X
Cylinder liners: wet, replaceable X X X
Number of inlet valves, per cylinder 2 2 2
Number of exhaust valves, per cylinder 2 2 2
Standard flywheel housing connecting flange (engine SAE 00 00 00
main PTO)
Flywheel interface DISC 21" 21" 21"

COMBUSTION AIR / EXHAUST GAS

Number of cylinders 8 12 16
Charge-air pressure before cylinder - CP R bar abs 2.7 2.5 2.5

COOLING SYSTEM (HT circuit)

Number of cylinders 8 12 16
Coolant temperature (at engine outlet to cooling A °C 95 95 95
equipment)
Coolant temperature after engine, alarm R °C 97 97 97
Coolant temperature after engine, shutdown L °C 99 99 99
Coolant antifreeze content, max. L % 50 50 50
Pressure loss in off-engine cooling system, max. L bar 0.7 0.7 0.7

COOLING SYSTEM (LT circuit)

TIM-ID: 0000003040 - 001

Number of cylinders 8 12 16
Coolant temperature before intercooler (at engine in- A °C 55 55 55
let from cooling equipment)
Coolant antifreeze content, max. L % 50 50 50
Pressure loss in off-engine cooling system, max. L bar 0.7 0.7 0.7

60 | Technical Data | M015570/05E 2019-07

LUBE OIL SYSTEM
Number of cylinders 8 12 16
Lube oil operating temperature upstream of engine, R °C 85 85 85
from
Lube oil operating temperature upstream of engine, to R °C 95 95 95
Lube oil temperature before engine, alarm R °C 95 95 95
Lube oil operating pressure upstream of engine, from R bar 5.0 5.0 5.0
Lube oil operating pressure upstream of engine, to R bar 6.0 6.0 6.0
Lube oil pressure before engine, alarm R bar 4.5 4.5 4.5
Lube oil pressure before engine, shutdown L bar 4.0 4.0 4.0

FUEL SYSTEM
Number of cylinders 8 12 16
Fuel pressure at engine inlet connection, min. (when L bar -0.1 -0.1 -0.1
engine is starting)
Fuel pressure at engine inlet connection, max. (when L bar 1.5 1.5 1.5
engine is starting)

GENERAL OPERATING DATA

Number of cylinders 8 12 16
Cold start capability: air temperature (w/o start aid, R °C 5 5 5
w/o preheating) - (case A)
Coolant preheating, preheating temperature (min.) R °C 32 32 32
Firing speed, from R rpm 80 80 80
Firing speed, to R rpm 120 120 120

CAPACITIES
Number of cylinders 8 12 16
Engine coolant capacity (without cooling equipment) R liter 145 160 175
Charge-air coolant capacity R liter 35 40 40
Engine oil capacity, initial filling (standard oil system) R liter 145 260 290
(Option: max. operating inclinations)
Oil pan capacity, dipstick mark min. (standard oil sys- L liter 85 160 160
tem) (Option: max. operating inclinations)
Oil pan capacity, dipstick mark max. (standard oil sys- L liter 115 200 230
tem) (Option: max. operating inclinations)
TIM-ID: 0000003040 - 001

WEIGHTS / MAIN DIMENSIONS

Number of cylinders 8 12 16
Dry engine weight (basic engine as per specified R kg 4450 5650 6950
scope of delivery)

M015570/05E 2019-07 | Technical Data | 61

ACOUSTICS
Number of cylinders 8 12 16
Exhaust noise, unsilenced - CP (sound power level LW, R db(A) approx. approx. approx.
ISO 6798) 123 124 126
Engine surface noise with attenuated intake noise (fil- R db(A) approx. approx. approx.
ter) - CP (sound power level LW, ISO 6798) 121 123 125

TIM-ID: 0000003040 - 001

62 | Technical Data | M015570/05E 2019-07

4.9 8/12/16V 4000G engine data: Continuous operation, unlimited
3A, optimized exhaust emission (EPA)
Explanation:
CP Ref. value: Continuous power (CP)
FSP Ref. value: Fuel stop power (FSP)
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power setting)
N Not yet defined value
- Not applicable
X Applicable

REFERENCE CONDITIONS
Engine model 8V 12V 12V 16 V 16 V
4000 G81 4000 G41 4000 G81 4000 G41 4000 G81
Application group 3A 3A 3A 3A 3A
Intake air temperature °C 25 25 25 25 25
Charge-air coolant tempera- °C 55 55 55 55 55
ture
Barometric pressure mbar 1000 1000 1000 1000 1000
Site altitude above sea level m 100 100 100 100 100

POWER-RELATED DATA (power ratings are net brake power to ISO 3046)
Number of cylinders 8 12 12 16 16
Engine rated speed A rpm 1800 1800 1800 1800 1800
Continuous power ISO 3046 A kW 750 1020 1120 1360 1495
(10% overload capability) (de-
sign power DIN 6280, ISO
8528)

GENERAL CONDITIONS (for maximum power)

Number of cylinders 8 12 12 16 16
Intake depression (new filter) A mbar 30 30 30 30 30
Intake depression, max. L mbar 50 50 50 50 50
Exhaust gas overpressure A mbar 30 30 30 30 30
Exhaust gas overpressure, L mbar 51 51 51 51 51
TIM-ID: 0000003048 - 001

max.

CONSUMPTION
Number of cylinders 8 12 12 16 16
Lube oil consumption in run-in R % of B 0.5 0.5 0.5 0.5 0.5
state (B = hourly fuel con-
sumption)

M015570/05E 2019-07 | Technical Data | 63

MODEL-RELATED DATA (basic design)
Number of cylinders 8 12 12 16 16
Engine with exhaust turbo- X X X X X
charging (ETC) and charge-air
cooling (CAC)
Exhaust piping, non-cooled X X X X X
Operating method: four-stroke X X X X X
cycle, diesel, single-acting
Combustion method: direct X X X X X
injection
Cooling system: conditioned X X X X X
water
Direction of rotation: c.c.w. X X X X X
(facing driving end)
Number of cylinders 8 12 12 16 16
Cylinder configuration: V an- Degrees 90 90 90 90 90
gle (°)
Bore mm 165 165 165 165 165
Stroke mm 190 190 190 190 190
Cylinder displacement liter 4.06 4.06 4.06 4.06 4.06
Total displacement liter 32.5 48.7 48.7 65.0 65.0
Compression ratio 15.5 15.5 15.5 15.5 15.5
Cylinder heads: single-cylin- X X X X X
der
Cylinder liners: wet, replacea- X X X X X
ble
Number of inlet valves, per 2 2 2 2 2
cylinder
Number of exhaust valves, per 2 2 2 2 2
cylinder
Standard flywheel housing SAE 00 00 00 00 00
connecting flange (engine
main PTO)
Flywheel interface DISC 21" 21" 21" 21" 21"

COMBUSTION AIR / EXHAUST GAS

Number of cylinders 8 12 12 16 16
Charge-air pressure before R bar abs 2.8 2.4 2.6 2.5 2.6
TIM-ID: 0000003048 - 001

cylinder - CP

COOLING SYSTEM (HT circuit)

Number of cylinders 8 12 12 16 16
Coolant temperature (at en- A °C 95 95 95 95 95
gine outlet to cooling equip-
ment)
Coolant temperature after en- R °C 97 97 97 97 97
gine, alarm

64 | Technical Data | M015570/05E 2019-07

Number of cylinders 8 12 12 16 16
Coolant temperature after en- L °C 99 99 99 99 99
gine, shutdown
Coolant antifreeze content, L % 50 50 50 50 50
max.
Pressure loss in off-engine L bar 0.7 0.7 0.7 0.7 0.7
cooling system, max.

COOLING SYSTEM (LT circuit)

Number of cylinders 8 12 12 16 16
Coolant temperature before A °C 55 55 55 55 55
intercooler (at engine inlet
from cooling equipment)
Coolant antifreeze content, L % 50 50 50 50 50
max.
Pressure loss in off-engine L bar 0.7 0.7 0.7 0.7 0.7
cooling system, max.

LUBE OIL SYSTEM

Number of cylinders 8 12 12 16 16
Lube oil operating tempera- R °C 85 85 85 85 85
ture upstream of engine, from
Lube oil operating tempera- R °C 95 95 95 95 95
ture upstream of engine, to
Lube oil temperature before R °C 95 95 95 95 95
engine, alarm
Lube oil operating pressure R bar 5.0 5.0 5.0 5.0 5.0
upstream of engine, from
Lube oil operating pressure R bar 6.0 6.0 6.0 6.0 6.0
upstream of engine, to
Lube oil pressure before en- R bar 4.5 4.5 4.5 4.5 4.5
gine, alarm
Lube oil pressure before en- L bar 4.0 4.0 4.0 4.0 4.0
gine, shutdown

FUEL SYSTEM
Number of cylinders 8 12 12 16 16
Fuel pressure at engine inlet L bar -0.1 -0.1 -0.1 -0.1 -0.1
connection, min. (when en-
TIM-ID: 0000003048 - 001

gine is starting)
Fuel pressure at engine inlet L bar 1.5 1.5 1.5 1.5 1.5
connection, max. (when en-
gine is starting)

M015570/05E 2019-07 | Technical Data | 65

GENERAL OPERATING DATA
Number of cylinders 8 12 12 16 16
Cold start capability: air tem- R °C 10 10 10 10 10
perature (w/o start aid, w/o
preheating) - (case A)
Coolant preheating, preheat- R °C 32 32 32 32 32
ing temperature (min.)
Firing speed, from R rpm 80 80 80 80 80
Firing speed, to R rpm 120 120 120 120 120

CAPACITIES
Number of cylinders 8 12 12 16 16
Engine coolant capacity (with- R liter 145 160 160 175 175
out cooling equipment)
Charge-air coolant capacity R liter 35 40 40 40 40
Engine oil capacity, initial fill- R liter 145 260 260 290 290
ing (standard oil system) (Op-
tion: max. operating inclina-
tions)
Oil pan capacity, dipstick L liter 85 160 160 160 160
mark min. (standard oil sys-
tem) (Option: max. operating
inclinations)
Oil pan capacity, dipstick L liter 115 200 200 230 230
mark max. (standard oil sys-
tem) (Option: max. operating
inclinations)

WEIGHTS / MAIN DIMENSIONS

Number of cylinders 8 12 12 16 16
Dry engine weight (basic en- R kg 4450 5650 5650 6950 6950
gine as per specified scope of
delivery)

ACOUSTICS
Number of cylinders 8 12 12 16 16
Exhaust noise, unsilenced - R db(A) approx. approx. approx. approx. approx.
CP (sound power level LW, 124 124 125 125 126
ISO 6798)
TIM-ID: 0000003048 - 001

Engine surface noise with at- R db(A) approx. approx. approx. approx. approx.
tenuated intake noise (filter) - 125 126 127 125 125
CP (sound power level LW,
ISO 6798)

66 | Technical Data | M015570/05E 2019-07

4.10 Firing order
Firing order
Number of cylin- Firing order
ders
8V A1-B4-A4-A2-B3-A3-B2-B1
12V A1-B2-A5-B4-A3-B1-A6-B5-A2-B3-A4-B6
16V A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B7
20V A1-B5-A8-B7-A5-B2-A7-B10-A2-B3-A10-B6-A3-B4-A6-B9-A4-B1-A9-B8
TIM-ID: 0000002794 - 005

M015570/05E 2019-07 | Technical Data | 67

4.11 Engine – Main dimensions

Engine model Length (A) Width (B) Height (C)

8V4000Gx1 approx. 1940 mm approx. 1550 mm approx. 1760 mm
12V4000Gx1 approx. 2410 mm approx. 1550 mm approx. 1760 mm
12V4000Gx1R
16V4000Gx1 approx. 2880 mm approx. 1550 mm approx. 1760 mm

TIM-ID: 0000002130 - 003

68 | Technical Data | M015570/05E 2019-07

5 Operation
5.1 Preparations for putting 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 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 108).
Lube oil system Check engine oil level (→ Page 138).
Fuel prefilter Fill with fuel (→ Page 131).
Fuel prefilter, pressure Align adjustable pointer with position of pressure gauge (→ Page 125).
gauge
Fuel system Vent (→ Page 122).
Coolant circuit Change engine coolant if engine has been out of service for more than one
year (→ Page 148).
Change charge-air coolant (→ Page 158).
Coolant circuit Check engine coolant level (→ Page 146).
Check charge-air coolant level (→ Page 156).
Coolant circuit Heat engine coolant with coolant preheating unit.
ECU Check plug-in connections (→ Page 174).
Monitoring system Carry out lamp test (see manufacturer's documentation).
Engine/generator control Switch on;
system Operating mode, e.g.: MANUAL, AUTOMATIC OPERATION.
Belt drive Checking drive belt condition(→ Page 168)
TIM-ID: 0000002193 - 003

M015570/05E 2019-07 | Operation | 69

5.2 Preparations for putting into operation after scheduled out-of-
service-period
Preconditions
☑ Engine is stopped and starting disabled.

Putting into operation

Item Measure
Lube oil system Check engine oil level (→ Page 138).
Coolant circuit Check engine coolant level (→ Page 146).
Check charge-air coolant level (→ Page 156).
Coolant circuit Heat coolant with preheating unit.
Fuel prefilter Drain water (→ Page 126).
Monitoring system Carry out lamp test (see manufacturer's documentation).
Engine/generator control Switch on;
system Operating mode, e.g.: MANUAL, AUTOMATIC OPERATION.
Belt drive Checking drive belt condition(→ Page 168)

TIM-ID: 0000002677 - 002

70 | Operation | M015570/05E 2019-07

5.3 Starting the engine in manual mode (test run)
Preconditions
☑ Generator (if fitted) is not connected to network.
☑ External start interlock is not activated.

DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Before cranking the engine with starter system, make sure that there are no persons in the engine's
danger zone.

WARNING
A high level of noise is produced when the engine is running.
Risk of hearing loss!
• Wear suitable hearing protection.

NOTICE
Re-starting the engine following an automatic safety shutdown.
Risk of severe engine damage!
• Before starting the engine, make sure the root cause of the safety shutdown was eliminated.
• If the root cause cannot be identified or eliminated, contact Service.

Preparation
Item Action
Operating mode switch (if Change to manual mode.
fitted)
Preheating pump (if fitted) Switch on.

Starting the engine

Item Action
Control cabinet, operator If coolant temperature is
station etc. (depending on • > 40 °C (with preheating system), or
manufacturer) • > 5 °C (without preheating system):
Press start button.
• Automatic starting sequence is performed;
• Engine speed display instrument indicates increasing crankshaft speed;
• After the starting sequence is completed, engine is running at rated
speed.

Connecting the generator (if fitted) to network, engine warm-up procedure to

TIM-ID: 0000002226 - 006

reach operating temperature

Item Action
Control cabinet, operator Close the generator circuit breaker.
station etc. (depending on
manufacturer)
Engine Apply full load only after engine has reached operating temperature (coolant
temperature approx. 75 °C).

M015570/05E 2019-07 | Operation | 71

5.4 Re-starting the engine following an automatic safety
shutdown
NOTICE
Re-starting the engine following an automatic safety shutdown.
Risk of severe engine damage!
• Before starting the engine, make sure the root cause of the safety shutdown was eliminated.
• If the root cause cannot be identified or eliminated, contact Service.

Note: • If an engine has been shutdown by a fault (red alarm), the engine may only be re-started when the fault
has been identified and eliminated.

Procedure following an automatic safety shutdown

1. Eliminate fault.
2. If the root cause cannot be identified or eliminated, contact Service.
Important
The function "Overdrive safety system" (if fitted), which is only used in emergency situations, is not affect-
ed.

TIM-ID: 0000081383 - 001

72 | Operation | M015570/05E 2019-07

5.5 Safety system – Override
NOTICE
Safety functions and engine shutdown alarms will be disregarded.
Severe material damage!
• Initiate emergency start only in emergency situations.

NOTICE
Inadmissible operating status.
Severe damage to property!
• Use override function only in hazardous situations to ensure full capability in the event of engine
faults.

Preparation
Note: This function is only available when a pushbutton is provided.

Safety system – Override

Item Action
Switchgear cabinet, control Activate pushbutton for Override input of the ECU.
panel etc. (depending on • Certain shutdown criteria and/or starting prerequisites are ignored.
manufacturer)
Switchgear cabinet, control Actuate start button, for further starting sequence, refer to engine start
panel etc. (depending on (→ Page 71).
manufacturer)
Control and display panels During operation, check the displayed operational data (speed, temperature,
pressures).
Constantly monitor plant limit values.
TIM-ID: 0000000984 - 003

M015570/05E 2019-07 | Operation | 73

5.6 Emergency engine start (Override mode)
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
A high level of noise is produced when the engine is running.
Risk of hearing loss!
• Wear suitable hearing protection.

WARNING
Exhaust gases are harmful to health and may cause cancer.
Risk of poisoning and suffocation!
• Keep the engine room well-ventilated at all times.
• Repair leaking exhaust pipework immediately.

NOTICE
Safety functions and engine shutdown alarms will be disregarded.
Severe material damage!
• Initiate emergency start only in emergency situations.

Preparation
Item Action
Operating mode selector Change to Override mode (Manual mode, if applicable).
switch

Starting the engine in emergency situations

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

Connecting the generator (if fitted) to mains

Item Action
Control cabinet If generator is not connected to mains: Close the generator circuit breaker.
TIM-ID: 0000010665 - 004

Engine Operate engine at rated power.

74 | Operation | M015570/05E 2019-07

5.7 Operational checks
DANGER
Components are moving or rotating.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Operate the engine at low load only. Keep clear of the danger zone of the engine.

WARNING
Exhaust gases are harmful to health and may cause cancer.
Risk of poisoning and suffocation!
• Keep the engine room well-ventilated at all times.
• Repair leaking exhaust pipework immediately.

WARNING
A high level of noise is produced when the engine is running.
Risk of hearing loss!
• Wear suitable hearing protection.

WARNING
Hot components/surfaces
Risk of burns!
• Wear suitable protective equipment/heat protective gloves.
• Avoid unprotected contact with hot surfaces.

Operational checks
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 115).
Fuel prefilter Check reading on differential pressure gage to ensure that maximum admis-
sible value is not exceeded (→ Page 125).
Exhaust gas system Check exhaust color (→ Page 84).
Intercooler Check condensate drain(s) for water discharge and obstruction
(→ Page 133).
Air filter Check signal ring position of service indicator (→ Page 136).
Replace air filter (→ Page 134), if the signal ring is completely visible in the
service indicator control window.
Engine coolant pump Check relief bore (→ Page 153).
TIM-ID: 0000002257 - 003

Charge-air coolant pump Check relief bore (→ Page 165).

Compressed-air system (if Check operating pressure on pressure gauge;
installed) Always fill compressed-air tank to max. pressure;
Drain condensate from compressed-air tank, pressure drop must not exceed
1 bar.

M015570/05E 2019-07 | Operation | 75

5.8 Engine – Stopping in Manual mode (test run)
Preconditions
☑ Generator (if applicable) is not connected to network
☑ Engine is in Manual mode

DANGER
Components are moving or rotating.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Operate the engine at low load only. Keep clear of the danger zone of the engine.

WARNING
A high level of noise is produced when the engine is running.
Risk of hearing loss!
• Wear suitable hearing protection.

WARNING
Exhaust gases are harmful to health and may cause cancer.
Risk of poisoning and suffocation!
• Keep the engine room well-ventilated at all times.
• Repair leaking exhaust pipework immediately.

NOTICE
Stopping the engine when it is running at full load subjects it to extreme thermal and mechanical stress-
es.
Overheating of and, therefore, damage to components is possible!
• Before shutting down the engine, allow it to idle until the engine temperatures decrease and constant
levels are indicated.

Preparing the generator drive (only with generator breaker)

Item Action
Engine After opening the generator breaker (if applicable), allow to cool down off-
load for approx. 5 minutes.

Preparing the pump drive (diesel-mechanical / diesel-electric)

Item Action
Engine Allow to cool down for approx. 5 minutes at reduced engine speed. Observe
natural resonance of engine (installation-dependent)!

Engine shutdown
TIM-ID: 0000002285 - 006

Item Action
Control cabinet, operator Note: The engine may only be shut down using the Stop button in normal op-
station etc. (depending on eration.
manufacturer) Press Stop button.
• Automatic stopping sequence is performed;
• Engine is at standstill.

76 | Operation | M015570/05E 2019-07

After engine shutdown
Item Action
Coolant circulating pump Allow to run on for sufficient time after stopping.
TIM-ID: 0000002285 - 006

M015570/05E 2019-07 | Operation | 77

5.9 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

78 | Operation | M015570/05E 2019-07

5.10 After stopping the engine – Engine remains ready for
operation

After stopping the engine

Item Action
Engine/generator/pump Select operating mode, e.g. MANUAL, AUTOMATIC OPERATION.
control
TIM-ID: 0000000983 - 003

M015570/05E 2019-07 | Operation | 79

5.11 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 149);
Drain charge-air coolant (→ Page 159) 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

80 | Operation | M015570/05E 2019-07

5.12 Plant – Cleaning
Preconditions
☑ Engine is stopped and starting disabled.
☑ No operating voltage applied.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
High-pressure cleaner (→ Tools Catalog) 1
Cleaner (Hakupur 50/136) X00056700 1

WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and hearing protection.

WARNING
Water jet from high-pressure cleaning unit.
Risk of eye injury, risk of scalding!
• Do not direct water jet at persons.
• Wear protective clothing, protective gloves, and goggles/safety mask.

NOTICE
Cleaning agents should not be left to take effect for too long.
Damage to components is possible!
• Observe manufacturer's instructions.

NOTICE
Blowing down product with compressed air.
Entry of dirt and damage to components is possible!
• Do not aim compressed air gun directly at seals or electronic components such as connectors or
ECUs.

Cleaning the plant

1. Carry out plant cleaning only in areas where an appropriate oil separator is provided (environmental protec-
tion).
2. Prior to putting the cleaning unit into operation, read the operating instructions of the high-pressure cleaning
units carefully and observe the safety precautions.
3. The following requirements apply for cleaning the plant outside with a high-pressure cleaning unit:
• The pressure of the high-pressure jet (cleaning jet) must not exceed 50 bar.
• A minimum distance between spray nozzle and plant of 1 m must be observed.
TIM-ID: 0000010171 - 034

• The temperature of the cleaning medium must not exceed 80 °C.

4. For external cleaning with high-pressure jet, use a fan jet nozzle only.
Note: Never direct compressed air directly at electronic components.
5. Carry out external cleaning as follows:
a) Seal all openings in a suitable way.
b) Remove coarse dirt.
c) Spray on cleaner sparingly and leave it for 1 to 5 minutes.
d) Use high-pressure jet to remove loosened dirt.
e) Dry engine with compressed air.

M015570/05E 2019-07 | Operation | 81

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 (→ Page 138)

level.
W0501 Visually inspect en- (→ Page 75)
gine for leaks and
check general con-
dition.
W0502 Check intercooler (→ Page 133)
X
condensate drain.
W0503 Check signal ring (→ Page 136)
position of service
indicator on air fil-
ter.
W0504 Check telltale (→ Page 75)
bores of HP fuel
pump.
W0505 Check relief bores (→ Page 153)
of coolant pump(s).
W0506 Check for abnor- (→ Page 75)
mal running noise,
exhaust color and
vibrations.
W0507 Drain water and (→ Page 75)
X contaminants from
fuel prefilter.
W0508 Check reading on (→ Page 75)
differential pres-
X
sure gauge of fuel
prefilter.
W1001 Replace fuel filter (→ Page 123)
or fuel filter ele-
TIM-ID: 0000087208 - 001

ment.
W1002 Check valve clear- (→ Page 109)
ance, adjust as
necessary.
W1003 Check belt condi- (→ Page 168)
tion and tension,
replace belt(s) if
necessary.
W1005 Replace air filters. (→ Page 134)

82 | Maintenance | M015570/05E 2019-07

Option
Task Maintenance
tasks

W1006 Replace fuel injec- (→ Page 116)

tors.
W1008 Replace engine oil (→ Page 143)
filter when chang-
ing engine oil, or
when the interval
(years) is reached,
at the latest.
W1009 Check layer thick- (→ Page 144)
ness of oil residue,
clean and replace
X filter sleeve, to-
gether with every
engine oil change,
at the latest .
W1011 Perform endoscop- (→ Page 101)
ic examination.
W1046 Replace filter or fil- (→ Page 105)
ter element of
X
crankcase breath-
er.
W3009 Replace oil separa- (→ Page 105)
X tor of crankcase
breather.

Table 2: Maintenance task reference table [QL1]

TIM-ID: 0000087208 - 001

M015570/05E 2019-07 | Maintenance | 83

7 Troubleshooting
7.1 Troubleshooting
Engine does not turn when starter is actuated
Cause Corrective action
Battery low or faulty u Charge or replace (→ manufacturer's documentation).
Cable connections faulty u Check cable connections for secure seating (→ manufacturer's
documentation).
Starter (electric): Engine cabling u Check whether cable connections are properly secured.
or starter faulty Contact Service.
Starter (compressed air): Cabling u Check whether cable connections are properly secured.
on starting valve or starter Contact Service.
defective
Engine wiring faulty u Check (→ Page 172).
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 174).
connections loose
Running gear blocked (engine u Contact Service.
cannot be barred manually)

Engine turns on starting but does not fire

Cause Corrective action
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.
Engine wiring faulty u Check (→ Page 172).
Air in fuel system u Vent fuel system (→ Page 122).
Engine governor defective u Contact Service.

Engine fires unevenly

Cause Corrective action
Injector defective u Check, replace as necessary (→ Page 116).
TIM-ID: 0000087150 - 001

Engine wiring faulty u Check (→ Page 172).

Air in fuel system u Vent fuel system (→ Page 122).
Engine governor defective u Contact Service.

84 | Troubleshooting | M015570/05E 2019-07

Engine does not reach nominal speed
Cause Corrective action
Fuel prefilter contaminated u Replace (→ Page 131).
Fuel filter clogged u Replace (→ Page 123).
Air filter clogged u Check signal ring position of service indicator (→ Page 136).
Injector defective u Replace (→ Page 116).
Engine wiring faulty u Check (→ Page 172).
Engine: Overload u Contact Service.

Engine speed not steady

Cause Corrective action
Injector defective u Replace (→ Page 116).
Speed transmitter defective u Contact Service.
Air in fuel system u Vent fuel system (→ Page 122).
Engine governor defective u Contact Service.

Charge-air temperature too high

Cause Corrective action
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

Cause Corrective action
Air pipework leaking u Check air pipework for leakage.
Air filter clogged u Check signal ring position of service indicator (→ Page 136).
Intercooler dirty u Contact Service.
Exhaust turbocharger defective u Contact Service.

Coolant discharge at intercooler

Cause Corrective action
Leaking, major coolant discharge u Contact Service.
TIM-ID: 0000087150 - 001

Black exhaust gas

Cause Corrective action
Air filter clogged u Check signal ring position of service indicator (→ Page 136).
Injector defective u Replace (→ Page 116).
Engine: Overload u Contact Service.

M015570/05E 2019-07 | Troubleshooting | 85

Blue exhaust gas
Cause Corrective action
Too much engine oil in the engine u Drain engine oil (→ Page 139).
Oil separator of crankcase u Replace filter (→ Page 105).
breather contaminated
Exhaust turbocharger, cylinder u Contact Service.
head, piston rings or cylinder liner
defective

White exhaust gas

Cause Corrective action
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 126).
Intercooler leaky u Contact Service.

TIM-ID: 0000087150 - 001

86 | Troubleshooting | M015570/05E 2019-07

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.
Fault messages can also be caused by faulty sensors/actuators. If troubleshooting in accordance with the
following table is not successful, contact Service to have the sensors / actuators checked and replaced as
required.
Fault Fault text Explanation Measure
code
005 L1 T-CHARGE AIR Charge-air temperature too Reduce power. Change over to idle and
high (1st limit) contact Service.
006 L2 T-CHARGE AIR Charge-air temperature too Reduce power. Change over to idle and
high (2nd limit) contact Service.
009 L1 T-INTERCOOL- Charge-air coolant temperature Reduce power. Change over to idle and
TIM-ID: 0000003158 - 002

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 138);
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 138);
automatic engine shutdown 2. Attempt to restart engine (→ Page 71).
3. Contact Service.
023 L1 COOLANT LEV- Engine coolant level too low Check coolant level and top up as necessa-
EL ry (→ Page 146).

M015570/05E 2019-07 | Troubleshooting | 87

Fault Fault text Explanation Measure
code
024 L2 COOLANT LEV- Engine coolant level too low Check coolant level and top up as necessa-
EL ry (→ Page 146).
030 ENGINE OVER- Engine overspeed; automatic 1. Acknowledge alarm.
SPEED emergency engine stop 2. Attempt to restart engine (→ Page 71).
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 156).
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 156).
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.
2. If fault occurs repeatedly: Contact
Service.
065 L1 P-FUEL Fuel supply pressure too low 1. Check fuel lines for leaks; repair any
(1st limit value) leaks.
2. Clean fuel prefilter (→ Page 124).
3. Flush fuel prefilter (→ Page 128).
4. Replace filter element of fuel prefilter
(→ Page 131).
5. Replace fuel filter (→ Page 123).
6. If fault is not rectified: Contact Service.
066 L2 P-FUEL Fuel supply pressure too low 1. Check fuel lines for leaks; repair any
(2nd limit value) leaks.
2. Clean fuel prefilter (→ Page 124).
3. Flush fuel prefilter (→ Page 128).
4. Replace filter element of fuel prefilter
(→ Page 131).
5. Replace fuel filter (→ Page 123).
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 engine to cool down.
(2nd limit value); 2. Check coolant cooler (fins, etc.) and
automatic engine shutdown clean contaminated parts (see manu-
facturer's documentation).
3. Restart engine (→ Page 71).
4. If fault occurs repeatedly: Contact
Service.
TIM-ID: 0000003158 - 002

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)

88 | Troubleshooting | M015570/05E 2019-07

Fault Fault text Explanation Measure
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 Restart engine (→ Page 71).
LOW 200 rpm;
automatic engine shutdown
090 IDLE SPEED LOW Idling speed not reached within Observe any other messages.
a specified time;
Start terminated
091 RUN UP SPEED Runup speed not reached with- Observe any other messages.
LOW in a specified time;
Start terminated
TIM-ID: 0000003158 - 002

092 START SPEED Starter speed not reached with- Observe any other messages.
LOW in a specified time;
Start terminated
093 PREHEAT TEMP. Coolant preheating tempera- Check preheating pump / preheating sys-
LIMIT2 ture during start too low (2nd tem (see manufacturer's documentation).
limit value);
Termination of start sequence
(depending on project design)

M015570/05E 2019-07 | Troubleshooting | 89

Fault Fault text Explanation Measure
code
094 PREHEAT TEMP. Coolant preheating tempera- Check preheating pump / preheating sys-
LIMIT1 ture during start too low (1st tem (see manufacturer's documentation).
limit value);
100 EDM NOT VALID Checksum error of measuring- If fault occurs repeatedly: Contact Service.
point data in EDM
101 IDM NOT VALID Checksum error of measuring- If fault occurs repeatedly: Contact Service.
point data in IDM
102 INVALID FUEL Checksum error of accumulat- If fault occurs repeatedly: Contact Service.
CONS. 1 ed fuel consumption data in
EDM (redundant data record 1)
103 INVALID FUEL Checksum 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 Checksum error of hour meter If fault occurs repeatedly: Contact Service.
VALID data in EDM
105 OP HOURS2 NOT Checksum error of hour meter If fault occurs repeatedly: Contact Service.
VALID data in IDM
106 ERR REC1 NOT Checksum error of fault memo- If fault occurs repeatedly: Contact Service.
VALID ry in EDM (redundant data re-
cord 1)
107 ERR REC2 NOT Checksum error of fault memo- If fault occurs repeatedly: Contact Service.
VALID ry 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 has been shut down: Start engine
automatic engine shutdown (→ Page 71).
(depending on project design)
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 fault; Contact Service.
FECT automatic engine shutdown
136 15V NEG ECU DE- Electronic fault; Contact Service.
FECT automatic engine shutdown
TIM-ID: 0000003158 - 002

137 L1 5V BUFFER Power supply for pressure sen- 1. Disconnect connectors X2 and X3 on
TEST sors faulty. Engine Control Unit. If alarm does not
disappear: Contact Service.
2. Check wiring (pressure sensors).
3. Contact Service.
138 SENSORPOWER- Power supply for pressure sen- 1. Disconnect connectors X2 and X3 on
DEFECT sors faulty. Engine Control Unit. If alarm does not
disappear: Contact Service.
2. Check wiring (pressure sensors).
3. Contact Service.

90 | Troubleshooting | M015570/05E 2019-07

Fault Fault text Explanation Measure
code
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 fault; 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 fault; Contact Service.
DEFECT automatic engine shutdown
148 L1 AD-TEST2 SUP- A/D-converter supply voltage Contact Service.
PLY too low
149 AD-TEST2 ECU Electronic fault; Contact Service.
DEFECT automatic engine shutdown
150 L1 AD-TEST3 SUP- A/D-converter supply voltage Contact Service.
PLY too low
151 AD-TEST3 ECU Electronic fault; Contact Service.
DEFECT automatic engine shutdown
170 MI MODULE FAIL Module in maintenance predic- Contact Service.
tor either defective or missing
171 MI NOT ACTIVE Maintenance indicator no lon- Contact Service.
ger active
173 MODULE WRITE EEPROM write limit reached Contact Service.
LIMIT
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.
184 CAN PU-DATA EE- Error during project design da- Contact Service.
FAIL ta download in EEPROMs
TIM-ID: 0000003158 - 002

185 CAN LESS MAIL- Error during CAN initialization. Contact Service.
BOXES
186 CAN1 BUS OFF Severe fault on Default CAN Contact Service.
bus;
automatic changeover to Re-
dundant CAN bus
187 CAN1 ERROR PAS- Light fault on Default CAN bus (None)
SIVE (e.g. short-time overload)

M015570/05E 2019-07 | Troubleshooting | 91

Fault Fault text Explanation Measure
code
188 CAN2 BUS OFF Serious 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.
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.
245 SD POWER SUP- Sensor defect (engine governor Contact Service.
PLY operating voltage)
TIM-ID: 0000003158 - 002

246 SD T-ELECTRONIC Sensor defect (temperature in Contact Service.

engine governor)
250 SD CAN SPEED Sensor defect (CAN nominal 1. Check setpoint speed transmitter.
DEMAND speed demand) 2. Check wiring (CAN bus).
3. Contact Service.
266 SD SPEED DE- Sensor defect (analog nominal 1. Check setpoint speed transmitter.
MAND AN. speed demand) 2. Check wiring.
3. Contact Service.

92 | Troubleshooting | M015570/05E 2019-07

Fault Fault text Explanation Measure
code
267 SD SP. DEM. TEST Sensor defect (analog speed 1. Check setpoint 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 setpoint 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
302 TIMING CYLINDER Injection timing fault cylinder If fault occurs repeatedly: Contact Service.
A2 A2
303 TIMING CYLINDER Injection timing fault cylinder If fault occurs repeatedly: Contact Service.
A3 A3
304 TIMING CYLINDER Injection timing fault cylinder If fault occurs repeatedly: Contact Service.
A4 A4
305 TIMING CYLINDER Injection timing fault cylinder If fault occurs repeatedly: Contact Service.
A5 A5
306 TIMING CYLINDER Injection timing fault cylinder If fault occurs repeatedly: Contact Service.
A6 A6
307 TIMING CYLINDER Injection timing fault cylinder If fault occurs repeatedly: Contact Service.
A7 A7
308 TIMING CYLINDER Injection timing fault cylinder If fault occurs repeatedly: Contact Service.
TIM-ID: 0000003158 - 002

A8 A8
309 TIMING CYLINDER Injection timing fault cylinder If fault occurs repeatedly: Contact Service.
A9 A9
310 TIMING CYLINDER Injection timing fault cylinder If fault occurs repeatedly: Contact Service.
A10 A10
311 TIMING CYLINDER Injection timing fault cylinder If fault occurs repeatedly: Contact Service.
B1 B1
312 TIMING CYLINDER Injection timing fault cylinder If fault occurs repeatedly: Contact Service.
B2 B2

M015570/05E 2019-07 | Troubleshooting | 93

Fault Fault text Explanation Measure
code
313 TIMING CYLINDER Injection timing fault cylinder If fault occurs repeatedly: Contact Service.
B3 B3
314 TIMING CYLINDER Injection timing fault cylinder If fault occurs repeatedly: Contact Service.
B4 B4
315 TIMING CYLINDER Injection timing fault cylinder If fault occurs repeatedly: Contact Service.
B5 B5
316 TIMING CYLINDER Injection timing fault cylinder If fault occurs repeatedly: Contact Service.
B6 B6
317 TIMING CYLINDER Injection timing fault cylinder If fault occurs repeatedly: Contact Service.
B7 B7
318 TIMING CYLINDER Injection timing fault cylinder If fault occurs repeatedly: Contact Service.
B8 B8
319 TIMING CYLINDER Injection timing fault cylinder If fault occurs repeatedly: Contact Service.
B9 B9
320 TIMING CYLINDER Injection timing fault cylinder If fault occurs repeatedly: Contact Service.
B10 B10
321 WIRING CYLINDER Faulty wiring to solenoid valve 1. Check wiring.
A1 cylinder A1; 2. Contact Service.
Misfire
322 WIRING CYLINDER Faulty wiring to solenoid valve 1. Check wiring.
A2 cylinder A2; 2. Contact Service.
Misfire
323 WIRING CYLINDER Faulty wiring to solenoid valve 1. Check wiring.
A3 cylinder A3; 2. Contact Service.
Misfire
324 WIRING CYLINDER Faulty wiring to solenoid valve 1. Check wiring.
A4 cylinder A4; 2. Contact Service.
Misfire
325 WIRING CYLINDER Faulty wiring to solenoid valve 1. Check wiring.
A5 cylinder A5; 2. Contact Service.
Misfire
326 WIRING CYLINDER Faulty wiring to solenoid valve 1. Check wiring.
A6 cylinder A6; 2. Contact Service.
Misfire
327 WIRING CYLINDER Faulty wiring to solenoid valve 1. Check wiring.
A7 cylinder A7; 2. Contact Service.
Misfire
328 WIRING CYLINDER Faulty wiring to solenoid valve 1. Check wiring.
A8 cylinder A8; 2. Contact Service.
Misfire
TIM-ID: 0000003158 - 002

329 WIRING CYLINDER Faulty wiring to solenoid valve 1. Check wiring.

A9 cylinder A9; 2. Contact Service.
Misfire
330 WIRING CYLINDER Faulty wiring to solenoid valve 1. Check wiring.
A10 cylinder A10; 2. Contact Service.
Misfire
331 WIRING CYLINDER Faulty wiring to solenoid valve 1. Check wiring.
B1 cylinder B1; 2. Contact Service.
Misfire

94 | Troubleshooting | M015570/05E 2019-07

Fault Fault text Explanation Measure
code
332 WIRING CYLINDER Faulty wiring to solenoid valve 1. Check wiring.
B2 cylinder B2; 2. Contact Service.
Misfire
333 WIRING CYLINDER Faulty wiring to solenoid valve 1. Check wiring.
B3 cylinder B3; 2. Contact Service.
Misfire
334 WIRING CYLINDER Faulty wiring to solenoid valve 1. Check wiring.
B4 cylinder B4; 2. Contact Service.
Misfire
335 WIRING CYLINDER Faulty wiring to solenoid valve 1. Check wiring.
B5 cylinder B5; 2. Contact Service.
Misfire
336 WIRING CYLINDER Faulty wiring to solenoid valve 1. Check wiring.
B6 cylinder B6; 2. Contact Service.
Misfire
337 WIRING CYLINDER Faulty wiring to solenoid valve 1. Check wiring.
B7 cylinder B7; 2. Contact Service.
Misfire
338 WIRING CYLINDER Faulty wiring to solenoid valve 1. Check wiring.
B8 cylinder B8; 2. Contact Service.
Misfire
339 WIRING CYLINDER Faulty wiring to solenoid valve 1. Check wiring.
B9 cylinder B9; 2. Contact Service.
Misfire
340 WIRING CYLINDER Faulty wiring to solenoid valve 1. Check wiring.
B10 cylinder B10; 2. Contact Service.
Misfire
341 OPEN_LOAD CYL. Disconnection in wiring to sole- 1. Check wiring.
A1 noid valve cylinder A1; 2. Contact Service.
Misfire
342 OPEN_LOAD CYL. Disconnection in wiring to sole- 1. Check wiring.
A2 noid valve cylinder A2; 2. Contact Service.
Misfire
343 OPEN_LOAD CYL. Disconnection in wiring to sole- 1. Check wiring.
A3 noid valve cylinder A3; 2. Contact Service.
Misfire
344 OPEN_LOAD CYL. Disconnection in wiring to sole- 1. Check wiring.
A4 noid valve cylinder A4; 2. Contact Service.
Misfire
345 OPEN_LOAD CYL. Disconnection in wiring to sole- 1. Check wiring.
A5 noid valve cylinder A5; 2. Contact Service.
TIM-ID: 0000003158 - 002

Misfire
346 OPEN_LOAD CYL. Disconnection in wiring to sole- 1. Check wiring.
A6 noid valve cylinder A6; 2. Contact Service.
Misfire
347 OPEN_LOAD CYL. Disconnection in wiring to sole- 1. Check wiring.
A7 noid valve cylinder A7; 2. Contact Service.
Misfire
348 OPEN_LOAD CYL. Disconnection in wiring to sole- 1. Check wiring.
A8 noid valve cylinder A8; 2. Contact Service.
Misfire

M015570/05E 2019-07 | Troubleshooting | 95

Fault Fault text Explanation Measure
code
349 OPEN_LOAD CYL. Disconnection in wiring to sole- 1. Check wiring.
A9 noid valve cylinder A9; 2. Contact Service.
Misfire
350 OPEN_LOAD CYL. Disconnection in wiring to sole- 1. Check wiring.
A10 noid valve cylinder A10; 2. Contact Service.
Misfire
351 OPEN_LOAD CYL. Disconnection in wiring to sole- 1. Check wiring.
B1 noid valve cylinder B1; 2. Contact Service.
Misfire
352 OPEN_LOAD CYL. Disconnection in wiring to sole- 1. Check wiring.
B2 noid valve cylinder B2; 2. Contact Service.
Misfire
353 OPEN_LOAD CYL. Disconnection in wiring to sole- 1. Check wiring.
B3 noid valve cylinder B3; 2. Contact Service.
Misfire
354 OPEN_LOAD CYL. Disconnection in wiring to sole- 1. Check wiring.
B4 noid valve cylinder B4; 2. Contact Service.
Misfire
355 OPEN_LOAD CYL. Disconnection in wiring to sole- 1. Check wiring.
B5 noid valve cylinder B5; 2. Contact Service.
Misfire
356 OPEN_LOAD CYL. Disconnection in wiring to sole- 1. Check wiring.
B6 noid valve cylinder B6; 2. Contact Service.
Misfire
357 OPEN_LOAD CYL. Disconnection in wiring to sole- 1. Check wiring.
B7 noid valve cylinder B7; 2. Contact Service.
Misfire
358 OPEN_LOAD CYL. Disconnection in wiring to sole- 1. Check wiring.
B8 noid valve cylinder B8; 2. Contact Service.
Misfire
359 OPEN_LOAD CYL. Disconnection in wiring to sole- 1. Check wiring.
B9 noid valve cylinder B9; 2. Contact Service.
Misfire
360 OPEN_LOAD CYL. Disconnection in wiring to sole- 1. Check wiring.
B10 noid valve cylinder B10; 2. Contact Service.
Misfire
361 POWER STAGE Fault in engine governor (sole- Contact Service.
FAIL 1 noid valve output stage)
362 POWER STAGE Fault in engine governor (sole- Contact Service.
FAIL 2 noid valve output stage)
TIM-ID: 0000003158 - 002

363 STOP POWER Solenoid valve or wiring or en- 1. Check wiring.

STAGE 1 gine governor defective 2. Attempt to restart engine (→ Page 71).
automatic engine shutdown 3. Contact Service.
364 STOP POWER Solenoid valve or wiring or en- 1. Check wiring.
STAGE 2 gine governor defective 2. Attempt to restart engine (→ Page 71).
automatic engine shutdown 3. Contact Service.
365 STOP MV-WIRING Fault in solenoid valve wiring; 1. Check wiring.
automatic engine shutdown 2. Attempt to restart engine (→ Page 71).
3. Contact Service.

96 | Troubleshooting | M015570/05E 2019-07

Fault Fault text Explanation Measure
code
381 TRAN.OUT1 Binary transistor output plant 1 Contact Service.
PLANT DEF defective
382 TRAN.OUT2 Binary transistor output plant 2 Contact Service.
PLANT DEF defective
383 TRAN.OUT3 Binary transistor output plant 3 Contact Service.
PLANT DEF defective
384 TRAN.OUT4 Binary transistor output plant 4 Contact Service.
PLANT DEF defective
385 TRAN.OUT5 Binary transistor output plant 5 Contact Service.
PLANT DEF defective
386 TRAN.OUT6 Binary transistor output plant 6 Contact Service.
PLANT DEF defective
TIM-ID: 0000003158 - 002

M015570/05E 2019-07 | Troubleshooting | 97

8 Task Description
8.1 Engine
8.1.1 Engine – Barring manually
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Barring tool F6555766 1
Adapter F6558528 1
Ratchet with extension F30006212 1

DANGER
Rotating/moving engine parts.
Risk of crushing, danger of body parts being caught up or drawn in!
• Ensure that all personnel is clear of the danger zone before cranking the engine on the starter.

Barring engine manually (lateral

installation)
1. Remove guard plate.
2. Engage barring tool (2) in ring gear (3) and in-
stall on flywheel housing.
3. Set ratchet (1) onto barring tool (2).
4. Rotate crankshaft in engine direction of rota-
tion. Apart from the normal compression re-
sistance, there should be no resistance.
5. Remove barring tool in reverse order.
TIM-ID: 0000002522 - 003

98 | Task Description | M015570/05E 2019-07

8.1.2 Engine – Cranking on starting system
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Pipe gripping pliers F30017884 1

DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• 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

M015570/05E 2019-07 | Engine | 99

8.1.3 Engine – Test run
DANGER
Components are moving or rotating.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Operate the engine at low load only. Keep clear of the danger zone of the engine.

WARNING
Exhaust gases are harmful to health and may cause cancer.
Risk of poisoning and suffocation!
• Keep the engine room well-ventilated at all times.
• Repair leaking exhaust pipework immediately.

WARNING
A high level of noise is produced when the engine is running.
Risk of hearing loss!
• Wear suitable hearing protection.

Engine – Test run

1. Start engine (→ Page 71).
2. Perform test run not below 1/3 load and at least until steady-state temperature is reached.
3. Carry out operational checks (→ Page 75).
4. Stop engine (→ Page 76).

TIM-ID: 0000000870 - 010

100 | Engine | M015570/05E 2019-07

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

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Endoscope Y20097353 1

Preparatory steps
1. Remove cylinder head cover (→ Page 114).
2. Remove injector (→ Page 117).

Positioning crankshaft at BDC

1. Use barring tool to turn crankshaft until crankshaft journal of the cylinder to be inspected has reached BDC
(→ Page 98).
2. Insert endoscope into cylinder liner through injector seat.

Cylinder liner – Endoscopic inspection

Findings Action
• Thin carbon coating around carbon scraper ring No action required
• Minor localized additive deposits at top edge
• Localized smooth areas at bottom edge
• Carbon deposits on entire circumference in clearance area 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
• Flawless, 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 can not be faulted
• Piston rings can not be faulted
• On the entire circumference, apart from light areas of discoloration (do Contact Service; cylinder liner
not impair operation) clearly darker stripes that start at the top piston must be replaced.
ring
TIM-ID: 0000003304 - 008

• Heat discoloration in the direction of stroke and honing pattern dam-

age
• Heat discoloration of piston rings

1. Compile endoscopic report using the table.

2. Use technical terms to describe the liner surface (→ Page 103).
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.

M015570/05E 2019-07 | Cylinder Liner | 101

Final steps
1. Install injector (→ Page 117).
2. Install cylinder head cover (→ Page 114).

TIM-ID: 0000003304 - 008

102 | Cylinder Liner | M015570/05E 2019-07

8.2.2 Cylinder liner – Instructions and comments on endoscopic and visual
examination
Terms used for endoscopic examination
Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic examina-
tion report.
Findings Explanations/Action
Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing products,
particles, broken-off burrs). Removed cylinders clearly show such scoring on the
running surface under endoscope magnification. Cannot be felt with the fingernail.
Findings not critical
Single scores Clearly visible scores caused by hard particles. They usually start in the TDC area
and cross through the honing pattern in the direction of stroke.
Findings not critical
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.
Findings not critical
Polished area Polished areas are on the running surface but almost the whole honing pattern is
still visible. Polished areas appear brighter and more shiny than the surrounding
running surface.
Findings not critical
Bright area Bright areas are on the running surface and show local removal of the honing pat-
tern. Grooves from the honing process are not visible any more.
Discoloration This is caused by oxidation (surface discoloration through oil or fuel) and tempera-
ture differences around the liner. It appears rather darker within the honed struc-
ture in contrast to the bright metallic running surface. The honing pattern is undis-
turbed. Discolorations extend in stroke direction and may be interrupted.
Findings not critical
Corrosion fields / Corrosion fields / spots result from moisture (condensate) with the valves in the
spots overlap (open) position. They are clearly visible due to the dark color of the honing
groove bottom.
This corrosion is not critical unless there is corrosion pitting.
Black lines Black lines are a preliminary stage of burn marks. They are visible as a clear discol-
oration from TDC to BDC in the running surface and the start of localized damage
to the honing pattern.
Cylinder liners with a large number of black lines around the running surface have
limited service life and should be replaced.
Burn mark These are caused by a disturbance in the liner / ring tribo system. Usually they run
over the whole ring-travel area (TDC/BDC), starting at the first TDC-ring and be-
coming more visible from the second TDC-ring 2 onwards and less pronounced
from TDC-ring 1. The honing pattern is usually no longer visible and displays a
TIM-ID: 0000000014 - 017

clearly defined (straight) edge to the undisturbed surface. The damaged surface is
usually discolored. The circumferential length varies.
Liners with burn marks starting in TDC ring 1 have to be replaced.
Seizure marks, scuff- Irregular circumference lengths and depths. Can be caused either by the piston
ing skirt or the piston crown. Material deposits on the liner (smear), heavy discolora-
tion. Severe, visible scoring.
Replace liner.

Table 3: Endoscopic examination – Terms used

M015570/05E 2019-07 | Cylinder Liner | 103

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

TIM-ID: 0000000014 - 017

104 | Cylinder Liner | M015570/05E 2019-07

8.3 Crankcase Breather
8.3.1 Crankcase breather – Filter element replacement
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Filter element (→ Spare Parts Catalog)

WARNING
Oil is hot.
Oil can contain residue/substances which are harmful to health.
Risk of injury and poisoning!
• Allow the product to cool to below 50 °C before beginning work.
• Wear protective clothing, protective gloves and goggles/safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.

Crankcase breather – Filter ele-

ment replacement
1. Loosen clamps (1), push rubber sleeve (2)
over pipe (3).
2. Release band clamp (4) with lever (6).
3. Remove cover (7).
4. Replace filter element (5).
5. Fit cover (7).
6. Operate lever (6) to tension clamping
band (4).
7. Replace further filter elements in the same
way.
TIM-ID: 0000003533 - 005

M015570/05E 2019-07 | Crankcase Breather | 105

8.3.2 Crankcase breather – Oil separator replacement, diaphragm check and
replacement
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Torque wrench, 4–20 Nm F30044239 1
Ratchet bit F30027340 1
Engine oil
Filter element (→ Spare Parts Catalog)
Diaphragm (→ Spare Parts Catalog)
Gasket (→ Spare Parts Catalog)

WARNING
Oil is hot.
Oil can contain residue/substances which are harmful to health.
Risk of injury and poisoning!
• Allow the product to cool to below 50 °C before beginning work.
• Wear protective clothing, protective gloves and goggles/safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.

Replacing filter element on

crankcase breather, version A
1. Loosen clamps (1).
2. Slide rubber sleeve (2) over pipe (3).
3. Loosen band clamp (4) with lever (6).
4. Remove cover (7).
5. Replace filter element (5).
6. Fit cover (7).
7. Tension band clamp (4) with lever (6).
8. Replace further oil filter elements in the same
way.
TIM-ID: 0000003534 - 008

106 | Crankcase Breather | M015570/05E 2019-07

Replacing filter element on
crankcase breather, version B
1. Remove cover (2) with O-ring (3).
2. Remove filter element (1) from housing (4).
3. Insert new filter element in housing (4).
4. Install cover (2) with new O-ring.

5. Use torque wrench to tighten the screws of cover (2) to the specified torque.
Name Size Type Lubricant Value/Standard
Screw Tightening torque (Engine oil) 6 Nm +2 Nm

6. Replace further oil separator elements in the same way.

Checking diaphragm, version B

1. Remove cover (4).
2. Remove spring (5), gasket (2) and dia-
phragm (3).
3. Check diaphragm (3) for damage, fit new dia-
phragm if used one is damaged.
4. Install diaphragm (3) on housing (1).
5. Install new gasket (2) and spring (5) together
with cover (4).

6. Tighten screws on cover (4) to specified torque using a torque wrench.

Name Size Type Lubricant Value/Standard
TIM-ID: 0000003534 - 008

Screw Tightening torque (Engine oil) 6 Nm +2 Nm

7. Check diaphragms in other oil separators in the same way.

M015570/05E 2019-07 | Crankcase Breather | 107

8.4 Valve Drive
8.4.1 Valve gear – Lubrication
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Engine oil

Lubricating valve gear (valve

bridge with guide)
1. Remove cylinder head covers (→ Page 114).
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 114).

Lubricating valve gear (flying

valve bridge)
1. Remove cylinder head covers (→ Page 114).
2. Fill oil chambers of rocker arms and adjusting
screws with oil.
3. Install cylinder head covers (→ Page 114).
TIM-ID: 0000004338 - 004

108 | Valve Drive | M015570/05E 2019-07

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

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Feeler gauge Y20098771 1
Torque wrench, 10–60 Nm F30452769 1
Torque wrench, 60–320 Nm F30452768 1
Socket box wrench F30039518 1
Engine oil

Preparatory steps
1. Remove cylinder head cover (→ Page 114).
2. Install barring tool (→ Page 98).
3. Use barring tool to turn crankshaft in direc-
tion of rotation until marking OT-A1 (1) (TDC)
and pointer (2) are aligned.
4. Secure crankshaft in this position.
TIM-ID: 0000004352 - 007

M015570/05E 2019-07 | Valve Drive | 109

Checking valve-bridge balance

Figure Component
A Valve bridge with guide
B 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 gauge to determine clearance be-
tween valve bridge and rocker arm.

TIM-ID: 0000004352 - 007

110 | Valve Drive | M015570/05E 2019-07

3. Insert feeler gauge of determined thickness
between valve bridge and valve-stem end (1).
4. At the opposite valve-stem end (2), a feeler
gauge 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) firmly in position with
open-end wrench and release locknut (2).

2. Use feeler gauge to determine clearance be-

tween valve bridge and rocker arm.
3. Place one feeler gauge (of the determined
value) each between valve bridge and the two
valve-stem ends (1) and (2).
4. Turn adjusting screw such that both feeler
gauges 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 - 007

6. Replace or rectify adjusting screws which do

not move freely.

M015570/05E 2019-07 | Valve Drive | 111

7. Tighten locknut (2) to specified torque using a torque wrench holding valve bridge (1) in place with open-end
wrench when doing so.
Name Size Type Lubricant Value/Standard
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 - 007

Item Explanation
1 Cylinder A1 is in firing TDC
2 Cylinder A1 is in overlap TDC

112 | Valve Drive | M015570/05E 2019-07

Item Explanation
I Inlet valve
X Exhaust valve

1. Check TDC position of piston in cylinder A1:

• If rocker arms on cylinder A1 are unloaded, the piston is in firing TDC.
• If rocker arms on cylinder A1 are loaded, the piston is in overlap TDC.
2. Check valve clearances with cold engine:
• Inlet valves (long rocker arm) = 0.2 mm
• Exhaust valves (short rocker arm) = 0.5 mm
3. Check all valve clearances at two crankshaft positions (firing TDC and overlap TDC of cylinder A1) as per
diagram.
4. Use feeler gage to determine the distance 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 gauge between valve bridge and
rocker arm.
3. Turn adjusting screw (2) with Allen key until
appropriate valve clearance is set.
4. Feeler gauge (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.
Name Size Type Lubricant Value/Standard
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 98).
2. Install cylinder head cover (→ Page 114).
TIM-ID: 0000004352 - 007

M015570/05E 2019-07 | Valve Drive | 113

8.4.3 Cylinder head cover – Removal and installation
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
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

114 | Valve Drive | M015570/05E 2019-07

8.5 Injection Pump / HP Pump
8.5.1 HP fuel pump – Relief bore check
DANGER
Components are moving or rotating.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Operate the engine at low load only. Keep clear of the danger zone of the engine.

WARNING
A high level of noise is produced when the engine is running.
Risk of hearing loss!
• Wear suitable hearing protection.

HP fuel pump – Relief bore

check
1. Check relief bore for oil and fuel discharge by
visual inspection.
2. If relief bore is found dirty, stop the engine,
disable engine start, and clean relief bore.
3. Note the following in case of fluid discharge:
• Heavy discharge means continuous dis-
charge of fluids (leakage). Contact Service.
• Minor discharge of fluids up to 10 drops
per day is normal (moistening) and not
considered a leakage.
TIM-ID: 0000000924 - 009

M015570/05E 2019-07 | Injection Pump / HP Pump | 115

8.6 Injection Valve / Injector
8.6.1 Injector – Replacement
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Injector (→ Spare Parts Catalog)

Injector – Replacement
u Remove injector and install new one (→ Page 117).

TIM-ID: 0000042329 - 002

116 | Injection Valve / Injector | M015570/05E 2019-07

8.6.2 Injector – Removal and installation
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Installation and removal jig F6794703 1
Milling cutter F30452739 1
Slotted screwdriver F30452578 1
Torque screwdriver, 1–5 Nm F30452774 1
Torque wrench, 10–60 Nm F30452769 1
Torque wrench, 60–320 Nm F30452768 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.
2. Remove cylinder head cover (→ Page 114).
TIM-ID: 0000000952 - 013

M015570/05E 2019-07 | Injection Valve / Injector | 117

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

118 | Injection Valve / Injector | M015570/05E 2019-07

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

M015570/05E 2019-07 | Injection Valve / Injector | 119

9. Use slotted screwdriver to check thrust ring
at both line ends for secure seating.

10. Tighten loose thrust ring to specified tightening torque.

Name Size Type Lubricant Value/Standard
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.
Name Size Type Lubricant Value/Standard
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.
Name Size Type Lubricant Value/Standard
HP line Preload torque (Engine oil) 5 Nm to 10 Nm

15. Tighten screw (2) to specified torque using a torque wrench.

Name Size Type Lubricant Value/Standard
Screw M12 Tightening torque 100 Nm + 10 Nm

120 | Injection Valve / Injector | M015570/05E 2019-07

16. Tighten union nut of adapter (limiting valve) to specified torque using a torque wrench.
Name Size Type Lubricant Value/Standard
Union nut Tightening torque 140 Nm + 10 Nm

17. Tighten union nut of adapter (injector) to specified torque using a torque wrench.
Name Size Type Lubricant Value/Standard
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.
Name Size Type Lubricant Value/Standard
Screw Tightening torque 1.5 Nm

Final steps
1. Install cylinder head cover (→ Page 114).
2. Open fuel supply to engine.
TIM-ID: 0000000952 - 013

M015570/05E 2019-07 | Injection Valve / Injector | 121

8.7 Fuel System
8.7.1 Fuel system – Venting
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Diesel fuel

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.

LP fuel system – Venting

1. Loosen flushing/return line of HP pump at
connection (1).
2. Unlock fuel priming pump (2), screw out han-
dle.
3. Operate fuel priming pump (2) with handle
until bubble-free fuel comes out of connec-
tion (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 flushing/return line at connec-
tion (1).

TIM-ID: 0000000953 - 003

122 | Fuel System | M015570/05E 2019-07

8.8 Fuel Filter
8.8.1 Fuel filter – Replacement
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Filter wrench F30379104 1
Engine oil
Easy-change filter (→ Spare Parts Catalog)

WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.

WARNING
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 smoke.
• Wear protective clothing, protective gloves, and safety glasses.
• If contact is made with skin, wash off with water and soap.
• Keep the engine room well ventilated at all times.

Replacing fuel filter

1. Use filter wrench to remove easy-change fil-
ter.
2. Clean sealing surface on filter head.
3. Slightly lubricate seal on easy-change filter
(arrow).
4. Screw on easy-change filter by hand until the
seal makes contact and tighten finger-tight.
5. Replace further easy-change filters in the
same way.
6. Vent fuel system (→ Page 122).
TIM-ID: 0000000927 - 011

M015570/05E 2019-07 | Fuel Filter | 123

8.8.2 Fuel prefilter – Cleaning
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Diesel fuel
Sealing ring (→ Spare Parts Catalog)

WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.

WARNING
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 smoke.
• Wear protective clothing, protective gloves, and safety glasses.
• If contact is made with skin, wash off with water and soap.
• Keep the engine room well ventilated at all times.

Fuel prefilter – Cleaning

1. Close fuel supply.
2. Remove nuts from filter head.
3. Remove filter bowl and drain fuel into a suita-
ble container.
4. Unscrew 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.
TIM-ID: 0000004936 - 008

10. Open fuel supply.

124 | Fuel Filter | M015570/05E 2019-07

8.8.3 Fuel prefilter – Differential pressure gauge check and adjustment
DANGER
Components are moving or rotating.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Operate the engine at low load only. Keep clear of the danger zone of the engine.

WARNING
A high level of noise is produced when the engine is running.
Risk of hearing loss!
• Wear suitable hearing protection.

Adjusting differential pressure

gauge
1. When putting the new filter element into op-
eration: Align adjustable pointer (2) with
pressure-indicating pointer (3) of pressure
gauge (1).
2. Verify that differential pressure is within the
limit.

Fuel prefilter – Differential pressure check

1. With the engine running at full load or rated power, read off pressure at gauge (1).
2. If differential pressure as indicated between position of adjustable pointer (2) and pressure-indicating point-
er (3) of pressure gauge is ≥ 0.3 bar, flush filter element of the cut-in filter (→ Page 128).
TIM-ID: 0000004925 - 012

M015570/05E 2019-07 | Fuel Filter | 125

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

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Diesel fuel
Gasket (→ Spare Parts Catalog)

DANGER
Components are moving or rotating.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Operate the engine at low load only. Keep clear of the danger zone of the engine.

WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.

WARNING
Liquid or gaseous media, e.g. fuel, are poisonous.
Escaping vapors of highly volatile media, e.g. fuel or ether.
Risk of fatal injury through swallowing; risk of poisoning through inhalation; irritation to eyes
and skin!
• Seek medical attention immediately; do not induce vomiting.
• Do not inhale vapors or smoke.
• Wear protective clothing, protective gloves, and safety glasses.
• If contact is made with skin, wash off with water and soap.
• Keep the engine room well ventilated at all times.

WARNING
A high level of noise is produced when the engine is running.
Risk of hearing loss!
• Wear suitable hearing protection.
TIM-ID: 0000004929 - 012

126 | Fuel Filter | M015570/05E 2019-07

Fuel prefilter – Draining
Note: Only for dual fuel prefilter:
1. Cut out filter to be drained.
1 Left filter cut in
2 Right filter cut in

2. Open threaded vent plug (5) of filter to be

drained.
3. Unlock drain valve (6) by pressing toggle and
open it.
4. Drain water and contaminants from filter until
pure fuel emerges.
5. Close drain valve (6).
6. Remove screws for cover and take off cov-
er (2).
7. Fill filter housing with clean fuel.
8. Place new gasket in cover (2).
9. Fit cover with gasket and secure it with
screws.
Note: Only for dual fuel prefilter:
10. Cut in the cut-out filter again.
11. Close threaded vent plug (5) when fuel
emerges from system.
TIM-ID: 0000004929 - 012

M015570/05E 2019-07 | Fuel Filter | 127

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

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Diesel fuel

DANGER
Components are moving or rotating.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Operate the engine at low load only. Keep clear of the danger zone of the engine.

WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.

WARNING
Liquid or gaseous media, e.g. fuel, are poisonous.
Escaping vapors of highly volatile media, e.g. fuel or ether.
Risk of fatal injury through swallowing; risk of poisoning through inhalation; irritation to eyes
and skin!
• Seek medical attention immediately; do not induce vomiting.
• Do not inhale vapors or smoke.
• Wear protective clothing, protective gloves, and safety glasses.
• If contact is made with skin, wash off with water and soap.
• Keep the engine room well ventilated at all times.

WARNING
A high level of noise is produced when the engine is running.
Risk of hearing loss!
• Wear suitable hearing protection.
TIM-ID: 0000004937 - 028

128 | Fuel Filter | M015570/05E 2019-07

Note: Only with duplex fuel prefilter:

Cutting out the contaminated

fuel prefilter
1 Left filter cut in
2 Right filter cut in

Flushing the fuel prefilter

1. Open threaded vent plug (5) of filter to be
flushed.
Note: Catch fuel and contaminants in a suitable
container and dispose of properly.
2. Drain fuel by actuating drain valve (6):
a) Press on toggle of drain valve (6) to un-
lock it and turn it anticlockwise by 90°
into the vertical position.
Result: Fuel flows from filtered side back to unfil-
tered side, flushing contaminants down-
wards out of the filter.
b) Drain fuel until all contaminants have
been flushed out of the bowl.
c) Turn toggle on valve by 90° clockwise
and make sure that it is engaged in the
correct position "closed" (horizontal posi-
tion) and that fuel no longer emerges.
d) If the valve toggle does not close proper-
ly: Open and close briefly several times
until contaminants have been flushed off
completely.
Result: • Toggle of valve closes properly and
engages in horizontal position when
the valve is closed.
TIM-ID: 0000004937 - 028

• Drain valve (6) is leak-tight.

Final steps
1. Cut in the cut-out filter again.
2. Vent fuel system.
• When fuel emerges from system, close vent plug (5).
Name Size Type Lubricant Value/Standard
Threaded vent plug M6 Tightening torque 4 Nm

M015570/05E 2019-07 | Fuel Filter | 129

3. Check differential pressure (→ Page 125).
4. If flushing did not lead to an improvement of the differential pressure, replace filter element (→ Page 131).

TIM-ID: 0000004937 - 028

130 | Fuel Filter | M015570/05E 2019-07

8.8.6 Fuel prefilter – Filter element replacement
Preconditions
☑ Engine is stopped and starting disabled. (only with single-stage fuel prefilter)

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Diesel fuel
Filter element (→ Spare Parts Catalog)
Seal (→ Spare Parts Catalog)

DANGER
Components are moving or rotating.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Operate the engine at low load only. Keep clear of the danger zone of the engine.

WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.

WARNING
Liquid or gaseous media, e.g. fuel, are poisonous.
Escaping vapors of highly volatile media, e.g. fuel or ether.
Risk of fatal injury through swallowing; risk of poisoning through inhalation; irritation to eyes
and skin!
• Seek medical attention immediately; do not induce vomiting.
• Do not inhale vapors or smoke.
• Wear protective clothing, protective gloves, and safety glasses.
• If contact is made with skin, wash off with water and soap.
• Keep the engine room well ventilated at all times.

NOTICE
Damage to component!
Severe material damage!
• For filter replacement with the engine running, operate the engine at low engine load.
• The filter which is to be replaced must be cut out for a brief period only.
TIM-ID: 0000004944 - 009

M015570/05E 2019-07 | Fuel Filter | 131

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

2. Release threaded vent plug (5) of contaminat-

ed filter.
3. Unlock drain valve (6) by pressing knob 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).
9. Fill filter housing with clean fuel.
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. Adjust differential pressure display instru-
ment (→ Page 125). TIM-ID: 0000004944 - 009

132 | Fuel Filter | M015570/05E 2019-07

8.9 Charge-Air Cooling
8.9.1 Intercooler – Checking condensate drain for coolant leakage and obstruction
DANGER
Components are moving or rotating.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Operate the engine at low load only. Keep clear of the danger zone of the engine.

WARNING
A high level of noise is produced when the engine is running.
Risk of hearing loss!
• Wear suitable hearing protection.

WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and hearing protection.

Intercooler – Checking conden-

sate drain for coolant leakage
and obstruction
1. With the engine running, verify that air es-
capes from the condensate drain bore(s) at
driving end, left and right engine side. If no
air escapes:
• Clean condensate drain bore(s)
• Blow out with compressed air
2. If a large amount of coolant is continuously
discharged, the intercooler is leaking. Con-
tact Service.

Emergency measures prior to engine start with a leaking intercooler

1. Remove the injectors (→ Page 117).
2. Bar engine manually (→ Page 98).
3. Bar engine with starting system to blow out combustion chambers (→ Page 99).
4. Install the injectors (→ Page 117).
TIM-ID: 0000000955 - 007

M015570/05E 2019-07 | Charge-Air Cooling | 133

8.10 Air Filter
8.10.1 Air filter ‒ Replacement
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Air filter (→ Spare Parts Catalog)

Air filter ‒ Replacement

1. Remove air filter and install new one (→ Page 135).
2. Reset signal ring of service indicator (→ Page 136).

TIM-ID: 0000000903 - 005

134 | Air Filter | M015570/05E 2019-07

8.10.2 Air filter – Removal and installation
Preconditions
☑ Engine is stopped and starting disabled.

DANGER
Falling from great heights.
Risk of serious injury – danger to life!
• When working high on the equipment, always use suitable ladders or work platforms.
• Use personal protective equipment.

WARNING
For all described tasks at the genset:
Risk of injury!
• For all tasks, the respective required personal protective equipment (safety shoes, ear protection,
protective gloves, safety goggles, respiratory protection, etc.) is to be used.

NOTICE
Stepping or climbing on the genset to perform installation tasks is to be avoided.
Otherwise, there is a risk of component damage or leakage!
• Use suitable and approved climbing aids or work platforms.

Removing and installing air fil-

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

M015570/05E 2019-07 | Air Filter | 135

8.11 Air Intake
8.11.1 Contamination indicator – Signal ring position check
Preconditions
☑ Engine is stopped and starting disabled.

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

Checking signal ring position

1. If the signal ring is completely visible in the
viewing window (2), replace air filter
(→ Page 134).
2. After installation of new filter, press reset
button (1).
Result: Engaged plunger with signal ring returns to
initial position.

TIM-ID: 0000005484 - 010

136 | Air Intake | M015570/05E 2019-07

8.12 Starting Equipment
8.12.1 Air starter – Manual operation
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
A high level of noise is produced when the engine is running.
Risk of hearing loss!
• Wear suitable hearing protection.

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 - 007

M015570/05E 2019-07 | Starting Equipment | 137

8.13 Lube Oil System, Lube Oil Circuit
8.13.1 Engine oil level – Check
Preconditions
☑ Engine is stopped and starting disabled.

WARNING
Oil is hot.
Oil can contain residue/substances which are harmful to health.
Risk of injury and poisoning!
• Allow the product to cool to below 50 °C before beginning work.
• Wear protective clothing, protective gloves and goggles/safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.

WARNING
Oils/oil vapors are combustible/explosive.
Risk of fire and explosion!
• Avoid open flames, electric sparks and ignition sources.
• Do not smoke.

Checking engine oil level after

extended standstill
1. Pull out dipstick from guide tube and wipe it.
2. Insert oil dipstick into guide tube up to the
stop, pull it out after approx. 10 seconds and
check oil level.
Note: After extended standstill, the oil level may be
up to 2 cm above mark (1). This may be
caused e.g. by oil from oil filters and heat ex-
changers flowing back into the oil pan. After
extended standstill, the oil level "2 cm above
mark (2)" is the minimum oil level.
3. Oil level must be at least 2 cm above
mark (2).
4. If necessary, top up with oil, maximum to
mark (1) (→ Page 139).
5. Insert oil dipstick into guide tube up to the
stop.

Checking oil level immediately after engine stop

1. 5 minutes after stopping the engine, pull out oil dipstick from guide tube and wipe it.
TIM-ID: 0000000931 - 019

2. Insert oil dipstick into guide tube up to the stop, pull it out after approx. 10 seconds and check oil level.
3. Oil level must be between marks (1) and (2).
4. If necessary, top up with oil, maximum to mark (1) (→ Page 139).
5. Insert oil dipstick into guide tube up to the stop.

138 | Lube Oil System, Lube Oil Circuit | M015570/05E 2019-07

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

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Torque wrench, 60–320 Nm F30452768 1
Ratchet bit F30027341 1
Engine oil
Sealing ring (→ Spare Parts Catalog)

WARNING
Oil is hot.
Oil can contain residue/substances which are harmful to health.
Risk of injury and poisoning!
• Allow the product to cool to below 50 °C before beginning work.
• Wear protective clothing, protective gloves and goggles/safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.

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

Oil change with semirotary hand pump: Extracting engine oil

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

Engine oil treatment

1. Check layer thickness of oil residues in the centrifugal oil filter, clean centrifugal oil filter and replace filter
sleeve (→ Page 144).
2. Replace engine oil filter (→ Page 143).
TIM-ID: 0000000930 - 015

M015570/05E 2019-07 | Lube Oil System, Lube Oil Circuit | 139

Draining residual oil from equip-
ment carrier (only with un-
scheduled engine oil change)
1. Provide a suitable container in which to col-
lect the engine oil.
2. Remove drain plug (1) and drain engine oil
from engine oil heat exchanger and from en-
gine oil filter.
3. Remove drain plugs (2) and (3) and drain en-
gine oil.
4. Install drain plug(s) with new sealing ring.

5. Use torque wrench to tighten drain plugs (2) and (3) to specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw M26 x 1.5 Tightening torque (Engine oil) 100 Nm +10 Nm

Filling with new engine oil

1. Open cover (1) on filler neck.
2. Pour oil in at filler neck up to 'max.' mark at
oil dipstick.
3. Close cover (1) on filler neck.
4. Check engine oil level (→ Page 138).
5. Bar engine with starting system (→ Page 99).

TIM-ID: 0000000930 - 015

140 | Lube Oil System, Lube Oil Circuit | M015570/05E 2019-07

8.13.3 Engine oil – Sample extraction and analysis
Preconditions
☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
MTU test kit F6798833 1
Engine oil

DANGER
Components are moving or rotating.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Operate the engine at low load only. Keep clear of the danger zone of the engine.

WARNING
Oil is hot.
Oil can contain residue/substances which are harmful to health.
Risk of injury and poisoning!
• Allow the product to cool to below 50 °C before beginning work.
• Wear protective clothing, protective gloves and goggles/safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.

WARNING
A high level of noise is produced when the engine is running.
Risk of hearing loss!
• Wear suitable hearing protection.

Engine oil – Sample extraction

and analysis
1. With the engine running at operating temper-
ature, open screw (1) on carrier of centrifugal
oil filter support by 1 to 2 rotations.
2. Drain approx. 2 liters engine oil to flush out
the oil sludge.
3. Drain approx. 1 liter engine oil into a clean
container.
TIM-ID: 0000000932 - 011

4. Close screw (1) and tighten to specified tightening torque.

Name Size Type Lubricant Value/Standard
Screw - Tightening torque (Engine oil) 20 Nm +2 Nm

M015570/05E 2019-07 | Lube Oil System, Lube Oil Circuit | 141

5. Use equipment and chemicals in MTU test kit to analyze engine oil for:
• Dispersancy (spot test)
• Water content
• Dilution by fuel

TIM-ID: 0000000932 - 011

142 | Lube Oil System, Lube Oil Circuit | M015570/05E 2019-07

8.14 Oil Filtration / Cooling
8.14.1 Engine oil filter – Replacement
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Filter wrench F30379104
Engine oil
Oil filter (→ Spare Parts Catalog)

WARNING
Oil is hot.
Oil can contain residue/substances which are harmful to health.
Risk of injury and poisoning!
• Allow the product to cool to below 50 °C before beginning work.
• Wear protective clothing, protective gloves and goggles/safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.

Engine oil filter – Replacement

1. Use filter wrench to remove engine oil filter.
2. Clean sealing surface on connecting piece.
3. Check condition of new engine oil filter seal-
ing ring and coat it with engine oil (arrow).
4. Screw on and tighten engine oil filter by
hand.
5. Replace further engine oil filters in the same
way.
6. Check engine oil level (→ Page 138).
7. After oil change and oil filter replacement,
bar engine with starting system (→ Page 99).
TIM-ID: 0000000957 - 006

M015570/05E 2019-07 | Oil Filtration / Cooling | 143

8.14.2 Centrifugal oil filter – Cleaning and filter sleeve replacement
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Filter wrench F30379104 1
Torque wrench, 4–20 Nm F30044239 1
Ratchet bit F30027340 1
Cold cleaner (Hakutex 60) X00056750 1
Assembly compound (Kluthe Hakuform 30-15) X00067260 1
Filter sleeve (→ Spare Parts Catalog)
Sealing ring (→ Spare Parts Catalog)
Sealing ring (→ Spare Parts Catalog)

WARNING
Oil is hot.
Oil can contain residue/substances which are harmful to health.
Risk of injury and poisoning!
• Allow the product to cool to below 50 °C before beginning work.
• Wear protective clothing, protective gloves and goggles/safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.

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 hearing protection.

TIM-ID: 0000031179 - 004

144 | Oil Filtration / Cooling | M015570/05E 2019-07

Centrifugal oil filter – Cleaning
and filter sleeve replacement
1. Loosen screw (1) and remove.
2. Remove clamp (3) and take off hood (2).
3. Carefully remove rotor assembly (5) from
housing.
4. Hold rotor assembly (5) firmly in position with
filter wrench and undo knurled nut (7).
5. Take off rotor cap (8).
6. Remove filter sleeve (9), stiffener plate (10)
and sealing ring (11).
7. Measure thickness of oil residue on filter
sleeve.
8. If maximum layer thickness (30 mm) is ex-
ceeded, shorten maintenance interval.
9. Remove standpipe (12) from lower rotor sec-
tion (13).
10. Wash hood (2), rotor cap (8), stiffener
plate, (10) standpipe (12), rotor lower sec-
tion (13) and nozzles (14) with cold cleaner
and blow out with compressed air. Do not
use sharp-edged implements for cleaning.
11. Check nozzles (14) for obstructions.
12. Press standpipe (12) onto rotor lower sec-
tion (13).
13. Insert new filter sleeve (9) with stiffener
plate (10) into rotor cap (8), ensuring that
smooth surface of filter sleeve (9) faces rotor
cap (8).
14. Check sealing ring (11), replace if necessary.
Coat sealing ring with assembly compound
and insert in groove of rotor cap (8).
15. Place rotor cap (8) onto standpipe (12).
16. Hold rotor assembly (5) firmly in position with
filter wrench and tighten knurled nut (7).
17. Lubricate bearings of rotor assembly (5), in-
sert into housing (6) and check for ease of
movement.
18. Check sealing ring (4), replace if necessary.
Fit sealing ring on housing (6).
19. Fit hood (2).
20. Tighten screw (1) by hand.
21. Install clamp (3) and tighten to specified torque using a torque wrench.
Name Size Type Lubricant Value/Standard
Clamp Tightening torque 8 Nm +1 Nm
TIM-ID: 0000031179 - 004

22. Tighten screw (1) to specified torque using a torque wrench.

Name Size Type Lubricant Value/Standard
Screw Tightening torque 5 Nm +2 Nm

M015570/05E 2019-07 | Oil Filtration / Cooling | 145

8.15 Coolant Circuit, General, High-Temperature Circuit
8.15.1 Engine coolant – Level check
Preconditions
☑ Engine is stopped and starting disabled.
☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.

WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.

Checking coolant level at 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 coolant level at exter-

nal cooler:
Note: Engine coolant must be visible at marker
plate.
1. Check engine coolant level.
2. Top up engine coolant as necessary
(→ Page 150).
3. Check and clean cap.
4. Place cap on filler neck and close.

Checking coolant level with 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 150).
TIM-ID: 0000000937 - 015

146 | Coolant Circuit, General, High-Temperature Circuit | M015570/05E 2019-07

Checking engine coolant level at
sight glass
1. Check coolant level (coolant level must be
between “min.” and “max.” mark).
2. Top up coolant if necessary (→ Page 150).
TIM-ID: 0000000937 - 015

M015570/05E 2019-07 | Coolant Circuit, General, High-Temperature Circuit | 147

8.15.2 Engine coolant – Change
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Coolant

Engine coolant change

1. Drain engine coolant (→ Page 149).
2. Fill with engine coolant (→ Page 150).

TIM-ID: 0000000036 - 031

148 | Coolant Circuit, General, High-Temperature Circuit | M015570/05E 2019-07

8.15.3 Engine coolant – Draining
Preconditions
☑ Engine is stopped and starting disabled.

WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.

Preparatory steps
1. Provide a suitable container in which to collect 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:
• Elbow of HT engine coolant pump
• Crankcase, left and right sides.
• Preheating unit

5. Use torque wrench to tighten shut-off cock on elbow of engine coolant pump to specified tightening torque.
Name Size Type Lubricant Value/Standard
Spindle SW11 Tightening torque 12 Nm

6. Use torque wrench to tighten shut-off cocks on crankcase, left and right sides, to specified tightening torque.
TIM-ID: 0000000936 - 006

Name Size Type Lubricant Value/Standard

Spindle SW11 Tightening torque 12 Nm

7. Close all remaining open drain points.

8. Place breather valve on filler neck and close.

M015570/05E 2019-07 | Coolant Circuit, General, High-Temperature Circuit | 149

8.15.4 Engine coolant – Filling
Preconditions
☑ Engine is stopped and starting disabled.
☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Coolant

WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.

WARNING
Coolant contains antifreeze and is toxic.
Risk of poisoning and slipping!
• Avoid contact with eyes and skin.
• Do not inhale vapors or mist, wear breathing protection.
• Do not eat, drink, smoke when working with antifreeze.
• Wear protective clothing, protective gloves and goggles/safety mask.
• Wipe up escaped/spilled coolant immediately.

NOTICE
Cold coolant in hot engine can cause thermal stress.
Possible formation of cracks in the engine!
• Fill / top up coolant only into cold engine.

Preparatory steps
1. Turn valve cover on coolant expansion
tank (1) counterclockwise to the first stop
and release pressure.
2. Continue to turn valve cover counterclock-
wise and remove.
TIM-ID: 0000087441 - 001

150 | Coolant Circuit, General, High-Temperature Circuit | M015570/05E 2019-07

Note: An empty engine must always be filled with coolant from below, i.e. using the drain valve connection of the
engine coolant pump.
Filling with coolant from below
using a pump
1. Connect appropriate pump with hose to drain
valve of engine coolant pump (arrow).

2. Loosen vent line union at distributor (1).

3. Open drain valve and pump coolant into en-
gine at 0.5 bar minimum.
4. Tighten union (1) if coolant leaks out at loose
union.
5. Fill expansion tank until coolant level reaches
overflow edge.

6. Close drain valve and use torque wrench to tighten to specified tightening torque.
Name Size Type Lubricant Value/Standard
Spindle 11 A/F Tightening torque 12 Nm

7. Check satisfactory condition of valve cover on coolant expansion tank, clean sealing faces if required.
8. Fit valve cover and close it.
9. Start engine (→ Page 71).
TIM-ID: 0000087441 - 001

10. After 10 seconds of running the engine without load, stop engine (→ Page 76).
11. Turn valve cover on coolant expansion tank counterclockwise to the first stop and release pressure.
12. Continue to turn valve cover counterclockwise and remove.
13. Check coolant level (→ Page 146) and top up coolant as necessary:
a) Fill in coolant in expansion tank via filler neck until coolant level at top edge of filler neck remains con-
stant.
b) Fit valve cover and close it.
14. Repeat the steps from "Start engine" (→ Step 9) until coolant no longer needs to be topped up.
15. Disconnect pump and hose.

M015570/05E 2019-07 | Coolant Circuit, General, High-Temperature Circuit | 151

Alternatively: Filling coolant
through filler neck
1. Loosen vent line union at distributor (1).
2. Fill in coolant in expansion tank via filler neck
until coolant level at top edge of filler neck
remains constant.
3. Tighten union (1) if coolant leaks out at loose
union.
4. Check satisfactory condition of valve cover
on coolant expansion tank, clean sealing
faces if required.
5. Fit valve cover and close it.
6. Start engine (→ Page 71).
7. After 10 seconds of running the engine with-
out load, stop engine (→ Page 76).
8. Turn valve cover on coolant expansion tank
counterclockwise to the first stop and release
pressure.
9. Turn valve cover counterclockwise and re-
move.
10. Check coolant level (→ Page 146) and top up
with coolant via filler neck as necessary:
a) Fill in coolant in expansion tank via filler
neck until coolant level at top edge of fill-
er neck remains constant.
b) Fit valve cover and close it.
11. Repeat the steps from “Start engine”
(→ Step 6) until coolant no longer needs to be
topped up.

Final steps
1. Start engine and run it without load for some minutes.
2. Check coolant level (→ Page 146) and top up coolant as necessary.

TIM-ID: 0000087441 - 001

152 | Coolant Circuit, General, High-Temperature Circuit | M015570/05E 2019-07

8.15.5 Engine coolant pump – Relief bore check
DANGER
Components are moving or rotating.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Operate the engine at low load only. Keep clear of the danger zone of the engine.

WARNING
Exhaust gases are harmful to health and may cause cancer.
Risk of poisoning and suffocation!
• Keep the engine room well-ventilated at all times.
• Repair leaking exhaust pipework immediately.

WARNING
A high level of noise is produced when the engine is running.
Risk of hearing loss!
• Wear suitable hearing protection.

Engine coolant pump – Relief

bore check
1. Check relief bore for oil and coolant dis-
charge.
• Permissible coolant discharge: up to 10
drops per hour
• Permissible oil discharge: up to 5 drops
per hour
• If discharge exceeds the specified limits:
Contact Service.
2. If the relief bore is dirty, stop the engine
(→ Page 76) and disable engine start, observe
general safety instructions for maintenance
and repair.
3. Clean relief bore with a wire.
TIM-ID: 0000000961 - 016

M015570/05E 2019-07 | Coolant Circuit, General, High-Temperature Circuit | 153

8.15.6 Engine coolant – Sample extraction and analysis
Preconditions
☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
MTU test kit F6798833 1

DANGER
Components are moving or rotating.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Operate the engine at low load only. Keep clear of the danger zone of the engine.

WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.

WARNING
Coolant contains antifreeze and is toxic.
Risk of poisoning and slipping!
• Avoid contact with eyes and skin.
• Do not inhale vapors or mist, wear breathing protection.
• Do not eat, drink, smoke when working with antifreeze.
• Wear protective clothing, protective gloves and goggles/safety mask.
• Wipe up escaped/spilled coolant immediately.

WARNING
Exhaust gases are harmful to health and may cause cancer.
Risk of poisoning and suffocation!
• Keep the engine room well-ventilated at all times.
• Repair leaking exhaust pipework immediately.

WARNING
A high level of noise is produced when the engine is running.
Risk of hearing loss!
• Wear suitable hearing protection.
TIM-ID: 0000000938 - 016

154 | Coolant Circuit, General, High-Temperature Circuit | M015570/05E 2019-07

Engine coolant – Sample extrac-
tion and analysis
1. With the engine running, open drain valve (1).
2. Flush sample-extraction point by draining ap-
prox. 1 liter coolant.
3. Drain approx. 1 liter coolant into a clean con-
tainer.

4. Use a torque wrench to tighten shut-off cock (2) to specified tightening torque.
Name Size Type Lubricant Value/Standard
Spindle 11 A/F Tightening torque 12 Nm

5. Using the equipment and chemicals from the MTU test kit, examine coolant for:
• antifreeze concentration
• Amount of corrosion protection oil
• pH value
6. For engine coolant change intervals, refer to (→ MTU Fluids and Lubricants Specifications (A001061/..)).
TIM-ID: 0000000938 - 016

M015570/05E 2019-07 | Coolant Circuit, General, High-Temperature Circuit | 155

8.16 Low-Temperature Circuit
8.16.1 Charge-air coolant level – Check
Preconditions
☑ Engine is stopped and starting disabled.
☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.

DANGER
Falling from great heights.
Risk of serious injury – danger to life!
• When working high on the equipment, always use suitable ladders or work platforms.
• Use personal protective equipment.

WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.

WARNING
Coolant contains antifreeze and is toxic.
Risk of poisoning and slipping!
• Avoid contact with eyes and skin.
• Do not inhale vapors or mist, wear breathing protection.
• Do not eat, drink, smoke when working with antifreeze.
• Wear protective clothing, protective gloves and goggles/safety mask.
• Wipe up escaped/spilled coolant immediately.

Checking charge-air coolant level at filler neck

1. Turn cover on coolant expansion tank counterclockwise to the first stop and allow pressure to escape.
2. Continue to turn cover 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 161).
5. Check that cover is in serviceable condition.
6. Clean sealing surfaces as necessary.
7. Fit cover and close it.
TIM-ID: 0000000042 - 009

156 | Low-Temperature Circuit | M015570/05E 2019-07

Checking charge-air coolant level by means of level sensor
Note: The charge-air coolant level is monitored automatically by the engine control system.
1. Switch on engine control system and check readings on the display.
2. Top up with charge-air coolant as necessary (→ Page 161).
TIM-ID: 0000000042 - 009

M015570/05E 2019-07 | Low-Temperature Circuit | 157

8.16.2 Charge-air coolant – Change
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Coolant

Charge-air coolant – Change

1. Drain charge-air coolant (→ Page 159).
2. Fill with charge-air coolant (→ Page 161).

TIM-ID: 0000000041 - 011

158 | Low-Temperature Circuit | M015570/05E 2019-07

8.16.3 Charge-air coolant – Draining
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Sealing ring (→ Spare Parts Catalog)

WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.

Draining charge-air coolant

1. Provide a suitable receptacle to catch the coolant.
2. Turn breather valve of coolant expansion tank counterclockwise until the first stop and allow pressure to es-
cape.
3. Continue to turn breather valve counterclockwise and remove.
4. Draw off separated corrosion inhibitor oil in expansion tank through the filler neck.
5. Open drain valve (1) at the LT coolant pump
and drain coolant.
TIM-ID: 0000000963 - 002

M015570/05E 2019-07 | Low-Temperature Circuit | 159

6. Open drain valves at the coolant lines to and
from the charge-air cooler.

7. Drain residual charge-air coolant from

charge-air cooler (1).

Final steps
1. Tighten drain valve on LT coolant pump to specified torque using a torque wrench.
Name Size Type Lubricant Value/Standard
Spindle 11 A/F Tightening torque 12 Nm

2. Close all open drain points.

3. Position breather valve on filler neck and close.
TIM-ID: 0000000963 - 002

160 | Low-Temperature Circuit | M015570/05E 2019-07

8.16.4 Charge-air coolant – Filling
Preconditions
☑ Engine is stopped and starting disabled.
☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Charge-air coolant

WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.

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 coolant expansion tank
counterclockwise until the first stop and al-
low pressure to escape.
2. Continue to turn breather valve counterclock-
wise and remove.
TIM-ID: 0000000962 - 003

M015570/05E 2019-07 | Low-Temperature Circuit | 161

Filling with charge-air coolant
using pump
1. Connect suitable pump with hose to the drain
valve of the charge-air coolant pump (1) or
drain and filling line between engine and
cooler.

2. Loosen the vent line union (1) at the distribu-

tor piece.

3. Release plug screws (1) at the coolant lines

to and from the charge-air cooler.
4. Open drain valve for charge-air coolant pump
and pump coolant into engine with a pressure
of at least 0.5 bar until coolant escapes from
the open connections.
5. Vent the external charge-air coolant system if
it is installed.
6. Tighten plug screws on coolant lines and vent
line union working from bottom to top.
TIM-ID: 0000000962 - 003

7. Fill coolant expansion tank until coolant level

reaches the bottom edge of the filler neck.

162 | Low-Temperature Circuit | M015570/05E 2019-07

8. Tighten drain valve on charge-air coolant pump to specified torque using a torque wrench.
Name Size Type Lubricant Value/Standard
Spindle 11 A/F Tightening torque 12 Nm

9. Check proper condition of breather valve and clean sealing faces if required.
10. Fit breather valve and close it.
11. Start engine (→ Page 71).
Note: There must be no decrease of pressure or excessive temperature.
12. Observe the coolant temperature and pressure.
Result: If the pressure drops or the temperature limit values are exceeded, shut down engine.
13. After 10 seconds of running the engine without load, shut down the engine (→ Page 76).
14. Turn breather valve of coolant expansion tank counterclockwise until the first stop and allow pressure to es-
cape.
15. Continue to turn breather valve counterclockwise and remove.
16. If an external charge-air coolant system is installed, vent it once again.
17. Check coolant level (→ Page 156) and top up coolant as required:
a) Add coolant via filler neck on expansion tank until the coolant level at bottom edge of filler neck remains
constant.
b) Fit breather valve and close it.
18. Repeat the steps from starting the engine (→ Step 11) until no coolant needs to be topped up any more.
19. Disconnect pump and hose.

Alternatively: Filling with cool-

ant through filler neck
1. Release the vent line union (1) at the distribu-
tor piece.
TIM-ID: 0000000962 - 003

M015570/05E 2019-07 | Low-Temperature Circuit | 163

2. Release plug screws (1) at the coolant lines
to and from the charge-air cooler.
3. Fill in coolant via filler neck on expansion
tank until the coolant level at bottom edge of
filler neck remains constant.
4. Vent the external charge-air coolant system if
it is installed.
5. Tighten plug screws on coolant lines and vent
line union working from bottom to top.
6. Check proper condition of breather valve and
clean sealing faces if required.
7. Fit breather valve and close it.
8. Start engine (→ Page 71).
Note: There must be no decrease of pressure or ex-
cessive temperature.
9. Observe the coolant temperature and pres-
sure.
Result: If the pressure drops or the temperature limit
values are exceeded, shut down engine.
10. After 10 seconds of running the engine with-
out load, shut down the engine (→ Page 76).
11. Turn breather valve of coolant expansion tank
counterclockwise until the first stop and al-
low pressure to escape.
12. Turn valve cover counterclockwise and re-
move.
13. If an external charge-air coolant system is in-
stalled, vent it once again.
14. Check coolant level (→ Page 156) and top up
coolant as required:
a) Add coolant via filler neck on expansion
tank until the coolant level at bottom
edge of filler neck remains constant.
b) Fit breather valve and close it.
15. Repeat the steps from starting the engine
(→ Step 8) until no coolant needs to be top-
ped up any more.

TIM-ID: 0000000962 - 003

164 | Low-Temperature Circuit | M015570/05E 2019-07

8.16.5 Charge-air coolant pump – Relief bore check
DANGER
Components are moving or rotating.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Operate the engine at low load only. Keep clear of the danger zone of the engine.

WARNING
A high level of noise is produced when the engine is running.
Risk of hearing loss!
• Wear suitable hearing protection.

WARNING
Hot components/surfaces.
Risk of burns!
• Allow the engine to cool down to below 50 °C before beginning work.
• Wear suitable protective equipment/thermal gloves.
• Avoid unprotected contact with hot surfaces.

Charge-air coolant pump – Re-

lief bore check
1. Check relief bore for oil and coolant dis-
charge.
2. Shut down engine (→ Page 76) and disable
engine start, observe general safety instruc-
tions “Maintenance and Repair”.
3. Clean relief bore with 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 - 006

M015570/05E 2019-07 | Low-Temperature Circuit | 165

8.16.6 Charge-air coolant – Sample extraction and analysis
Preconditions
☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
MTU test kit F6798833 1

DANGER
Components are moving or rotating.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Operate the engine at low load only. Keep clear of the danger zone of the engine.

WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.

WARNING
A high level of noise is produced when the engine is running.
Risk of hearing loss!
• Wear suitable hearing protection.

Charge-air coolant – Sample ex-

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

TIM-ID: 0000000942 - 003

4. Tighten drain valve (1) to specified tightening using a torque wrench.

Name Size Type Lubricant Value/Standard
Spindle 11 A/F Tightening torque 12 Nm

166 | Low-Temperature Circuit | M015570/05E 2019-07

5. Using the equipment and chemicals of the MTU test kit, check the charge-air coolant for:
• antifreeze concentration;
• corrosion inhibitor concentration;
• pH value.
6. Change charge-air coolant according to the intervals specified in the MTU Fluids and Lubricants Specifica-
tions (→ Page 158).
TIM-ID: 0000000942 - 003

M015570/05E 2019-07 | Low-Temperature Circuit | 167

8.17 Belt Drive
8.17.1 Drive belt – Condition check
Preconditions
☑ Engine is stopped and starting disabled.

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

Drive belt – Condition check

1. Remove cover.

2. Checking drive belt condition:

Item Findings Action
Drive belt A Singular cracks None
Drive belt B Cracks on entire circumference Replace (→ Page 171)
Drive belt C Chunking
Drive belt Belt is oily, shows signs of over-
heating

3. Install cover.
TIM-ID: 0000000920 - 014

168 | Belt Drive | M015570/05E 2019-07

8.18 Battery-Charging Generator
8.18.1 Battery-charging generator drive – Drive belt tension adjustment
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Torque wrench, 60–320 Nm F30452768 1
Ratchet adapter F30027341 1
Torque wrench, 10–60 Nm F30452769 1
Ratchet adapter F30027340 1

WARNING
Belt tensioner spring is pretensioned.
Risk of hands being crushed!
• Lock belt tensioner in position.
• Only use specified tools and devices.

Adjusting belt tension

1. Remove protective cover.
2. Slacken screws (1) and (2) by half a turn.
Result: Belt tensioner moves against the drive belt
and tensions it.

3. Tighten screw (2) with torque wrench to the specified tightening torque.
TIM-ID: 0000000945 - 008

Name Size Type Lubricant Value/Standard

Screw M10 Tightening torque 60 Nm +5 Nm

4. Tighten screw (1) with torque wrench to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw M10 Tightening torque 42 Nm

5. Install protective cover.

M015570/05E 2019-07 | Battery-Charging Generator | 169

8.18.2 Battery-charging generator drive – Drive belt condition check
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Belt tension tester Y4345711 1

Preparatory steps
1. Remove protective cover.
2. Check belt condition visually (→ Page 168).

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 169).

TIM-ID: 0000000946 - 002

170 | Battery-Charging Generator | M015570/05E 2019-07

8.18.3 Battery-charging generator drive – Drive belt replacement
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Torque wrench, 60–320 Nm F30452768 1
Ratchet bit F30027341 1
Torque wrench, 10–60 Nm F30452769 1
Ratchet bit F30027340 1
Drive belt (→ Spare Parts Catalog)

WARNING
Belt tensioner spring is pretensioned.
Risk of hands being crushed!
• Lock belt tensioner in position.
• Only use specified tools and devices.

Battery-charging generator drive – Drive belt replacement

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

8. Tighten screw (3) with torque wrench to specified tightening torque.

Name Size Type Lubricant Value/Standard
TIM-ID: 0000022970 - 007

Screw M10 Tightening torque 60 Nm +5 Nm

9. Tighten screw (2).

10. Install protective cover.
11. Readjust drive belt tension after 30 minutes and after 8 hours engine runtime (→ Page 169).

M015570/05E 2019-07 | Battery-Charging Generator | 171

8.19 Cabling
8.19.1 Engine cabling – Check
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Solvent (isopropyl alcohol) X00058037 1

Checking engine cabling

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 that cable clamps are secure, tighten loose clamps.
6. Replace faulty cable clamps.
7. Visually inspect the following electrical components for damage:
• Connector housings
• Contacts
• Sockets
• Cables and terminals
• Plug-in contacts
Result: Contact Service if cable conductors are damaged.
Note: Close off disconnected connectors with protective caps provided.
8. Use isopropyl alcohol to clean dirty connector housings, sockets and contacts.
9. Ensure that all connecting plugs of the sensors are correctly engaged.
Important
Connecting connectors to sensors is only permitted when the engine is stopped.

TIM-ID: 0000000029 - 026

172 | Cabling | M015570/05E 2019-07

8.20 Accessories for (Electronic) Engine Governor / Control System
8.20.1 Engine governor and connectors – Cleaning
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Pipe gripping pliers F30017884 1
Solvent (isopropyl alcohol) X00058037 1

Engine governor and connectors

– Cleaning
1. Remove coarse dirt on housing surface using
solvent.
2. Remove dirt on surface of connectors (1),
sockets and shrink pieces (2) with solvent.
3. Check legibility of cable labels. Clean or re-
place illegible labels.

Cleaning heavily soiled connec-

tors on engine governor
1. Use pliers (2) to disengage bayonet union
nut (4) and pull off connector (3).
2. Clean connector housings, socket hous-
ings (1) and all contacts with solvent.
3. When connectors, sockets and all contacts
are dry: Fit connectors and check Engine
Control Unit connections (→ Page 174).
TIM-ID: 0000000948 - 014

M015570/05E 2019-07 | Accessories for (Electronic) Engine Governor / Control System | 173
8.20.2 Engine Control Unit – Plug connection check
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Pipe gripping pliers F30017884 1

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

174 | Accessories for (Electronic) Engine Governor / Control System | M015570/05E 2019-07
9 Appendix A
9.1 Abbreviations
Abbre- Meaning Explanation
viation
A/D Analog/Digital Transformer: transforms sensor voltages into numer-
ic values
ADEC Advanced Diesel Engine Controller Engine management system
AFRS Air Filter Restriction Sensor Air filter differential pressure sensor
AGR Abgasrückführung Exhaust gas recirculation
AGN Abgasnachbehandlung Exhaust gas aftertreatment
AL Alarm –
ANSI American National Standards Institute Association of American standardization organiza-
tions
ATL Abgasturbolader Exhaust turbocharger/exhaust turbocharging
ATS Air Temperature Sensor –
BR Baureihe Series
BV Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU publica-
tion no. A00106x/...
CAN Controller Area Network Data bus system, bus standard
CDC Calibration Drift Compensation Reset for drift correction with DiaSys® in the Engine
Control Unit
CEL Check Engine Light • Warning lamp
• Readout of 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 –
CRC Cyclic Redundancy Check Checksum procedure to detect data transmission
faults
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
TIM-ID: 0000000858 - 017

Sys®
DIN Deutsches Institut für Normung German national standards intitute, at the same time
identifier of German standards (DIN = “Deutsche In-
dustrie-Norm”)
DL Default Lost Alarm: Default CAN bus failure
DMC Data Matrix Code –
DOC Diesel Oxidation Catalyst –
DPF Diesel Particulate Filter –

M015570/05E 2019-07 | Appendix A | 175

Abbre- Meaning Explanation
viation
DT Diagnostic Tool Diagnostic unit
ECM Electronic Control Module Electronic control unit of the DDEC system
ECS Engine Control System Engine management system
ECU Engine Control Unit Engine governor
EDM Engine Data Module Memory module for engine data
EE- Electrically Erasable Programmable Read –
PROM Only Memory
EFPA Electronic Foot Pedal Assembly Electronic accelerator pedal
EGR Exhaust Gas Recirculation –
EIL Engine Identification Label Electronic engine data plate
EIM-ID Emissions Ident Number –
EMU Engine Monitoring Unit –
ESCM Extreme Site Condition Management Power reduction for operation in extreme conditions
ESD Einzelspeicherdruck Single accumulator pressure
ETK Ersatzteilkatalog Spare Parts Catalog
EUI Electronic Unit Injector Electronic injection nozzle unit
FO Frequency Output –
FPS Fuel Pressure Sensor –
FRS Fuel Restriction Sensor Differential fuel pressure sensor
FTS Fuel Temperature Sensor –
FWCP Fire Water Control Panel Control cabinet
GND Ground –
HD Hochdruck High Pressure
HI High Range violation alarm (first upper limit value)
HIHI High High Range violation alarm (second upper limit value)
HT High Temperature –
IDM Interface Data Module Memory module for interface data
IIG Initiale Injektorgleichstellung Input of the injector code with DiaSys® in the en-
gine governor
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 Alarm: Measured value lower than 1st minimum limit
TIM-ID: 0000000858 - 017

value
L2 Limit 2 Alarm: Measured value lower than 2nd minimum lim-
it value
LED Light Emitting Diode –
LLK Ladeluftkühler/Ladeluftkühlung Intercooler
LO Low Range violation alarm (first lower limit value)
LOLO Low Low Range violation alarm (second lower limit value)
LSG Limiting Speed Governor Maximum-speed governor

176 | Appendix A | M015570/05E 2019-07

Abbre- Meaning Explanation
viation
LSU Lambda Sonde Universal Universal lambda sensor
LT Low Temperature –
MCR Maximum Continuous Rating Torque limitation curve
N/A Not applicable –
ND Niederdruck Low pressure
NN Normal Null Reference surface for heights above sea level
NT Niedertemperatur Low temperature
OEM Original Equipment Manufacturer Manufacturer of the original equipment
OI Optimized Idle –
OLS Oil Level Sensor –
OPS Oil Pressure Sensor –
OTS Oil Temperature Sensor –
OT Oberer Totpunkt Top Dead Center
PAN Panel Control panel
PIM Peripheral Interface Module –
PWM Pulsweitenmodulation Pulse width modulation
P-xyz Pressure-xyz Pressure measuring point xyz
RL Redundancy Lost Alarm Redundant CAN bus failure
rpm revolutions per minute –
SAE Society of Automotive Engineers U.S. standardization organization
SD Sensor Defect Alarm: Sensor failure
SEL Stop Engine Lamp Stop Engine Lamp
• Warning lamp
• Readout of fault codes
SID System Identifier –
SRS Synchronous Reference Sensor Camshaft angle sensor
SS Safety System Safety system alarm
TBO Time Before Overhaul Time to major overhaul
TBS Turbocharger Boost Sensor –
TCI Turbo Compressor Inlet –
TCO Turbo Compressor Outlet –
TD Transmitter Deviation –
TEN Technical Evolution Network Technical data for MTU products
TPS Throttle Position Sensor –
TIM-ID: 0000000858 - 017

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 Ueberdruckventil Pressure relief valve
UT Unterer Totpunkt Bottom Dead Center
VNT Variable Nozzle Turbine –
VSG Variable Speed Governor –
VSS Vehicle Speed Sensor –

M015570/05E 2019-07 | Appendix A | 177

Abbre- Meaning Explanation
viation
WZK Werkzeugkatalog Tool Catalog
ZKP Zuordnung - Kategorie - Parameter A number allocated to a parameter describing its
function and assignment

TIM-ID: 0000000858 - 017

178 | Appendix A | M015570/05E 2019-07

9.2 Conversion tables
Length
Unit A multiplied by factor = Unit B
in 25.4 = mm
ft 0.3048 =m
yd 0.9144 =m
stat. mile 1.609 = km
Nm 1.852 = km
yd 3 = ft
yd 36 = in

Unit B multiplied by factor = Unit A

mm 0.03937 = in
m 3.281 = ft
km 0.6215 = stat. mile

Area
Unit A multiplied by factor = Unit B
in2 645.16 = mm2
ft2 0.0929 = m2
yd2 0.8361 = m2
stat. mile2 2.59 = km2

Unit B multiplied by factor Unit A

mm 2 0.00155 = in2
m2 10.764 = ft2
m2 1.1960 = yd2
km2 0.3861 = stat. mile2

Volume
Unit A multiplied by factor = Unit B
in 3 16387 = mm3
ft3 0.02832 = m3
yd3 0.7646 = m3
gallon (U.S.) 3.785 = dm3
TIM-ID: 0000002173 - 017

gallon (UK) 4.546 = dm3

Unit B multiplied by factor = Unit A

cm 3 0.06102 = in3
m3 35.31 = ft3
dm3 0.2642 = gallon (U.S.)
dm3 0.22 = gallon (UK)

M015570/05E 2019-07 | Appendix A | 179

Volumetric flow
Unit A multiplied by factor = Unit B
gal/min (GPM, U.S.) 3.79 = l/min
gal/min (GPM, U.S.) 0.134 = ft3/min (cfm)
ft3/min (cfm) 1.70 = m3/h

Unit B multiplied by factor = Unit A

l/min 0.264 = gal/min (U.S.)
3
ft /min (cfm) 7.48 = gal/min (U.S.)
m3/h 0.589 = ft3/min (cfm)

Velocity
Unit A multiplied by factor = Unit B
ft/s 0.3048 = m/s
stat. mile/h (mph) 1.609 = km/h
knot (UK) 1.852 = km/h

Unit B multiplied by factor = Unit B

m/s 3.281 = ft/s
km/h 0.6214 = stat. mile/h (mph)
km/h 0.54 = knot (UK)

Mass
Unit A multiplied by factor = Unit B
lb 0.4536 = kg
oz 28.35 =g
ton (imp.) 1.016 =t

Unit B multiplied by factor = Unit A

g 0.03527 = oz
kg 2.205 = lb
t 0.9842 = ton (imp.)

Force
Unit A multiplied by factor = Unit B
lbf 0.4536 = kp
lbf 4.4482 =N
TIM-ID: 0000002173 - 017

kp 9.80665 =N

Unit B multiplied by factor = Unit A

kp 2.205 = lbf
N 0.10197 = kp
N 0.2248 = lbf

180 | Appendix A | M015570/05E 2019-07

Density
Unit A multiplied by factor = Unit B
slug/ft 3 515.4 = kg/m3

Unit B multiplied by factor = Unit A

kg/m 3 0.00194 = slug/ft3

Torque
Unit A multiplied by factor = Unit B
lbf ft 1.3558 = Nm

Unit B multiplied by factor = Unit A

Nm 0.7376 = lbf ft

Pressure
Unit A multiplied by factor = Unit B
2
lbf/in (psi) 703.1 = kp/m2 (mmH2O)
lbf/in2 (psi) 0.06895 = bar
2
lbf/ft (psf) 47.88 = Pa
inHg 0.03386 = bar
inHg 345.3 = kp/m2 (mmH2O)

Unit B multiplied by factor = Unit A

atm 760 = mmHg
atm 1.0133 = bar
atm 10332 = kp/m2 (mmH2O)
atm 1.0332 = kp/cm2 (at)
atm 14.696 = lbf/in2 (psi)
bar 14.504 = lbf/in2 (psi)
Pa 0.0209 = lbf/ft2 (psf)

2nd moment of mass

Unit A multiplied by factor = Unit B
slug ft 2 1.3558 = kg m2

Unit B multiplied by factor = Unit A

kg m 2 0.7376 = slug ft2
TIM-ID: 0000002173 - 017

Energy
Unit A multiplied by factor = Unit B
lbf ft 1.356 =J
kcal 4186.8 =J
BTU 1055 =J
CHU 1899 =J

M015570/05E 2019-07 | Appendix A | 181

Unit B multiplied by factor = Unit A
J 0.7376 = lbf ft
J 0.0002388 = kcal
J 0.0009478 = BTU
J 0.00052656 = CHU

Power
Unit A multiplied by factor = Unit B
PS 0.7355 = kW
HP 0.7457 = kW
BTU/s 1.054 = kW
kcal/h 1.163 =W
HP 550 = lbf ft/s

Unit B multiplied by factor = Unit A

kW 1.36 = PS
kW 1.341 = HP
kW 0.9487 = BTU/s
W 0.8598 = kcal/h
lbf ft/s 0.0018 = HP

Temperature
Celsius Kelvin
x °C - = x + 273.15 K
xK = x − 273.15 °C -
x °F = 5/9(x − 32) °C = 5/9(x − 32) + 273.15 K
x °R = 5/4x °C = (5/4x) + 273.15 K

Fahrenheit Réaumur
x °C = 9/5x + 32 °F = (4/5x) °R
xK = 9/5(x − 273.15) + 32 °F = 4/5(x − 273.15) °R
x °F - = 4/9(x − 32) °R
x °R = (9/4x) + 32 °F -

Fuel consumption
Unit A multiplied by factor = Unit B
mile/gal (US) 0.4251 = km/l
TIM-ID: 0000002173 - 017

gal/mile (US) 2.3527 = l/km

Unit B multiplied by factor = Unit A

km/l 2.3527 = mile/gal (US)
l/km 0.4251 = gal/mile (US)

182 | Appendix A | M015570/05E 2019-07

9.3 MTU Contact/Service Partners
The worldwide network of the sales organization with subsidiaries, sales offices, representatives and custom-
er service centers ensure fast and direct support on site and ensure the high availability of our products.

Local Support
Experienced and qualified specialists place their knowledge and expertise at your disposal.
For locally available support, go to the MTU Internet site: http://www.mtu-online.com

24h Hotline
With our 24h hotline and high flexibility, we're your contact around the clock: during each operating phase,
preventive maintenance and corrective operations in case of a malfunction, for information on changes in
conditions of use and for supplying spare parts.
Your contact person in our Customer Assistance Center:
E-mail: [email protected]
Tel.: +49 7541 9077777
Fax.: +49 7541 9077778
Asia/Pacific: +65 6100 2688
North and Latin America: +1 248 560 8000

Spare Parts Service

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

M015570/05E 2019-07 | Appendix A | 183

10 Appendix B
10.1 Special Tools
Adapter
Part No.: F6558528
Qty.: 1
Used in: 8.1.1 Engine – Barring manually (→ Page 98)

Barring tool
Part No.: F6555766
Qty.: 1
Used in: 8.1.1 Engine – Barring manually (→ Page 98)

Belt tension tester

Part No.: Y4345711
Qty.: 1
Used in: 8.18.2 Battery-charging generator drive – Drive belt con-
dition check (→ Page 170)
DCL-ID: 0000053939 - 001

184 | Appendix B | M015570/05E 2019-07

Endoscope
Part No.: Y20097353
Qty.: 1
Used in: 8.2.1 Cylinder liner – Endoscopic inspection (→ Page 101)

Feeler gauge
Part No.: Y20098771
Qty.: 1
Used in: 8.4.2 Valve clearance – Check and adjustment
(→ Page 109)

Filter wrench
Part No.: F30379104
Qty.: 1
Used in: 8.8.1 Fuel filter – Replacement (→ Page 123)
Qty.:
Used in: 8.14.1 Engine oil filter – Replacement (→ Page 143)
Qty.: 1
Used in: 8.14.2 Centrifugal oil filter – Cleaning and filter sleeve re-
placement (→ Page 144)

High-pressure cleaner
Part No.:
Qty.: 1
Used in: 5.12 Plant – Cleaning (→ Page 81)
DCL-ID: 0000053939 - 001

M015570/05E 2019-07 | Special Tools | 185

Installation and removal jig
Part No.: F6794703
Qty.: 1
Used in: 8.6.2 Injector – Removal and installation (→ Page 117)

Milling cutter
Part No.: F30452739
Qty.: 1
Used in: 8.6.2 Injector – Removal and installation (→ Page 117)

MTU test kit

Part No.: F6798833
Qty.: 1
Used in: 8.13.3 Engine oil – Sample extraction and analysis
(→ Page 141)
Qty.: 1
Used in: 8.15.6 Engine coolant – Sample extraction and analysis
(→ Page 154)
Qty.: 1
Used in: 8.16.6 Charge-air coolant – Sample extraction and analy-
sis (→ Page 166)

Pipe gripping pliers

Part No.: F30017884
Qty.: 1
Used in: 8.1.2 Engine – Cranking on starting system (→ Page 99)
Qty.: 1
DCL-ID: 0000053939 - 001

Used in: 8.20.1 Engine governor and connectors – Cleaning

(→ Page 173)
Qty.: 1
Used in: 8.20.2 Engine Control Unit – Plug connection check
(→ Page 174)

186 | Special Tools | M015570/05E 2019-07

Ratchet adapter
Part No.: F30027341
Qty.: 1
Used in: 8.18.1 Battery-charging generator drive – Drive belt ten-
sion adjustment (→ Page 169)

Ratchet adapter
Part No.: F30027340
Qty.: 1
Used in: 8.18.1 Battery-charging generator drive – Drive belt ten-
sion adjustment (→ Page 169)

Ratchet bit
Part No.: F30027340
Qty.: 1
Used in: 2.3 Crankshaft transport locking device (→ Page 22)
Qty.: 1
Used in: 8.3.2 Crankcase breather – Oil separator replacement, di-
aphragm check and replacement (→ Page 106)
Qty.: 1
Used in: 8.14.2 Centrifugal oil filter – Cleaning and filter sleeve re-
placement (→ Page 144)
Qty.: 1
Used in: 8.18.3 Battery-charging generator drive – Drive belt re-
placement (→ Page 171)

Ratchet bit
Part No.: F30027341
Qty.: 1
DCL-ID: 0000053939 - 001

Used in: 8.13.2 Engine oil – Change (→ Page 139)

Qty.: 1
Used in: 8.18.3 Battery-charging generator drive – Drive belt re-
placement (→ Page 171)

M015570/05E 2019-07 | Special Tools | 187

Ratchet with extension
Part No.: F30006212
Qty.: 1
Used in: 8.1.1 Engine – Barring manually (→ Page 98)

Slotted screwdriver
Part No.: F30452578
Qty.: 1
Used in: 8.6.2 Injector – Removal and installation (→ Page 117)

Socket box wrench

Part No.: F30039518
Qty.: 1
Used in: 8.4.2 Valve clearance – Check and adjustment
(→ Page 109)

Torque screwdriver, 1–5 Nm

Part No.: F30452774
Qty.: 1
Used in: 8.6.2 Injector – Removal and installation (→ Page 117)
DCL-ID: 0000053939 - 001

188 | Special Tools | M015570/05E 2019-07

Torque wrench, 10–60 Nm
Part No.: F30452769
Qty.: 1
Used in: 2.3 Crankshaft transport locking device (→ Page 22)
Qty.: 1
Used in: 8.4.2 Valve clearance – Check and adjustment
(→ Page 109)
Qty.: 1
Used in: 8.6.2 Injector – Removal and installation (→ Page 117)
Qty.: 1
Used in: 8.18.1 Battery-charging generator drive – Drive belt ten-
sion adjustment (→ Page 169)
Qty.: 1
Used in: 8.18.3 Battery-charging generator drive – Drive belt re-
placement (→ Page 171)

Torque wrench, 4–20 Nm

Part No.: F30044239
Qty.: 1
Used in: 8.3.2 Crankcase breather – Oil separator replacement, di-
aphragm check and replacement (→ Page 106)
Qty.: 1
Used in: 8.14.2 Centrifugal oil filter – Cleaning and filter sleeve re-
placement (→ Page 144)

Torque wrench, 60–320 Nm

Part No.: F30452768
Qty.: 1
Used in: 2.3 Crankshaft transport locking device (→ Page 22)
Qty.: 1
Used in: 8.4.2 Valve clearance – Check and adjustment
(→ Page 109)
Qty.: 1
Used in: 8.6.2 Injector – Removal and installation (→ Page 117)
Qty.: 1
Used in: 8.13.2 Engine oil – Change (→ Page 139)
Qty.: 1
Used in: 8.18.1 Battery-charging generator drive – Drive belt ten-
DCL-ID: 0000053939 - 001

sion adjustment (→ Page 169)

Qty.: 1
Used in: 8.18.3 Battery-charging generator drive – Drive belt re-
placement (→ Page 171)

M015570/05E 2019-07 | Special Tools | 189

10.2 Index
Numerics Charge-air cooler 
8/12/16V 4000 engine data: Continuous operation, limit- – Check water drain for coolant leakage and obstruction
ed, 3C, optimized exhaust emission ("TA-Luft")  43  133
8/12/16V 4000 engine data: Continuous operation, limited Connectors 
3C, optimized fuel consumption  39 – Engine governor  
8/12/16V 4000 engine data: Continuous operation, unlim- – Cleaning  173
ited 3A, optimized fuel consumption  59 Contact persons 183
8/12/16V 4000 engine data: Continuous operation, varia- Contamination indicator 
ble 3B, optimized exhaust emission (EPA) 55 – Signal ring position check  136
8/12/16V 4000 engine data: Continuous operation, varia- Conversion tables 179
ble 3B, optimized exhaust emission ("TA-Luft") 51 Coolant 
8/12/16V 4000 engine data: Continuous operation, varia- – Change  148, 158
ble 3B, optimized fuel consumption  47 – Filling  150
8/12/16V 4000 engine data: Standby operation 3D, opti- Coolant pump 
mized exhaust emission (EPA) 35 – Relief bore check  165
8/12/16V 4000 engine data: Standby operation 3D, opti- Crankcase breather 
mized fuel consumption 31 – Diaphragm check and replacement  106
8/12/16V 4000G engine data: Continuous operation, un- – Filter element replacement  105
limited 3A, optimized exhaust emission (EPA) 63 – Oil separator replacement  106
Crankshaft transport locking device 
A – Installation  22
Abbreviations 175 – Removal  22
After stopping the engine  Cylinder 
– Engine remains ready for operation  79 – Designation  25
– Putting the engine out of operation  80 Cylinder head cover 
Air filter  – Installation  114
– Installation  135 – Removal  114
– Removal  135 Cylinder liner 
– Replacement  134 – Endoscopic examination  101
Air starter  – Endoscopic inspection  
– Manual operation  137 – Instructions and comments on endoscopic and visu-
al examination  103
B
D
Battery-charging generator 
– Drive belt replacement  171 Differential pressure gauge 
– Drive belt tension adjustment  169 – Adjustment  
– Fuel prefilter  125
C – Check  
Cabling  – Fuel prefilter  125
– Check   Drive belt 
– On engine  172 – Condition check  168
Centrifugal oil filter 
E
– Cleaning  144
Emergency start 
DCL-ID: 0000053939 - 001

– Replacement  
– Filter sleeve  144 – Override mode  74
Charge-air coolant  Endoscopic inspection 
– Change  158 – Cylinder liner  
– Check   – Instructions and comments  103
– Level at filler neck  156
– Level via level sensor  156
– Filling  161
Charge-air coolant pump 
– Relief bore check  165

190 | Index | M015570/05E 2019-07

Engine  Fuel prefilter 
– Barring manually  98 – Adjustment  
– Cranking   – Differential pressure gage  125
– On starting system  99 – Check  
– Emergency start (Override mode)  74 – Differential pressure gauge  125
– Emergency stop  78 – Cleaning  124
– Main dimensions  68 – Draining  126
– Starting in manual mode (test run)  71 – Filter element  
– Stopping in Manual mode (test run)  76 – Replacement  131
– Test run  100 – Flushing  128
Engine cabling  Fuel system 
– Check  172 – Venting  122
Engine Control Unit 
– Plug connection check  174 H
Engine coolant  Hotline 183
– Analysis   HP pump 
– Sample  154 – Relief bore check  115
– Change  148
– Check   I
– Level at external cooler  146 Injector 
– Level at filler neck  146 – Installation  117
– Level via level sensor  146 – Removal  117
– Draining  149 – Replacement  116
– Extraction  
L
– Sample  154
– Filling  150 Lifting specifications 21
Engine coolant pump 
M
– Relief bore check  153
Engine driving end  Maintenance Schedule 
– Definition  25 – Maintenance task reference table [QL1]  82
Engine free end  MTU contact persons 183
– Definition  25
O
Engine governor 
– Cleaning  173 Operational checks 75
Engine layout 26
P
Engine oil 
– Change  139 Plant 
– Sample extraction and analysis  141 – Cleaning  81
Engine oil filter  Preparation 
– Replacement  143 – Putting into operation after extended out-of-service pe-
Engine oil level  riods (>3 months)  69
– Check  138 Preparations for putting into operation after scheduled
Engine sides  out-of-service-period 70
– Designation  25 Pump 
– Engine coolant  
F – Relief bore check  153
Fault messages on engine governor 87
DCL-ID: 0000053939 - 001

Firing order 67
Fuel filter 
– Replacement  123

M015570/05E 2019-07 | Index | 191

S
Safety regulations 
– Assembly work  11
– Auxiliary materials  15
– Environmental protection  15
– Fire prevention  15
– Fluids and lubricants  15
– Important provisions  5, 7
– Initial start-up  9
– Maintenance work  11
– Operation  9
– Organizational requirements  8
– Personnel requirements  8
– Repair work  11
Safety requirements 
– Warning notices, standards  18
Safety system 
– Override  73
Service partners 183
Spare parts service 183
Starting valve 
– Manual operation  137

T
Transport 19
– Lifting specifications  21
Troubleshooting 84

V
Valve clearance 
– Adjustment  109
– Check  109
Valve gear 
– Lubrication  108

W
Warning notices, standards 18

DCL-ID: 0000053939 - 001

192 | Index | M015570/05E 2019-07