MTU 8V4000Mx4 Operating Instructions Manual

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Operating Instructions

Diesel Engine

8V4000Mx4

8V4000Mx4S

8V4000Mx4R

MS150109/01E

Table of Contents

Troubleshooting

Summary of Contents for MTU 8V4000Mx4

Page 1: Operating Instructions
Operating Instructions Diesel Engine 8V4000Mx4 8V4000Mx4S 8V4000Mx4R MS150109/01E...
Page 2 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.
Page 3: Table Of Contents
Table of Contents 1 Safety 4.11 Emergency engine shutdown via automation system 1.1 Correct use for all products 4.12 Engaging from LOP 1.2 Personnel and organizational requirements 4.13 Disengaging from LOP 1.3 Transport 4.14 Waterjet – Flushing from LOP (optional) 1.4 Safety regulations for startup and operation 4.15 Engine shutdown via the automation 1.5 Safety precautions when working on the...
Page 4 Circuit 7.16.1 Engine coolant level – Check 8.1 Abbreviations 7.16.2 Engine coolant – Change 8.2 MTU contact persons/service partners 7.16.3 Engine coolant – Draining 7.16.4 Engine coolant – Filling 9 Appendix B 7.16.5 HT coolant pump – Relief bore check 7.16.6 Engine coolant –...
Page 5: Safety
• With preservation approved by the manufacturer in accordance with the (→ Preservation and Represerva- tion Specifications of the manufacturer) • With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU con- tact/Service partner) • In the original as-delivered configuration or in a configuration approved by the manufacturer in writing (in- cluding engine control/parameters) •...
Page 6: Personnel And Organizational Requirements
1.2 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.
Page 7: 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. Never set down engines onto the oil pan unless expressly permitted by MTU on an engine-specific base. MS150109/01E 2015-11 | Safety | 7...
Page 8: Safety Regulations For Startup And Operation
1.4 Safety regulations for startup and operation Safety regulations for startup Install the product correctly and carry out acceptance in accordance with the manufacturer's specifications before putting the product into service. All necessary approvals must be granted by the relevant authorities and all requirements for initial startup must be fulfilled.
Page 9 Follow the applicable warning instructions pertaining to such devices. MS150109/01E 2015-11 | Safety | 9...
Page 10: Safety Precautions When Working On The Engine
1.5 Safety precautions when working on the engine Safety regulations prior to maintenance and repair work Have maintenance or repair work carried out by qualified and authorized personnel only. Allow the product to cool down to less than 50 °C (risk of explosion for oil vapors, fluids and lubricants, risk of burning).
Page 11 Never bend lines and avoid damaging lines, particularly the fuel lines. Ensure that all retainers and dampers are installed correctly. Ensure that O-rings are not installed in a slanted/twisted condition. Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent contact with other components.
Page 12 During hydraulic installation/removal of components, ensure that no persons are in the direct vicinity of the component being pressed. Working with batteries Observe the safety instructions of the battery manufacturer when working with batteries. Gases released from the battery are explosive. Avoid sparks and naked flames. Do not allow battery acids to come into contact with skin or clothing.
Page 13: Fire Prevention And Environmental Protection, Fluids And Lubricants, Auxiliary Materials
The safety data sheet may be obtained from the relevant manufacturer or from MTU. Take special care when using hot, chilled or caustic materials.
Page 14: Compressed Air
Compressed air Observe special safety precautions when working with compressed air: • Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII and B) out of con- tainers, risks causing an explosion. • Wear goggles when blowing dirt off workpieces or blowing away swarf. •...
Page 15: Standards For Safety Notices In The Text
1.7 Standards for safety notices in the text DANGER In the event of immediate danger. Consequences: Death, serious or permanent injury! • Remedial action. WARNING In the event of a situation involving potential danger. Consequences: Death, serious or permanent injury! •...
Page 16: General Information
2 General Information 2.1 Tightening specifications for screws, nuts and bolts Tightening torques for setscrew and stud joints to MTN 5008 standard This standard applies to setscrews not subject to dynamic loads and the associated nuts according to: • MMN 384 •...
Page 17 Hand-tightening Machine-tightening Thread 8.8 M (Nm) 10.9 M (Nm) 8.8 M (Nm) 10.9 M (Nm) M18 x 1.5 M20 x 1.5 M22 x 1.5 M24 x 1.5 M24 x 2 1250 1175 M27 x 2 1350 1275 1200 1700 1100 1600 M30 x 2 1350...
Page 18 Strength class Material Basic size (Nm) (Nm) A2 / A4 = tightening torques Tightening torque for self-locking hex nuts (Nm) Lubricant Thread 7,5 +1 – 17 +2 – 35 +4 – 59 +6 – 100 +10 – 140 +14 – 290 +29 –...
Page 19 Torsion-protected M (Nm) Not torsion-protected M (Nm) Thread M20 x 1.5 M22 x 1.5 M24 x 2 1170 M27 x 2 1000 1230 1250 1575 *Protect screw shaft from torsion when tightening. = tightening torques Tightening torques for plug screws to MTN 5183-1 standard This standard applies to plug screws to DIN 908, DIN 910 and DIN 7604 with threaded end to DIN 3852 Form A (sealed with sealing ring to DIN 7603-Cu).
Page 20 Tightening torques M are given for screw plugs made of steel (St) with surface protected by a phosphate coating and oiled or galvanized. Threads and mating faces beneath heads must be coated with engine oil prior to assembly. An assembly tolerance of +10% of the figures in the table is permitted due to unavoidable deviations during the tightening process.
Page 21 Screwed into Thread Steel/gray cast iron M AI alloy M (Nm) (Nm) M64 x 2 = tightening torques Tightening torques for plug screws to DIN 7604C (with long threaded end) Screwed into Thread Steel/gray cast iron M Al alloy M (Nm) (Nm) M8 x 1...
Page 22 The stated tightening torques M apply to steel (St) banjo screws with a phosphatized surface coating and oiled, or galvanized, and to banjo screws made of copper/aluminum alloys. Threads and mating faces beneath heads must be coated with engine oil prior to assembly. An assembly tolerance of +10% of the figures in the table is permitted due to unavoidable deviations during the tightening process.
Page 23 Tightening torques for male unions to MTN 5183-3 standard This standard applies to male unions to DIN 2353 Series L with threaded end to DIN 3852 Form A (sealed by sealing ring to DIN 7603-Cu). Tightening torques M are given for male unions made of steel (St) with phosphatized surface coating and oiled, or galvanized.
Page 24 Tightening torques for union nuts to DIN 3859-2 1 Union nut 2 Union body 3 O-ring 4 Ferrule Union nut: On installing the ball-type union, after tightening the union nut firmly by hand (noticeable increase in force), it should be tightened another 1/4 turn (90°) past this point. Tightening torques for spigot unions with O-ring to ISO 6149-2 Torque (Nm) +10% Thread...
Page 25 Torque (Nm) +10% Thread M27 x 2 M33 x 2 M42 x 2 M48 x 2 M60 x 2 Only for sealing off installation spaces for screw-in valves (see ISO 6149-47 and ISO 7789) Tightening torques for spigot unions with O-ring to ISO 6149-3 Torque (Nm) +10% Thread M8 x 1...
Page 26 Tightening torques for plug screws to MTN 5183-6 Screwed into Thread Steel/gray cast iron M AI alloy M (Nm) (Nm) M10 x 1 10 +2 M12 x 1.5 14 +2 M14 x 1.5 15 +3 M16 x 1.5 18 +3 M18 x 1.5 23 +3 M22 x 1.5...
Page 27 Sealing head/sealing cone with metric union nut Metric thread Pipe outer dia. Torque (Nm) M16 x 1.5 M18 x 1.5 M20 x 1.5 M22 x 1.5 M24 x 1.5 M26 x 1.5 M30 x 2 M36 x 2 M42 x 2 M45 x 2 M52 x 2 Sealing head with BSP union nut...
Page 28 ORFS – flat sealing with union nut UNF thread Size Torque (Nm) 9/16–18 –4 14 +2 11/16–16 –6 24 +3 13/16–16 –8 43 +4 1–14 –10 60 +8 1.3/16–12 –12 90 +5 1.3/16–12 –14 90 +5 1.7/16–12 –16 125 +10 1.11/16–12 –20 170 +20...
Page 29: Engine Side And Cylinder Designations
2.2 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).
Page 30: Product Description
2.3 Product description Description of the engine Engine The engine is a liquid-cooled four-stroke diesel engine, rotating counterclockwise (seen from driving end), with direct injection, sequential turbocharging and charge-air cooling. The engine is monitored by an engine control and monitoring system (ADEC). Monitoring in the engine room is carried out by the engine control and monitoring unit (LOP).
Page 31 • Interface to ECU and EMU • MCS5 dialog interface • Control of an MTU lube-oil priming pump (power components in separate MTU PPC Box) • Connection facility for an MTU Local Operating Station (LOS) • Serial RS422 interface for diagnosis The engine interface is divided into two parts.
Page 32 2 Cleaning cycle 3 Cleaning cycle MTU Series 8V4000M54/M54R marine engines are suitable for low-load operation. State-of-the-art design and equipment featuring e.g. TE coolant circuit, ETC sequencing, triple-walled water- cooled exhaust pipes, Common Rail fuel injection and cylinder cutout facilitate this type of operation.
Page 33 B Engine speed ETC Exhaust turbocharger MTU Series 8V4000M24S marine “Genset” engines are suitable for low-load operation. State-of-the-art design and equipment featuring e.g. TE coolant circuit, triple-walled water-cooled exhaust pipe, Common Rail fuel injection and cylinder cutout facilitate this type of operation.
Page 34 SOLAS – Fire safety requirements Special connections The aforementioned types of union are spray-proof in case of leakage even without covers and have been confirmed as being SOLAS-compliant by GL and DNV. Plug-in pipe union The sleeve (3) covers the joint to prevent lateral spray. Only leak-off along the line is possible, the pressure is decreases significantly if an O-ring (2) defect occurs.
Page 35 HP line between fuel injector and HP accumulator 1 Support ring 4 HP line 7 Thrust ring 2 V-ring 5 Thrust screw 8 V-ring 3 Thrust ring 6 Support ring 9 Union nut MS150109/01E 2015-11 | General Information | 35...
Page 36 HP line between distributor and HP accumulator 1 Union nut 4 Thrust screw 7 Thrust ring 2 O-ring 5 O-ring 8 Pressure pipe 3 Thrust ring 6 O-ring 9 Jacket pipe 36 | General Information | MS150109/01E 2015-11...
Page 37 HP line between distributor and HP accumulator 1 Jacket pipe 5 O-ring 9 HP line 2 O-ring 6 Thrust screw 10 Pressure pipe 3 O-ring 7 Thrust ring 4 Thrust ring 8 O-ring MS150109/01E 2015-11 | General Information | 37...
Page 38: Engine Overview
2.4 Engine overview Overview with remote heat exchanger, driving end 1 Exhaust outlet 7 EIM (Engine Interface Mod- 13 Intercooler 2 Recirculation line ule) 14 Exhaust turbocharger carri- 3 Crankcase breather 8 Oil filler neck er housing 4 Oil cooler 9 Oil pan 15 Air pipe to intercooler 5 Coolant pump...
Page 39 Overview with remote heat exchanger, free end 1 Centrifugal oil filter 6 Oil filter 11 Coolant outlet from remote 2 Dry-type air filter 7 Battery-charging generator cooling system 3 Exhaust manifold (optional) 12 Coolant outlet to remote 4 Cylinder head 8 HP fuel pump cooling system 5 Fuel filter...
Page 40 Overview with engine-mounted heat exchanger, driving end 1 Exhaust outlet 7 EIM (Engine Interface Mod- 13 Intercooler 2 Recirculation line ule) 14 Exhaust turbocharger carri- 3 Crankcase breather 8 Oil filler neck er housing 4 Oil cooler 9 Oil pan 15 Air pipe to intercooler 5 Coolant pump 10 Crankcase...
Page 41 Overview with engine-mounted heat exchanger, free end 1 Raw-water outlet 6 Cylinder head 11 Bilge pump (option) 2 Coolant expansion tank 7 Fuel filter 12 Raw water pump 3 Centrifugal oil filter 8 Oil filter 13 Plate-core heat exchanger 4 Dry-type air filter 9 Battery-charging generator 14 Engine management and 5 Exhaust manifold...
Page 42: Sensors And Actuators - Overview
2.5 Sensors and actuators – Overview Engine-mounted heat exchanger Plan view 1 Y27 (turbocharger control 4 Y26 (air recirculation valve) 7 B5.9 (lube-oil pressure be- valve) 5 B49 (charge air temperature fore turbocharger B) 2 B50 (crankcase pressure) from air recirculation valve) 3 B4.A1-B4B4 (cylinder ex- 6 B3 (intake air pressure) haust temperature A1-A4,...
Page 43 Left engine side 1 B44.2 (turbocharger B 4 B34.2 (fuel pressure before 7 F46 (leak fuel level) speed) filter) 8 B33 (fuel temperature in 2 B4.21 (exhaust tempera- 5 B34.3 (fuel pressure before common rail) ture, A-side) filter) 3 B10 (charge-air pressure) 6 B34.1 (fuel pressure after filter) MS150109/01E 2015-11 | General Information | 43...
Page 44 Free end 1 B48 (fuel pressure in com- 5 B5.3 (lube oil pressure be- 9 B6 (coolant temperature) mon rail) fore filter) 10 Connector XD1 – Dialog 2 B7 (lube oil temperature) 6 B1 (camshaft speed) unit 3 B5.2 (lube oil pressure after 7 B54 (oil refill pump pres- filter), only with reversible sure)
Page 45 Right engine side 1 F33 (coolant level) 3 B21 (raw water pressure) 5 B4.22 (exhaust tempera- 2 B16 (coolant pressure) 4 B9 (charge-air temperature) ture, B-side) 6 B44.1 (turbocharger A speed) MS150109/01E 2015-11 | General Information | 45...
Page 46 Driving end 1 S37.1 (safety switch) 3 B13 (crankshaft speed) 2 B13.2 (crankshaft speed) 4 S37.2 (safety switch) 46 | General Information | MS150109/01E 2015-11...
Page 47 Remote heat exchanger Plan view 1 Y27 (turbocharger control 4 B4.A1-B4B4 (cylinder ex- 7 B5.9 (lube-oil pressure be- valve) haust temperature A1-A4, fore turbocharger B) 2 Y26 (air recirculation valve) B1-B4) 3 B50 (crankcase pressure) 5 B49 (charge air temperature from air recirculation valve) 6 B3 (intake air pressure) MS150109/01E 2015-11 | General Information | 47...
Page 48 Left engine side 1 B44.2 (turbocharger B 4 B34.2 (fuel pressure before 7 F46 (leak fuel level) speed) filter) 2 B4.21 (exhaust tempera- 5 B34.3 (fuel pressure before ture, A-side) filter) 3 B10 (charge-air pressure) 6 B34.1 (fuel pressure after filter) 48 | General Information | MS150109/01E 2015-11...
Page 49 Free end 1 B33 (fuel temperature in 5 B5.3 (lube oil pressure be- 9 B6.2 (coolant temperature) common rail) fore filter) 10 B6 (coolant temperature) 2 B7 (lube oil temperature) 6 B48 (fuel pressure in com- 11 Connector XD1 – Dialog 3 B5.2 (lube oil pressure after mon rail) unit...
Page 50 Right engine side 1 B16 (coolant pressure) 3 B4.22 (exhaust tempera- 2 B9 (charge-air temperature) ture, B-side) 4 B44.1 (turbocharger A speed) 50 | General Information | MS150109/01E 2015-11...
Page 51 Driving end 1 S37.1 (safety switch) 3 B13 (crankshaft speed) 2 B13.2 (crankshaft speed) 4 S37.2 (safety switch) MS150109/01E 2015-11 | General Information | 51...
Page 52: Engine Wiring Harness - Overview
2.6 Engine wiring harness – Overview Designation Connection Engine wiring harness B1 Camshaft speed Intake air temperature B4.21 Exhaust temperature, A-side B4.22 Exhaust temperature, B-side B5.1 Lube oil pressure after filter B5.3 Lube oil pressure before filter B5.8 Lube oil pressure before turbocharger Coolant temperature Lube oil temperature Charge-air temperature...
Page 53 Designation Connection Adaptation Governor ECU Governor ECU Power EMU Power Start interlock EIM engine box XB19 Starting-air pressure Dialog unit Starter Engine wiring harness for sensors 1 B10 13 F46 25 F33 2 B4.21 14 M8 26 XXF33 3 B44.2 15 B1 27 B4.22 4 B5.1...
Page 54 Engine wiring harness for injectors 1 Y39A1 4 Y39A4 7 Y39B3 2 Y39A2 5 X4 8 Y39B2 3 Y39A3 6 Y39B4 9 Y39B1 54 | General Information | MS150109/01E 2015-11...
Page 55 Engine wiring harness for EIM 1 XD1 4 X52 7 XB19 2 X1 5 XY1 8 X37 3 X3 6 X11 MS150109/01E 2015-11 | General Information | 55...
Page 56 Engine wiring harness for electric starter 1 Connecting terminals EIM 2 Fuse F1 3 Connecting terminals for starter 56 | General Information | MS150109/01E 2015-11...
Page 57: Technical Data
3 Technical Data 3.1 Engine data 8V4000M24S, Marine EPA Tier 3, IMO Tier II Explanation Index (I) Meaning Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value up to which the engine can be operated, without change (e.g. of power setting) Not yet defined value Not applicable Applicable...
Page 58 Model related data (basic design) (I) Unit Engine-mounted heat Remote heat ex- exchanger changer Cylinder arrangement: V angle Degrees (°) Bore Stroke Cylinder displacement Liters 4.77 4.77 4.77 4.77 Total displacement Liters 38.1 38.1 38.1 38.1 Number of inlet valves per cylinder Number of exhaust valves per cylinder Raw water circuit (open circuit) (I) Unit...
Page 59 General operating data (I) Unit Engine-mounted heat Remote heat ex- exchanger changer Firing speed, from Firing speed, to Starter (electric) (I) Unit Engine-mounted heat Remote heat ex- exchanger changer Rated starter voltage (standard design) Starter (with compressed air/hydraulic starter motor) (I) Unit Engine-mounted heat Remote heat ex-...
Page 60 (I) Unit Engine-mounted heat Remote heat ex- exchanger changer Oil pan at dipstick mark “min.” (standard Liters oil system) (Option: max. operating incli- nations) Oil pan at dipstick mark “max.” (standard Liters oil system) (Option: max. operating incli- nations) Weights / main dimensions (I) Unit Engine-mounted heat Remote heat ex-...
Page 61: Engine Data 8V4000M54, Marine Epa Tier 3, Imo Tier
3.2 Engine data 8V4000M54, Marine EPA Tier 3, IMO Tier II Explanation Index (I) Meaning Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value up to which the engine can be operated, without change (e.g. of power setting) Not yet defined value Not applicable Applicable...
Page 62 Model related data (basic design) Engine-mounted heat Remote heat ex- exchanger changer Cylinder arrangement: V angle Degrees (°) Bore Stroke Cylinder displacement Liters 4.77 4.77 4.77 4.77 Total displacement Liters 38.1 38.1 38.1 38.1 Number of inlet valves per cylinder Number of exhaust valves per cylinder Raw water circuit (open circuit) Engine-mounted heat...
Page 63 General operating data Engine-mounted heat Remote heat ex- exchanger changer Firing speed, from Firing speed, to Starter (electric) Engine-mounted heat Remote heat ex- exchanger changer Rated starter voltage (standard design) Starter (with compressed air/hydraulic starter motor) Engine-mounted heat Remote heat ex- exchanger changer Starting-air pressure before starter, min.
Page 64 (I) Unit Engine-mounted heat Remote heat ex- exchanger changer Oil pan at dipstick mark “min.” (standard Liters oil system) (Option: max. operating incli- nations) Oil pan at dipstick mark “max.” (standard Liters oil system) (Option: max. operating incli- nations) Weights / main dimensions Engine-mounted heat Remote heat ex- exchanger...
Page 65: Engine Data 8V4000M54R, Marine Epa Tier 3, Imo Tier
3.3 Engine data 8V4000M54R, Marine EPA Tier 3, IMO Tier II Explanation Index (I) Meaning Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value up to which the engine can be operated, without change (e.g. of power setting) Not yet defined value Not applicable Applicable...
Page 66 Model-related data (basic design) (I) Unit Engine-mounted heat Remote heat ex- exchanger changer Cylinder arrangement: V angle Degrees (°) Bore Stroke Cylinder displacement Liters 4.77 4.77 4.77 4.77 Total displacement Liters 38.1 38.1 38.1 38.1 Number of inlet valves per cylinder Number of exhaust valves per cylinder Raw water circuit (open circuit) (I) Unit...
Page 67 General operating data (I) Unit Engine-mounted heat Remote heat ex- exchanger changer Firing speed, from Firing speed, to Starter (electric) (I) Unit Engine-mounted heat Remote heat ex- exchanger changer Rated starter voltage (standard design) Starter (with compressed air/hydraulic starter motor) (I) Unit Engine-mounted heat Remote heat ex-...
Page 68 (I) Unit Engine-mounted heat Remote heat ex- exchanger changer Oil pan at dipstick mark “min.” (standard Liters oil system) (Option: max. operating incli- nations) Oil pan at dipstick mark “max.” (standard Liters oil system) (Option: max. operating incli- nations) Weights / main dimensions (I) Unit Engine-mounted heat Remote heat ex-...
Page 69: Firing Order
3.4 Firing order Firing order Number of cylinders A1-B4-A4-A2-B3-A3-B2-B1 MS150109/01E 2015-11 | Technical Data | 69...
Page 70: Main Engine Dimensions
3.5 Main engine dimensions Main engine dimensions Engines with remote heat exchanger Height (C) Engine model Length (A) Width (B) 8V4000Mx4 approx. 2386 mm approx. 1613 mm approx. 1959 mm 70 | Technical Data | MS150109/01E 2015-11...
Page 71 Engines with engine-mounted heat exchanger Height (C) Engine model Length (A) Width (B) 8V4000Mx4 approx. 2609 mm approx. 1613 mm approx. 2060 mm MS150109/01E 2015-11 | Technical Data | 71...
Page 72: Operation
4 Operation 4.1 LOP controls LOP controls Item Measure Start engine via the automation system (→ Automation system Operating In- structions). 72 | Operation | MS150109/01E 2015-11...
Page 73: Putting The Engine Into Operation After Extended Out-Of-Service Periods (>3 Months)
4.2 Putting the engine into operation after extended out-of-service periods (>3 months) Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Preservation and Represervation Specifications (A001070/..) are available. Putting the engine into operation after extended out-of-service-periods (>3 months) Item...
Page 74: Putting The Engine Into Operation After Scheduled Out-Of-Service-Period
4.3 Putting the engine into operation after scheduled out-of- service-period Preconditions ☑ Engine is stopped and starting disabled. Putting into operation Item Action Lube oil system Check engine oil level (→ Page 219); Preheat engine oil if required. Coolant circuit Check coolant level (→...
Page 75: Starting The Engine Via The Automation System
4.4 Starting the engine via the automation system Starting the engine via the automation system Item Measure Automation system Start engine via the automation system (→ Automation system Operating In- structions). MS150109/01E 2015-11 | Operation | 75...
Page 76: Operational Checks
4.5 Operational checks DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running. Risk of damage to hearing! •...
Page 77: Tasks After Extended Out-Of-Service Periods (>3 Weeks)
4.6 Tasks after extended out-of-service periods (>3 weeks) Tasks after extended out-of-service periods (>3 weeks) Note: Operate fuel treatment system for at least 5 minutes. Start up fuel treatment system (→ Page 80). Shut down fuel treatment system (→ Page 90). MS150109/01E 2015-11 | Operation | 77...
Page 78: Fuel Treatment System Control Cabinet - Controls
4.7 Fuel treatment system control cabinet – Controls Item Color Lettering Meaning/function Green Signal lamp Indicates “Pump running” Signal lamp Indicates “Pump fault” Yellow Illuminated Indicates “Water drain” / Press to drain water manually pushbutton Illuminated Indicates “Water alarm” / Press to acknowledge pushbutton Yellow Signal lamp...
Page 79: Checks Prior To Start-Up
Check tank and the entire pipework for cleanness. If microorganisms are detected: a) Clean affected components. b) Disinfect affected components with biocides (→ MTU Fluids and Lubricants Specifications A001061/..). Close drain valves on housing. Open all supply and discharge valves.
Page 80: Fuel Treatment System - Initial Start-Up
4.9 Fuel treatment system – Initial start-up Overview of fuel treatment system 1 Pressure-free overflow 9 Ball valve, outlet 17 Automatic water drain 2 Bypass 1 10 Check valve 700 mbar 18 Water level electrode 3 Bypass 2 11 Check valve 5 mbar 19 Ball valve, sample extrac- 4 Safety valve, 3 bar 12 Return to overflow tank...
Page 81 Initial start-up: HAT Replace fuel filter on engine (→ Page 198). Note: Determine the suction pressure upstream of the engine-mounted fuel delivery pump. Install pressure gage in fuel supply line from Yard fuel system to engine. Switch on fuel treatment system and operate it for some minutes (→ Page 83). Result: Fuel is drawn from the tank (24).
Page 82 Simulating power failure (emergency): SAT Switch on fuel treatment system (→ Page 83). Start engine (→ Page 75). Run engine at idling speed. Switch off pump (21) at switchgear cabinet (20). Result: The engine-mounted fuel delivery pump draws fuel via bypass (2) directly from tank (24). Check suction pressure at the engine-mounted fuel delivery pump.
Page 83: Fuel Treatment System - Switching On
4.10 Fuel treatment system – Switching on Preconditions ☑ The on-board power supply is switched on. NOTICE Risk of damage to engine/system. Risk of severe damage to property! • Before switching on, ensure that the engine/system is ready for operation. •...
Page 84: Emergency Engine Shutdown Via Automation System
4.11 Emergency engine shutdown via automation system 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 shutdown via automation system Item Measure Automation system...
Page 85: Engaging From Lop
4.12 Engaging from LOP DANGER Vessel is sailing blind. In Local Operation mode, the propulsion plant is controlled from the engine room. Risk of accidents! • Only execute vessel movements on the instructions of a person who has visual contact with the area outside the vessel.
Page 86: Disengaging From Lop
4.13 Disengaging from LOP DANGER Vessel is sailing blind. In Local Operation mode, the propulsion plant is controlled from the engine room. Risk of accidents! • Only execute vessel movements on the instructions of a person who has visual contact with the area outside the vessel.
Page 87: Waterjet - Flushing From Lop (Optional)
4.14 Waterjet – Flushing from LOP (optional) Preconditions ☑ LOCAL OPERATION illuminated switch is lit brightly (local operating mode is active). ☑ Waterjet-BucketVessel at standstill and waterjet bucket is below the waterline. ☑ Engine speed is in engagement window. ☑ No external engagement interlock is active. NOTICE Waterjet flushing puts excessive strain on the bearings.
Page 88: Engine Shutdown Via The Automation System
4.15 Engine shutdown via the automation system NOTICE Stopping the engine when it is running at full load causes extreme stress to the engine. Risk of overheating, damage to components! • Before shutting down, disengage gear and run the engine at idle speed for at least 10 minutes until engine temperatures have dropped and constant values are displayed.
Page 89: After Stopping The Engine
4.16 After stopping the engine Preconditions ☑ MTU Preservation and Re-preservation Specifications (A001070/..) are available. After stopping the engine Item Measure Coolant circuit Drain coolant (→ Page 236) if: • freezing temperatures are expected and the engine is to remain out of service for an extended period, but engine coolant has no antifreeze addi- tive;...
Page 90: Fuel Treatment System - Shutdown
4.17 Fuel treatment system – Shutdown Shutting down fuel treatment system Press the illuminated pushbutton "Water drain" on the switch cabinet until water discharge from the outlet stops. Switch off fuel treatment system. Close ball valve at the inlet to the fuel treatment system. Close ball valve at the outlet of the fuel treatment system.
Page 91: Plant - Cleaning
4.18 Plant – Cleaning Preconditions ☑ Engine is stopped and starting disabled. ☑ No operating voltage is applied. Special tools, Material, Spare parts Designation / Use Part No. Qty. High-pressure cleaning unit Cleaner (Hakupur 50/136) X00056700 WARNING Compressed air gun ejects a jet of pressurized air. Risk of injury to eyes and damage to hearing, risk of rupturing internal organs! •...
Page 92: Maintenance
5 Maintenance 5.1 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.
Page 93: Troubleshooting
6 Troubleshooting 6.1 Troubleshooting Engine does not turn when starter is actuated Cause Corrective action Battery low or faulty u Charge or replace (see separate documentation). Battery: Cable connections faulty u Check firm seating of cable connections (see separate documentation). u Check firm seating of cable connections, contact Service.
Page 94 Speed transmitter faulty u Contact Service. Engine Control Unit faulty Charge-air temperature too high Cause Corrective action u Check (MTU test kit). Incorrect coolant concentration u Contact Service. Intercooler dirty Engine room: Air-intake u Check fans and air supply/ventilation ducts.
Page 95 White exhaust gas Cause Corrective action u Run engine to reach operating temperature. Engine is not at operating temperature Intercooler leaking u Contact Service. MS150109/01E 2015-11 | Troubleshooting | 95...
Page 96: Control Cabinet Of Fuel Treatment System - Troubleshooting
6.2 Control cabinet of fuel treatment system – Troubleshooting Water alarm Cause Corrective action When the maximum water level is 1. Press illuminated pushbutton 'Water alarm' for acknowledgment. reached, the water level electrode 2. In addition to the automatic water drain function, water can also be opens the water drain valve and drained manually: Press illuminated pushbutton 'Water drain'.
Page 97: Engine Governor Adec (Ecu 7) Fault Messages For Series 4000 Engines, Marine Application
6.3 Engine governor ADEC (ECU 7) fault messages for Series 4000 engines, marine application The fault code numbers are generated by the engine governor and transmitted to the display below (if fitted). The fault code (1) comprises 3 digits. Fault messages may also be caused by faulty sensors/actuators. Contact Service to have sensors/actuators tested and replaced as necessary if troubleshooting as described in the table (→...
Page 98: Engine Control Unit Adec (Ecu 7) - Fault Codes
6.4 Engine Control Unit ADEC (ECU 7) – Fault codes 3 – HI T-Fuel ZKP-Number: 2.0122.931 Fuel temperature too high (limit value 1) Yellow alarm; warning Cause Corrective action Fuel tank may be exposed to heat. 1. Reduce power. 2. Contact Service. 4 –...
Page 99 9 – HI T-Coolant Intercooler ZKP-Number: 2.0124.931 Coolant temperature in intercooler too high (limit value 1) Yellow alarm; warning Cause Corrective action Coolant circuit for charge-air 1. Reduce power. faulty. 2. Check intercooler and coolant cooler. 3. Contact Service. 10 – SS T-Coolant Intercooler ZKP-Number: 2.0124.932 Coolant temperature in intercooler too high (limit value 2) Red alarm;...
Page 100 19 – HI T-Exhaust A ZKP-Number: 2.0126.931 Exhaust temperature too high, A side (limit value 1) Yellow alarm; warning Cause Corrective action Wiring damage. 1. Check air filter and wiring (→ Page 254). 2. Contact Service. 20 – SS T-Exhaust A ZKP-Number: 2.0126.932 Exhaust temperature too high, A side (limit value 2) Red alarm;...
Page 101 25 – HI P-Diff. Lube Oil ZKP-Number: 2.0154.931 Differential oil pressure at oil filter too high (limit value 1) Yellow alarm; warning Cause Corrective action Oil filter out of order. u Replace oil filter (→ Page 226). 26 – HI P-Diff. Lube Oil ZKP-Number: 2.0154.932 Differential oil pressure at oil filter too high (limit value 2) Red alarm;...
Page 102 31 – HI ETC1 Overspeed ZKP-Number: 2.3011.931 Speed of primary turbocharger too high (limit value 1) Yellow alarm; warning Cause Corrective action Clogged charge-air circuit or fault 1. Reduce power. in turbocharger. 2. Check air filter. 3. Contact Service. 32 – SS ETC1 Overspeed ZKP-Number: 2.3012.932 Speed of primary turbocharger too high (limit value 2) Red alarm;...
Page 103 37 – SS ETC2 Overspeed ZKP-Number: 2.3013.912 Speed of 1st secondary turbocharger too high (limit value 2) Red alarm; engine shutdown Cause Corrective action Clogged charge-air circuit or fault u Contact Service. in turbocharger. 38 – AL ETC Speed Deviation ZKP-Number: 1.8004.205 Yellow alarm;...
Page 104 52 – SS T-Lube Oil ZKP-Number: 2.0125.932 Lube oil temperature too high (limit value 2) Red alarm; engine shutdown Cause Corrective action Insufficient oil. 1. Check engine oil level (→ Page 219). 2. Contact Service. 57 – LO P-Coolant ZKP-Number: 2.0101.921 Coolant pressure too low (limit value 1) Yellow alarm;...
Page 105 60 – SS T-Coolant L4 ZKP-Number: 2.0120.934 Coolant temperature too high / low (limit value 4) Red alarm; engine shutdown Cause Corrective action Coolant circuit out of order (e.g. 1. Activate fan emergency operating mode as necessary. damage, leaks, low coolant level). 2.
Page 106 66 – SS P-Fuel ZKP-Number: 2.0102.922 Fuel supply pressure too low (limit value 2) Red alarm; engine shutdown Cause Corrective action Leaking or clogged fuel lines or 1. Check fuel lines for leakage. fuel filter. 2. Check filter, fuel low-pressure side. 3.
Page 107 82 – HI P-Fuel (Common Rail) ZKP-Number: 2.0104.931 Rail pressure > set value Red alarm - DBR fuel limitation, start of injection retarded; Cause Corrective action Suction restrictor of HP fuel block 1. Check wiring (→ Page 254). jamming or HP fuel control block 2.
Page 108 90 – SS Starter Speed Not Reached ZKP-Number: 2.1090.925 Idling speed not attained Red alarm; warning Cause Corrective action Various causes possible. 1. Check for additional messages. 2. Contact Service. 91 – SS Release Speed Not Reached ZKP-Number: 2.1090.924 Runup speed was not attained Red alarm;...
Page 109 95 – AL Prelubrication Fault ZKP-Number: 2.1090.920 Oil priming fault Yellow alarm; warning Cause Corrective action Priming oil pressure not reached. 1. Check priming system. 2. Contact Service. 102 – AL Fuel Cons. Counter Defect ZKP-Number: 1.8004.624 Error in fuel consumption checksum Yellow alarm;...
Page 110 120 – HI ECU Power Supply Voltage ZKP-Number: 2.0140.931 Supply voltage too high (limit value 1) Yellow alarm; warning Cause Corrective action Supply voltage at Engine Control 1. Check Engine Control Unit supply voltage. Unit too high. 2. Contact Service. 121 –...
Page 111 176 – AL LifeData not available ZKP-Number: 2.4000.004 No (matching) LifeData backup system available Yellow alarm; warning Cause Corrective action After a wait time has elapsed after u Contact Service. ECU reset: Backup system has no LifeData function or CAN bus to backup system disconnected.
Page 112 182 – AL CAN Wrong Parameters ZKP-Number: 2.0500.682 Incorrect parameters on CAN Yellow alarm; warning Cause Corrective action Wrong parameter value entered in u Contact Service. data record. 183 – AL CAN No PU-Data ZKP-Number: 2.0500.683 CAN PU data not present or available Yellow alarm;...
Page 113 187 – AL CAN1 Error Passive ZKP-Number: 2.0500.687 CAN controller 1 error Yellow alarm; warning Cause Corrective action Missing associated node, minor 1. Check CAN bus for short circuit, rectify short circuit as necessary. disruptions or temporary bus 2. Check shielding, improve shielding as necessary. overload.
Page 114 202 – SD T-Fuel ZKP-Number: 1.8004.572 Signal error, fuel temperature sensor Yellow alarm; warning Cause Corrective action Fuel temperature sensor faulty. 1. Check sensor and wiring (B33), replace as necessary (→ Page 254). Short circuit or wire break. 2. Fault is rectified when engine is restarted (→ Page 75). 3.
Page 115 206 – SD T-Exhaust A ZKP-Number: 1.8004.576 Signal error, exhaust temperature sensor on A side Yellow alarm; warning Cause Corrective action Exhaust temperature sensor on A 1. Check sensor and wiring (B4.21), replace as necessary side faulty. (→ Page 254). Short circuit or wire break.
Page 116 212 – SD P-Coolant ZKP-Number: 1.8004.564 Signal error, coolant pressure sensor Yellow alarm; warning Cause Corrective action Coolant pressure sensor faulty. 1. Check sensor and wiring (B16), replace as necessary (→ Page 254). Short circuit or wire break. 2. Fault is rectified when engine is restarted (→ Page 75). 3.
Page 117 216 – SD T-Lube Oil ZKP-Number: 1.8004.575 Signal error, lube oil temperature sensor Yellow alarm; warning Cause Corrective action Lube oil temperature sensor 1. Check sensor and wiring (B7), replace as necessary (→ Page 254). faulty. 2. Fault is rectified when engine is restarted (→ Page 75). Short circuit or wire break.
Page 118 222 – SD Level Leak-off Fuel ZKP-Number: 1.8004.582 Signal error, leak fuel level sensor Yellow alarm; warning Cause Corrective action Leak fuel level sensor faulty. 1. Check sensor and wiring (F46), replace as necessary (→ Page 254). Short circuit or wire break. 2.
Page 119 229 – AL Stop Camshaft Sensor Defect ZKP-Number: 1.8004.562 Stop signal error, camshaft sensor Red alarm; engine shutdown Cause Corrective action Camshaft sensor faulty (and a 1. Check sensor and wiring to connector B1, replace as necessary fault that occurred previously in (→...
Page 120 233 – SD Charger 2 Speed ZKP-Number: 1.3011.129 Signal error, secondary turbocharger speed sensor Yellow alarm; warning Cause Corrective action Speed sensor of secondary 1. Check sensor and wiring (B44.2), replace as necessary turbocharger faulty. (→ Page 254). Short circuit or wire break. 2.
Page 121 244 – SD P-Lube Oil (R) ZKP-Number: 1.8004.621 Cause Corrective action Redundant lube oil pressure u Check sensor and wiring, replace as necessary. sensor faulty; Short circuit or wire Fault is rectified when engine is restarted. break. 245 – SD ECU Power Supply Voltage ZKP-Number: 2.8006.589 Signal error, Engine Control Unit supply voltage Yellow alarm;...
Page 122 270 – SD Frequency Input ZKP-Number: 2.8006.590 Signal error, frequency input Red alarm; forced idle Cause Corrective action Frequency input faulty. 1. Check wiring (→ Page 254). Short circuit or wire break. 2. Check speed demand transmitter. 3. Contact Service. 301 –...
Page 123 305 – AL Timing Cylinder A5 ZKP-Number: 1.8004.504 Flight time measuring fault of injector Cause Corrective action Flight time value extremely low or u Replace injector if the fault message appears frequently extremely high. (→ Page 186). 306 – AL Timing Cylinder A6 ZKP-Number: 1.8004.505 Flight time measuring fault of injector Cause...
Page 124 311 – AL Timing Cylinder B1 ZKP-Number: 1.8004.510 Flight time measuring fault of injector Cause Corrective action Flight time value extremely low or u Replace injector if the fault message appears frequently extremely high. (→ Page 186). 312 – AL Timing Cylinder B2 ZKP-Number: 1.8004.511 Flight time measuring fault of injector Cause...
Page 125 317 – AL Timing Cylinder B7 ZKP-Number: 1.8004.516 Flight time measuring fault of injector Cause Corrective action Flight time value extremely low or u Replace injector if the fault message appears frequently extremely high. (→ Page 186). 318 – AL Timing Cylinder B8 ZKP-Number: 1.8004.517 Flight time measuring fault of injector Cause...
Page 126 322 – AL Wiring Cylinder A2 ZKP-Number: 1.8004.521 Wiring fault cylinder A2 Yellow alarm; misfire Cause Corrective action Short circuit fault in injector 1. Check injector solenoid, replace injector as necessary wiring cylinder A2. (→ Page 186). 2. Fault is rectified when engine is restarted (→ Page 75). 3.
Page 127 326 – AL Wiring Cylinder A6 ZKP-Number: 1.8004.525 Wiring fault cylinder A6 Yellow alarm; misfire Cause Corrective action Short circuit fault in injector 1. Check injector solenoid, replace injector as necessary wiring cylinder A6. (→ Page 186). 2. Fault is rectified when engine is restarted (→ Page 75). 3.
Page 128 330 – AL Wiring Cylinder A10 ZKP-Number: 1.8004.529 Wiring fault cylinder A10 Yellow alarm; misfire Cause Corrective action Short circuit fault in injector 1. Check injector solenoid, replace injector as necessary wiring cylinder A10. (→ Page 186). 2. Fault is rectified when engine is restarted (→ Page 75). 3.
Page 129 334 – AL Wiring Cylinder B4 ZKP-Number: 1.8004.533 Wiring fault cylinder B4 Yellow alarm; misfire Cause Corrective action Short circuit fault in injector 1. Check injector solenoid, replace injector as necessary wiring cylinder B4. (→ Page 186). 2. Fault is rectified when engine is restarted (→ Page 75). 3.
Page 130 338 – AL Wiring Cylinder B8 ZKP-Number: 1.8004.537 Wiring fault cylinder B8 Yellow alarm; misfire Cause Corrective action Short circuit fault in injector 1. Check injector solenoid, replace injector as necessary wiring cylinder B8. (→ Page 186). 2. Fault is rectified when engine is restarted (→ Page 75). 3.
Page 131 342 – AL Open Load Cylinder A2 ZKP-Number: 1.8004.541 Injector wiring fault cylinder A2 Yellow alarm; misfire Cause Corrective action Disruption in injector wiring 1. Check injector wiring for disruption. cylinder A2. 2. Exclude possible injector solenoid fault, replace injector as necessary (→...
Page 132 346 – AL Open Load Cylinder A6 ZKP-Number: 1.8004.545 Injector wiring fault cylinder A6 Yellow alarm; misfire Cause Corrective action Disruption in injector wiring 1. Check injector wiring for disruption. cylinder A6. 2. Exclude possible injector solenoid fault, replace injector as necessary (→...
Page 133 350 – AL Open Load Cylinder A10 ZKP-Number: 1.8004.549 Injector wiring fault cylinder A10 Yellow alarm; misfire Cause Corrective action Disruption in injector wiring 1. Check injector wiring for disruption. cylinder A10. 2. Exclude possible injector solenoid fault, replace injector as necessary (→...
Page 134 354 – AL Open Load Cylinder B4 ZKP-Number: 1.8004.553 Injector wiring fault cylinder B4 Yellow alarm; misfire Cause Corrective action Disruption in injector wiring 1. Check injector wiring for disruption. cylinder B4. 2. Exclude possible injector solenoid fault, replace injector as necessary (→...
Page 135 358 – AL Open Load Cylinder B8 ZKP-Number: 1.8004.557 Injector wiring fault cylinder B8 Yellow alarm; misfire Cause Corrective action Disruption in injector wiring 1. Check injector wiring for disruption. cylinder B8. 2. Exclude possible injector solenoid fault, replace injector as necessary (→...
Page 136 362 – AL Power Stage high ZKP-Number: 1.8004.497 Internal electronic fault. Red alarm; engine shutdown possible Cause Corrective action Electronics faulty. 1. Start ITS. 2. Replace Engine Control Unit as necessary. 3. Check additional messages if ITS indicates diagnosis “Electronics OK”...
Page 137 372 – AL Wiring TO 2 ZKP-Number: 1.8004.635 Line disruption Cause Corrective action Short circuit or wire break on 1. Check recirculation valve/wiring, repair as necessary. transistor output 2 (TO 2). 2. Replace Engine Control Unit. 373 – AL Wiring TO 3 ZKP-Number: 1.8004.636 Line disruption Cause...
Page 138 383 – AL Wiring TOP 3 ZKP-Number: 2.8006.640 Line disruption on digital input 3 Yellow alarm; warning Cause Corrective action Short circuit or wire break on u Check wiring to plant. transistor output, plant-side 3 (TOP 3). 384 – AL Wiring TOP 4 ZKP-Number: 2.8006.641 Line disruption on digital input 4 Yellow alarm;...
Page 139 394 – LO P-Lube Oil Red ZKP-Number: 2.0112.921 Limit value 1 Cause Corrective action Redundant lube oil pressure 1. Check wiring and sensor. reading too low. 2. Contact Service. 395 – SS P-Lube Oil Red ZKP-Number: 2.0112.922 Limit value 2 Cause Corrective action Redundant lube oil pressure...
Page 140 401 – AL Open Load Digital Input 2 ZKP-Number: 2.8006.626 Line disruption on digital input 2 Yellow alarm; warning Cause Corrective action Wiring faulty. 1. Check wiring (→ Page 254). No resistance over switch. 2. Check target device input. 3. Contact Service. 402 –...
Page 141 405 – AL Open Load Digital Input 6 ZKP-Number: 2.8006.630 Line disruption on digital input 6 Yellow alarm; warning Cause Corrective action Wiring faulty. 1. Check wiring (→ Page 254). No resistance over switch. 2. Check target device input. 3. Contact Service. 406 –...
Page 142 410 – LO U-PDU ZKP-Number: 2.0141.921 Injector voltage too low (limit value 1) Yellow alarm; warning Cause Corrective action Wiring damage or faulty power 1. Check wiring (→ Page 254). supply. 2. Check supply. 3. Contact Service. 411 – LOLO U-PDU ZKP-Number: 2.0141.922 Injector voltage too low (limit value 2) Red alarm;...
Page 143 414 – HI Level Water Fuel Prefilter ZKP-Number: 2.0156.931 Water level in fuel prefilter too high (limit value 1) Yellow alarm; warning Cause Corrective action Water content in fuel too high. u Empty fuel prefilter. Water ingress in fuel tank. 415 –...
Page 144 420 – AL L1 Aux 1 ZKP-Number: 2.0160.921 Limit value 1 Cause Corrective action Input signal of Aux 1 has u Determine cause of limit value violation and rectify fault. exceeded/not attained limit value 1, depending on configuration. 421 – AL L2 Aux 1 ZKP-Number: 2.0160.922 Limit value 2 Cause...
Page 145 442 – AL L2 P-Aux 1 ZKP-Number: 2.0110.931 Limit value 2 Cause Corrective action Pressure signal of Aux 1 has u Determine cause of limit value violation and rectify fault. exceeded / not attained limit value 2, depending on configuration. 444 –...
Page 146 449 – SS P-Charge-Air ZKP-Number: 2.0103.932 Charge-air pressure too high (limit value 2) Red alarm; engine shutdown Cause Corrective action Fault at turbine bypass flap. u Contact Service. 450 – SD Idle/End-Torque Input [%] ZKP-Number: 2.8006.592 Signal error, start/end torque Yellow alarm;...
Page 147 456 – AL L2 Aux1 Plant ZKP-Number: 2.8006.651 Limit value 2 Cause Corrective action Input signal of Aux 1 (plant side) u Determine cause of limit value violation and rectify fault. has exceeded/not attained limit value 2, depending on configuration. 460 –...
Page 148 467 – AL L2 T-Aux 1 ZKP-Number: 2.0130.922 Limit value 2 Cause Corrective action Temperature signal of Aux 1 has u Determine cause of limit value violation and rectify fault. exceeded / not attained limit value 2, depending on configuration. 468 –...
Page 149 472 – AL Stop SD ZKP-Number: 2.8006.593 Engine stops Red alarm; engine shutdown Cause Corrective action Engine stops because “Sensor 1. Check wiring (→ Page 254). faulty" present at channels. 2. Contact Service. 473 – AL Wiring PWM_CM2 ZKP-Number: 1.8004.593 Cause Corrective action Wire break or short circuit on...
Page 150 478 – AL Comb. Alarm Yel (Plant) ZKP-Number: 2.8006.001 Yellow combined alarm from system Yellow alarm; warning Cause Corrective action Various causes possible. u Check for additional messages. 479 – AL Comb. Alarm Red (Plant) ZKP-Number: 2.8006.002 Red combined alarm from system Red alarm Cause Corrective action...
Page 151 484 – HI T-Exhaust C ZKP-Number: 20.133.931 Limit value 1 Cause Corrective action Exhaust gas temperature (C-side) 1. Reduce power. too high. 2. Contact Service. 485 – SS T-Exhaust C ZKP-Number: 20.133.932 Limit value 2 Cause Corrective action Exhaust gas temperature (C-side) 1.
Page 152 489 – SS ETC3 Overspeed ZKP-Number: 2.3014.932 Speed of 2nd secondary turbocharger too high (limit value 2) Red alarm; engine shutdown Cause Corrective action Clogged charge-air circuit or fault u Reduce power. in turbocharger. 490 – HI ETC4 Overspeed ZKP-Number: 2.3015.931 Speed of the 3rd secondary turbocharger too high (limit value 1) Yellow alarm;...
Page 153 500 – AL Wiring POM Starter 1 ZKP-Number: 1.4500.900 Wiring fault, connection of starter 1 at POM Yellow alarm; warning Cause Corrective action Missing consumer. u Check connection between POM and starter. Short circuit or wire break 501 – AL Wiring POM Starter 2 ZKP-Number: 1.4500.901 Wiring fault, connection of starter 2 at POM Yellow alarm;...
Page 154 506 – AL Low Starter Voltage ZKP-Number: 1.4500.906 The battery voltage is too low for the starting process Yellow alarm; warning Cause Corrective action Wiring faulty or battery is flat. u Check starter battery and wiring (→ Page 254). 507 – AL POM Fault ZKP-Number: 1.4500.907 A general POM fault occurred Yellow alarm;...
Page 155 519 – Oil Level Calibration Error ZKP-Number: 1.0158.921 Error writing calibration value into flash or SD of level sensor. Yellow alarm; warning Cause Corrective action Oil level sensor or wiring faulty. 1. Check sensor and wiring, replace as necessary (→ Page 254). 2.
Page 156 Limit value 2 Cause Corrective action Camshaft overspeed. 1. Acknowledge alarm. 2. Attempt engine restart. 555 – AL Call MTU Field Service ZKP-Number: 20.555.001 Cause Corrective action u Request activation code via Internet. This fault becomes active if a maintenance case has been...
Page 157 576 – AL ESCM Override ZKP-Number: 1.1075.083 Engine overload Yellow alarm; warning Cause Corrective action Violation of corrected MCR or u Reduce power. DBR/MCR curve. 577 – SD T-Lube Oil Pan ZKP-Number: 1.0137.900 Signal error, oil pan temperature sensor Yellow alarm; warning Cause Corrective action Oil pan temperature sensor faulty.
Page 158 588 – SD P-Oil Refill Pump ZKP-Number: 1.0159.910 Signal error, refill pump oil pressure sensor Yellow alarm; warning Cause Corrective action Pressure sensor faulty. 1. Check sensor and wiring, replace as necessary (→ Page 254). Short circuit or wire break. 2.
Page 159 602 – AL CAN Engine Start Lock ZKP-Number: 2.1090.930 Start interlock from plant pending Yellow alarm; warning Cause Corrective action Start interlock initiated by plant. u The alarm is reset by canceling the engine start instruction or the CAN request. 606 –...
Page 160 687 – SD Oil Level Switch ZKP-Number: 1.0150.920 Level switch faulty Cause Corrective action Lube oil level switch is faulty. 1. Check sensor and wiring (B24), replace as necessary. Alarm is ==> Short circuit or wire break. reset when fault is eliminated. (→ Page 254). 2.
Page 161 788 – Cyl. cutout detects turbocharger speed error ZKP-Number: 1.3000.069 Cause Corrective action The cyl. cutout system has detected an invalid turbocharger speed at turbochargers 1 or 2. 850 – SD Alive FIP ZKP-Number: 2.0900.002 Frequency input faulty. Cause Corrective action Short circuit or wire break.
Page 162 869 – AL L2 P-Lube Oil ETC B ZKP-Number: 1.0223.922 Limit value 2 Cause Corrective action Lube oil pressure too low. u Check ETC oil lubrication. 162 | Troubleshooting | MS150109/01E 2015-11...
Page 163: Task Description
7 Task Description 7.1 SOLAS 7.1.1 SOLAS shielding as per MTN 5233 – Installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Shield A4 735233000100 Shield A5 735233000101 Shield A6 735233000102 Shield A8 735233000104...
Page 164: Solas Shielding - Installation
7.1.2 SOLAS shielding – Installation Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine cooled down to ambient temperature. Special tools, Material, Spare parts Designation / Use Part No. Qty. Oil filter shield X00040625 Installing SOLAS shielding for oil filter Pinpoint installation location .
Page 165: Solas Shielding - Installation Locations
7.1.3 SOLAS shielding – Installation locations General information Fit SOLAS shielding as per MTN 5233 by way of preference (→ Page 163). Fuel system, fuel lines with fuel pressure >1.8 bar These shields must be installed on the assembly line! These locations are no longer accessible, or only with great difficulty, following assembly of the air pipework and fuel filters.
Page 166 Item Type of shielding Comments Shield (E5) Fuel line on HP pump Shield (E5) Fuel line downstream of fuel filter head Item Type of shielding Comments Shields (A8) (2 x) Fuel line at fuel filter head holder 166 | Task Description | MS150109/01E 2015-11...
Page 167 Item Type of shielding Comments Shields (B6) (2 x) Fuel line: at fuel filter head Lube oil system, oil lines with oil pressure >1.8 bar Item Type of shielding Comments Shields (A5) (2 x) Air flap actuator cylinder exhaust turbocharger A1 MS150109/01E 2015-11 | Task Description | 167...
Page 168 Item Type of shielding Comments Shields (A5) (4 x) On 4/2 directional control valve Shield (A6) Oil supply from main oil gallery at distributor Shield (A6) Oil supply from main oil gallery at distributor Shield (A6) Oil supply from main oil gallery at distributor Shield (A5) Oil drain to crankcase...
Page 169 Item Type of shielding Comments Shields (A4) Exhaust turbocharger oil supply, A side Shields (A5) (2 x) Exhaust turbocharger oil supply, A side 1 SOLAS clip on ETC: Oil supply B side Item Type of shielding Comments Shields (A4) Oil supply exhaust turbocharger, B side MS150109/01E 2015-11 | Task Description | 169...
Page 170 Item Type of shielding Comments Shields (A4) (2 x) Oil supply pressure monitor, B side Item Type of shielding Comments Shields (A6) Oil supply to HP pump 170 | Task Description | MS150109/01E 2015-11...
Page 171 Item Type of shielding Comments Shields (B4) Oil supply of HP pump on equip- ment carrier Item Type of shielding Comments Shields (B2) (2 x) Oil line on gearcase MS150109/01E 2015-11 | Task Description | 171...
Page 172: Engine
7.2 Engine 7.2.1 Engine – Barring manually Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Barring device F6555766 Ratchet with extension F30006212 DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...
Page 173 Engage barring device (2) in ring gear of fly- wheel and install it on flywheel housing. Fit ratchet (1) onto barring device (2). Note: No resistance other than compression resist- ance must be encountered. Rotate crankshaft in engine direction of rota- tion.
Page 174: Engine - Barring With Starting System
7.2.2 Engine – Barring with starting system Barring using the automation system Refer to automation system operating instructions 174 | Task Description | MS150109/01E 2015-11...
Page 175: Cylinder Liner
7.3 Cylinder Liner 7.3.1 Cylinder liner – Endoscopic examination Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Barring device F6792918 Ratchet with extension F30006212 Endoscope Y20097353 Preparatory steps Remove cylinder head cover (→ Page 179). Remove injector (→...
Page 176 Compile endoscopic report using the table. Use technical terms for description of the liner surface (→ Page 177). Depending on findings: • Do not take any action or • carry out a further endoscopic examination as part of maintenance work or •...
Page 177: Instructions And Comments On Endoscopic And Visual Examination Of Cylinder Liners
7.3.2 Instructions and comments on endoscopic and visual examination of cylinder liners Terms used for endoscopic examination Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic examina- tion report. Findings Explanations/Action Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing products, particles, broken-off burrs).
Page 178 Evaluation of findings and further measures The findings in the start phase of oxidation discoloration and heat discoloration are similar. A thorough inves- tigation and compliance with the above evaluation criteria allow an unambiguous evaluation. To avoid unnec- essary disassembly work, it is recommended that another inspection be carried out after further operation of the engine.
Page 179: Valve Drive
7.4 Valve Drive 7.4.1 Cylinder head cover – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Assembly compound (Kluthe Hakuform 30-15) X00067260 O-ring (→ Spare Parts Catalog) Removing cylinder head cover Clean very dirty cylinder head covers (1) prior to removal.
Page 180: Valve Gear - Lubrication
7.4.2 Valve gear – Lubrication Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil Valve gear – Lubrication Remove cylinder head covers (→ Page 179). Fill oil chambers of valve bridges with oil. Fill oil chambers of rocker arms and adjusting screws with oil.
Page 181: Valve Clearance - Check And Adjustment
7.4.3 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 gage Y20010128 Torque wrench, 60–320 Nm F30047446...
Page 182 Rotate crankshaft with barring gear in engine direction of rotation until “OT-A1” mark and pointer are aligned. Diagram for 8V engines (two crankshaft positions) 1 Cylinder A1 is in firing TDC 2 Cylinder A1 is in overlap TDC I Inlet valve X Exhaust valve Checking valve clearance at two crankshaft positions Check TDC position of piston in cylinder A1:...
Page 183: Adjusting Valve Clearance
Adjusting valve clearance Release locknut (1). Insert feeler gage (3) between valve bridge and rocker arm. Using Allen key, set adjusting screw (2) so that the specified valve clearance is provided. Note: Feeler gage must just pass through the gap. Pull feeler gage (3) between valve bridge and rocker arm.
Page 184: Injection Pump / Hp Pump
7.5 Injection Pump / HP Pump 7.5.1 HP pump – Filling with engine oil Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil WARNING Fuels are combustible and explosive. Risk of fire and explosion! •...
Page 185: Hp Pump - Relief Bore Check
7.5.2 HP pump – Relief bore check DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running.
Page 186: Injector
7.6 Injector 7.6.1 Injector – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Injector (→ Spare Parts Catalog) Injector – Replacement Remove injector and install new one (→ Page 187). 186 | Task Description | MS150109/01E 2015-11...
Page 187 7.6.2 Injector – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Installation/removal jig F6795690 Milling cutter F30452739 Torque wrench, 0.5-5 Nm 0015384230 Torque wrench, 10-60 Nm F30452769 Torque wrench, 60–320 Nm F30452768...
Page 188 Unscrew union nuts (2, 5) and remove HP line (3) from rail (4) and cylinder head. Note: Accumulated fuel in the injector runs out when the adapter is unscrewed. Provide suitable vessel to collect escaping fuel. Remove adapter (1). Remove return line (6). Remove screw (2) from hold-down clamp (1).
Page 189 Remove O-rings (2) and damper ring (3) from injector (1). Clean all contact and sealing surfaces. If carbon residue is present, clean sealing face on cylinder head and protective sleeve with milling cutter. Cover all connections and bores, or seal with suitable plugs.
Page 190 Press in injector (1) and hold-down clamp with installation/removal jig (2). Remove press-fitting tool. Coat screw head mating face and thread (2) of hold-down clamp (1) with engine oil. Insert screw (2) and tighten to specified initial tightening torque using a torque wrench. Name Size Type...
Page 191 Note: Ensure immaculate cleanliness. Coat thread and sealing cone of adapter (1) with engine oil. Install adapter (1) and tighten to specified initial tightening torque using a torque wrench. Name Size Type Lubricant Value/Standard Adapter Preload torque (Engine oil) 5 Nm to 10 Nm Tighten screw of hold-down clamp (→...
Page 192 Note: Only in connection with steel sealing ring. Tighten both unions of the return line (6) to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Union M12x1.5 Tightening torque 50 Nm Fit connectors on injector. Note: If the CDC parameters are not reset, the emission certification of the engine becomes invalid.
Page 193 7.7 Fuel System 7.7.1 Fuel system – Venting Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...
Page 194 Venting LP fuel system Turn three-way cock (3) into position (C) where both filters are operational. Open threaded vent plugs (1). Unlock fuel priming pump (2), screw out han- dle by turning it counterclockwise. Operate fuel priming pump (2) until bubble- free fuel emerges from the threaded vent plugs (1).
Page 195: Fuel Filter
7.8 Fuel Filter 7.8.1 Additional fuel filter – Overview 1 Storage tank 3 Passive fuel prefilter with 5 Additional fuel filter, switch- 2 Day tank water separator able 4 LP pump 6 Main engine filter, switcha- MS150109/01E 2015-11 | Task Description | 195...
Page 196 7.8.2 Additional fuel filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Diesel fuel Easy-change filter (→ Spare Parts Catalog) Synthetic ring (→ Spare Parts Catalog) DANGER Rotating and moving engine parts.
Page 197 Replacing fuel filter with engine stopped A Both filters cut in B Left filter cut out C Right filter cut out 1 Fuel vent 2 Fuel filter 3 Control lever on three-way cock Cut out the filter to be replaced. Unscrew cut-out easy-change filter with filter wrench.
Page 198 7.8.3 Fuel filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Diesel fuel Easy-change filter (→ Spare Parts Catalog) Synthetic ring (→ Spare Parts Catalog) DANGER Rotating and moving engine parts.
Page 199 Replacing fuel filter with engine stopped Cut out the filter to be replaced (1): B Left-hand filter switched off C Right-hand filter switched off Remove the cut-out oil filter (1) using an oil filter wrench. Clean sealing surface on filter head. Check sealing ring of new filter (1) and coat with fuel.
Page 200 7.8.4 Fuel prefilter – Differential pressure gage check and adjustment of gage DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running.
Page 201 7.8.5 Fuel prefilter – Draining Preconditions ☑ Engine is stopped and starting disabled. 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! •...
Page 202 Open vent plug (1) of filter to be drained. Open drain valve (2). Drain water and contaminants from filter until pure fuel emerges. Close drain valve (2). Connect filling pump to filling connection (1) on the suction side of the filter. Open vent valve (2) and fill with fuel until fuel emerges from the vent pipe (3).
Page 203 7.8.6 Fuel prefilter – Flushing Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING Liquid or gaseous media, e.g.
Page 204 Open vent plug (1) of filter to be flushed. Open drain valve (2) and drain fuel. Result: Fuel flows from filtered side back to the unfil- tered side, flushing the filter deposits down- wards out of the filter. Close vent plug (1) and drain valve (2). Fuel prefilter –...
Page 205 7.8.7 Fuel prefilter with water separator – Filter element replacement Preconditions ☑ Engine is stopped and starting disabled. ☑ System is at atmospheric pressure. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10–60 Nm F30452769 Ratchet adapter F30027340 Filter element...
Page 206 Fuel prefilter with water separa- tor – Filter element replacement Cut out the filter to be replaced (A or B): 1 Filter A cut out 2 Filter B cut out Open vent valve (1) of the filter to be re- placed.
Page 207 Connect filling pump to filling connection (1) on the suction side of the filter. Open vent valve (2) and fill with fuel until fuel emerges from the vent pipe (3). Close vent valve (2). Turn rotary slide valve (4) a little (by approx. 30°) and open vent valve(s) (2), until fuel emerges from the vent pipe (3).
Page 208 7.8.8 Fuel prefilter with water separator – O-ring replacement in rotary slide valve Preconditions ☑ Engine is stopped and starting disabled. ☑ System is at atmospheric pressure. Special tools, Material, Spare parts Designation / Use Part No. Qty. O-ring (→ Spare Parts Catalog) WARNING Tank is pressurized.
Page 209: Exhaust Turbocharger
7.9 Exhaust Turbocharger 7.9.1 Compressor wheel – Cleaning Preconditions ☑ Engine is stopped and starting disabled Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 4-20 Nm F30044239 Cleaning agent 40377 Engine oil Engine coolant Sealing rings (→...
Page 210 Remove air pipework (1) from exhaust turbo- charger to intercooler. Disconnect oil lines (2) from air flap actuator cylinder. Undo screws (3) and clamp (2). Remove intake housing (1) with actuating cyl- inder. Remove coolant lines (1) on compressor housing. 210 | Task Description | MS150109/01E 2015-11...
Page 211 Undo clamp (2). Remove compressor housing (1). Compressor wheel – Clean Note: Do not use wire brushes, scrapers or similar implements for cleaning! Clean compressor housing with a soft brush. Clean compressor wheel (2) and bearing housing (1). Thoroughly remove cleaning agent from all parts.
Page 212 Align clamp (2) and tighten to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Clamp Tightening torque (Engine oil) 5 Nm +1 Nm Install coolant lines (1) on compressor hous- ing. Install intake housing (1) with actuating cylin- der.
Page 213 Install oil lines (2). Install air pipework (1) from exhaust turbo- charger to intercooler. Install air filter (→ Page 216). Fill with engine coolant (→ Page 237). MS150109/01E 2015-11 | Task Description | 213...
Page 214 7.10 Charge-Air Cooling 7.10.1 Intercooler – Check water drain for coolant leakage and obstruction DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running.
Page 215: Air Filter
7.11 Air Filter 7.11.1 Air filter – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Air filter (→ Spare Parts Catalog) Replacing the air filter Remove old air filter and install new air filter (→ Page 216). Reset signal ring of contamination indicator (→...
Page 216 7.11.2 Air filter – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Removing and installing air fil- Loosen clamp (2). Remove air filter (3) and clamp (2) from con- necting flange of intake housing (1). Verify that there are no objects in the con- necting flange of the intake housing (1) and clean it.
Page 217: Air Intake
7.12 Air Intake 7.12.1 Service indicator – Signal ring position check Preconditions ☑ Engine is stopped and starting disabled. Checking signal ring position If the signal ring is completely visible in the control window (2), replace air filter (→ Page 215). After installation of new filter, press reset button (1).
Page 218: Starting Equipment
7.13 Starting Equipment 7.13.1 Starter – Condition check Preconditions ☑ Engine is stopped and starting disabled. Checking starter condition Check securing screws of starter for secure seating and tighten if required. Check wiring (→ Page 254). 218 | Task Description | MS150109/01E 2015-11...
Page 219 7.14 Lube Oil System, Lube Oil Circuit 7.14.1 Engine oil – Level check Preconditions ☑ Engine is stopped and starting disabled. WARNING Hot oil. Oil can contain combustion residues which are harmful to health. Risk of injury and poisoning! • Wear protective clothing, gloves, and goggles / safety mask. •...
Page 220 7.14.2 Oil indicator filter – Cleaning and check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Cleaner (Snow-White 11-0) X00054118 Cleaner (Hakupur 50/136) X00056700 Engine oil Strainer (→ Spare Parts Catalog) Square-section ring (→...
Page 221 Removing strainer Clean oil indicator filter before disassembling Remove screws (1). Take off cover (2) with O-ring (3). Take strainer (5) from filter housing. Checking strainer Item Findings Action Strainer Metallic residues • Clean • Monitor engine operation • Check strainer daily •...
Page 222 7.14.3 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, 40-200 Nm...
Page 223 Tighten drain plugs (1) and (2) to specified torque using a torque wrench: Name Size Type Lubricant Value/Standard Screw M26x1.5 Tightening torque (Engine oil) 100 Nm +10 Nm Filling with new engine oil Open cap (1) on filler neck. Pour oil in at filler neck up to “max.” mark on oil dipstick.
Page 224 7.14.4 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 5605892099/00 DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...
Page 225 Drain approx. 1 liter engine oil into a clean vessel. Close screw. Using the equipment and chemicals in the MTU test kit, analyze the engine oil for: • Dispersancy (spot test); • Water content; • Dilution by fuel. Extracting and analyzing engine oil sample (variant B –...
Page 226 7.15 Oil Filtration / Cooling 7.15.1 Engine oil filter ‒ Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Engine oil Oil filter (→ Spare Parts Catalog) DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...
Page 227 Engine oil filter with diverter (option) – Oil filter replacement with engine at standstill Stop engine (→ Page 88) and disable engine start. Unscrew engine oil filter using filter wrench. Clean sealing surface on connecting piece. Check condition of the new engine oil filter sealing ring and coat it with engine oil.
Page 228 7.15.2 Automatic oil filter – Oil filter candles replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Assembly compound (Kluthe Hakuform 30-15) X00067260 Engine oil O-ring (→ Spare Parts Catalog) Oil filter candles (→...
Page 229 Pull out oil filter element (1). Remove O-ring. Remove screw (2). Pull out plastic spinner (1) with spring. Remove nut (3). Take off spring washer and washer. Remove screw (4). Remove flushing arm (5) from screen plate (6). Turn filter element by 180° and use appropri- ate tool to push out filter candles (1).
Page 230 Installing oil filter candles Install in reverse order of removal. Additionally, the following instructions are to be observed: • Replace all seals with new parts • Apply assembly compound to O-rings • Insert O-rings in grooves • Observe position of fillister-head screw to elongated hole in shaft 230 | Task Description | MS150109/01E 2015-11...
Page 231 7.15.3 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. Torque wrench, 4-20 Nm F30044239 Torque wrench, 10-60 Nm F30452769 Torque wrench, 60–320 Nm F30452768 Cold cleaner(Hakutex 60) X00056750...
Page 232 Centrifugal oil filter – Cleaning and filter sleeve replacement Remove clamp (14). Release Tommy nut (2) and remove cover (1). Carefully lift rotor (11), allow oil to drain and remove from housing. Holding the rotor (11) firmly, release rotor cover nut (3). Take off rotor cover (4).
Page 233 Cleaning centrifugal oil filter and replacing filter sleeve (en- gines with switchable oil filter) Undo and remove screw (1). Remove clamp (3) and take off hood (2). Carefully remove rotor (5) from housing. Hold rotor assembly (5) firmly in position with filter wrench and undo knurled nut (7).
Page 234 7.16 Coolant Circuit, General, High-Temperature Circuit 7.16.1 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! •...
Page 235 7.16.2 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant change Drain engine coolant (→ Page 236). Fill with engine coolant (→ Page 237). MS150109/01E 2015-11 | Task Description | 235...
Page 236: Draining Engine Coolant
7.16.3 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 Provide a suitable vessel to catch the coolant.
Page 237 7.16.4 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. Engine coolant WARNING Coolant is hot and under pressure.
Page 238 Filling with coolant through fill- er neck Open vent points on the exhaust turbocharg- er, on the intercooler, on the crankcase breather and on the plate-core heat exchang- er (arrowed). Fill coolant through the filler neck of the ex- pansion tank (for engines with remote heat exchanger: the expansion tank is part of the remote cooling system) until the coolant level at the top edge of the filler neck remains con-...
Page 239 7.16.5 HT coolant pump – Relief bore check DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running.
Page 240 Spindle 11 A/F Tightening torque 12 Nm Using the equipment and chemicals of the MTU test kit, examine engine coolant for: • Antifreeze concentration • Amount of corrosion protection oil • pH value Change intervals for engine coolant (→ MTU Fluids and Lubricants Specifications).
Page 241: Preheating Unit
7.16.7 Preheating unit HotstartPreheating unit 1 Plastic cap (drain) 4 Shut-off valve 7 Thermostat 2 On/Off switch 5 Continuous flow heater 8 Circulating pump 3 Plastic cap (inlet) 6 Vent valve Heating output kW Number of Rated voltage / frequency cylinders 230 V / 50 Hz 400 V / 50 Hz...
Page 242 HilzingerPreheating unit 1 On/Off switch Heating output kW Number of Rated voltage / frequency cylinders 230 V / 50 Hz 400 V / 50 Hz 230 V / 60 Hz 440 V / 60 Hz 242 | Task Description | MS150109/01E 2015-11...
Page 243 1 Flange (supply and return) 3 Non-return flap 5 Thermostat 2 Junction box 4 Continuous flow heater 6 Circulating pump Function The preheating unit heats up the engine coolant. The circulating pump (6) ensures the circulation of the pre- heated coolant through the engine. The flow heater (4) incorporates a heating element.
Page 244: Raw Water Pump With Connections
7.17 Raw Water Pump with Connections 7.17.1 Raw water pump – Relief bore check DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running.
Page 245 7.18 Battery-Charging Generator 7.18.1 Battery-charging generator drive – Coupling condition check Preconditions ☑ Engine is stopped and starting disabled. Battery-charging generator drive – Coupling condition check Remove screws (1). Remove protective cover (2). Check resilient coupling (3) for cracks and plastic deformation.
Page 246 7.19 Engine Mounting / Support 7.19.1 Engine mounting – Check Engine mounting – Check Item Findings Action Visually inspect resilient mounts. • Damage Replace (contact Service). • Brittleness • Deformation • Crack formation • Swelling 246 | Task Description | MS150109/01E 2015-11...
Page 247: Auxiliary Pto
7.20 Auxiliary PTO 7.20.1 Bilge pump – Relief bore check DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running.
Page 248: Fuel Supply System
7.21 Fuel Supply System 7.21.1 Water drain valve – Check Water drain valve – Check Open water drain valve. Check water outlet for obstructions. Close water drain valve. 248 | Task Description | MS150109/01E 2015-11...
Page 249 7.21.2 Differential pressure gauge – Check 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. Checking differential pressure gauge Switch on fuel treatment system (→...
Page 250 7.21.3 Water level probe (3-in-1 rod electrode) – Check Preconditions ☑ System is put out of service and emptied. WARNING Fuels are combustible and explosive. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. •...
Page 251 7.21.4 Pump capacity – Check 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. Checking pump capacity Install suitable pressure gauge in the intake connection of the pump.
Page 252 7.21.5 Coalescer filter element – Replacement Preconditions ☑ System is switched off and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 6–50 Nm F30027336 Ratchet adapter F30027339 Diesel fuel Engine oil Coalescer filter element (→...
Page 253 Use torque wrench to tighten nut (3) to the specified tightening torque. Name Size Type Lubricant Value/Standard Tightening torque (Engine oil) 30 Nm +3 Nm Fit seal (10). Install cover. Install screws (1), washers (2) and nuts (9). Tighten nuts (9). Open ball valve at the inlet and outlet of the fuel treatment system.
Page 254 7.22 Wiring (General) for Engine/Gearbox/Unit 7.22.1 Engine cabling – Check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Solvent (isopropyl alcohol) X00058037 Engine cabling – Check Check securing screws of cable clamps on engine and tighten loose screw connections. Ensure that cables are securely seated in clamps and cannot move freely.
Page 255 7.23 Accessories for (Electronic) Engine Governor / Control System 7.23.1 Resetting CDC parameter and entering IIG with DiaSys® Preconditions ☑ Engine is stopped and starting disabled. Note: If the parameters for the drift correction (CDC) are not reset, the emission certification becomes invalid. Resetting parameters for drift correction (CDC) with DiaSys®...
Page 256 7.23.2 Limit switch for start interlock ‒ Check Preconditions ☑ Engine is stopped and starting disabled. Note: In the OFF position, the limit switch initiates a start interlock, i.e. the engine cannot be started. Checking limit switch for start interlock Check whether switches (3) and guard plate (1) with engine support (4) are installed on both sides of flywheel housing (2).
Page 257 7.23.3 Engine Control Unit ECU 7 – Checking plug connections Preconditions ☑ Engine is stopped and starting disabled. Check plug connections on ECU Check all connectors on ECU for firm seating. Ensure that the clips (1) are engaged. Check screws (2) of cable clamps on ECU for firm seating.
Page 258 7.23.4 Engine Monitoring Unit EMU 8 – Plug connections check Preconditions ☑ Engine is stopped and starting disabled. Checking EMU plug connections Check both connectors on EMU (2) for firm seating. Ensure that the clips (1) are engag- Check screws (3) of cable clamps on EMU (2) for firm seating.
Page 259 7.23.5 Interface module EIM plug connections – Check Preconditions ☑ Engine is stopped and starting disabled. Checking EIM plug connections Check both Tyco plugs (62-pole) (2) on EIM for firm seating. Ensure that clips (3) are en- gaged. Check screws (1) of cable clamps on EIM for firm seating.
Page 260 7.23.6 Engine Control Unit ECU 7 – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. NOTICE Wrong engine governor installed. Engine damage! • When reassembling an engine, make sure that the governor with the data record for the given engine is installed.
Page 261 7.23.7 EMU 8 – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. NOTICE Wrong engine governor installed. Engine damage! • When reassembling an engine, make sure that the governor with the data record for the given engine is installed.
Page 262 7.23.8 Engine Interface Module EIM – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Removing EIM from the engine Note or mark assignment of cables and con- nectors. Unscrew all screws (1). Undo clips (2) on connectors. Disconnect all connectors.
Page 263 7.23.9 Diagnostic features on EIM Diagnostic lamp (DILA) A diagnostic lamp (LED, blue) is integrated in the housing of the Engine Interface Module (EIM). It indicates the operating status of the EIM. Functions of diagnostic lamp DILA DILA lights Engine Interface Module (EIM) is OK. DILA dark EIM supply voltage missing or diagnostic lamp activation is faulty.
Page 264 1 Preamble 6 VSP current path failed (S5) 11 ES pushbutton current path 2 ECU current path failed (S1) 7 SLD current path failed (S6) failed – 24 V external (S10) 3 MCS current path failed 8 DDV current path failed (S7) 12 Key switch current path (S2) 9 Gear monitoring current...
Page 265 Sample flashing sequences A Fuse S5 failure (1/2 second B Fuse S1 and fuse S4 failure steps) (1/2 second steps) Note: These bit patterns are continuously transmitted. The CAN message "Status of internal power supply" also contains information on the current path states of the EIM.
Page 266 7.24 Emergency Instrumentation (Local Operating Panel) 7.24.1 LOP and connectors – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Isopropyl alcohol X00058037 Cleaning LOP Wipe LCD display with dry cloth, without applying excessive pressure. Remove dirt from keys using isopropyl alcohol.
Page 267 American National Standards Institute Governing body for US American standards Exhaust turbocharger Baureihe (Series) Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU Publication No. A01061/.. Controller Area Network Data bus system, bus standard Calibration Drift Compensation Setting for drift correction with DiaSys in engine gov-...
Page 268 Explanation Abbrevia- Meaning tion Kraftseite Engine driving end in accordance with DIN ISO 1204 Liquid Crystal Display, Liquid Crystal Device Local Control Unit LOP subassembly Light Emitting Diode Local Monitoring Unit LOP subassembly Alarm: Measured value lower than 1st minimum limit LOLO Low Low Alarm: Measured value lower than 2nd minimum limit...
Page 269 Local support Experienced and qualified specialists place their knowledge and expertise at your disposal. For locally available support, go to the MTU Internet site: http://www.mtu-online.com 24h hotline With our 24h hotline and the outstanding flexibility of our service staff, we are always ready to assist you –...
Page 270: Special Tools
9 Appendix B 9.1 Special Tools Barring device Part No.: F6555766 Qty.: Used in: 7.2.1 Engine – Barring manually (→ Page 172) Barring device Part No.: F6792918 Qty.: Used in: 7.3.1 Cylinder liner – Endoscopic examination (→ Page 175) Endoscope Part No.: Y20097353 Qty.:...
Page 271 Feeler gage Part No.: Y20010128 Qty.: Used in: 7.4.3 Valve clearance – Check and adjustment (→ Page 181) Filter wrench Part No.: F30379104 Qty.: Used in: 7.8.2 Additional fuel filter – Replacement (→ Page 196) Qty.: Used in: 7.8.3 Fuel filter – Replacement (→ Page 198) Qty.: Used in: 7.15.1 Engine oil filter ‒...
Page 272 Milling cutter Part No.: F30452739 Qty.: Used in: 7.6.2 Injector – Removal and installation (→ Page 187) MTU test kit Part No.: 5605892099/00 Qty.: Used in: 7.14.4 Engine oil – Sample extraction and analysis (→ Page 224) Qty.: Used in: 7.16.6 Engine coolant –...
Page 273 Ratchet adapter Part No.: F30027339 Qty.: Used in: 7.21.5 Coalescer filter element – Replacement (→ Page 252) Ratchet with extension Part No.: F30006212 Qty.: Used in: 7.2.1 Engine – Barring manually (→ Page 172) Qty.: Used in: 7.3.1 Cylinder liner – Endoscopic examination (→...
Page 274 Torque wrench, 10-60 Nm Part No.: F30452769 Qty.: Used in: 7.6.2 Injector – Removal and installation (→ Page 187) Qty.: Used in: 7.15.3 Centrifugal oil filter – Cleaning and filter sleeve re- placement (→ Page 231) Torque wrench, 10–60 Nm Part No.: F30452769 Qty.:...
Page 275 Torque wrench, 60–320 Nm Part No.: F30452768 Qty.: Used in: 7.6.2 Injector – Removal and installation (→ Page 187) Qty.: Used in: 7.15.3 Centrifugal oil filter – Cleaning and filter sleeve re- placement (→ Page 231) Torque wrench, 6–50 Nm Part No.: F30027336 Qty.:...
Page 276 9.2 Index Differential pressure gage – Adjustment Abbreviations 267 – Fuel prefilter 200 Actuators – Check – Overview 42 – Fuel prefilter 200 Additional fuel filter Differential pressure gauge – Overview 195 – Check 249 – Replacement 196 Disengaging ADEC (ECU 7) ...
Page 277 – Differential pressure gage 200 Maintenance schedule – Check – Maintenance task reference table [QL1] 92 – Differential pressure gage 200 MTU contact persons 269 – Flushing 203 Fuel prefilter – Draining 201 Oil filter Fuel prefilter with water separator ...
Page 278 Transport 7 Troubleshooting 93 Parameters for drift correction (CDC) – Fuel treatment system 96 – Reset 255 Plant – Cleaning 91 Valve clearance Plug connections – Adjustment 181 – Check 259 – Check 181 Preheating unit 241 Valve gear Product description 30 – Lubrication 180 Pump capacity ...

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MTU 8V4000Mx4 Operating Instructions Manual

1 Safety

2 General Information

3 Technical Data

4 Operation

5 Maintenance

6 Troubleshooting

7 Task Description

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Troubleshooting

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