MTU 8V4000M*3 series Operating Instructions Manual
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MTU 8V4000M*3 series Operating Instructions Manual

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Operating Instructions
Diesel engine
8V4000Mx3x
MS15034/00E

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Summary of Contents for MTU 8V4000M*3 series

  • Page 1 Operating Instructions Diesel engine 8V4000Mx3x MS15034/00E...
  • 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 5.10 Fuel treatment system – Switching on 5.11 Fuel treatment system – Shutdown 1.1 Important provisions for all products 5.12 Stopping the engine 1.2 Correct use of all products 5.13 Emergency engine stop 1.3 Personnel and organizational requirements 5.14 After shutdown 1.4 Initial start-up and operation –...
  • Page 6 8.16 Coolant Circuit, General, High-Temperature 9 Appendix A Circuit 9.1 List of abbreviations 8.16.1 Drain and vent points 9.2 MTU Contact/Service Partners 8.16.2 Engine coolant level – Check 8.16.3 Engine coolant – Change 10 Appendix B 8.16.4 Engine coolant – Draining 8.16.5 Engine coolant, filling...

  • Page 7: 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 8 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 9: 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 10: 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 11: 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 12 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 13: 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 14 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 15 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 16 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 17: 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 18 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 19: 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 20: Transport

    Place the engine only on an even, firm surface. Ensure appropriate consistency and load-bearing capacity of the ground or support surface. Never place an engine on the oil pan, unless expressively authorized by MTU on a case-to-case basis to do 18 | Transport | MS15034/00E 2018-08...

  • Page 21: 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 for installed heat exchanger 1 Maximum permissible diag- 2 Center of gravity onal pull 10°...
  • Page 22 Lifting requirements for remote heat exchanger 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 23: General Information

    3 General Information 3.1 Engine layout Overview with remote heat exchanger, free end 1 Centrifugal oil filter 5 Fuel filter 9 Bilge pump (option) 2 Dry-type air filter 6 Oil filter 10 Raw water pump (option for 3 Exhaust manifold 7 Battery-charging generator engines with remote heat 4 Cylinder head...
  • Page 24 Overview with remote heat exchanger, driving end 1 Exhaust outlet 6 Engine mounting 11 Compressor housing 2 Recirculation line 7 Oil filler neck 12 Charge-air cooler 3 Crankcase breather coolant 8 Oil pan 13 Exhaust turbocharger carri- expansion tank 9 Crankcase er housing 4 Oil cooler 10 Charge-air line...
  • Page 25 Overview with engine-mounted heat exchanger, free end 1 Raw-water outlet 6 Cylinder head 11 Raw water pump 2 Coolant expansion tank 7 Fuel filter 12 Heat exchanger 3 Centrifugal oil filter 8 Oil filter 13 Engine management and 4 Dry-type air filter 9 Battery-charging generator monitoring 5 Exhaust manifold...
  • Page 26 Overview with engine-mounted heat exchanger, driving end 1 Exhaust outlet 6 Oil filler neck 11 Charge-air cooler 2 Crankcase breather 7 Oil pan 12 Air pipe to charge-air cooler 3 Oil cooler 8 Crankcase 13 Exhaust turbocharger carri- 4 Coolant pump 9 Charge-air line er housing 5 Engine mounting...

  • Page 27: Product Description

    3.2 Product description Engine description 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 28 • 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 29 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 30 100 operating hours in low-load operation, at the lat- est. SOLAS – Fire protection specifications Fuel system, fuel lines with fuel pressure >1.8 bar All lines with SOLAS-compliant covers for pipe joints, according to MTU standard MTN5233, are shown. 28 | General Information | MS15034/00E 2018-08...
  • Page 31 1 Fuel line after LP pump 1 Fuel line to fuel filter head retainer MS15034/00E 2018-08 | General Information | 29...
  • Page 32 1 Fuel line from fuel filter head 1 Fuel line on HP pump 30 | General Information | MS15034/00E 2018-08...
  • Page 33 1 Fuel line on fuel filter head 1 Fuel line on fuel filter head Lube oil system, oil lines with oil pressure >1.8 bar All lines with SOLAS-compliant covers for pipe joints, according to MTU standard MTN5233, are shown. MS15034/00E 2018-08 | General Information | 31...
  • Page 34 1 Oil supply to actuating cylinder and air flap - Turbocharger A1 1 Actuating cylinder of exhaust flap - Turbocharger A1 2 Oil line to actuating cylinder of ex- haust flap - Turbocharger A1 3 4/2-way valve 4 From distributor 5 Oil return from 4/2-way directional control valve 1 Oil return from 4/2-way directional...
  • Page 35 Item Type of shielding Comments Shields (A4) Exhaust turbocharger oil supply, A side Shields (A5) (2 x) Exhaust turbocharger oil supply, A side 1 Oil supply for exhaust turbocharger MS15034/00E 2018-08 | General Information | 33...
  • Page 36 Item Type of shielding Comments Shields (A6) Oil supply to HP pump 34 | General Information | MS15034/00E 2018-08...
  • Page 37 1 Oil supply line of HP pump on equipment carrier 1 Oil supply on equipment carrier MS15034/00E 2018-08 | General Information | 35...
  • Page 38 1 Cover on oil filter cartridge Special connections The following types of connections are spray-proof in case of leakage even without covers and have been confirmed as being SOLAS-compliant by GL and DnV. 36 | General Information | MS15034/00E 2018-08...
  • Page 39 Plug-in pipe connection The sleeve (4) covers the joint to prevent lateral spray. Only leak-off along the line is possible, the pressure is decreased significantly if an O-ring (3) defect occurs. The union is confirmed as being SOLAS-compliant by DnV and GL. Plugs and sensors Screwed-in plugs (2) are either sealed with copper sealing rings (1) as per DIN or O-rings (ISO).
  • Page 40 High-pressure connections 1 Jacket pipe 8 Thrust ring 15 Union nut 2 HP line 9 Union nut 16 Thrust ring 3 O-ring 10 Union nut 17 Outer high-pressure line 4 Union nut 11 Connecting piece pipe 5 Recess for O-ring 12 Snap ring 18 Internal pipe of HP line 6 Thrust ring...

  • Page 41: Tightening Specifications For Screws, Nuts And Bolts

    3.3 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 • ISO 4762 (DIN 912) •...
  • Page 42 Hand-tightening Machine-tightening Thread 8.8 M (Nm) 10.9 M (Nm) 8.8 M (Nm) 10.9 M (Nm) 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 1900 1250...
  • Page 43 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 44 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 45 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 46 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 47 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 48 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 49 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 50 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 51 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 52 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 53 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 54: Engine Side And Cylinder Designations

    3.4 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 55: Sensors And Actuators - Overview

    3.5 Sensors and actuators – Overview Remote heat exchanger Left engine side 8V4000Mx3 1 B44.2 (N-Turbocharger B) 4 B34.2 (P-Fuel before filter) 7 F46 (H fuel leakage) 2 B4.21 (T-Exhaust, A side) 5 B34.3 (P-Fuel before filter) 3 B10 (P-Charge air) 6 B34.1 (P-Fuel after filter) MS15034/00E 2018-08 | General Information | 53...
  • Page 56 Engine free end (KGS) 8V4000Mx3 1 B33 (T-Fuel, rail) 5 B5.3 (P-Lube oil before fil- 9 B6.2 (T-Coolant) 2 B7 (T-Lube oil) ter) 10 B6 (T-Coolant) 3 B5.2 (P-Lube oil after filter), 6 B48 (P-Fuel in common rail) 11 Connector XD1 – Dialog only with switchable oil fil- 7 B1 (N-Camshaft) unit...
  • Page 57 Right engine side 8V4000Mx3 1 B16 (P-Coolant) 3 B4.22 (T-Exhaust, B bank) 2 B9 (T-Charge Air) 4 B44.1 (N-Turbocharger A) MS15034/00E 2018-08 | General Information | 55...
  • Page 58 Driving end (KS) 8V4000Mx3 1 S37.1 (S-Safety switch) 3 B13 (N-Crankshaft) 2 B13.2 (N-Crankshaft) 4 S37.2 (safety switch) 56 | General Information | MS15034/00E 2018-08...
  • Page 59 Plan view 8V4000Mx3 1 Y27 (turbocharger control 3 B50 (P-Crankcase) 5 B49 (T-Charge-air, air recir- valve) 4 B4.A1-B4B4 (T-Individual ex- culation valve) 2 Y26 (A-Air recirculation haust A1-A4, B1-B4) 6 B3 (T-Intake air) valve) MS15034/00E 2018-08 | General Information | 57...
  • Page 60 Engine-mounted heat exchanger Left engine side 8V4000Mx3 1 B44.2 (N-Turbocharger B) 4 B34.2 (P-Fuel before filter) 7 F46 (H-Fuel leakage) 2 B4.21 (T-Exhaust, A side) 5 B34.3 (P-Fuel before filter) 8 B33 (T-Fuel in common rail) 3 B10 (P-Charge air) 6 B34.1 (P-Fuel after filter) 58 | General Information | MS15034/00E 2018-08...
  • Page 61 Engine free end (KGS) 8V4000Mx3 1 B48 (P-Fuel in common rail) 5 B5.3 (P-Lube oil before of 9 B6 (T-Coolant) 2 B7 (T-Lube oil) filter) 10 Connector XD1 – Dialog 3 B5.2 (P-Lube oil after filter), 6 B1 (N-Camshaft) unit only with switchable oil fil- 7 B54 (P-Oil refill pump) 8 B6.2 (T-Coolant)
  • Page 62 Right engine side 8V4000Mx3 1 F33 (H-Coolant) 3 B21 (P-Raw water) 5 B4.22 (T-Exhaust, B bank) 2 B16 (P-Coolant) 4 B9 (T-Charge Air) 6 B44.1 (N-Turbocharger A) 60 | General Information | MS15034/00E 2018-08...
  • Page 63 Driving end (KS) 8V4000Mx3 1 S37.1 (S-Safety switch) 3 B13 (N-Crankshaft) 2 B13.2 (N-Crankshaft) 4 S37.2 (S-Safety switch) MS15034/00E 2018-08 | General Information | 61...
  • Page 64 Plan view 8V4000Mx3 1 Y27 (turbocharger control 3 B4.A1-B4B4 (T-Individual ex- 5 B49 (T-Charge-air, air recir- valve) haust A1-A4, B1-B4) culation valve) 2 B50 (P-Crankcase) 4 Y26 (A-Air recirculation 6 B3 (T-Intake air) valve) 62 | General Information | MS15034/00E 2018-08...

  • Page 65: Technical Data

    4 Technical Data 4.1 ENGINE DATA 8V4000M53R (provisional) Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power settings). N Value not yet defined - Not applicable X Applicable...
  • Page 66 Number of cylinders Engine-mounted heat Remote heat ex- exchanger changer Inlet valves per cylinder Number of exhaust valves per cylinder RAW WATER CIRCUIT (open circuit) Number of cylinders Engine-mounted heat Remote heat ex- exchanger changer Raw water pump: Inlet pressure, min. -0.4 -0.4 Raw water pump: Inlet pressure, max.
  • Page 67 STARTING SYSTEM (electric) Number of cylinders Engine-mounted heat Remote heat ex- exchanger changer Rated starter voltage (standard design) STARTING (with compressed air/hydraulic starter) Number of cylinders Engine-mounted heat Remote heat ex- exchanger changer Starting-air pressure before starter motor, min. Starting-air pressure before starter, max. INCLINATIONS, STANDARD OIL SYSTEM (reference: waterline) Number of cylinders Engine-mounted heat...
  • Page 68 WEIGHTS / MAIN DIMENSIONS Number of cylinders Engine-mounted heat Remote heat ex- exchanger changer Engine dry weight (with attached standard 5875 5875 5505* 5505* accessories, without coupling) ACOUSTICS Number of cylinders Engine-mounted heat Remote heat ex- exchanger changer Exhaust noise, unsilenced - BL (free-field dB(A) 108* 108*...

  • Page 69: Product Data 8V4000M53

    4.2 Product data 8V4000M53 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 70 Product type Application Engine speed Listed output 8V4000M53 Marine / ship main 1800 rpm 920 kW Ref. 45 °C/32; heat propulsion 1234 bhp exchanger installed on 1A continuous power, engine unlimited IMO Tier II (Marpol convention) EU Nonroad St IIIA (97/68/EC) IMO Tier I Marpol Comp...
  • Page 71 Fuel temperature at engine inlet connec- °C tion Fuel temperature at engine supply con- °C nection, max. 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 38.1 38.1...
  • Page 72 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 73 Sound Exhaust noise, unsilenced - BL (free-field dB(A) sound pressure level Lp, 1m distance, ISO 6798, +3dB(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, +2dB(A) tolerance) MS15034/00E 2018-08 | Technical Data | 71...

  • Page 74: Product Data 8V4000M63

    4.3 Product data 8V4000M63 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 75 Product type Application Engine speed Listed output 8V4000M63 Marine / ship main 1800 rpm 1000 kW Ref. 45 °C/32 °C; propulsion 1341 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 76 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 38.1 38.1 38.1 38.1 Raw-water circuit (open circuit) Raw water pump: Inlet pressure, min. -0.2 -0.2 Raw water pump: inlet pressure, max.
  • Page 77 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 22.5 22.5...
  • Page 78 22. Sound Exhaust noise, unsilenced - BL (free-field dB(A) sound pressure level Lp, 1m distance, ISO 6798, +3dB(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, +2dB(A) tolerance) 76 | Technical Data | MS15034/00E 2018-08...

  • Page 79: Firing Order

    4.4 Firing order A1-B4-A4-A2-B3-A3-B2-B1 12 V A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1 16 V A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B7 MS15034/00E 2018-08 | Technical Data | 77...

  • Page 80: Engine - Main Dimensions

    4.5 Engine – Main dimensions Main engine dimensions Engines with remote heat exchanger Engine model Length (A) Width (B) Height (C) 8V4000 M23S/23F/33S/33S/53/53R/63 approx. 2386 approx. 1613 approx. 1959 Engines with engine-mounted heat exchanger Engine model Length (A) Width (B) Height (C) 8V4000 M23S/23F/33S/33S/53/53R/63 approx.

  • Page 81: Operation

    5 Operation 5.1 Controls Automation system controls Refer to automation system operating instructions MS15034/00E 2018-08 | Operation | 79...

  • Page 82: 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 83: 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 189); Preheat engine oil if required. Coolant system Check coolant level (→...

  • Page 84: Re-Starting The Engine Following An Automatic Safety Shutdown

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

  • Page 85: Starting The Engine

    5.5 Starting the engine Start the engine via the automation system Refer to automation system operating instructions MS15034/00E 2018-08 | Operation | 83...

  • Page 86: Operational Checks

    5.6 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 87: Tasks After Extended Out-Of-Service Periods (>3 Weeks)

    5.7 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 87). Shut down fuel treatment system (→ Page 91). MS15034/00E 2018-08 | Operation | 85...

  • Page 88: 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 89: Fuel Treatment System - Initial Start-Up

    5.9 Fuel treatment system – Initial start-up Overview of fuel treatment system 1 Pressure-free overflow 9 Ball valve, outlet 17 Automatic water drain 2 Bypass 1 10 Check valve 700 mbar 18 Water level electrode 3 Bypass 2 11 Check valve 5 mbar 19 Ball valve, sample extrac- 4 Safety valve, 3 bar 12 Return to overflow tank...
  • Page 90 Initial start-up: HAT Replace fuel filter on engine (→ Page 168). 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 90). Result: Fuel is drawn from the tank (24).
  • Page 91 Simulating power failure (emergency): SAT Switch on fuel treatment system (→ Page 90). Start engine (→ Page 83). 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 92: Fuel Treatment System - Switching On

    5.10 Fuel treatment system – Switching on Preconditions ☑ The on-board power supply is switched on. NOTICE Risk of damage to engine/system. Risk of severe damage to property! • Before switching on, ensure that the engine/system is ready for operation. •...

  • Page 93: Fuel Treatment System - Shutdown

    5.11 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 94: Stopping The Engine

    5.12 Stopping the engine Stopping the engine via the automation system Refer to automation system operating instructions 92 | Operation | MS15034/00E 2018-08...

  • Page 95: Emergency Engine Stop

    5.13 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 96: 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/..). 94 | Operation | MS15034/00E 2018-08...

  • Page 97: Plant - Cleaning

    5.15 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 98: 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 99 Task Maintenance tasks W1713 Injector: reset drift compensation parameters (CDC). (→ Page 245) W1864 Check and clean oil indicator filter. (REFDM TARGET NOT FOUND) Table 2: Maintenance task reference table [QL1] MS15034/00E 2018-08 | Maintenance | 97...

  • Page 100: 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 101 Task Maintenance tasks W1675 Fit new fuel prefilter or new fuel prefilter insert. W1713 Injector: reset drift compensation parameters (CDC). (→ Page 245) Table 3: Maintenance task reference table [QL1] MS15034/00E 2018-08 | Maintenance | 99...

  • Page 102: 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 103 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 104 White exhaust gas Cause Corrective action u Run engine to reach operating temperature. Engine is not at operating temperature Intercooler leaking u Contact Service. 102 | Troubleshooting | MS15034/00E 2018-08...

  • Page 105: 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 106: 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 107: 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 108 141 – 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 109 205 – 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 110 213 – 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 111 221 – 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 112 230 – 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 113 241 – 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 114 304 – 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 115 309 – 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 116 314 – 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 117 319 – 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 118 325 – 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 119 331 – 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 120 337 – 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 121 343 – 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 122 349 – 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 123 355 – 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 124 361 – 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 125 371 – 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 126 397 – 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 127 468 – 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 128 476 – 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 129 501 – 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 130 508 – 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 131 576 – 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 132 601 – 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 133: 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 A4 735233000100 Shield A5 735233000101 Shield A6 735233000102 Shield A7 735233000103...

  • Page 134: 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 135: Installation Locations For Solas Shielding

    8.1.3 Installation locations for SOLAS shielding General information Primarily fit SOLAS shielding as per MTN 5233 (→ Page 131). Shield unions with adhesive tape if SOLAS shielding as per MTN 5233 is not possible (→ Page 140). When affixing adhesive connections ensure that escaping fluid can flow out without pressure (→ Page 140). Fuel system, fuel lines with fuel pressures exceeding >1.8 bar Item Type of shielding...
  • Page 136 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 137 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 138 Item Type of shielding Installation location 2 x shielding A5 Actuating cylinder exhaust flap turbocharger A1 2 x shielding A5 Actuating cylinder air flap turbocharger A1 4 x shielding A5 4/2-way directional control valve Item Type of shielding Installation location 2 x shielding A5 Air recirculation valve 2 x shielding A5...
  • Page 139 Item Type of shielding Installation location Shield A4 ETC oil supply 2 x shielding A5 ETC oil supply Item Type of shielding Installation location Shield A4 ETC oil supply MS15034/00E 2018-08 | SOLAS | 137...
  • Page 140 Item Type of shielding Installation location Shield A6 Oil supply line to HP pump: To HP pump Item Type of shielding Installation location Shield B4 Oil supply line to HP pump: On equipment carrier 138 | SOLAS | MS15034/00E 2018-08...
  • Page 141 Item Type of shielding Installation location Shield B2 Oil line on equipment carrier Shield B2 Oil line on pressure reducing valve Item Type of shielding Installation location Cover Oil/easy-change fuel filter MS15034/00E 2018-08 | SOLAS | 139...

  • Page 142: 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 143: 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 144 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 145: Barring Engine With Starting System

    8.2.2 Barring engine with starting system Barring using the automation system Refer to automation system operating instructions MS15034/00E 2018-08 | Engine | 143...

  • Page 146: 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 154). Remove injector (→...
  • Page 147 Compile endoscopic report using the table. Use technical terms to describe the liner surface (→ Page 146). Depending on findings: • Do not take any action or • carry out a further endoscopic examination as part of maintenance work or •...

  • Page 148: 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 149 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 150: Crankcase Breather

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

  • Page 151: 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 153). Fill oil chambers of valve bridges with oil.

  • Page 152: 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 gauge Y20098771 Torque wrench, 60–320 Nm F30452768...
  • Page 153 Note: Danger of interchanging: 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 8V engines (two crankshaft positions) Checking valve clearance at two crankshaft positions Check TDC position of piston in cylinder A1: •...
  • Page 154 Adjusting valve clearance Release locknut (1). Insert feeler gauge (3) between valve bridge and rocker arm. Note: Replace or loosen stiff adjusting screws and/or locknuts. Using Allen key, set adjusting screw (2) so that the specified valve clearance is provided. Note: Feeler gauge must just pass through the gap.

  • Page 155: 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. Gasket (→ Spare Parts Catalog) Removing cylinder head cover Clean very dirty cylinder head covers (3) prior to removal.

  • Page 156: Cylinder Head Cover - Removal And Installation

    8.5.4 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 157 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 158 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 159 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 160 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 159). 158 | Injection Valve / Injector | MS15034/00E 2018-08...

  • Page 161: Injector – Removal And Installation (Jacketed

    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 162 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 163 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 164 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 165 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 166 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 167 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 168 8.8 Fuel Filter 8.8.1 Additional fuel filter – Overview 1 Storage tank 3 Passive fuel prefilter with 5 Additional fuel filter, switch- 2 Day tank water separator able 4 LP pump 6 Main engine filter, switcha- 166 | Fuel Filter | MS15034/00E 2018-08...
  • Page 169 8.8.2 Additional fuel filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Diesel fuel Easy-change filter (→ Spare Parts Catalog) Synthetic ring (→ Spare Parts Catalog) DANGER Components are moving or rotating.
  • Page 170 8.8.3 Fuel filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Diesel fuel Easy-change filter (→ Spare Parts Catalog) Synthetic ring (→ Spare Parts Catalog) DANGER Components are moving or rotating.
  • Page 171 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 (REFDM TARGET NOT FOUND).

  • Page 172: Fuel Prefilter – Differential Pressure Gage

    8.8.4 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 173 8.8.5 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 174 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 175 8.8.6 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 176 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 177: Fuel Prefilter With Water Separator – Filter

    8.8.7 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 178 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 179 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 180: Fuel Prefilter With Water Separator – O-Ring

    8.8.8 Fuel prefilter with water separator – O-ring replacement in rotary slide valve Preconditions ☑ Engine is stopped and starting disabled. ☑ System is at atmospheric pressure. Special tools, Material, Spare parts Designation / Use Part No. Qty. O-ring (→ Spare Parts Catalog) WARNING Tank is pressurized.
  • Page 181 8.9 Exhaust Turbocharger 8.9.1 Compressor wheel – Cleaning Preconditions ☑ Engine is stopped and starting disabled Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 4-20 Nm F30044239 Cleaning agent 40377 Engine oil Engine coolant Sealing rings (→...
  • Page 182 Remove air pipework (1) from exhaust turbo- charger to charge-air cooler. Disconnect oil lines (2) from air flap actuator cylinder. Undo screws (3) and clamp (2). Remove intake housing (1) with actuating cyl- inder. Remove coolant lines (1) on compressor cas- ing.
  • Page 183 Undo clamp (2). Remove compressor casing (1). Cleaning compressor wheel Note: Do not use wire brushes, scrapers or similar implements for cleaning! Clean compressor casing with a soft brush. Clean compressor wheel (2) and bearing housing (1). Thoroughly remove cleaning agent from all parts.
  • Page 184 Align clamp (2) and tighten to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Clamp Tightening torque (Engine oil) 5 Nm +1 Nm Install coolant lines (1) on compressor cas- ing. Install intake housing (1) with actuating cylin- der.
  • Page 185 Install oil lines (2). Install air pipework (1) from exhaust turbo- charger to charge-air cooler. Install air filter (→ Page 186). Fill with engine coolant (→ Page 208). MS15034/00E 2018-08 | Exhaust Turbocharger | 183...

  • Page 186: Charge-Air Cooling

    8.10 Charge-Air Cooling 8.10.1 Intercooler – Check water drain for coolant leakage and obstruction DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING High level of engine noise when the engine is running.

  • Page 187: Air Filter

    8.11 Air Filter 8.11.1 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 186). Reset signal ring of contamination indicator (→...
  • Page 188 8.11.2 Air filter – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Air filter – Removal and installa- tion 1 Intake housing 2 Clamp 3 Air filter Loosen clamp (2). Remove air filter (3) and clamp (2) from flange of intake housing (1). Verify that there are no objects in the flange of the intake housing (1) and clean it.

  • Page 189: Air Intake

    8.12 Air Intake 8.12.1 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 190: Starting Equipment

    8.13 Starting Equipment 8.13.1 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 234). 188 | Starting Equipment | MS15034/00E 2018-08...

  • Page 191: Lube Oil System, Lube Oil Circuit

    8.14 Lube Oil System, Lube Oil Circuit 8.14.1 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 192 8.14.2 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 193 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 194 8.14.3 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 195 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 196: Oil Filtration / Cooling

    8.15 Oil Filtration / Cooling 8.15.1 Engine oil filter – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Engine oil Oil filter (→ Spare Parts Catalog) DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! •...
  • Page 197 Engine oil filter with diverter (option) – Oil filter replacement with engine at standstill Stop engine (→ Page 92) 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 198 8.15.2 Oil indicator filter – Cleaning and check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Cleaner (Snow-White 11-0) X00054118 Cleaner (Hakupur 50/136) X00056700 Engine oil Strainer (→ Spare Parts Catalog) Square-section ring (→...
  • Page 199 Cleaning strainer Shake coarse contamination out of strainer (6). Clean all metallic parts with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 50/136). Note: Do not damage the fabric of the strainer. Use a soft brush to remove stubborn deposits from strainer as necessary. Blow out strainer (6) with compressed air from outside to inside.
  • Page 200 Checking strainer Item Findings Task Strainer Metallic residues • Clean • Monitor engine operation • Check strainer daily • Contact Service. Strainer Damaged Replace Square section ring Damaged Replace Spring Damaged Replace O-ring Damaged Replace Installing strainer Coat square section ring on basket strainer (5) with engine oil and install basket strainer (5). Coat O-ring (3) with engine and install in filter housing.

  • Page 201: Centrifugal Oil Filter – Cleaning And Filter

    8.15.3 Centrifugal oil filter – Cleaning and filter sleeve replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 4–20 Nm F30044239 Torque wrench, 20–100 Nm F30026582 Ratchet bit F30027340 Cold cleaner (Hakutex 60) X00056750...
  • Page 202 Centrifugal oil filter – Cleaning and filter sleeve replacement Remove clamp (14). Loosen Tommy nut (2) and take off hood (1). Carefully lift rotor (11), allow oil to drain and remove from housing. Holding the rotor (11) firmly, loosen rotor cover nut (3).
  • Page 203 Cleaning centrifugal oil filter and replacing filter sleeve (oil filters with diverter) Undo screw (1) and remove. Remove clamp (3) and take off hood (2). Carefully remove rotor assembly (5) from housing. Hold rotor assembly (5) firmly in position with filter wrench and undo knurled nut (7).

  • Page 204: Coolant Circuit, General, High-Temperature

    8.16 Coolant Circuit, General, High-Temperature Circuit 8.16.1 Drain and vent points Coolant line to carrier housing 1 Venting point Coolant line to intercooler Arrows Vent points 202 | Coolant Circuit, General, High-Temperature Circuit | MS15034/00E 2018-08...
  • Page 205 Coolant line to crankcase breather 1 Venting point Coolant line to raw water cooler 1 Distribution cross 2 Venting point MS15034/00E 2018-08 | Coolant Circuit, General, High-Temperature Circuit | 203...
  • Page 206 Coolant drain point, driving end 1 Drain points Coolant drain point, free end 1 Drain point 204 | Coolant Circuit, General, High-Temperature Circuit | MS15034/00E 2018-08...
  • Page 207 8.16.2 Engine coolant level – Check Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down.
  • Page 208 8.16.3 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant change Drain engine coolant (→ Page 207). Fill with engine coolant (→ Page 208). 206 | Coolant Circuit, General, High-Temperature Circuit | MS15034/00E 2018-08...
  • Page 209 8.16.4 Engine coolant – Draining Preconditions ☑ Engine is stopped and starting disabled. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down. • Wear protective clothing, gloves, and goggles / safety mask. Preparatory steps Provide an appropriate container to drain the coolant into.
  • Page 210 8.16.5 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 211 Filling with coolant through fill- er neck Open vent points on exhaust turbocharger, charge-air cooler, at the crankcase ventila- tion and on plate-core heat exchanger (ar- rows). Fill coolant through the filler neck of the ex- pansion tank (for engines with remote heat exchanger: the expansion tank is part of the remote cooling system) until the coolant level at the top edge of the filler neck remains con-...
  • Page 212 8.16.6 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 213: Engine Coolant – Sample Extraction And

    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 214: Engine Coolant Filter – Replacement

    8.16.8 Engine coolant filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Engine oil Engine coolant filter (→ Spare Parts Catalog) WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...

  • Page 215: Preheater – Function And Leak-Tightness Check

    8.16.9 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 216: Preheating Unit

    8.16.10 Preheating unit HotstartPreheating unit 1 Plastic cap (drain) 4 Shut-off valve 7 Thermostat 2 On/Off switch 5 Continuous flow heater 8 Circulating pump 3 Plastic cap (inlet) 6 Vent valve Number of Rated voltage / frequency Heating output kW cylinders 230 V / 50 Hz 400 V / 50 Hz...
  • Page 217 HilzingerPreheating unit 1 On/Off switch Number of Rated voltage / frequency Heating output kW cylinders 230 V / 50 Hz 400 V / 50 Hz 230 V / 60 Hz 440 V / 60 Hz MS15034/00E 2018-08 | Coolant Circuit, General, High-Temperature Circuit | 215...
  • Page 218 1 Flange (supply and return) 3 Non-return flap 5 Thermostat 2 Junction box 4 Continuous flow heater 6 Circulating pump Function The preheating unit heats up the engine coolant. The circulating pump (6) ensures the circulation of the pre- heated coolant through the engine. The flow heater (4) incorporates a heating element.

  • Page 219: Preheater – Overhaul

    8.16.11 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 220: Raw Water Pump With Connections

    8.17 Raw Water Pump with Connections 8.17.1 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 221: Battery-Charging Generator

    8.18 Battery-Charging Generator 8.18.1 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 141). Guide endoscope optics between guard plate (1) and battery-charging generator car- rier (2) (arrow).

  • Page 222: Engine Mounting / Support

    8.19 Engine Mounting / Support 8.19.1 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 223: 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 224: Fuel Supply System

    8.21 Fuel Supply System 8.21.1 Water drain valve – Check Water drain valve – Check Open water drain valve. Check water outlet for obstructions. Close water drain valve. 222 | Fuel Supply System | MS15034/00E 2018-08...

  • Page 225: Differential Pressure Gage – Alarm Function

    8.21.2 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 226: Water Level Probe (3-In-1 Rod Electrode

    8.21.3 Water level probe (3-in-1 rod electrode) – Check Preconditions ☑ System is put out of service and emptied. WARNING Fuels are combustible and explosive. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. •...

  • Page 227: Pump Capacity – Check

    8.21.4 Pump capacity – Check WARNING Fuels are combustible and explosive. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. • Wear protective clothing, protective gloves, and safety glasses / facial protection. Checking pump capacity Install suitable pressure gauge in the intake connection of the pump.

  • Page 228: Coalescer Filter Element ‒ Replacement

    8.21.5 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 229 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 230: Wiring (General) For Engine/Gearbox/Unit

    8.22 Wiring (General) for Engine/Gearbox/Unit 8.22.1 Engine wiring harness and mounts – Overview Designation Terminal assignment Sensors Camshaft speed Intake air temperature B4.21 Exhaust gas temperature, A-side B4.22 Exhaust temperature, B-side B5.1 Lube oil pressure after filter B5.3 Lube oil pressure before filter B5.8 Lube oil pressure before ETC, A-side (optional) Coolant temperature...
  • Page 231 Designation Terminal assignment Adaption Governor ECU-7 ECU Power Governor ECU-7 Start interlock turning 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 side A Y39B1 to Y39BX Engine side B MS15034/00E 2018-08 | Wiring (General) for Engine/Gearbox/Unit | 229...
  • Page 232 Engine wiring harness for sensors X2 Engine governor B16 Coolant pressure M8 Fuel pump B1 Camshaft speed B33 Fuel temperature F46 Leak fuel level B3 Intake air temperature B34.1 Fuel pressure after filter S37.1 Start interlock limit switch A B4.21 Exhaust gas temperature, A- B34.2 Fuel pressure before filter S37.2 Start interlock limit switch B side...
  • Page 233 Engine wiring harness for injectors 80 Injector wiring harness MS15034/00E 2018-08 | Wiring (General) for Engine/Gearbox/Unit | 231...
  • Page 234 Engine wiring harness for EIM 1 XD1 4 X52 7 XB19 2 X1 5 XY1 8 X37 3 X3 6 X11 232 | Wiring (General) for Engine/Gearbox/Unit | MS15034/00E 2018-08...
  • Page 235 Engine wiring harness for electric starter 1 EIM terminals 2 Fuse FM1 3 Starter connecting termi- nals MS15034/00E 2018-08 | Wiring (General) for Engine/Gearbox/Unit | 233...

  • Page 236: Engine Cabling – Check

    8.22.2 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 237: Accessories For (Electronic) Engine

    8.23 Accessories for (Electronic) Engine Governor / Control System 8.23.1 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 238: Engine Control Unit Ecu 7 – Checking Plug

    8.23.2 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 239: Engine Monitoring Unit Emu 7 – Plug

    8.23.3 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 240: Interface Module Eim Plug Connections

    8.23.4 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 241: Check

    8.23.5 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 242: Engine Interface Module Eim 2 – Removal And

    8.23.6 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 243: Engine Interface Module Eim 2 – Diagnostic

    8.23.7 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 244 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 245 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 246: Emu 7 – Removal And Installation

    8.23.8 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 247: Cdc Parameters – Reset

    8.23.9 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 248: Appendix A

    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 249 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 250: 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 251: Appendix B

    10 Appendix B 10.1 Special Tools Barring tool Part No.: F6555766 Qty.: Used in: 8.2.1 Engine – Barring manually (→ Page 141) Qty.: Used in: 8.3.1 Cylinder liner – Endoscopic examination (→ Page 144) Endoscope Part No.: Y20097353 Qty.: Used in: 8.3.1 Cylinder liner –...

  • Page 252: Special Tools

    Filter wrench Part No.: F30379104 Qty.: Used in: 8.8.2 Additional fuel filter – Replacement (→ Page 167) Qty.: Used in: 8.8.3 Fuel filter – Replacement (→ Page 168) Qty.: Used in: 8.15.1 Engine oil filter – Replacement (→ Page 194) Qty.: Used in: 8.16.8 Engine coolant filter –...
  • Page 253 Milling cutter Part No.: F30452739 Qty.: Used in: 8.7.2 Injector – Removal and installation (jacketed fuel system) (→ Page 159) MTU test kit Part No.: 5605892099/00 Qty.: Used in: 8.14.3 Engine oil – Sample extraction and analysis (→ Page 192) MTU test kit Part No.:...

  • Page 254: Cylinder Liner - Endoscopic Examination

    Ratchet bit Part No.: F30027341 Qty.: Used in: 8.5.4 Cylinder head cover – Removal and installation (→ Page 154) Qty.: Used in: 8.14.2 Engine oil – Change (→ Page 190) Ratchet bit Part No.: F30027340 Qty.: Used in: 8.7.2 Injector – Removal and installation (jacketed fuel system) (→...

  • Page 255: Valve Clearance - Check And Adjustment

    Socket wrench, 24 mm Part No.: F30039526 Qty.: Used in: 8.5.2 Valve clearance – Check and adjustment (→ Page 150) Torque wrench, 10–60 Nm Part No.: F30510423 Qty.: Used in: 8.5.4 Cylinder head cover – Removal and installation (→ Page 154) Torque wrench, 10–60 Nm Part No.: F30452769...
  • Page 256 Torque wrench, 4-20 Nm Part No.: F30044239 Qty.: Used in: 8.9.1 Compressor wheel – Cleaning (→ Page 179) Torque wrench, 40–200 Nm Part No.: F30027337 Qty.: Used in: 8.14.2 Engine oil – Change (→ Page 190) Torque wrench, 4–20 Nm Part No.: F30044239 Qty.:...
  • Page 257 Torque wrench, 8–40 Nm Part No.: F30043446 Qty.: Used in: 8.21.5 Coalescer filter element ‒ Replacement (→ Page 226) MS15034/00E 2018-08 | Special Tools | 255...

  • Page 258: Index

    10.2 Index Additional fuel filter  Diagnostic lamp (DILA)  – Overview  166 – EIM 2  241 – Replacement  167 Diagnostics  ADEC (ECU 7)  – EIM 2  241 – Fault messages  104 Differential pressure gage  Adhesive tape for SOLAS shielding  – Adjustment   –...
  • Page 259  78 – Treatment system   Maintenance Schedule  – Switching on  90 – Maintenance task reference table [QL1]  96, 98 – Troubleshooting  103 MTU contact persons 248 – treatment system   – Shutdown  91 Fuel filter  Oil indicator filter  – Replacement  168 –...
  • Page 260 Raw water pump  – Relief bore check  218 Safety regulations  – Assembly work  11 – Auxiliary materials  15 – Environmental protection  15 – Fire prevention  15 – Fluids and lubricants  15 – Important provisions  5, 7 – Initial start-up  9 –...

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