Operating Instructions Diesel engine 12 V 4000 M73 x 16 V 4000 M73 x MS150045/02E...
Page 2
This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, mi- crofilming and storage or processing on electronic systems including data bases and online services.
Page 5
8 Appendix A 9.2 Index 8.1 Abbreviations 8.2 MTU contact persons/service partners 9 Appendix B 9.1 Special Tools MS150045/02E 2013-07 | Table of Contents | 5...
1 Safety 1.1 Important provisions for all products Nameplate The product is identified by nameplate, model designation or serial number and must match with the information on the title page of this manual. Nameplate, model designation or serial number can be found on the product. General information This product may pose a risk of injury or damage in the following cases: •...
1.2 Personnel and organizational requirements Organizational measures of the operator This manual must be issued to all personnel involved in operation, maintenance, repair or transporta- tion. Keep this manual handy in the vicinity of the product such that it is accessible to operating, mainte- nance, repair and transport personnel at all times.
1.3 Safety regulations for startup and operation Safety regulations for startup Install the product correctly and carry out acceptance in accordance the manufacturer's specifications before putting the product into service. Before the product is put into operation for the first time, all official authorizations must be available and commissioning preconditions met.
1.4 Safety regulations for maintenance and repair work 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 before starting maintenance work (risk of explosion of oil vapors, fluids and lubricants, risk of burning).
Page 10
Ensure particular cleanness during maintenance and repair work on the product. After completion of maintenance and repair work, make sure that no loose objects are in/on the product (e.g. cloths and cable ties) Safety regulations after completion of maintenance and repair work Before barring, make sure that nobody is standing in the danger zone of the product.
Page 11
Working on electrical and electronic assemblies Always obtain the permission of the person in charge before commencing maintenance and repair work or switching off any part of the electronic system required to do so. De-energize the appropriate areas prior to working on assemblies. Do not damage cabling during removal work.
The latest version can be found on the website on the "Technical Info" tab at http://www.mtu-online.com. Consumable fluids and materials may also be hazardous or toxic. When using fluids, lubricants, consum- ables and other chemical substances, follow the safety instructions that apply to the product.
Lead • Adopt suitable measures to avoid the formation of lead dust. • Switch on extraction system. • When working with lead or pastes that contain lead, avoid direct contact with the skin. Do not inhale lead vapors. • Wash hands after contact with lead or lead-containing substances. Compressed air Observe special safety precautions when working with compressed air: •...
1.6 Standards for safety notices in the text DANGER In the event of immediate danger. Consequences: Death, serious or permanent injury! • Remedial action. WARNING In the event of a situation involving potential danger. Consequences: Death, serious or permanent injury! •...
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 place an engine on the oil pan, unless expressively authorized by MTU on a case-to-case basis to do so.
2.2 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 18
• 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 comprises two parts.
Page 19
• Interface to CAN field bus for connected, communicating monitoring system components. SOLAS – Fire safety requirements All lines with SOLAS-compliant covers for pipe connections, according to MTU standard MTN5233, are shown below. Fuel system, fuel lines with fuel pressures exceeding 1.8 bar...
Page 20
1 Fuel line from/to fuel filter head 1 Fuel line to HP pump Lube oil system, oil lines with oil pressures exceeding 1.8 bar 1 Parting line ETC oil supply free end 20 | General Information | MS150045/02E 2013-07...
Page 21
1 Oil line on equipment carrier 1 Oil supply to HP pump 1 Oil supply to flap control free end MS150045/02E 2013-07 | General Information | 21...
Page 22
1 ETC oil supply on main oil gallery 1 Switching cylinder air flap turbo- charger B1 2 T piece flap control 1 Switching cylinder exhaust flap tur- bocharger B1 22 | General Information | MS150045/02E 2013-07...
Page 23
1 Oil line from main oil gallery 2 Oil line to main oil gallery 1 Flap control distributor 1 Air recirculation valve MS150045/02E 2013-07 | General Information | 23...
Page 24
Special connections The following connection types are spray-proof in case of leakage even without covers and have been confirmed as being SOLAS-compliant by GL and DNV. Plugs and sensors, plug-in pipe connections Plugs and sensors (a) Screw plugs (4) are either sealed with copper sealing rings (1) as per DIN or O-rings (ISO). The fluid must first pass the thread in case of a loose threaded union or faulty sealing ring (1).
Page 25
High-pressure unions 1 Jacketed pipe 8 Thrust ring 15 Union nut 2 HP line 9 Union nut 16 Thrust ring 3 O-ring 10 Union nut 17 Outer tube of HP fuel line 4 Union nut 11 Connecting piece 18 Internal tube of HP fuel 5 Recess for O-ring 12 Snap ring line...
2.3 Engine side and cylinder designations Engine sides are always designated as viewed from the driving end (KS) (4). For designation of the cylinders (to DIN ISO 1204) the letter "A" (1) is used to refer to the cylinders on the left-hand side of the engine and the letter "B"...
3 Technical Data 3.1 12V 4000M73 engine data: EPA Tier 2, engine-mounted heat exchanger, copper-based alloy intercooler Explanation: DL Reference value: Continuous power BL Reference value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
Page 45
RAW WATER CIRCUIT (open circuit) Number of cylinders Raw water pump: inlet pressure, min. -0.2 Raw water pump: inlet pressure, max. Pressure loss in off-engine raw water system, max. LUBE-OIL SYSTEM Number of cylinders Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C...
Page 46
Number of cylinders Longitudinal inclination, continuous max. driving end up (Option: max. operat- Degrees ing inclinations) Transverse inclination, continuous max. (Option: max. operating inclinations) Degrees 22.5 CAPACITIES Number of cylinders Engine coolant, engine side (with cooling system) Liters Engine oil capacity, initial filling (standard oil system) (Option: max. operating Liters inclinations) Oil change quantity, max.
3.2 12V 4000 M73 engine data: IMO, engine-mounted heat exchanger, copper-based alloy intercooler Explanation: DL Reference value: Continuous power BL Reference value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
Page 48
RAW WATER CIRCUIT (open circuit) Number of cylinders Raw water pump: inlet pressure, min. -0.2 Raw water pump: inlet pressure, max. Pressure loss in off-engine raw water system, max. LUBE-OIL SYSTEM Number of cylinders Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C...
Page 49
Number of cylinders Longitudinal inclination, continuous max. driving end up (Option: max. operat- Degrees ing inclinations) Transverse inclination, continuous max. (Option: max. operating inclinations) Degrees 22.5 CAPACITIES Number of cylinders Engine coolant, engine side (with cooling system) Liters Engine oil capacity, initial filling (standard oil system) (Option: max. operating Liters inclinations) Oil change quantity, max.
3.3 12V 4000M73 engine data: IMO Tier II, engine-mounted heat exchanger Explanation: DL Reference value: Continuous power BL Reference value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
Page 51
RAW WATER CIRCUIT (open circuit) Number of cylinders Raw water pump: inlet pressure, min. -0.2 Raw water pump: inlet pressure, max. Pressure loss in off-engine raw water system, max. LUBE-OIL SYSTEM Number of cylinders Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C...
Page 52
Number of cylinders Longitudinal inclination, continuous max. driving end up (Option: max. operat- Degrees ing inclinations) Transverse inclination, continuous max. (Option: max. operating inclinations) Degrees 22.5 CAPACITIES Number of cylinders Engine coolant, engine side (with cooling system) Liters Engine oil capacity, initial filling (standard oil system) (Option: max. operating Liters inclinations) Oil change quantity, max.
3.4 12V 4000M73L engine data: IMO Tier II, engine-mounted heat exchanger Explanation: DL Reference value: Continuous power BL Reference value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
Page 54
RAW WATER CIRCUIT (open circuit) Number of cylinders Raw water pump: inlet pressure, min. -0.2 Raw water pump: inlet pressure, max. Pressure loss in off-engine raw water system, max. LUBE-OIL SYSTEM Number of cylinders Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C...
Page 55
Number of cylinders Longitudinal inclination, continuous max. driving end up (Option: max. operat- Degrees ing inclinations) Transverse inclination, continuous max. (Option: max. operating inclinations) Degrees 22.5 CAPACITIES Number of cylinders Engine coolant, engine side (with cooling system) Liters Engine oil capacity, initial filling (standard oil system) (Option: max. operating Liters inclinations) Oil change quantity, max.
3.5 12V 4000M73L engine data: IMO, engine-mounted heat exchanger, copper-based alloy intercooler Explanation: DL Reference value: Continuous power BL Reference value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
Page 57
RAW WATER CIRCUIT (open circuit) Number of cylinders Raw water pump: inlet pressure, min. -0.2 Raw water pump: inlet pressure, max. Pressure loss in off-engine raw water system, max. LUBE-OIL SYSTEM Number of cylinders Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C...
Page 58
Number of cylinders Longitudinal inclination, continuous max. driving end up (Option: max. operat- Degrees ing inclinations) Transverse inclination, continuous max. (Option: max. operating inclinations) Degrees 22.5 CAPACITIES Number of cylinders Engine coolant, engine side (with cooling system) Liters Engine oil capacity, initial filling (standard oil system) (Option: max. operating Liters inclinations) Oil change quantity, max.
3.6 12V 4000M73L engine data: EPA Tier 2, engine-mounted heat exchanger, copper-based alloy intercooler Explanation: DL Reference value: Continuous power BL Reference value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
Page 60
RAW WATER CIRCUIT (open circuit) Number of cylinders Raw water pump: inlet pressure, min. -0.2 Raw water pump: inlet pressure, max. Pressure loss in off-engine raw water system, max. LUBE-OIL SYSTEM Number of cylinders Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C...
Page 61
Number of cylinders Longitudinal inclination, continuous max. driving end up (Option: max. operat- Degrees ing inclinations) Transverse inclination, continuous max. (Option: max. operating inclinations) Degrees 22.5 CAPACITIES Number of cylinders Engine coolant, engine side (with cooling system) Liters Engine oil capacity, initial filling (standard oil system) (Option: max. operating Liters inclinations) Oil change quantity, max.
3.7 16V 4000M73 engine data: EPA Tier 2, engine-mounted heat exchanger, copper-based alloy intercooler Explanation: DL Reference value: Continuous power BL Reference value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
Page 63
RAW WATER CIRCUIT (open circuit) Number of cylinders Raw water pump: inlet pressure, min. -0.2 Raw water pump: inlet pressure, max. Pressure loss in off-engine raw water system, max. LUBE-OIL SYSTEM Number of cylinders Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C...
Page 64
Number of cylinders Longitudinal inclination, continuous max. driving end up (Option: max. operat- Degrees ing inclinations) Transverse inclination, continuous max. (Option: max. operating inclinations) Degrees 22.5 CAPACITIES Number of cylinders Engine coolant, engine side (with cooling system) Liters Engine oil capacity, initial filling (standard oil system) (Option: max. operating Liters inclinations) Oil change quantity, max.
3.8 16V 4000M73 engine data: IMO, engine-mounted heat exchanger, copper-based alloy intercooler Explanation: DL Reference value: Continuous power BL Reference value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
Page 66
RAW WATER CIRCUIT (open circuit) Number of cylinders Raw water pump: inlet pressure, min. -0.2 Raw water pump: inlet pressure, max. Pressure loss in off-engine raw water system, max. LUBE-OIL SYSTEM Number of cylinders Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C...
Page 67
Number of cylinders Longitudinal inclination, continuous max. driving end up (Option: max. operat- Degrees ing inclinations) Transverse inclination, continuous max. (Option: max. operating inclinations) Degrees 22.5 CAPACITIES Number of cylinders Engine coolant, engine side (with cooling system) Liters Engine oil capacity, initial filling (standard oil system) (Option: max. operating Liters inclinations) Oil change quantity, max.
3.9 16V 4000M73 engine data: IMO Tier II, engine-mounted heat exchanger Explanation: DL Reference value: Continuous power BL Reference value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
Page 69
RAW WATER CIRCUIT (open circuit) Number of cylinders Raw water pump: inlet pressure, min. -0.2 Raw water pump: inlet pressure, max. Pressure loss in off-engine raw water system, max. LUBE-OIL SYSTEM Number of cylinders Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C...
Page 70
Number of cylinders Longitudinal inclination, continuous max. driving end up (Option: max. operat- Degrees ing inclinations) Transverse inclination, continuous max. (Option: max. operating inclinations) Degrees 22.5 CAPACITIES Number of cylinders Engine coolant, engine side (with cooling system) Liters Engine oil capacity, initial filling (standard oil system) (Option: max. operating Liters inclinations) Oil change quantity, max.
3.10 16V 4000M73L engine data: IMO Tier II, engine-mounted heat exchanger Explanation: DL Reference value: Continuous power BL Reference value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
Page 72
RAW WATER CIRCUIT (open circuit) Number of cylinders Raw water pump: inlet pressure, min. -0.2 Raw water pump: inlet pressure, max. Pressure loss in off-engine raw water system, max. LUBE-OIL SYSTEM Number of cylinders Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C...
Page 73
Number of cylinders Longitudinal inclination, continuous max. driving end up (Option: max. operat- Degrees ing inclinations) Transverse inclination, continuous max. (Option: max. operating inclinations) Degrees 22.5 CAPACITIES Number of cylinders Engine coolant, engine side (with cooling system) Liters Engine oil capacity, initial filling (standard oil system) (Option: max. operating Liters inclinations) Oil change quantity, max.
3.11 16V 4000M73L engine data: IMO, engine-mounted heat exchanger, copper-based alloy intercooler Explanation: DL Reference value: Continuous power BL Reference value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
Page 75
RAW WATER CIRCUIT (open circuit) Number of cylinders Raw water pump: inlet pressure, min. -0.2 Raw water pump: inlet pressure, max. Pressure loss in off-engine raw water system, max. LUBE-OIL SYSTEM Number of cylinders Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C...
Page 76
Number of cylinders Longitudinal inclination, continuous max. driving end up (Option: max. operat- Degrees ing inclinations) Transverse inclination, continuous max. (Option: max. operating inclinations) Degrees 22.5 CAPACITIES Number of cylinders Engine coolant, engine side (with cooling system) Liters Engine oil capacity, initial filling (standard oil system) (Option: max. operating Liters inclinations) Oil change quantity, max.
3.12 16V 4000M73L engine data: EPA Tier 2, engine-mounted heat exchanger, copper-based alloy intercooler Explanation: DL Reference value: Continuous power BL Reference value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
Page 78
RAW WATER CIRCUIT (open circuit) Number of cylinders Raw water pump: inlet pressure, min. -0.2 Raw water pump: inlet pressure, max. Pressure loss in off-engine raw water system, max. LUBE-OIL SYSTEM Number of cylinders Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C...
Page 79
Number of cylinders Longitudinal inclination, continuous max. driving end up (Option: max. operat- Degrees ing inclinations) Transverse inclination, continuous max. (Option: max. operating inclinations) Degrees 22.5 CAPACITIES Number of cylinders Engine coolant, engine side (with cooling system) Liters Engine oil capacity, initial filling (standard oil system) (Option: max. operating Liters inclinations) Oil change quantity, max.
3.13 Engine – Main dimensions Engine – Main dimensions Engine model Length (A) Width (B) Height (C) 12 V 4000 M73/93 (L) approx. 2991 mm approx. 1463 mm approx. 2368 mm 16 V 4000 M73/93 (L) approx. 3583 mm approx. 1463 mm approx.
3.14 Firing order Firing order 12 V A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1 16 V A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B7 A1-B5-A8-B7-A5-B2-A7-B10-A2-B3-A10-B6-A3-B4-A6-B9-A4-B1-A9-B8 MS150045/02E 2013-07 | Technical Data | 81...
4.2 Putting the engine into operation after extended out-of-service periods (>3 months) Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Putting into operation after extended out-of-service periods (>3 months) Item Action Engine Depreserve (→...
4.4 Starting the engine Start the engine via the automation system Refer to automation system operating instructions MS150045/02E 2013-07 | Operation | 85...
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! •...
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 90). Shut down fuel treatment system (→ Page 105). MS150045/02E 2013-07 | Operation | 87...
4.7 Fuel treatment system control cabinet – Control elements Color Inscription 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...
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.
4.9 Fuel treatment system – Putting into operation Overview of fuel treatment system 1 Pressure-free overflow 9 Ball valve, outlet 17 Automatic water drain 2 Bypass 1 10 Check valve 700 mbar 18 Water level electrode 3 Bypass 2 11 Check valve 5 mbar 19 Ball valve, sample extrac- 4 Safety valve, 3 bar 12 Return to overflow con-...
Page 91
Initial operation: HAT Replace fuel filter on engine (→ Page 158). 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 93). Result: The fuel is drawn from tank (24), cleaned by the water separator filter (15) and then routed via overflow tank (14) back to tank (24).
Page 92
Simulation of power failure (emergency): SAT Switch on fuel treatment system (→ Page 93). Start engine (→ Page 85). 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.
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. •...
4.11 Engine – Stopping in manual mode (test run) Preconditions ☑ Generator (if fitted) is not connected to network ☑ Engine in manual mode NOTICE Stopping the engine when it is running at full load subjects it to extreme thermal and mechanical stresses.
4.12 Engine emergency stop at BlueLine automation system (control stand) NOTICE An emergency stop causes extreme stress to the engine plant. Risk of overheating, damage to components! • Initiate emergency stop only in emergency situations. Engine emergency stop at BlueLine automation system Item Measure Engine...
4.13 Coupling – Engaging from LOP Preconditions ☑ LOCAL OPERATION illuminated pushbutton lights up brightly (local operating mode is active). ☑ Engine speed in engagement window. ☑ No external engagement interlock active. DANGER Vessel is sailing blind. In Local Operation mode, the propulsion plant is controlled from the engine room. Risk of accidents! •...
4.15 Waterjet – Flushing from LOP (optional) Preconditions ☑ LOCAL OPERATION illuminated pushbutton is lit brightly (local operating mode is active). ☑ Vessel is at a standstill and waterjet bucket is below the waterline. ☑ Engine speed is in engagement window. ☑...
4.16 Stopping the engine from LOP Preconditions ☑ Engine is running in local mode. 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.
4.17 Stopping the engine at the BlueLine automation system (control stand) 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.
4.18 Emergency stop from LOP NOTICE An emergency stop causes extreme stress to the engine plant. Risk of overheating, damage to components! • Initiate emergency stop only in emergency situations. Emergency stop from LOP Item Measure Open cap of illuminated EMERGENCY STOP pushbutton (→ Page 82). Press EMERGENCY STOP illuminated pushbutton.
4.19 Stopping the engine Stopping the engine via the automation system Refer to automation system operating instructions 102 | Operation | MS150045/02E 2013-07...
4.20 Emergency engine stop NOTICE An emergency stop causes extreme stress to the engine plant. Risk of overheating, damage to components! • Initiate emergency stop only in emergency situations. Emergency stop Refer to automation system operating instructions. Follow instructions. MS150045/02E 2013-07 | Operation | 103...
4.21 After stopping the engine Preconditions ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. After stopping the engine Item Action Coolant circuit Drain coolant (→ Page 193) if: freezing temperatures are expected and the engine is to remain out of •...
4.22 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.
4.23 Plant – Cleaning Preconditions ☑ Engine stopped and starting disabled. ☑ Operating voltage is not present. Special tools, Material, Spare parts Designation / Use Part No. Qty. Steam jet cleaner Cleaner (Hakupur 312) 30390 WARNING Compressed air gun ejects a jet of pressurized air. Risk of injury to eyes and damage to hearing, risk of rupturing internal organs! •...
5 Maintenance 5.1 Maintenance task reference table [QL1] The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Maintenance Schedule is a stand-alone publication. The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance Schedule.
6 Troubleshooting 6.1 Fuel treatment system – Troubleshooting Illuminated pushbutton “Water alarm” is lit. Cause Corrective action When the maximum water level 1. Press illuminated pushbutton “Water alarm” to acknowledge. is reached, the water level 2. In addition to the automatic water drain function, water can electrode opens the water drain also be drained manually.
6.2 Troubleshooting Engine does not turn when starter is actuated Cause Corrective action Battery low or faulty u Charge or replace (see special documentation). Battery: Cable connections u Check if cable connections are properly secured (see special faulty documentation). Engine cabling or starter faulty u Check if cable connections are properly secured, contact Service.
Page 110
Engine Control Unit defective u Contact Service. Charge air temperature too high Cause Corrective action Engine coolant treatment u Check (MTU test kit). incorrect Intercooler clogged u Contact Service. Engine room: Air-intake u Check fans and air supply / ventilation ducts.
Page 111
White exhaust gas Cause Corrective action Engine is not at operating u Run engine to reach operating temperature. temperature Intercooler leaky u Contact Service. MS150045/02E 2013-07 | Troubleshooting | 111...
6.3 ADEC (ECU 7) fault codes 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 (→...
6.4 ADEC engine governor – Fault codes 29 – HI ETC Idle Speed too High ZKP-Number: 18.004.206 Cause Corrective action Idle speed of one of the u Contact Service. secondary turbochargers is too high. 38 – AL ETC Speed Deviation ZKP-Number: 18.004.205 Cause Corrective action...
Page 114
141 – AL Power too high ZKP-Number: 11.088.007 Cause Corrective action This alarm occurs if the average u Reduce power. value of power over the last 24 hours exceeded the maximum value specified in PR1.1088.001. 142 – AL MCR exceeded 1 hour ZKP-Number: 11.088.006 Cause Corrective action...
Page 115
205 – SD T-Coolant Intercooler ZKP-Number: 18.004.574 Cause Corrective action Intercooler coolant temperature u Check sensor and cabling (B26), replace as necessary. sensor faulty; Short circuit or wire break 206 – SD T-Exhaust A ZKP-Number: 18.004.576 Cause Corrective action Exhaust temperature sensor on u Check sensor and cabling (B4.21), replace as necessary.
Page 116
213 – SD P-Coolant Intercooler ZKP-Number: 18.004.569 Cause Corrective action Intercooler coolant pressure 1. Check sensor and cabling (B43), replace as necessary. sensor faulty; Short circuit or 2. Error cleared after restarting the engine. wire break 214 – SD P-CrankCase ZKP-Number: 18.004.568 Cause Corrective action...
Page 117
221 – SD P-Diff-Lube Oil ZKP-Number: 18.004.585 Cause Corrective action Lube oil differential pressure 1. Check sensor and cabling (F25), replace as necessary. sensor faulty; Short circuit or 2. Error cleared after restarting the engine. wire break 222 – SD Level Leakage Fuel ZKP-Number: 18.004.582 Cause Corrective action...
Page 118
230 – SD Crankshaft Speed ZKP-Number: 18.004.498 Cause Corrective action Crankshaft sensor faulty; Short 1. Check sensor and cabling (B13), replace as necessary. circuit or wire break 2. Error cleared after restarting the engine. 231 – SD Camshaft Speed ZKP-Number: 18.004.499 Cause Corrective action Camshaft sensor faulty;...
Page 119
241 – SD T-Umblasen ZKP-Number: 18.004.581 Cause Corrective action Recirculation temperature 1. Check sensor and cabling (B49), replace as necessary. sensor faulty; Short circuit or 2. Error cleared after restarting the engine. wire break 242 – SD T-Coolant (R) ZKP-Number: 18.004.622 Cause Corrective action Redundant coolant temperature...
Page 120
303 – AL Timing Cylinder A3 ZKP-Number: 18.004.502 Cause Corrective action Time-of-flight measuring fault of u If alarm occurs frequently, replace solenoid valve of injector injector in cylinder A3: Time-of flight measured value extremely low or extremely high. 304 – AL Timing Cylinder A4 ZKP-Number: 18.004.503 Cause Corrective action...
Page 121
308 – AL Timing Cylinder A8 ZKP-Number: 18.004.507 Cause Corrective action Time-of-flight measuring fault of u If alarm occurs frequently, replace solenoid valve of injector injector in cylinder A8: Time-of flight measured value extremely low or extremely high. 309 – AL Timing Cylinder A9 ZKP-Number: 18.004.508 Cause Corrective action...
Page 122
313 – AL Timing Cylinder B3 ZKP-Number: 18.004.512 Cause Corrective action Time-of-flight measuring fault of u If alarm occurs frequently, replace solenoid valve of injector injector B3: Time-of flight measured value extremely low or extremely high. 314 – AL Timing Cylinder B4 ZKP-Number: 18.004.513 Cause Corrective action...
Page 123
318 – AL Timing Cylinder B8 ZKP-Number: 18.004.517 Cause Corrective action Time-of-flight measuring fault of u If alarm occurs frequently, replace solenoid valve of injector injector B8: Time-of flight measured value extremely low or extremely high. 319 – AL Timing Cylinder B9 ZKP-Number: 18.004.518 Cause Corrective action...
Page 124
323 – AL Wiring Cylinder A3 ZKP-Number: 18.004.522 Cause Corrective action Short-circuit in injector cabling 1. Rectify short circuit in injector solenoid valve circuit (positive to to cylinder A3. Result: Misfiring negative) (e.g. by injector replacement) 2. Error cleared after restarting the engine. 324 –...
Page 125
329 – AL Wiring Cylinder A9 ZKP-Number: 18.004.528 Cause Corrective action Short-circuit in injector cabling 1. Rectify short circuit in injector solenoid valve circuit (positive to to cylinder A9. Result: Misfiring negative) (e.g. by injector replacement) 2. Error cleared after restarting the engine. 330 –...
Page 126
335 – AL Wiring Cylinder B5 ZKP-Number: 18.004.534 Cause Corrective action Cabling fault in injector cabling 1. Rectify short circuit in injector solenoid valve circuit (positive to to cylinder B5. Result: Misfiring negative) (e.g. by injector replacement) 2. Error cleared after restarting the engine. 336 –...
Page 127
341 – AL Open Load Cylinder A1 ZKP-Number: 18.004.540 Cause Corrective action Disruption fault in injector 1. Check continuity of injector cabling or exclude open load in cabling to cylinder A1. Result: solenoid valve circuit (e.g. by injector replacement) Misfiring 2.
Page 128
347 – AL Open Load Cylinder A7 ZKP-Number: 18.004.546 Cause Corrective action Disruption fault in injector 1. Check continuity of injector cabling or exclude open load in cabling to cylinder A7. Result: solenoid valve circuit (e.g. by injector replacement) Misfiring 2.
Page 129
353 – AL Open Load Cylinder B3 ZKP-Number: 18.004.552 Cause Corrective action Disruption fault in injector 1. Check continuity of injector cabling or exclude open load in cabling to cylinder B3. Result: solenoid valve circuit (e.g. by injector replacement) Misfiring 2.
Page 130
359 – AL Open Load Cylinder B9 ZKP-Number: 18.004.558 Cause Corrective action Disruption fault in injector 1. Check continuity of injector cabling or exclude open load in cabling to cylinder B9. Result: solenoid valve circuit (e.g. by injector replacement) Misfiring 2.
Page 131
365 – AL Stop MV-Wiring Ground ZKP-Number: 18.004.561 Cause Corrective action Injector cabling fault. If bit u Check wiring, replace wiring harness as necessary. "1.1020.021" (Power Stage Failure: Stop Engine) is set, engine will be shut down as additional measure. Possible causes: 1.
Page 132
390 – AL MCR exceeded ZKP-Number: 11.085.009 Cause Corrective action DBR/MCR feature: MCR 1. If the alarm occurs temporarily, no action required. (maximum continuous rating) 2. If the alarm is permanently active, contact Service. was exceeded. 396 – TD T-Coolant Sensor Deviation ZKP-Number: 10.480.193 Cause Corrective action...
Page 133
445 – SD P-Ambient Air ZKP-Number: 18.004.580 Cause Corrective action Ambient air pressure sensor 1. Check pressure sensor and cabling, replace as necessary. faulty. 2. Replace engine governor. 464 – SD P-AUX 1 ZKP-Number: 18.004.589 Cause Corrective action Analog input signal for Aux 1 u Check pressure sensor and cabling, replace as necessary.
Page 134
473 – AL Wiring PWM_CM2 ZKP-Number: 18.004.593 Cause Corrective action Cable break or short circuit on 1. Check cabling. channel PWM_CM2. 2. Contact Service. 475 – AL CR Trigger Engine Stop ZKP-Number: 18.010.009 Cause Corrective action Activated if the crash recorder 1.
Page 135
493 – AL ETC3 CutIn Failure ZKP-Number: 18.004.203 Cause Corrective action ETC3 could not be cut in. u Check control valve on ETC 3. 500 – AL Wiring POM Starter 1 ZKP-Number: 14.500.900 Cause Corrective action A wiring fault was detected in u Check connection between POM and starter.
Page 136
506 – AL Low Starter Voltage ZKP-Number: 14.500.906 Cause Corrective action battery voltage is too low to u Check battery-charging generator and cabling. accomplish a starting procedure. 507 – AL POM Error ZKP-Number: 14.500.907 Cause Corrective action A general POM error occurred. u Replace POM.
Page 137
527 – TD EngineSpd. Sensor Deviation ZKP-Number: 10.480.093 Cause Corrective action Maximum deviation of speed 1. Check cabling of speed sensors. Observe additional messages. sensors 2. Contact Service. 528 – SD Engine Speed 3rd Sensor ZKP-Number: 12.500.102 Cause Corrective action Redundant crankshaft sensor u Check sensor and cabling, replace as necessary.
Page 138
596 – AL Develop PR Set ZKP-Number: 18.004.645 Cause Corrective action The parameter set used is a test u The alarm remains active until a series-production parameter parameter set. set was installed. 600 – SD T-Exhaust A+B ZKP-Number: 18.004.646 Cause Corrective action SD T-Exhaust A and T-Exhaust B u Check sensor and cabling, replace as necessary.
7 Task Description 7.1 Engine 7.1.1 Engine – Barring manually Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Barring tool F6555766 Ratchet with extension F30006212 DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...
7.2.2 Instructions and comments on endoscopic and visual examination of cylinder liners Terms used for endoscopic examination Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic ex- amination 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 144
Evaluation of findings and further measures The findings in the start phase of oxidation discoloration and heat discoloration 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.
7.3 Valve Drive 7.3.1 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 150). Fill oil chambers of valve bridges with oil.
7.3.2 Valve clearance – Check and adjustment Preconditions ☑ Engine shut down 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 Torque wrench, 60-320 Nm F30452768...
Page 147
Rotate crankshaft with barring device in di- rection of engine rotation until the "OT-A1" marking and pointer are aligned. Diagram for 8V engines (two crankshaft positions) Diagram for 12V engines (two crankshaft positions) MS150045/02E 2013-07 | Task Description | 147...
Page 148
Diagram for 16V engines (two crankshaft positions) Diagram for 20V engines (two crankshaft positions) Checking valve clearance at two crankshaft positions Check TDC position of piston in cylinder A1: • If the rocker arms are unloaded on cylinder A1, the piston is in firing TDC. •...
Adjusting valve clearance Release locknut (1). Insert feeler gauge (3) between valve bridge and rocker arm. Use Allen key to set adjusting screw (2) so that the specified valve clearance is estab- lished. Feeler gauge (3) must just pass through gap.
7.3.3 Cylinder head cover – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 O-ring (→ Spare Parts Catalog) Removing cylinder head cover Clean very dirty cylinder head covers (1) prior to removal.
7.4 Injection Pump / HP Pump 7.4.1 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. Risk of fire and explosion! •...
7.5.2 Injector – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Installation/removal tool F6789889 Milling cutter F30452739 Torque wrench, 0.5-5 Nm 0015384230 Torque wrench, 10-60 Nm F30452769 Ratchet F30027340...
Page 154
Remove HP fuel line (4). Remove return line (5). Note: While the adapter is removed, the injector is drained. Remove adapter (3). Remove screw (2) and take off hold-down clamp (1). Install installation/removal tool on cylinder head. Remove injector with installation/removal tool.
Page 155
Installing injector Remove plug before installing the injec- tor. (Do not remove the plug from the HP line before installing the adapter.) Coat injector with assembly paste at the seat of the nozzle retaining nut. Fit new sealing ring (included in the scope of supply of the injector) with grease on in- jector, observe installation position of seal- ing ring.
Page 156
Coat screw head mating face (2) and thread with engine oil. Fit hold-down clamp (1) in the correct position and use torque wrench to tighten screw (2) to the speci- fied initial tightening torque. Name Size Type Lubricant Value/Standard Screw Preload torque (Engine oil) 5 Nm to 10 Nm...
Page 157
Mount double-walled HP line (5) and use torque wrench to tighten to the specified torque. Tightening sequence: 1 Adapter (4) 2 Rail (6) Name Size Type Lubricant Value/Standard Union nut / thrust Tightening torque 40 Nm + 5 Nm screw Fit connectors on injector.
Fuel filter replacement with the engine stopped A Both filters cut in B Left filter cut out C Right filter cut out 1 Fuel vent 2 Fuel filter Cut out the filter to be replaced. Unscrew switched off easy-change filter with oil filter wrench. Clean sealing surface on filter head.
7.6.2 Fuel prefilter – Differential pressure gauge check and adjustment 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.
7.6.3 Fuel prefilter – Draining Preconditions ☑ Engine is stopped and starting disabled. WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Draining fuel prefilter 1 Filter A cut out 2 Filter B cut out Cut out the filter to be drained.
Page 162
Connect filling pump to filling connection (1 or 3) on the suction side of the filter. Open vent valve (2 or 4) and fill with fuel until fuel emerges from the vent pipe (7 or Close vent valve (2 or 4). Open rotary slide valve (6) a little (by ap- prox.
7.6.4 Fuel prefilter – Flushing Special tools, Material, Spare parts Designation / Use Part No. Qty. Fuel Seal (→ Spare Parts Catalog) DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...
Page 164
Open vent plug (5) of the filter to be flush- Unlock drain cock (6) by pressing toggle, open it and drain fuel. Result: Fuel flows from filtered side back to the un- filtered side, flushing the filter deposits downwards out of the filter. Close vent plug (5) and drain cock (6).
7.6.5 Fuel prefilter – Filter element replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel Filter element (→ Spare Parts Catalog) Gasket (→ Spare Parts Catalog) WARNING Fuels are combustible.
Page 166
Open threaded vent plug (5) of contaminat- ed filter. Unlock drain valve (6) by pressing toggle and open it. Drain water and dirt from filter. Close drain valve (6). Remove screws securing the cover and take off cover (2). Remove spring housing (4) and filter ele- ment (3).
7.7 Exhaust Turbocharger 7.7.1 Compressor wheel – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10-60 Nm F30452769 Ratchet F30027340 Cleaner 40377 Engine oil Sealing rings 007603030101 Sealing rings 007603042101...
Page 168
Remove charge-air pipework (1) from ex- haust turbocharger to intercooler. Remove oil lines (2). Loosen clamp (1). Remove intake housing (3) with actuating cylinder (2). Remove coolant lines (1) from compressor housing (3). Remove coolant vent line (2) from com- pressor housing (3).
Page 169
Undo screws (1). Remove compressor housing (2). Compressor wheel – Cleaning Note: Do not use wire brush, scraper or similar tools for cleaning! Clean compressor housing with a smooth paint brush or brush. Clean compressor wheel (2) and bearing housing (1). Thoroughly remove cleaner from all compo- nents.
Page 170
Tighten screws (1) to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Screw M10x18 Tightening torque (Engine oil) 20 Nm + 2.5 Nm Install coolant vent line on compressor housing. Install intake housing (3) with actuating cyl- inder (2).
7.8 Charge-Air Cooling 7.8.1 Intercooler – Check water drain for coolant discharge 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.
7.9 Air Filter 7.9.1 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 173). Reset signal ring of contamination indicator (→...
7.9.2 Air filter – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 4-20 Nm F30044239 Air filter – Removal and installa- tion Release clamp (2). Remove air filter (1) and clamp (2) from connecting flange of intake housing (3).
7.10 Air Intake 7.10.1 Service indicator – Signal ring position check (optional) 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 172). After installation of new filter, press reset button (1).
7.10.2 Air pipework from air filter to ETC – Check Special tools, Material, Spare parts Designation / Use Part No. Qty. Air hose 0229979482 Checking air pipework from air filter to ETC Item Findings Measure Damage Visually check outer layer of air •...
7.12.2 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...
Page 179
Tighten drain plugs (1) and (2) with torque wrench to the specified torque: Name Size Type Lubricant Value/Standard Screw M26 x 1.5 Tightening torque 100 Nm+10Nm Filling with new oil Open cover (1) on filler neck. Pour oil in at filler neck up to "max." mark at oil dipstick.
7.12.3 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 5605892099/00 DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...
Page 181
Drain approx. 1 liter engine oil into a clean container. Close screw. Using the equipment and chemicals of the MTU test kit, check engine oil for: • Dispersion capability (spot test); • Water content; • Dilution by fuel. MS150045/02E 2013-07 | Task Description | 181...
7.12.4 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! •...
7.13 Oil Filtration / Cooling 7.13.1 Automatic oil filter – Oil filter candles replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 Engine oil O-ring (→...
Page 184
Withdraw oil filter element (1). Remove O-ring. Remove screw (2). Withdraw 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 appro- priate tool to push out filter candles (1).
Page 185
Installing oil filter candles For installation follow reverse sequence of working steps. Additionally, the following instructions are to be observed: • Replace all sealing elements. • Coat O-rings with grease. • Insert O-rings in grooves. • Observe position of cylinder screw to elongated hole on shaft. MS150045/02E 2013-07 | Task Description | 185...
7.13.2 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) 40460 Cleaner (Hakupur 312) 30390 Engine oil Strainer (→ Spare Parts Catalog) Square-section ring (→...
Page 187
Checking strainer Item Findings Measure Strainer Metallic residues • Clean Monitor engine operation • Check strainer daily • Contact Service • Strainer Damaged Fit new part Square-section ring Damaged Fit new part O-ring Damaged Fit new part Cleaning strainer Wash strainer (5) with cleaner. Remove stubborn deposits with soft brush.
7.13.3 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, 6-50 Nm F30027336 Cold cleaner (Hakutex 60) X00056750 Filter sleeve (→...
Page 189
Centrifugal oil filter – Cleaning and filter-sleeve replacement Remove clamp (14). Release cover screw (2) and take off cov- er (1). Carefully lift rotor (11), allow oil to drain and remove from housing. Holding the rotor (11) firmly, release rotor cover nut (3).
7.14.2 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.
7.14.4 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 an appropriate container to drain the coolant into.
7.14.5 Engine coolant– Filling up Preconditions ☑ Engine is cold. ☑ 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 195
Filling with coolant through fill- er neck Turn breather valve on filler neck of expan- sion tank counterclockwise to first stop and allow pressure to escape. Continue to turn breather valve counter- clockwise and remove. Open vent points on intercooler, on coolant cooler and on exhaust turbochargers (→...
Page 196
Filling with coolant using a pump Connect appropriate pump (pressure at least 0.5 bar) with hose to filling connec- tion (arrowed) on A side or B side. Alterna- tively: Connect appropriate pump (pressure at least 0.5 bar) with a hose to the drain valve (arrowed).
Page 197
Open expansion tank and fill until overflow edge is reached. Start engine with expansion tank open (→ Page 85) and leave running at idling speed. Open the vent points in sequence from bot- tom to top until air stops emerging, then close them again.
7.14.6 Engine 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.
7.14.7 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 5605892099/00 DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...
7.15 Raw Water Pump with Connections 7.15.1 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.
7.18 Auxiliary PTO 7.18.1 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.
7.19 Fuel Supply System 7.19.1 Water drain valve – Check Water drain valve – Check Open water drain valve. Check water outlet for obstructions. Close water drain valve. 204 | Task Description | MS150045/02E 2013-07...
7.19.2 Differential pressure gauge – Check WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Checking differential pressure gauge Switch on fuel treatment system (→ Page 93). Set the alarm points at the differential pressure gauge to zero.
7.19.3 Water level probe (3-in-1 rod electrode) – Check Preconditions ☑ System is put out of operation and emptied. WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Checking water level probe (3-in-1 rod electrode) Disconnect connector from water level probe.
7.19.4 Pump capacity – Check WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Pump capacity – Check Install suitable pressure gauge at the neck of the intake side of the pump. Check pump pressure.
7.19.5 Coalescer filter element – Replacement Preconditions ☑ System is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 6-50 Nm F30027336 Ratchet F30027339 Diesel fuel Engine oil Coalescer filter element (→ Spare Parts Catalog) Gasket (→...
Page 209
Tighten nut (3) to specified tightening torque using a torque wrench. Name Size Type Lubricant Value/Standard Tightening torque (Engine oil) 30 Nm +3 Nm Fit gasket (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.
7.20 Wiring (General) for Engine/Gearbox/Unit 7.20.1 Engine wiring – Check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Isopropyl alcohol X00058037 Checking engine wiring Check securing screws of cable clamps on engine and tighten loose threaded connections. Ensure that cables are fixed in their clamps and cannot swing freely.
7.21 Accessories for (Electronic) Engine Governor / Control System 7.21.1 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...
7.21.2 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 seat- ing. Ensure that clips (3) are engaged. Check screws (2) of cable clamps on ECU for firm seating.
7.21.3 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. Make sure that clips (3) are engag- Check screws (1) of cable clamps on EMU (2) for firm seating.
7.21.4 Interface module plug connections – Check Preconditions ☑ Engine is stopped and starting disabled. Checking EIM plug connections Check both Tyco plugs (62-pole) (1) on EIM for firm seating. Make sure that the clips (2) are engaged. Check screws (3) of cable clamps on EIM for firm seating.
7.21.5 ECU 7 engine governor – 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.
7.21.6 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. Remove ECU with EMU from en- gine Note or mark assignment of cables and...
7.21.7 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 connectors. Unscrew all screws (1). Undo clips (2) on connectors. Disconnect all connectors. Unscrew power and starter cable.
7.21.8 Diagnostic features of 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 219
1 Preamble 6 VSP current path failed 11 ES pushbutton current 2 ECU current path failed (S5) path failed – 24V external (S1) 7 SLD current path failed (S10) 3 MCS current path failed (S6) 12 Key switch current path (S2) 8 DDV current path failed failed (S11)
Page 220
Sample flashing sequences A Fuse S5 failure (1/2 sec- B Fuse S1 and fuse S4 fail- ond steps) ure (1/2 second steps) Note: These bit sequences are transmitted constantly. Information about the status of the current paths of the EIM is also provided in the CAN message "Sta- tus internal power supply".
7.22 Emergency Instrumentation (Local Operating Panel) 7.22.1 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.
American National Standards Institute Association of American standardization organiza- tions Abgasturbolader Exhaust turbocharger Baureihe Series Betriebsstoffvorschrift MTU Publication No. A01061/.. Controller Area Network Data bus system, bus standard Controllable Pitch Propeller DILA Diagnostic lamp on EIM Deutsches Institut für Normung e. V.
Page 223
Abbrevia- Meaning Explanation tion Light Emitting Diode Light emitting diode Local Monitoring Unit Local monitoring unit (LOP subassembly) Alarm: Measured value lower than 1st minimum limit LOLO Low Low Alarm: Measured value lower than 2nd minimum limit Local Operating Panel Control console, control panel Local Operating Station Local operating station...
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 –...