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MTU 16V4000M*3 series Operating Instructions Manual

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Operating Instructions
Diesel engine
12V4000Mx3x
16V4000Mx3x
MS15035/00E

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Summary of Contents for MTU 16V4000M*3 series

  • Page 1 Operating Instructions Diesel engine 12V4000Mx3x 16V4000Mx3x MS15035/00E...
  • 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 5: Table Of Contents

    Table of Contents 1 Safety 5.6 Stopping the engine 5.7 Operational checks 1.1 Important provisions for all products 5.8 Emission label – Check 1.2 Correct use of all products 5.9 Tasks after extended out-of-service periods 1.3 Personnel and organizational requirements (>3 weeks) 1.4 Initial start-up and operation –...
  • Page 6 8.16.3 Centrifugal oil filter – Cleaning and filter 9 Appendix A sleeve replacement 9.1 List of abbreviations 8.17 Coolant Circuit, General, High-Temperature 9.2 MTU Contact/Service Partners Circuit 8.17.1 Engine coolant level – Check 4 | Table of Contents | MS15035/00E 2018-08...
  • Page 7 10 Appendix B 10.2 Index 10.1 Special Tools MS15035/00E 2018-08 | Table of Contents | 5...

  • Page 8: Safety

    Nameplates, model designation or serial number can be found on the product. All EU-certified engines delivered by MTU come with a second nameplate. This second nameplate is deliv- ered "loosely" with the engine. If the nameplate secured to the engine after installation in the vehicle/system is not visible without the removal of components, the system integrator must install the second nameplate in a clearly visible area on the vehicle/system.
  • Page 9 Replacing components with emission labels On all MTU engines fitted with emission labels, these labels must remain on the engine throughout its opera- tional life. Exception: Engines used exclusively in land-based, military applications other than by US government agen- cies.

  • Page 10: Correct Use Of All Products

    • With preservation approved by the manufacturer in accordance with the (→ Preservation and Represerva- tion Specifications of the manufacturer) • With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU con- tact/Service partner) • In the original as-delivered configuration or in a configuration approved by the manufacturer in writing (al- so applies to engine control/parameters) •...

  • Page 11: Personnel And Organizational Requirements

    1.3 Personnel and organizational requirements Organizational measures of the user/manufacturer This manual must be issued to all personnel involved in operation, maintenance, repair, assembly, installa- tion, or transportation. Keep this manual handy in the vicinity of the product such that it is accessible to operating, maintenance, repair, assembly, installation, and transport personnel at all times.

  • Page 12: Initial Start-Up And Operation - Safety Regulations

    1.4 Initial start-up and operation – Safety regulations Safety regulations for initial start-up Install the product correctly and carry out acceptance in accordance with the manufacturer's specifications before putting the product into service. All necessary approvals must be granted by the relevant authorities and all requirements for initial startup must be fulfilled.
  • Page 13 Do not inhale the exhaust gases of the product. The following requirements must be fulfilled before the product is started: • Wear ear protectors. • Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binding agent. Operation of electrical equipment When electrical equipment is in operation, certain components of these appliances are electrically live.

  • Page 14: Assembly, Maintenance, And Repair Work - Safety Regulations

    1.5 Assembly, maintenance, and repair work – Safety regulations Safety regulations for work prior to assembly, maintenance, and repair Have assembly, maintenance, or repair work carried out by qualified and authorized personnel only. Allow the product to cool down to less than 50 °C (risk of explosion from oil vapors, fluids and lubricants, risk of burning).
  • Page 15 When working high on the equipment, always use suitable ladders and work platforms. Special instructions for outdoor areas: There must be no risk of slipping e.g. due to icing. Removing, installing and cleanliness Pay particular attention to cleanliness at all times. Completely wipe up escaped fluids and lubricants due to the risk of slipping.
  • Page 16 Welding work Welding operations on the product or mounted units are not permitted. Cover the product when welding in its vicinity. Before starting welding work: • Switch off the power supply master switch. • Disconnect the battery cables or actuate the battery isolating switch. •...
  • Page 17 Do not damage wiring during removal work. When reconnecting, ensure that cabling cannot be damaged dur- ing operation by: • Contact with sharp edges • Chafing on components • Contact with hot surfaces. Do not secure cables on lines carrying fluids. Do not use cable ties to secure lines.

  • Page 18: Fire And Environmental Protection, Fluids And Lubricants

    Process materials can also be or contain hazardous or toxic substances. When using process materials and other chemical substances, observe the associated safety data sheet. The safety data sheet may be obtained from the relevant manufacturer or from MTU. Only process materials approved by the manufacturer in accordance with the Fluids and Lubricants Specifi- cations must be used.
  • Page 19 Particularly hazardous substances used with our products are named in a list: www.mtu-online.com/mtu/technische-info → SVHC as per REACH in MTU products Compressed air • Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII and B) out of con- tainers, risks causing an explosion.

  • Page 20: Standards For Warning Notices In The Text And Highlighted Information

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

  • Page 21: Transport

    Setting the engine down after transport • Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate. • Never set an engine/genset/system down on the oil pan unless expressively authorized to do so by MTU on a case-to-case basis.

  • Page 22: Lifting Requirements

    2.2 Lifting requirements DANGER Suspended load. Danger to life! • Use suitable equipment and lifting devices. • Never stand beneath a suspended load and keep a safe distance. • Wear personal protective equipment (e.g. protective helmet, safety shoes). Lifting requirements 12V, heat exchanger installed, vertical air intake 1 Maximum permissible diag- 2 Center of gravity onal pull 10°...
  • Page 23 Lifting requirements 12V, separate heat exchanger, horizontal air intake 1 Maximum permissible diag- 2 Center of gravity onal pull 10° (*) (*) Max. permissible diagonal pull must be observed: • Max. permissible diagonal pull in longitudinal direction is 10 degrees; simultaneous diagonal pull in trans- verse direction is impermissible.
  • Page 24 Lifting requirements 16V, heat exchanger installed, vertical air intake 1 Maximum permissible diag- 2 Center of gravity onal pull 10° (*) (*) Max. permissible diagonal pull must be observed: • Max. permissible diagonal pull in longitudinal direction is 10 degrees; simultaneous diagonal pull in trans- verse direction is impermissible.
  • Page 25 Lifting requirements 16V, separate heat exchanger, horizontal air intake 1 Maximum permissible diag- 2 Center of gravity onal pull 10° (*) (*) Max. permissible diagonal pull must be observed: • Max. permissible diagonal pull in longitudinal direction is 10 degrees; simultaneous diagonal pull in trans- verse direction is impermissible.

  • Page 26: Crankshaft Transport Locking Device

    2.3 Crankshaft transport locking device Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10–60 Nm F30452769 Torque wrench, 60–320 Nm F30452768 Engine oil Transport locking devices Note: The transport locking device on both sides protects the crankshaft bearings from shocks and vibration dam- age during engine transport.
  • Page 27 Installing the transport locking device on driving end (KS) Note: Install plate (6) on the upper part of the openings only. Secure the plates (6) with screws (4) and washers (5) at the lateral openings on both sides of the flywheel housing and tighten to the specified tightening torque.
  • Page 28 Installing guard plates and en- gine mounting brackets (if appli- cable) on driving end (KS) Note: Always use the screws supplied with the equipment or removed from the guard plates and engine supports to secure them on the engine. Install engine supports (2) on both sides with guard plates (1) washers (3) and screws (4) and tighten to specified tightening torque tightening.

  • Page 29: General Information

    3 General Information 3.1 Tightening specifications for screws, nuts and bolts Tightening torques for setscrew and connections as per MTN 5008 standard This standard applies to setscrews not subject to dynamic loads and the associated nuts according to: • MMN 384 •...
  • Page 30 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 31 Tightening torque for self-locking hex nuts (Nm) Thread Lubricants 7.5 +1 – 17 +2 – 35 +4 – 59 +6 – 100 +10 – 140 +14 – 290 +29 – = tightening torques Tightening torque for stress bolt connections as per MTN 5007 standard This standard applies to stress pin bolts and stress bolts which are subjected to static and dynamic load of strength class 10.9 as well as to the associated nuts.
  • Page 32 Not torsion-protected M (Nm) Torsion-protected M (Nm) Thread 1250 1575 *Protect screw shaft from torsion when tightening. = tightening torques. Tightening torques for plug screws as per 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 33 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 34 screwed into Thread Steel/gray cast iron M AI alloy M (Nm) (Nm) M64 x 2 = tightening torques Tightening torque for plug screws DIN 7604C (with long screwed end) screwed into Thread Steel/gray cast iron M AI alloy M (Nm) (Nm) M8 x 1 M22 x 1.5...
  • Page 35 The stated tightening torques M apply to steel (St) banjo screws with a phosphatized surface and oiled or galvanized and for copper-aluminum alloy. 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 36 Tightening torques for male connectors as per 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 37 Tightening torques for union nuts as per DIN 3859-2 1 Union nut 2 Screw fixture 3 O-ring 4 Linear ball bearing 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 Thread Torque (Nm) +10%...
  • Page 38 Thread Torque (Nm) +10% 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 screwed plugs with O-ring as per ISO 6149-3 Thread Torque (Nm) +10% M8 x 1...
  • Page 39 Tightening torques for plug screw joints as per 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...
  • Page 40 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 41 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 42: Engine Side And Cylinder Designations

    3.2 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 43: Product Description

    3.3 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). Fuel system Electronically controlled common-rail-injection system with HP pump, pressure accumulator (rail) and single injectors with integrated individual store.
  • Page 44 • 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 45 2 Cleaning cycle 3 ditto MTU marine engine Series 4000M53R to …M93L may be operated in low-load operation. State-of-the-art de- sign and equipment features, e.g. TE coolant circuit, sequential turbocharging, jacketed, coolant-cooled ex- haust lines, Common Rail fuel injection and cylinder cutout allow engine operation at low load.
  • Page 46 Plugs and sensors (a) Screw-in plugs (4) are sealed toward the outside either with a copper sealing ring (1), according to DIn, or an O-ring (ISO). In case of a loose thread or a defective sealing ring (1), the liquid first has to pass the thread. The pressure is so greatly reduced by this and the faulty sealing ring (1) that any leakage is not under pres- sure.
  • Page 47 HP connections 1 Jacket pipe 8 Thrust ring 15 Union nut 2 HP fuel line 9 Union nut 16 Thrust ring 3 O-ring 10 Union nut 17 HP line outer pipe 4 Union nut 11 Connecting piece 18 Internal pipe of HP line 5 Recess for O-ring 12 Snap ring 19 Ball-type seal area...

  • Page 48: Engine - Overview

    3.4 Engine – Overview Engines with remote raw water cooler and horizontal air intake The following overviews also apply to 12V4000Mx3. 1 Engine management and 10 Recirculation line 19 Battery-charging generator monitoring 11 Exhaust manifold 20 HP fuel pump 2 Oil cooler 12 Engine mounting 21 Oil filter 3 Centrifugal oil filter...
  • Page 49 Engines with installed raw water cooler and horizontal air intake 1 Raw-water outlet 10 Exhaust outlet 19 Cylinder head 2 Engine management and 11 Air pipe to charge-air cooler 20 Crankcase monitoring 12 Recirculation line 21 Fuel filter 3 Plate-core heat exchanger 13 Exhaust manifold 22 Battery-charging generator 4 Oil cooler...
  • Page 50 Engines with remote raw water cooler and vertical air intake 1 Coolant outlet to remote 10 Exhaust turbocharger 19 Cylinder head cooling system 11 Exhaust outlet 20 Fuel filter 2 Coolant inlet from remote 12 Air pipe to charge-air cooler 21 Oil filter cooling system 13 Charge-air cooler...
  • Page 51 Engines with installed raw water cooler and vertical air intake 1 Raw-water outlet 10 Recirculation line 19 Crankcase 2 Engine management and 11 Exhaust turbocharger 20 Cylinder head monitoring 12 Exhaust outlet 21 Fuel filter 3 Oil cooler 13 Air pipe to charge-air cooler 22 Oil filter 4 Plate-core heat exchanger 14 Charge-air cooler...

  • Page 52: Sensors, Actuators And Injectors On 12V Engines - Overview

    3.5 Sensors, actuators and injectors on 12V engines – Overview Engines with remote raw water cooler and horizontal air intake Left engine side 12V4000Mx3 1 B50 (P-Crankcase) 4 B10 (P-Charge air) 7 B34.1 (P-Fuel after filter) 2 B3 (T-Intake air) 5 B34.3 (fuel pressure before 8 F46 (leak fuel level) 3 B44.1 (N-Turbocharger A)
  • Page 53 Free end 12V4000Mx3 1 B33 (fuel temperature in 5 B5.1 (P-Lube oil after filter) 9 B6.2 (coolant temperature) common rail) 6 B48 (P-Fuel in common rail) (optional) 2 B7 (T-Lube oil) 7 B1 (N-Camshaft) 10 B6 (T-Coolant) 3 B5.2 (lube oil pressure after 8 B54 (oil refill pump pres- 11 XD1 connector (dialog unit) filter) (optional)
  • Page 54 Right engine side 12V4000Mx3 1 B44.2 (N-Turbocharger B) 3 B16 (P-Coolant) 2 Y27 (turbocharger control 4 B9 (T-Charge Air) valve) 52 | General Information | MS15035/00E 2018-08...
  • Page 55 Driving end 12V4000Mx3 1 B4.21 (T-Exhaust, A side) 3 B13 (N-Crankshaft) 5 S37.1 (S-Safety switch) 2 B4.22 (T-Exhaust, B bank) 4 S37.2 (S-Safety switch) 6 B13.2 (N-Crankshaft speed) (optional) MS15035/00E 2018-08 | General Information | 53...
  • Page 56 Plan view 12V4000Mx3 1 B5.8 (P-Lube before exhaust 3 B4 (T-Individual exhaust turbocharger A) temperature A1-A6, B1-B6) 2 B49/Y26 (T-Charge-air be- (optional) fore recirculation valve/ 4 B5.9 (P-Lube oil before tur- recirculation valve A) bocharger B) 54 | General Information | MS15035/00E 2018-08...
  • Page 57 Engines with installed raw water cooler and horizontal air intake Left engine side 12V4000Mx3 1 B50 (P-Crankcase) 5 B10 (P-Charge air) 9 F46 (leak fuel level) 2 B49/Y26 (charge-air tem- 6 B34.3 (fuel pressure before 10 B33 (fuel temperature in perature before recircula- filter) (only if supplementary common rail)
  • Page 58 Free end 12V4000Mx3 1 B48 (P-Fuel in common rail) 5 B5.3 (P-Lube oil before fil- 9 B6 (T-Coolant) 2 B7 (T-Lube oil) ter) 10 XD1 connector (dialog unit) 3 B5.2 (P-Lube oil after filter) 6 B1 (N-Camshaft) (optional) 7 B54 (P-Oil refill pump) (op- 4 B5.1 (P-Lube oil after filter) tional) 8 B6.2 (T-Coolant tempera-...
  • Page 59 Right engine side 12V4000Mx3 1 B44.2 (N-Turbocharger B) 3 B16 (P-Coolant) 5 B9 (T-Charge Air) 2 Y27 (turbocharger control 4 B21 (raw-water pressure) valve) (optional) MS15035/00E 2018-08 | General Information | 57...
  • Page 60 Driving end 12V4000Mx3 1 B4.21 (T-Exhaust, A side) 3 B13 (N-Crankshaft) 5 S37.1 (S-Safety switch) 2 B4.22 (T-Exhaust, B bank) 4 S37.2 (S-Safety switch) 6 B13.2 (N-Crankshaft) (op- tional) 58 | General Information | MS15035/00E 2018-08...
  • Page 61 Plan view 12V4000Mx3 1 B5.8 (P-Lube before exhaust 3 F33 (H-Coolant) turbocharger A) 4 B5.9 (P-Lube oil before tur- 2 B4 (cylinder exhaust tem- bocharger B) perature A1-A6, B1-B6) (op- tional) MS15035/00E 2018-08 | General Information | 59...

  • Page 62: Sensors, Actuators And Injectors On 16V Engines - Overview

    3.6 Sensors, actuators and injectors on 16V engines – Overview Engines with remote raw water cooler and horizontal air intake Left engine side 16V4000Mx3 1 B50 (P-Crankcase) 4 B10 (P-Charge air) 7 B34.1 (P-Fuel after filter) 2 B3 (T-Intake air) 5 B34.3 (fuel pressure before 8 F46 (leak fuel level) 3 B44.1 (N-Turbocharger A)
  • Page 63 Free end 16V4000Mx3 1 B33 (T-Fuel in common rail) 5 B5.1 (P-Lube oil after filter) 9 B6.2 (T-Coolant) (optional) 2 B7 (T-Lube oil) 6 B48 (P-Fuel in common rail) 10 B6 (T-Coolant) 3 B5.2 (P-Lube oil after filter) 7 B1 (N-Camshaft) 11 XD1 connector (dialog unit) (optional) 8 B54 (P-Oil refill pump) (op-...
  • Page 64 Right engine side 16V4000Mx3 1 B44.2 (N-Turbocharger B) 3 B16 (P-Coolant) 2 Y27 (turbocharger control 4 B9 (T-Charge Air) valve) 62 | General Information | MS15035/00E 2018-08...
  • Page 65 Driving end 16V4000Mx3 1 B4.21 (T-Exhaust, A side) 3 B13 (N-Crankshaft) 5 S37.1 (S-Safety switch) 2 B4.22 (T-Exhaust, B bank) 4 S37.2 (S-Safety switch) 6 B13.2 (N-Crankshaft) (op- tional) MS15035/00E 2018-08 | General Information | 63...
  • Page 66 Plan view 16V4000Mx3 1 B5.8 (P-Lube before exhaust 3 B4 (cylinder exhaust tem- turbocharger A) perature A1-A6, B1-B6) (op- 2 B49/Y26 (T-Charge-air be- tional) fore recirculation valve/ 4 B5.9 (P-Lube oil before tur- recirculation valve A) bocharger B) 64 | General Information | MS15035/00E 2018-08...
  • Page 67 Engines with installed raw water cooler and horizontal air intake Left engine side 16V4000Mx3 1 B50 (P-Crankcase) 5 B10 (P-Charge air) 9 F46 (leak fuel level) 2 B49/Y26 (charge-air tem- 6 B34.3 (fuel pressure before 10 B33 (T-Fuel in common rail) perature before recircula- filter) (only if supplementary tion valve/recirculation...
  • Page 68 Free end 16V4000Mx3 1 B48 (P-Fuel in common rail) 5 B5.3 (P-Lube oil before fil- 9 B6 (T-Coolant) 2 B7 (T-Lube oil) ter) 10 XD1 connector (dialog unit) 3 B5.2 (P-Lube oil after filter) 6 B1 (N-Camshaft) (optional) 7 B54 (P-Oil refill pump) (op- 4 B5.1 (P-Lube oil after filter) tional) 8 B6.2 (T-Coolant) (optional)
  • Page 69 Right engine side 16V4000Mx3 1 B44.2 (N-Turbocharger B) 3 B16 (P-Coolant) 5 B9 (T-Charge Air) 2 Y27 (turbocharger control 4 B21 (raw-water pressure) valve) (optional) MS15035/00E 2018-08 | General Information | 67...
  • Page 70 Driving end 16V4000Mx3 1 B4.21 (T-Exhaust, A side) 3 B13 (N-Crankshaft) 5 S37.1 (S-Safety switch) 2 B4.22 (T-Exhaust, B side) 4 S37.2 (S-Safety switch) 6 B13.2 (N-Crankshaft) (op- tional) 68 | General Information | MS15035/00E 2018-08...
  • Page 71 Plan view 16V4000Mx3 1 B5.8 (P-Lube before exhaust 3 F33 (H-Coolant) turbocharger A) 4 B5.9 (P-Lube oil before tur- 2 B4 (cylinder exhaust tem- bocharger B) perature A1-A6, B1-B6) (op- tional) MS15035/00E 2018-08 | General Information | 69...

  • Page 72: Technical Data

    4 Technical Data 4.1 Product data 12V4000M53 Legend DL Reference value: Continuous power. Continuous driving performance under standard conditions BL Reference value: Fuel stop power. Maximum engine power. With some applications, not drivable on continuous basis (adjustment reserve) A Design value. Value required to design an external system (plant) R Guideline value.
  • Page 73 Product type Application Engine speed Listed output 12V4000M53 Marine / ship main 1800 rpm 1380 kW Ref. 45 °C/32 °C; propulsion 1851 bhp Heat exchanger instal- 1A continuous power, led on the engine unlimited IMO Tier II (Marpol convention) EU nonroad St IIIA (97/68/EC) IMO Tier I Marpol Comp...
  • Page 74 Model related data (basic design) Cylinder arrangement: V angle Degrees (°) Bore Stroke Displacement of a cylinder Liters 4.77 4.77 4.77 4.77 Total displacement Liters 57.2 57.2 57.2 57.2 Raw-water circuit (open circuit) Raw water pump: Inlet pressure, min. -0.2 -0.2 Raw water pump: inlet pressure, max.
  • Page 75 Starter (with air/hydraulic starter motor) Starting-air pressure before starter mo- tor, min. Starting air pressure before starter mo- tor, max. Inclinations, standard oil system (reference: waterline) Longitudinal inclination, continuous max. Degrees driving end down (option: max. operating (°) inclinations) Longitudinal inclination, temporary max. Degrees 19.5 19.5...
  • Page 76 Sound Exhaust noise, unsilenced - BL (free-field dB(A) sound pressure level Lp, 1 m distance, ISO 6798, +3 dB(A) tolerance) Engine surface noise with attenuated in- dB(A) take noise (filter) - BL (free-field sound power level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance) 74 | Technical Data | MS15035/00E 2018-08...

  • Page 77: Product Data 12V4000M63

    4.2 Product data 12V4000M63 Legend DL Reference value: Continuous power. Continuous driving performance under standard conditions BL Reference value: Fuel stop power. Maximum engine power. With some applications, not drivable on continuous basis (adjustment reserve) A Design value. Value required to design an external system (plant) R Guideline value.
  • Page 78 Product type Application Engine speed Listed output 12V4000M63 Marine / ship main 1800 rpm 1500 kW Ref. 45 °C/32 °C; propulsion 2012 bhp Heat exchanger instal- 1A continuous power, led on the engine unlimited IMO Tier II (Marpol convention) EU nonroad St IIIA (97/68/EC) IMO Tier I Marpol Comp...
  • Page 79 Model related data (basic design) Cylinder arrangement: V angle Degrees (°) Bore Stroke Displacement of a cylinder Liters 4.77 4.77 4.77 4.77 Total displacement Liters 57.2 57.2 57.2 57.2 Raw-water circuit (open circuit) Raw water pump: Inlet pressure, min. -0.2 -0.2 Raw water pump: inlet pressure, max.
  • Page 80 Starter (electric) Rated starter voltage (standard rating) Starter (with air/hydraulic starter motor) Starting-air pressure before starter mo- tor, min. Starting air pressure before starter mo- tor, max. Inclinations, standard oil system (reference: waterline) Longitudinal inclination, continuous max. Degrees driving end down (option: max. operating (°) inclinations) Longitudinal inclination, temporary max.
  • Page 81 Weights / main dimensions Engine dry weight (with standard acces- 7950 7600 7950 7600 sories installed, w/o coupling) Heaviest component to be lifted during extended component maintenance (W5) Sound Exhaust noise, unsilenced - BL (free-field dB(A) sound pressure level Lp, 1 m distance, ISO 6798, +3 dB(A) tolerance) Engine surface noise with attenuated in- dB(A)

  • Page 82: Product Data 16V4000M53

    4.3 Product data 16V4000M53 Legend DL Reference value: Continuous power. Continuous driving performance under standard conditions BL Reference value: Fuel stop power. Maximum engine power. With some applications, not drivable on continuous basis (adjustment reserve) A Design value. Value required to design an external system (plant) R Guideline value.
  • Page 83 Product type Application Engine speed Listed output 16V4000M53 Marine / ship main 1800 rpm 1840 kW Ref. 45 °C/32 °C; propulsion 2467 bhp Heat exchanger instal- 1A continuous power, led on the engine unlimited IMO Tier II (Marpol convention) EU nonroad St IIIA (97/68/EC) IMO Tier I Marpol Comp...
  • Page 84 Model related data (basic design) Cylinder arrangement: V angle Degrees (°) Bore Stroke Displacement of a cylinder Liters 4.77 4.77 4.77 4.77 Total displacement Liters 76.3 76.3 76.3 76.3 Raw-water circuit (open circuit) Raw water pump: Inlet pressure, min. -0.2 -0.2 Raw water pump: inlet pressure, max.
  • Page 85 Starter (with air/hydraulic starter motor) Starting-air pressure before starter mo- tor, min. Starting air pressure before starter mo- tor, max. Inclinations, standard oil system (reference: waterline) Longitudinal inclination, continuous max. Degrees driving end down (option: max. operating (°) inclinations) Longitudinal inclination, temporary max. Degrees 19.5 19.5...
  • Page 86 22. Sound Exhaust noise, unsilenced - BL (free-field dB(A) sound pressure level Lp, 1 m distance, ISO 6798, +3 dB(A) tolerance) 84 | Technical Data | MS15035/00E 2018-08...

  • Page 87: Product Data 16V4000M63

    4.4 Product data 16V4000M63 Legend DL Reference value: Continuous power. Continuous driving performance under standard conditions BL Reference value: Fuel stop power. Maximum engine power. With some applications, not drivable on continuous basis (adjustment reserve) A Design value. Value required to design an external system (plant) R Guideline value.
  • Page 88 Product type Application Engine speed Listed output 16V4000M63 Marine / ship main 1800 rpm 2000 kW Ref. 45 °C/32 °C; propulsion 2682 bhp Heat exchanger instal- 1A continuous power, led on the engine unlimited IMO Tier II (Marpol convention) EU nonroad St IIIA (97/68/EC) IMO Tier I Marpol Comp...
  • Page 89 Model related data (basic design) Cylinder arrangement: V angle Degrees (°) Bore Stroke Displacement of a cylinder Liters 4.77 4.77 4.77 4.77 Total displacement Liters 76.3 76.3 76.3 76.3 Raw-water circuit (open circuit) Raw water pump: Inlet pressure, min. -0.2 -0.2 Raw water pump: inlet pressure, max.
  • Page 90 Starter (with air/hydraulic starter motor) Starting-air pressure upstream of starter motor, min. Starting-air pressure upstream of starter motor, max. Inclinations, standard oil system (reference: waterline) Longitudinal inclination, continuous max. Degrees driving end down (option: max. operating (°) inclinations) Longitudinal inclination, temporary max. Degrees 19.5 19.5...
  • Page 91 Sound Exhaust noise, unsilenced - BL (free-field dB(A) sound pressure level Lp, 1 m distance, ISO 6798, +3 dB(A) tolerance) MS15035/00E 2018-08 | Technical Data | 89...

  • Page 92: Firing Order

    4.5 Firing order Cylinders Firing order A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1 A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B7 90 | Technical Data | MS15035/00E 2018-08...

  • Page 93: Engine - Main Dimensions

    4.6 Engine – Main dimensions Engines with horizontal air intake With remote heat exchanger Engine model Length (A) Width (B) without Width (B) with si- Height (C) silencer lencer 12V 4000 M53/63 approx. 2638 mm approx. 1690 mm approx. 1850 mm approx.
  • Page 94 Engines with vertical air intake With remote heat exchanger Engine model Length (A) Width (B) Height (C) without Height (C) with si- silencer lencer 12V 4000 M53/63 approx. 2628 mm approx. 1613 mm approx. 2368 mm approx. 2448 mm 16V 4000 M53/63 approx.

  • Page 95: Operation

    5 Operation 5.1 Controls Automation system controls Refer to automation system operating instructions MS15035/00E 2018-08 | Operation | 93...

  • Page 96: Putting The Engine Into Operation After Extended Out-Of-Service Periods (>3 Months)

    5.2 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 97: Putting The Engine Into Operation After Scheduled Out-Of-Service-Period

    5.3 Putting the engine into operation after scheduled out-of- service-period Preconditions ☑ Engine is stopped and starting disabled. Putting into operation Item Task Lube oil system Check engine oil level (→ Page 211); Preheat engine oil if required. Coolant system Check coolant level (→...

  • Page 98: Starting The Engine

    5.4 Starting the engine Start the engine via the automation system Refer to automation system operating instructions 96 | Operation | MS15035/00E 2018-08...

  • Page 99: Re-Starting The Engine Following An Automatic Safety Shutdown

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

  • Page 100: Stopping The Engine

    5.6 Stopping the engine Stopping the engine via the automation system Refer to automation system operating instructions 98 | Operation | MS15035/00E 2018-08...

  • Page 101: Operational Checks

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

  • Page 102: Emission Label - Check

    5.8 Emission label – Check Emission label – Check Note: If there are any irregularities, notify your MTU contact person/service partner without delay. Check that emission labels are present (there can be more than one). Check emission label for intactness.

  • Page 103: Tasks After Extended Out-Of-Service Periods (>3 Weeks)

    5.9 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 103). Shut down fuel treatment system (→ Page 107). MS15035/00E 2018-08 | Operation | 101...

  • Page 104: 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 105: Fuel Treatment System - Initial Start-Up

    5.11 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 106 Initial start-up: HAT Replace fuel filter on engine (→ Page 187). 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 106). Result: Fuel is drawn from the tank (24).
  • Page 107 Simulating power failure (emergency): SAT Switch on fuel treatment system (→ Page 106). Start engine (→ Page 96). 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 108: Fuel Treatment System - Switching On

    5.12 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 109: Fuel Treatment System - Shutdown

    5.13 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 110: Emergency Engine Stop

    5.14 Emergency engine stop NOTICE An emergency stop subjects the engine system to an extremely high load. Risk of overheating, damage to components! • Trigger an emergency stop only in emergency situations. Emergency stop Refer to automation system operating instructions. Follow instructions.

  • Page 111: After Shutdown

    Switch off. Air intake and exhaust sys- Out-of-service-period > 1 week • Seal engine on air and exhaust sides. Out-of-service-period > 1 month • Carry out engine preservation (→ MTU Preservation and Represervation Specifications A001070/..). MS15035/00E 2018-08 | Operation | 109...

  • Page 112: Plant - Cleaning

    5.16 Plant – Cleaning Preconditions ☑ Engine is stopped and starting disabled. ☑ No operating voltage applied. Special tools, Material, Spare parts Designation / Use Part No. Qty. High-pressure cleaner (→ Tools Catalog) 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 113: Maintenance

    6 Maintenance 6.1 Maintenance task reference table [QL1] for EPA regions 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 114 Task Maintenance tasks W1713 Injector: reset drift compensation parameters (CDC). (→ Page 268) W1864 Check and clean oil indicator filter. (→ Page 216) Table 2: Maintenance task reference table [QL1] 112 | Maintenance | MS15035/00E 2018-08...

  • Page 115: Maintenance Task Reference Table [Ql1] For Non Epa Regions

    6.2 Maintenance task reference table [QL1] for Non EPA regions 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 116 Task Maintenance tasks W1675 Fit new fuel prefilter or new fuel prefilter insert. W1713 Injector: reset drift compensation parameters (CDC). (→ Page 268) Table 3: Maintenance task reference table [QL1] 114 | Maintenance | MS15035/00E 2018-08...

  • Page 117: Troubleshooting

    7 Troubleshooting 7.1 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 118 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 119 White exhaust gas Cause Corrective action u Run engine to reach operating temperature. Engine is not at operating temperature Intercooler leaking u Contact Service. MS15035/00E 2018-08 | Troubleshooting | 117...

  • Page 120: Control Cabinet Of Fuel Treatment System - Troubleshooting

    7.2 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 121: Engine Governor Adec (Ecu 7) Fault Messages For Series 4000 Engines, Marine Application

    7.3 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 122: Adec Engine Governor - Fault Codes

    7.4 ADEC engine governor – Fault codes 29 – HI ETC Idle Speed too High ZKP-Number: 1.8004.206 Cause Corrective action Idle speed of one of the u Contact Service. secondary turbochargers is too high. 38 – AL ETC Speed Deviation ZKP-Number: 1.8004.205 Cause Corrective action...
  • Page 123 141 – AL Power too high ZKP-Number: 1.1088.007 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: 1.1088.006 Cause Corrective action...
  • Page 124 205 – SD T-Coolant Intercooler ZKP-Number: 1.8004.574 Cause Corrective action Charge-air cooler coolant u Check sensor and cabling (B26), replace as necessary. temperature sensor faulty; Short circuit or wire break 206 – SD T-Exhaust A ZKP-Number: 1.8004.576 Cause Corrective action u Check sensor and cabling (B4.21), replace as necessary.
  • Page 125 213 – SD P-Coolant charge-air cooler ZKP-Number: 1.8004.569 Cause Corrective action Charge-air cooler coolant 1. Check sensor and cabling (B43), replace as necessary. pressure sensor faulty; Short 2. Error cleared after restarting the engine. circuit or wire break 214 – SD P-CrankCase ZKP-Number: 1.8004.568 Cause Corrective action...
  • Page 126 221 – SD P-Diff-Lube Oil ZKP-Number: 1.8004.585 Cause Corrective action Lube oil differential pressure 1. Check sensor and cabling (F25), replace as necessary. sensor faulty; Short circuit or wire 2. Error cleared after restarting the engine. break 222 – SD Level Leakage Fuel ZKP-Number: 1.8004.582 Cause Corrective action...
  • Page 127 230 – SD Crankshaft Speed ZKP-Number: 1.8004.498 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: 1.8004.499 Cause Corrective action Camshaft sensor faulty;...
  • Page 128 241 – SD T-Circulating air ZKP-Number: 1.8004.581 Cause Corrective action Recirculation temperature sensor 1. Check sensor and cabling (B49), replace as necessary. faulty; Short circuit or wire break 2. Error cleared after restarting the engine. 242 – SD T-Coolant (R) ZKP-Number: 1.8004.622 Cause Corrective action...
  • Page 129 304 – AL Timing Cylinder A4 ZKP-Number: 1.8004.503 Cause Corrective action Time-of-flight measuring fault of u If alarm occurs frequently, replace solenoid valve of injector injector in cylinder A4: Time-of flight measured value extremely low or extremely high. 305 – AL Timing Cylinder A5 ZKP-Number: 1.8004.504 Cause Corrective action...
  • Page 130 309 – AL Timing Cylinder A9 ZKP-Number: 1.8004.508 Cause Corrective action Time-of-flight measuring fault of u If alarm occurs frequently, replace solenoid valve of injector injector in cylinder A9: Time-of flight measured value extremely low or extremely high. 310 – AL Timing Cylinder A10 ZKP-Number: 1.8004.509 Cause Corrective action...
  • Page 131 314 – AL Timing Cylinder B4 ZKP-Number: 1.8004.513 Cause Corrective action Time-of-flight measuring fault of u If alarm occurs frequently, replace solenoid valve of injector injector B4: Time-of flight measured value extremely low or extremely high. 315 – AL Timing Cylinder B5 ZKP-Number: 1.8004.514 Cause Corrective action...
  • Page 132 319 – AL Timing Cylinder B9 ZKP-Number: 1.8004.518 Cause Corrective action Time-of-flight measuring fault of u If alarm occurs frequently, replace solenoid valve of injector injector B9: Time-of flight measured value extremely low or extremely high. 320 – AL Timing Cylinder B10 ZKP-Number: 1.8004.519 Cause Corrective action...
  • Page 133 325 – AL Wiring Cylinder A5 ZKP-Number: 1.8004.524 Cause Corrective action Short-circuit in injector cabling to 1. Rectify injector solenoid valve short circuit (positive to negative) cylinder A5. Result: Misfiring (e.g. by exchanging injectors). 2. Error cleared after restarting the engine. 326 –...
  • Page 134 331 – AL Wiring Cylinder B1 ZKP-Number: 1.8004.530 Cause Corrective action Cabling fault in injector cabling to 1. Rectify injector solenoid valve short circuit (positive to negative) cylinder B1. Result: Misfiring (e.g. by exchanging injectors). 2. Error cleared after restarting the engine. 332 –...
  • Page 135 337 – AL Wiring Cylinder B7 ZKP-Number: 1.8004.536 Cause Corrective action Cabling fault in injector cabling to 1. Rectify injector solenoid valve short circuit (positive to negative) cylinder B7. Result: Misfiring (e.g. by exchanging injectors). 2. Error cleared after restarting the engine. 338 –...
  • Page 136 343 – AL Open Load Cylinder A3 ZKP-Number: 1.8004.542 Cause Corrective action Disruption fault in injector cabling 1. Check continuity of injector cabling or exclude open load in to cylinder A3. Result: Misfiring solenoid valve circuit (e.g. by injector replacement) 2.
  • Page 137 349 – AL Open Load Cylinder A9 ZKP-Number: 1.8004.548 Cause Corrective action Disruption fault in injector cabling 1. Check injector wiring for disruption or rule out any discontinuity in to cylinder A9. Result: Misfiring the solenoid valve (e.g. by replacing the injector) 2.
  • Page 138 355 – AL Open Load Cylinder B5 ZKP-Number: 1.8004.554 Cause Corrective action Disruption fault in injector cabling 1. Check injector wiring for disruption or rule out any discontinuity in to cylinder B5. Result: Misfiring the solenoid valve (e.g. by replacing the injector) 2.
  • Page 139 361 – AL Power Stage Low ZKP-Number: 1.8004.496 Cause Corrective action Internal electronic fault u Start ITS. If the ITS diagnosis result is "electronics OK", note (electronics possibly faulty). If bit further fault messages (e.g. cabling faults). "1.1020.021" (Power Stage Failure: Stop Engine) is set, engine will be shut down as additional measure.
  • Page 140 371 – AL Wiring TO 1 ZKP-Number: 1.8004.634 Cause Corrective action Short circuit or wire break on 1. Check charger valve/cabling, repair as necessary. transistor output 1 (TO 1). 2. Replace engine governor 372 – AL Wiring TO 2 ZKP-Number: 1.8004.635 Cause Corrective action Short circuit or wire break on...
  • Page 141 397 – TD P-Lube Oil ZKP-Number: 1.8004.625 Cause Corrective action Maximum deviation of lube oil 1. Check sensor and cabling, replace as necessary. pressure values from sensors 2. Contact Service. 417 – SD Level Water Fuel Prefilter ZKP-Number: 1.8004.594 Cause Corrective action Water level sensor in fuel prefilter u Check sensor and cabling, replace as necessary.
  • Page 142 468 – SD T-AUX 1 ZKP-Number: 1.8004.579 Cause Corrective action Analog input signal for Aux 1 1. Check signal transmitter and cabling, replace as necessary. temperature faulty;. 2. Replace engine governor. 469 – SD AUX 1 ZKP-Number: 1.8004.590 Cause Corrective action Analog input signal for Aux 1 u Check signal transmitter and cabling, replace as necessary.
  • Page 143 476 – AL Crash Rec. Init. Error ZKP-Number: 1.8010.007 Cause Corrective action Crash recorder initialization error. 1. Check setting with DiaSys. 2. Contact Service. 482 – SD T-Exhaust C ZKP-Number: 1.8004.596 Cause Corrective action Exhaust temperature sensor on A- u Check sensor and cabling (B4.23), replace as necessary. side faulty;...
  • Page 144 501 – AL Wiring POM Starter 2 ZKP-Number: 1.4500.901 Cause Corrective action A wiring fault was detected in the u Check connection between POM and starter. connection between starter 2 and POM. This may be a missing consumer, a wire break, or a short circuit.
  • Page 145 508 – AL Wrong POM-ID ZKP-Number: 1.4500.908 Cause Corrective action POM transmits an unexpected ID u Check POM wiring harness. number. If alarm occurs in combination with alarm 504, the resistor in the POM cabling is missing. 519 – Oillevel Calibration Error ZKP-Number: 1.0158.921 Cause Corrective action...
  • Page 146 576 – AL ESCM Override ZKP-Number: 1.1075.083 Cause Corrective action Violation of corrected MCR or u Reduce power. DBR/MCR curve. Engine overload! 577 – SD T-Lube Oil Pan ZKP-Number: 1.0137.900 Cause Corrective action Temperature sensor in oil pan u Check sensor and cabling, replace as necessary. defective;...
  • Page 147 601 – SD ETC1+ETC2 ZKP-Number: 1.3011.227 Cause Corrective action SD ETC1 and ETC2 u Check sensor and cabling, replace as necessary. 625 – SD P-Fuel before Prefilter ZKP-Number: 1.8004.600 Cause Corrective action Analog input signal for pressure 1. Check pressure sensor and cabling, replace as necessary. before prefilter faulty;...

  • Page 148: Task Description

    8 Task Description 8.1 SOLAS 8.1.1 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 A5 735233000101 Shield A6 735233000102 Shield A7 735233000103 Shield A8 735233000104...

  • Page 149: Solas Shielding - Installation

    8.1.2 SOLAS shielding – Installation Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine is cooled down to ambient temperature. Special tools, Material, Spare parts Designation / Use Part No. Qty. Oil filter shield X00040625 Shield for switchable oil filter X00040625 Installing SOLAS shield Pinpoint installation location.

  • Page 150: Installation Locations For Solas Shielding

    8.1.3 Installation locations for SOLAS shielding General information Primarily fit SOLAS shielding as per MTN 5233 (→ Page 146). Shield unions with adhesive tape if SOLAS shielding as per MTN 5233 is not possible (→ Page 157). When affixing adhesive connections ensure that escaping fluid can flow out without pressure (→ Page 157). Fuel system, fuel lines with fuel pressure >1.8 bar Item Type of shielding...
  • Page 151 Item Type of shielding Installation location Shield A8 Fuel filter head holder * This shield must be installed on the assembly line. This location is no longer accessible, or only with great difficulty, following assembly of the air pipework and/or fuel filters. Item Type of shielding Installation location...
  • Page 152 Item Type of shielding Installation location 2 x shielding B6 Fuel line at fuel filter head * This shield must be installed on the assembly line. This location is no longer accessible, or only with great difficulty, following assembly of the air pipework. Lube oil system, oil lines with oil pressures exceeding 1.8 bar Item Type of shielding...
  • Page 153 Item Type of shielding Installation location 2 x shielding A5 Switching cylinder air flap ETC B1 3 x shielding A5 T adapter for flap control ETC B1 Item Type of shielding Installation location 5 x shielding A5 Distributor piece 2 x shielding A5 Oil return MS15035/00E 2018-08 | SOLAS | 151...
  • Page 154 Item Type of shielding Installation location Shield A7 Oil return Item Type of shielding Installation location Shield A7 Oil line to ETC Shield A5 Oil line to flap control Shield A5 Oil line to recirculation valve 2 x shielding E5 Oil line from main gallery * These shields must be installed on the assembly line.
  • Page 155 Item Type of shielding Installation location 2 x shielding A5 Air recirculation valve Item Type of shielding Installation location Shield A6 Oil supply line to HP pump: on HP pump MS15035/00E 2018-08 | SOLAS | 153...
  • Page 156 Item Type of shielding Installation location Shield B4 Oil supply line to HP pump: on equipment carrier * This shield must be installed on the assembly line. Assembly in this position is no longer possible after painting. Item Type of shielding Installation location Shield A6 ETC oil supply...
  • Page 157 Item Type of shielding Installation location 2 x shielding A6 ETC oil supply Item Type of shielding Installation location Shield B2 Oil line on equipment carrier Shield B2 Oil line on pressure reducing valve * This shield must be installed on the assembly line. Assembly in this position is no longer possible after painting.
  • Page 158 Item Type of shielding Installation location Cover Oil/easy-change fuel filter 156 | SOLAS | MS15035/00E 2018-08...

  • Page 159: Adhesive Tape For Solas Shielding - Application

    8.1.4 Adhesive tape for SOLAS shielding – Application Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Adhesive tape Applying adhesive tape – gener- al information Note: Use the cable clamp to make a drainage channel.

  • Page 160: Engine

    8.2 Engine 8.2.1 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! •...
  • Page 161 Note: Use barring device F6555766. 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 162: Barring Engine With Starting System

    8.2.2 Barring engine with starting system Barring using the automation system Refer to automation system operating instructions 160 | Engine | MS15035/00E 2018-08...

  • Page 163: Cylinder Liner

    8.3 Cylinder Liner 8.3.1 Cylinder liner – Endoscopic examination Preconditions ☑ Engine is stopped and starting disabled Special tools, Material, Spare parts Designation / Use Part No. Qty. Barring tool F6555766 Ratchet with extension F30006212 Endoscope Y20097353 Preparatory steps Remove cylinder head cover (→ Page 170). Remove injector (→...
  • Page 164 Compile endoscopic report using the table. Use technical terms to describe the liner surface (→ Page 163). Depending on findings: • Do not take any action or • carry out a further endoscopic examination as part of maintenance work or •...

  • Page 165: Cylinder Liner - Instructions And Comments On Endoscopic And Visual Examination

    8.3.2 Cylinder liner – Instructions and comments on endoscopic and visual examination Terms used for endoscopic examination Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic examina- tion report. Findings Explanations/Action Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing products, particles, broken-off burrs).
  • Page 166 Evaluation of findings and further measures The findings in the start phase of oxidation discoloration and burn marks are similar. A thorough investigation and compliance with the above evaluation criteria allow an unambiguous evaluation. To avoid unnecessary disassembly work, it is recommended that another inspection be carried out after further operation of the engine.

  • Page 167: Crankcase Breather

    8.4 Crankcase Breather 8.4.1 Crankcase breather – Oil mist separator replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil Oil mist separator (→ Spare Parts Catalog) O-ring (→...

  • Page 168: Valve Drive

    8.5 Valve Drive 8.5.1 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 170). Fill oil chambers of valve bridges with oil.

  • Page 169: Valve Clearance - Check And Adjustment

    8.5.2 Valve clearance – Check and adjustment Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine coolant temperature is max. 40 °C. ☑ Valves are closed. Special tools, Material, Spare parts Designation / Use Part No. Qty. Feeler gage Y20010128 Valve setting gage Y4349603...
  • Page 170 Note: Danger of confusion: Additional marking OT/A1 (1) on outer circumference, if applica- ble. Additional OT/A1 (1) marking on the outer circumference of flywheel must not be used. Diagram for 12V engines (two crankshaft positions) Diagram for 16V engines (two crankshaft positions) 168 | Valve Drive | MS15035/00E 2018-08...
  • Page 171 Checking valve clearance in 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. • If the rocker arms are loaded on cylinder A1, the piston is in overlap TDC. Check valve clearance adjustment with engine cold: •...

  • Page 172: Cylinder Head Cover - Removal And Installation

    8.5.3 Cylinder head cover – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10–60 Nm F30510423 Ratchet bit F30027341 Assembly compound (Kluthe Hakuform 30-15) X00067260 Engine oil O-ring...

  • Page 173: Injection Pump / Hp Pump

    8.6 Injection Pump / HP Pump 8.6.1 HP fuel pump – Filling with engine oil Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10–60 Nm F30452769 Fuel suction device F30378207 Engine oil WARNING...
  • Page 174 Preparatory steps Loosen nut (2) and remove oil line (1) from HP pump. HP pump – Filling Remove union (1). Note: Excess engine oil runs into gear box. Use fuel suction device to fill HP pump with 2 liters of clean engine oil. Screw in union (1) and use torque wrench to tighten to specified tightening torque.

  • Page 175: Hp Fuel Pump - Relief Bore Check

    8.6.2 HP fuel pump – Relief bore check DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING High level of engine noise when the engine is running.

  • Page 176: Injection Valve / Injector

    8.7 Injection Valve / Injector 8.7.1 Injector – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Injector (→ Spare Parts Catalog) Replacing injector Remove injector and install new injector (→ Page 175). 174 | Injection Valve / Injector | MS15035/00E 2018-08...

  • Page 177: Injector - Removal And Installation (Jacketed Fuel System)

    8.7.2 Injector – Removal and installation (jacketed fuel system) Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Installation/removal jig F6789889 Milling cutter F30452739 Torque wrench, 10–60 Nm F30452769 Ratchet bit F30027340 Torque wrench, 60–320 Nm F30452768...
  • Page 178 WARNING Internal load and residual pressure in the HP fuel system. Parts may be expelled at high speed on re- lease. Fuel may spurt out. Risk of injury by flying parts and sprayed fuel! • Only use specified tools and devices. •...
  • Page 179 Note: Observe system pressure. Slowly loosen union on HP line (4). Remove HP line (4). Note: The fuel stored in the injector drains out when the adapter (3) is unscrewed. Unscrew adapter (3). Note: Components are sensitive. Protect contact surfaces of HP line (4) and adapter (3) on cylinder head and the HP line (4) itself against damage.
  • Page 180 Installing injector Note: • The new sealing ring is included in the scope of supply of the injector (new part). • Use a multi-purpose grease without solids content. Install new sealing ring (1) with multi-purpose grease and ensure that the installation posi- tion is correct.
  • Page 181 Press in injector with installation/removal jig. Remove installation/removal jig. Coat screw mating face (2) and thread with engine oil. Fit hold-down clamp (1) in correct position, fit screw (2) and tighten by hand. Note: Make sure parts are perfectly clean. Apply engine oil to thread, sealing taper and thrust ring of adapter (3).
  • Page 182 Use torque wrench to tighten jacketed HP line (5) according to tightening sequence to specified tightening torque. Tightening sequence: 1 Adapter (4) 2 Rail (6) Name Size Type Lubricant Value/Standard Union nut / thrust Tightening torque (Engine oil) 40 Nm +5 Nm screw Note: Do not hold in place by hand.
  • Page 183 Fit cable connector on injector. For new assembly: CDC parameters – Reset Note: Failure to reset drift compensation (CDC) will void the emissions certification of the engine. Reset drift compensation (CDC) with DiaSys® (→ Dialog system DiaSys® E531920/..). If DiaSys® is not available, contact Service.

  • Page 184: Fuel System

    8.8 Fuel System 8.8.1 Fuel system – Venting Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! •...
  • Page 185 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 186: Fuel Filter

    8.9 Fuel Filter 8.9.1 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- 184 | Fuel Filter | MS15035/00E 2018-08...

  • Page 187: Supplementary Fuel Filter - Replacement

    8.9.2 Supplementary 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 Components are moving or rotating.
  • Page 188 Replacing fuel filter with the engine running Cut out the filter to be replaced (2) using three-way cock (3): B Left-hand filter switched off C Right-hand filter switched off Remove the cut-out oil filter (2) using an oil filter wrench. Clean sealing surface on filter head.

  • Page 189: Fuel Filter - Replacement

    8.9.3 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 Components are moving or rotating.
  • Page 190 Cut out the filter to be replaced. Unscrew cut-out easy-change filter with oil filter wrench. Clean sealing surface on filter head. Check sealing ring of the new easy-change filter and moisten it with fuel. Fit SOLAS shield (→ Page 41). Screw on easy-change filter and tighten by hand.

  • Page 191: Fuel Prefilter - Differential Pressure Gage Check And Adjustment

    8.9.4 Fuel prefilter – Differential pressure gage check and adjustment DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING High level of engine noise when the engine is running.

  • Page 192: Fuel Prefilter - Draining

    8.9.5 Fuel prefilter – Draining DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING Liquid or gaseous media, e.g.
  • Page 193 Open vent valves (1) of filter to be drained. Open drain valve (2). Drain water and contamination from filter un- til clean fuel emerges. Close drain valve (2). Open rotary slide valve (2) a little (turning to approx. 30°) to introduce fuel into the filter housing with the new filter element.

  • Page 194: Fuel Prefilter - Flushing

    8.9.6 Fuel prefilter – Flushing Preconditions ☑ Positive pressure at the prefilter inlet. DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING Liquid or gaseous media, e.g.
  • Page 195 Open threaded vent plug (1) of the filter to be flushed. Remove 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 threaded vent plug (1) and drain valve (2).

  • Page 196: Fuel Prefilter With Water Separator - Filter Element Replacement

    8.9.7 Fuel prefilter with water separator – Filter element replacement Preconditions ☑ Positive pressure at the prefilter inlet Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10–60 Nm F30452769 Ratchet adapter F30027340 Filter element (→ Spare Parts Catalog) O-ring (→...
  • Page 197 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 (3) of the filter to be re- placed.
  • Page 198 Open rotary slide valve (2) a little (turning to approx. 30°) to introduce fuel into the filter housing with the new filter element. Close vent valve (1) as soon as fuel emerges from vent pipe (4). Turn the rotary slide valve to the upright posi- tion (3) until it engages.

  • Page 199: Fuel Prefilter With Water Separator - O-Ring Replacement In Rotary Slide Valve

    8.9.8 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 200: Exhaust Turbocharger

    8.10 Exhaust Turbocharger 8.10.1 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 adapter F30027340 Cleaner 40377 Engine oil Engine coolant Sealing rings (→...
  • Page 201 Remove charge-air pipework (1) from exhaust turbocharger to intercooler. Remove oil lines (2). Loosen clamp (1). Remove intake housing (3) with actuating cyl- inder (2). Remove coolant lines (1) from compressor housing (3). Remove coolant ventilation line (2) from com- pressor housing (3).
  • Page 202 Undo screws (1). Remove compressor housing (2). Cleaning compressor wheel Note: Do not use wire brushes, scrapers 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 203 Tighten screws (1) to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Screw Tightening torque (Engine oil) 20 Nm + 2.5 Nm Install coolant ventilation line and coolant lines on compressor housing. Install intake housing (3) with actuating cylin- der (2).
  • Page 204 Preparatory steps – Vertical air intake Drain engine coolant (→ Page 227). Remove air filter (→ Page 208). Seal all openings with suitable covers. Remove charge-air pipework (1) from exhaust turbocharger to intercooler. Remove oil lines (2). Loosen clamp (1). Remove intake housing (3) with actuating cyl- inder (2).
  • Page 205 Remove coolant lines (1) from compressor housing (3). Remove coolant ventilation line (2) from com- pressor housing (3). Undo screws (1). Remove compressor housing (2). Cleaning compressor wheel Note: Do not use wire brushes, scrapers or similar tools for cleaning! Clean compressor housing with a smooth paint brush or brush.
  • Page 206 Final steps – Vertical air intake Install compressor casing (2). Tighten screws (1) to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Screw Tightening torque (Engine oil) 20 Nm + 2.5 Nm Install coolant ventilation line and coolant lines on compressor housing. Install intake housing (3) with actuating cylin- der (2).
  • Page 207 Install oil lines (2). Tighten threaded adapter at actuating cylinder to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Threaded adapter 10 G 1/4 Tightening torque (Engine oil) 40 Nm +4 Nm Install charge-air pipework (1) between exhaust turbocharger and intercooler. Install air filter (→...

  • Page 208: Charge-Air Cooling

    8.11 Charge-Air Cooling 8.11.1 Intercooler – Checking condensate drain for water discharge and obstruction DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING High level of engine noise when the engine is running.

  • Page 209: Air Filter

    8.12 Air Filter 8.12.1 Air filter – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Air filter (→ Spare Parts Catalog) Replacing air filter Remove old air filter and install new air filter (→ Page 208). Reset signal ring of contamination indicator (→...

  • Page 210: Air Filter - Removal And Installation

    8.12.2 Air filter – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10–60 Nm F30452769 Air filter Loosen clamp (2). Remove air filter (1) and clamp (2) from con- necting flange of housing (3).

  • Page 211: Air Intake

    8.13 Air Intake 8.13.1 Contamination indicator – Signal ring position check Preconditions ☑ Engine is stopped and starting disabled. WARNING The engine draws in large volumes of ambient air for combustion. This air intake results in a strong vac- uum. Risk of injury if body parts are drawn in! There is also a danger if opening of the entrance door can be prevented! •...

  • Page 212: Starting Equipment

    8.14 Starting Equipment 8.14.1 Starter – Condition check Preconditions ☑ Engine is stopped and starting disabled. Starter – Condition check Check securing screws of starter and nut on cable connection for secure seating and tighten if required. Check cabling (→ Page 257). 210 | Starting Equipment | MS15035/00E 2018-08...

  • Page 213: Lube Oil System, Lube Oil Circuit

    8.15 Lube Oil System, Lube Oil Circuit 8.15.1 Engine oil level – Check Preconditions ☑ Engine is stopped and starting disabled. WARNING Oil is hot. Oil can contain residue/substances which are harmful to health. Risk of injury and poisoning! • Allow the product to cool to below 50 °C before beginning work. •...

  • Page 214: Engine Oil - Change

    8.15.2 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, 40–200 Nm...
  • Page 215 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 216: Engine Oil - Sample Extraction And Analysis

    8.15.3 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 Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! •...
  • Page 217 Drain approx. 1 liter engine oil into a clean container. Close screw. Using the equipment and chemicals in the MTU test kit, analyze the engine oil for: • Dispersion capability (spot test) • Proportion of water • Fuel dilution Engine oil, sample extraction...

  • Page 218: Oil Filtration / Cooling

    8.16 Oil Filtration / Cooling 8.16.1 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 (→...
  • Page 219 Removing basket strainer – var- iant A Clean oil indicator filter before disassembling Remove screws (1). Take off cover (2) and O-ring (3). Remove spring (4) and strainer (6) from filter housing and allow oil to drip into container. Cleaning strainer Shake coarse contamination out of strainer (6).
  • Page 220 Removing basket strainer – var- iant B Note: Cover (2) is under tension due to spring (4). Remove screws (1). Take off cover (2) and O-ring (3). Remove spring (4). Take strainer (5) out of filter housing. Cleaning strainer Shake coarse contamination out of strainer (5). Clean all metallic parts with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 50/136).

  • Page 221: Engine Oil Filter - Replacement

    8.16.2 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 Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! •...
  • Page 222 Engine oil filter with diverter (option) – Oil filter replacement with engine at standstill Stop engine (→ Page 98) 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 223: Centrifugal Oil Filter - Cleaning And Filter Sleeve Replacement

    8.16.3 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 Ratchet bit F30027340...
  • Page 224 Centrifugal oil filter, cleaning and filter sleeve replacement Remove clamp (17). Release Tommy nut (2) and remove cover (1). Carefully lift rotor (14), allow oil to drain and remove from housing. Note: Do not clamp rotor in a bench vise. Holding rotor unit (14) firmly, release rotor cover nut (3).
  • Page 225 Note: Do not clamp rotor unit in a bench vise.Use an oil filter wrench. Install rotor cap (3) tighten nut for rotor cover (3) with torque wrench to specified tightening torque. Name Size Type Lubricant Value/Standard Tightening torque 80 Nm ±12 Nm Place rotor (14) in housing (15) and check for ease of movement.
  • Page 226 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 227: Coolant Circuit, General, High-Temperature Circuit

    8.17 Coolant Circuit, General, High-Temperature Circuit 8.17.1 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 228: Engine Coolant Change

    8.17.2 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant change Drain engine coolant (→ Page 227). Fill with engine coolant (→ Page 230). 226 | Coolant Circuit, General, High-Temperature Circuit | MS15035/00E 2018-08...

  • Page 229: Engine Coolant - Draining

    8.17.3 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 an appropriate container to drain the coolant into.
  • Page 230 Open vent valve on exhaust pipework (driving end) (1). Open vent valve on seawater cooler (1) (or re- mote heat exchanger). Open drain plug (1) and drain coolant at crankcase. 228 | Coolant Circuit, General, High-Temperature Circuit | MS15035/00E 2018-08...
  • Page 231 Open drain screw (1) and drain coolant on coolant pump elbow. Final steps Seal all open vent and drain points. Set breather valve onto filler neck and close it. MS15035/00E 2018-08 | Coolant Circuit, General, High-Temperature Circuit | 229...

  • Page 232: Engine Coolant - Filling

    8.17.4 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 233 Filling coolant through filler neck Open vent points on charge-air cooler, ex- haust turbochargers and on plate-core heat exchanger (arrows). Note: On engines with a separate heat exchanger, the expansion tank is connected separately from the engine to the external cooling sys- tem.

  • Page 234: Ht Coolant Pump - Relief Bore Check

    8.17.5 HT coolant pump – Relief bore check DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING High level of engine noise when the engine is running.

  • Page 235: Engine Coolant - Sample Extraction And Analysis

    Spindle 11a/f Tightening torque 12 Nm Using the equipment and chemicals of the MTU test kit, examine engine coolant for: • antifreeze concentration • concentration of corrosion protection oil • pH value For engine coolant change intervals, see (→ MTU Fluids and Lubricants Specifications).

  • Page 236: Preheating Unit

    8.17.7 Preheating unit Hotstart preheating unit 1 Plastic cap (drain) 4 Shutoff valve 7 Thermostat 2 On/Off switch 5 Continuous flow heater 8 Circulation pump 3 Plastic cap (supply line) 6 Vent valve Cylinders Rated voltage / frequency Heating power kW 230 V / 50 Hz 400 V / 50 Hz 230 V / 60 Hz...
  • Page 237 Hilzinger preheating unit 1 On/Off switch Cylinders Rated voltage / frequency Heating power kW 12V and 16V 230 V / 50 Hz 400 V / 50 Hz 230 V / 60 Hz 440 V / 60 Hz MS15035/00E 2018-08 | Coolant Circuit, General, High-Temperature Circuit | 235...
  • Page 238 Hilzinger preheating unit, side view 1 Flange (supply and return) 3 Non-return flap 5 Thermostat 2 Junction box 4 Continuous flow heater 6 Circulation pump Function The preheating unit is intended to warm up the engine coolant. The circulation pump (6) ensures the circula- tion of the preheated coolant through the engine.

  • Page 239: Preheater - Overhaul

    8.17.8 Preheater – Overhaul Preconditions ☑ Engine is stopped and starting disabled. DANGER Electric voltage supply for operation. Danger of burns and fatal electric shock! • Make certain that the power supply to the product is switched off before starting work. Secure against unintentional switching on! WARNING Coolant is hot and under pressure.

  • Page 240: Preheater - Function And Leak-Tightness Check

    8.17.9 Preheater – Function and leak-tightness check Preconditions ☑ Preheater is switched on. WARNING Coolant is hot and highly pressurized. Risk of injury! Risk of scalding! • Allow engine to cool down. • Wear protective clothing, protective gloves, and safety glasses / facial protection. Checking operation Note: The coolant temperature must correlate to the control range of the thermostat when the preheater is ready...

  • Page 241: Raw Water Pump With Connections

    8.18 Raw Water Pump with Connections 8.18.1 Raw water pump – Relief bore check DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING High level of engine noise when the engine is running.

  • Page 242: Battery-Charging Generator

    8.19 Battery-Charging Generator 8.19.1 Battery-charging generator drive – Coupling condition check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Endoscope Y20097353 Battery-charging generator drive, coupling condition check Install barring tool (→ Page 158). Guide endoscope optics between guard plate (1) and battery-charging generator car- rier (2) (arrow).

  • Page 243: Auxiliary Pto

    8.20 Auxiliary PTO 8.20.1 Bilge pump – Relief bore check DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING High level of engine noise when the engine is running.

  • Page 244: Engine Mounting / Support

    8.21 Engine Mounting / Support 8.21.1 Engine mounting – Checking resilient element NOTICE Contamination of engine mounts made of natural rubber with fuel or oil. Engine mounts swell. Risk of shorter service life or destruction of the mounts! • Cover engine mounts when working with fuel or oil. •...

  • Page 245: Fuel Supply System

    8.22 Fuel Supply System 8.22.1 Water drain valve – Check Water drain valve – Check Open water drain valve. Check water outlet for obstructions. Close water drain valve. MS15035/00E 2018-08 | Fuel Supply System | 243...

  • Page 246: Differential Pressure Gage - Alarm Function Check

    8.22.2 Differential pressure gage – Alarm function 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 gage alarm function Switch on fuel treatment system (→...

  • Page 247: Water Level Probe (3-In-1 Rod Electrode) - Check

    8.22.3 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 248: Pump Capacity - Check

    8.22.4 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 249: Coalescer Filter Element - Replacement

    8.22.5 Coalescer filter element ‒ Replacement Preconditions ☑ System is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 8–40 Nm F30043446 Ratchet adapter F30027340 Fuel Engine oil Coalescer filter element (→ Spare Parts Catalog) Gasket (→...
  • Page 250 Tighten nut (3) to specified torque using a torque wrench. 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. Result: The fuel treatment system is ready for operation.

  • Page 251: Wiring (General) For Engine/Gearbox/Unit

    8.23 Wiring (General) for Engine/Gearbox/Unit 8.23.1 Engine wiring harness – Overview Engine wiring harnesses – Terminal assignment Description Terminal assignment Sensors Camshaft speed Intake air temperature B4.21 Exhaust temperature, A side B4.22 Exhaust temperature, B-side B5.1 Oil pressure downstream of filter B5.3 Oil pressure upstream of filter B5.8...
  • Page 252 Description Terminal assignment Adaptation ECU-7 governor ECU Power ECU-7 governor Cranking start interlock EIM engine box XB19 Starting air pressure Dialog XG03 Battery-charging generator Starting system Valves Charge-air recirculation Exhaust turbocharger Injectors Y39A1 to Y39AX Engine A side Y39B1 to Y39BX Engine B side 250 | Wiring (General) for Engine/Gearbox/Unit | MS15035/00E 2018-08...
  • Page 253 Engine wiring harness for sensors, 12V engine 1 M8 13 B4.22 25 B4.21 2 B1 14 B9 26 B10 3 B6 15 S37.1 27 B13 4 X2 16 B34.3 28 S37.2 5 XF33 17 B34.2 29 B7 6 X37 18 B34.1 30 B5.1 7 B54 19 B50...
  • Page 254 Engine wiring harness for sensors, 16V engine 1 M8 13 B4.22 25 B4.21 2 B1 14 B9 26 B10 3 B6 15 S37.1 27 B13 4 X2 16 B34.3 28 S37.2 5 XF33 17 B34.2 29 B7 6 X37 18 B34.1 30 B5.1 7 B54 19 B50...
  • Page 255 Engine wiring harness for injectors, 12V engine 1 Y39A1 6 Y39A6 11 Y39B3 2 Y39A2 7 X4 12 Y39B2 3 Y39A3 8 Y39B6 13 Y39B1 4 Y39A4 9 Y39B5 5 Y39A5 10 Y39B4 MS15035/00E 2018-08 | Wiring (General) for Engine/Gearbox/Unit | 253...
  • Page 256 Engine wiring harness for injectors, 16V engine 1 Y39A1 7 Y39A7 13 Y39B5 2 Y39A2 8 Y39A8 14 Y39B4 3 Y39A3 9 X4 15 Y39B3 4 Y39A4 10 Y39B8 16 Y39B2 5 Y39A5 11 Y39B7 17 Y39B1 6 Y39A6 12 Y39B6 254 | Wiring (General) for Engine/Gearbox/Unit | MS15035/00E 2018-08...
  • Page 257 Engine wiring harness for EIM 1 XD1 4 X52 7 XB19 2 X1 5 XY1 8 X37 3 X3 6 X11 MS15035/00E 2018-08 | Wiring (General) for Engine/Gearbox/Unit | 255...
  • Page 258 Engine wiring harness for electric starter 1 Connection terminals, EIM 2 Fuse F1 3 Connection terminals, start- 256 | Wiring (General) for Engine/Gearbox/Unit | MS15035/00E 2018-08...

  • Page 259: Engine Cabling - Check

    8.23.2 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 260: Accessories For (Electronic) Engine Governor / Control System

    8.24 Accessories for (Electronic) Engine Governor / Control System 8.24.1 Limit switch for start interlock – Check Preconditions ☑ Engine is stopped and starting disabled. Note: In the OFF position, the limit switch activates a start interlock, i.e. the engine cannot be started. Limit switch for start interlock –...

  • Page 261: Engine Control Unit Ecu 7 - Checking Plug Connections

    8.24.2 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 seating. Ensure that the clips (1) are engaged. Check screws (2) of cable clamps on ECU for firm seating.

  • Page 262: Engine Monitoring Unit Emu 7 - Plug Connection Check

    8.24.3 Engine Monitoring Unit EMU 7 – Plug connection check Preconditions ☑ Engine is stopped and starting disabled. Checking EMU plug connections Check both connectors on EMU (2) for firm seating. Make sure that frames (3) are engag- Check screws (1) of cable clamps on EMU (2) for firm seating.

  • Page 263: Interface Module Eim Plug Connections - Check

    8.24.4 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 264: Engine Governor Ecu 7 - Removal And Installation

    8.24.5 Engine governor ECU 7 – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine electronics is powered off. 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 265: Emu 7 - Removal And Installation

    8.24.6 EMU 7 – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine electronics is powered off. 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 266: Engine Interface Module Eim 2 - Diagnostic Features

    8.24.7 Engine Interface Module EIM 2 – Diagnostic features Diagnostic lamp (DILA) A diagnostic lamp (LED, blue) is integrated in the housing of the Engine Interface Module (EIM 2). It indicates the operating status of the EIM 2. Functions of diagnostic lamp DILA DILA glows Engine Interface Module (EIM 2) is OK.
  • Page 267 1 Preamble 6 VSP current path failed (S5) 11 ES pushbutton current path 2 Engine Control Unit current 7 SLD current path failed (S6) failed – 24 V external (S10) path failed (S1) 8 DDV current path failed (S7) 12 Key switch current path 3 MCS current path failed 9 Gear monitoring current failed (S11)
  • Page 268 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 2.

  • Page 269: Engine Interface Module Eim 2 - Removal And Installation

    8.24.8 Engine Interface Module EIM 2 – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Removing Engine Interface Mod- ule from engine Note or mark assignment of cables and con- nectors. Unscrew all screws (1). Undo clips (2) on connectors. Disconnect all connectors.

  • Page 270: Cdc Parameters - Reset

    8.24.9 CDC parameters – Reset Preconditions ☑ Engine is stopped and starting disabled. Note: Failure to reset drift compensation (CDC parameters) will void the emissions certification. Resetting CDC parameters with DiaSys® (→ Dialog system DiaSys® E531920/..). Resetting CDC parameters without DiaSys® If no DiaSys®...

  • Page 271: List Of Abbreviations

    Association of American standardization organiza- tions Abgasturbulader 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 Con- trol Unit...
  • Page 272 Abbrevia- Meaning Explanation tion Initial Injector Equalization Entering of injector code with DiaSys in engine gover- International Maritime Organization International Organization for Stand- International umbrella organization for all national ardization standardization institutes Kraftgegenseite Engine free end in accordance with DIN ISO 1204 Kraftseite Engine driving end in accordance with DIN ISO 1204 Liquid Crystal Display, Liquid Crystal...

  • Page 273: Mtu Contact/Service Partners

    Local Support Experienced and qualified specialists place their knowledge and expertise at your disposal. For locally available support, go to the MTU Internet site: http://www.mtu-online.com 24h Hotline With our 24h hotline and high flexibility, we're your contact around the clock: during each operating phase, preventive maintenance and corrective operations in case of a malfunction, for information on changes in conditions of use and for supplying spare parts.
  • Page 274 10 Appendix B 10.1 Special Tools Barring tool Part No.: F6555766 Qty.: Used in: 8.2.1 Engine – Barring manually (→ Page 158) Qty.: Used in: 8.3.1 Cylinder liner – Endoscopic examination (→ Page 161) Endoscope Part No.: Y20097353 Qty.: Used in: 8.3.1 Cylinder liner –...
  • Page 275 Filter wrench Part No.: F30379104 Qty.: Used in: 8.9.2 Supplementary fuel filter – Replacement (→ Page 185) Qty.: Used in: 8.9.3 Fuel filter – Replacement (→ Page 187) Qty.: Used in: 8.16.2 Engine oil filter – Replacement (→ Page 219) Fuel suction device Part No.: F30378207...
  • Page 276 Milling cutter Part No.: F30452739 Qty.: Used in: 8.7.2 Injector – Removal and installation (jacketed fuel system) (→ Page 175) MTU test kit Part No.: 5605892099/00 Qty.: Used in: 8.15.3 Engine oil – Sample extraction and analysis (→ Page 214) MTU test kit Part No.:...
  • Page 277 Ratchet adapter Part No.: F30027340 Qty.: Used in: 8.9.7 Fuel prefilter with water separator – Filter element replacement (→ Page 194) Qty.: Used in: 8.10.1 Compressor wheel – Cleaning (→ Page 198) Qty.: Used in: 8.22.5 Coalescer filter element ‒ Replacement (→...
  • Page 278 Ratchet with extension Part No.: F30006212 Qty.: Used in: 8.2.1 Engine – Barring manually (→ Page 158) Qty.: Used in: 8.3.1 Cylinder liner – Endoscopic examination (→ Page 161) Socket wrench, 24 mm Part No.: F30039526 Qty.: Used in: 8.5.2 Valve clearance – Check and adjustment (→...
  • Page 279 Torque wrench, 10–60 Nm Part No.: F30510423 Qty.: Used in: 8.5.3 Cylinder head cover – Removal and installation (→ Page 170) Torque wrench, 40–200 Nm Part No.: F30027337 Qty.: Used in: 8.15.2 Engine oil – Change (→ Page 212) Torque wrench, 4–20 Nm Part No.: F30044239 Qty.:...
  • Page 280 Torque wrench, 8–40 Nm Part No.: F30043446 Qty.: Used in: 8.22.5 Coalescer filter element ‒ Replacement (→ Page 247) Valve setting gage Part No.: Y4349603 Qty.: Used in: 8.5.2 Valve clearance – Check and adjustment (→ Page 167) 278 | Special Tools | MS15035/00E 2018-08...
  • Page 281 10.2 Index Cylinder  Preheating unit 234 – Designation  40 Cylinder head cover  – Installation  170 Actuators  – Removal  170 – Overview  60 Cylinder liner  Additional fuel filter  – Endoscopic examination  161 – Overview  184 – Endoscopic inspection   ADEC (ECU 7)  –...
  • Page 282 Firing order 90 Fuel  Maintenance Schedule  – Treatment system   – Maintenance task reference table [QL1]  111, 113 – Switching on  106 MTU contact persons 271 – Troubleshooting  118 – treatment system   – Shutdown  107 Oil indicator filter  Fuel filter  – Check  216...
  • Page 283 Plug connections  Transport locking device  – Check  261 – Crankshaft   Preheater  – Installation/removal  24 – Overhaul  237 Transportation  – Function and leak-tightness   – Lifting requirements  20 – check  238 Troubleshooting 115 Product description 41 – Fuel treatment system  118 Pump capacity  –...

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