MTU 12V4000M93 series Operating Instructions Manual
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MTU 12V4000M93 series Operating Instructions Manual

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Operating Instructions
Diesel engine
12V4000M93x
16V4000M93x
MS150047/05E

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Summary of Contents for MTU 12V4000M93 series

  • Page 1 Operating Instructions Diesel engine 12V4000M93x 16V4000M93x MS150047/05E...
  • 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 4.3 Putting the engine into operation after scheduled out-of-service-period 1.1 Important provisions for all products 4.4 Re-starting the engine following an 1.2 Correct use of all products automatic safety shutdown 1.3 Personnel and organizational requirements 4.5 Starting the engine 1.4 Initial start-up and operation –...
  • Page 6 7.2 Engine 7.15.3 Oil indicator filter – Cleaning and check 7.15.4 Centrifugal oil filter – Cleaning and filter- 7.2.1 Engine – Barring manually sleeve replacement 7.2.2 Barring engine with starting system 7.16 Coolant Circuit, General, High-Temperature 7.3 Cylinder Liner Circuit 7.3.1 Cylinder liner –...
  • Page 7 7.24 Emergency Instrumentation (Local 8.2 MTU Contact/Service Partners Operating Panel) 7.24.1 LOP and connectors – Cleaning 9 Appendix B 9.1 Index 8 Appendix A 9.2 Spare Parts 9.3 Consumables 8.1 List of abbreviations 9.4 Special Tools MS150047/05E 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

    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 MS150047/05E 2018-08 | Safety | 19...

  • Page 22: General Information

    2 General Information 2.1 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 23 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 24 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 25 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 26 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 27 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 28 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 29 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 30 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 31 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 32 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 33 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 34 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 35: Engine - Overview

    2.2 Engine – Overview Also valid for 12V engines 1 Oil cooler 7 Cylinder head 13 Automatic oil filter 2 Coolant expansion tank 8 Charge-air pipework 14 Fuel filter 3 Crankcase breather 9 Oil filler neck 15 Centrifugal oil filter(s) 4 Air filter 10 Oil pan 16 Coolant cooler...

  • Page 36: Product Description

    2.3 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). Monitoring in the engine room is carried out by the engine control and monitoring unit (LOP).
  • Page 37 • 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 38 • Interface to CAN field bus for connected, communicating monitoring system components SOLAS – Fire safety specifications The following figures show all lines with SOLAS-compliant covers for pipe connections according to MTU standard MTN 5233. Fuel system, fuel lines with fuel pressure >1.8 bar...
  • Page 39 1 Fuel line to HP pump Lube oil system, oil lines with oil pressure >1.8 bar 1 Connection: ETC oil supply free end 1 Oil line on equipment carrier MS150047/05E 2018-08 | General Information | 37...
  • Page 40 1 Oil supply to HP pump 1 Oil supply to flap control, free end 1 ETC oil supply on main oil gallery 38 | General Information | MS150047/05E 2018-08...
  • Page 41 1 Actuating cylinder of air flap for turbo- charger B1 2 T piece of flap control 1 Actuating cylinder of exhaust flap for turbocharger B1 1 Oil line from main oil gallery 2 Oil line to main oil gallery MS150047/05E 2018-08 | General Information | 39...
  • Page 42 1 Flap control distributor 1 Recirculation valve Special connections In case of leaks, the following connection types are spray-protected even without a cover and have been con- firmed compliant with SOLAS by GL and DNV. 40 | General Information | MS150047/05E 2018-08...
  • Page 43 Plugs and sensors, plug-in pipe unions Seal plugs and sensors (a) Screw seal plugs (4) are either sealed with copper sealing rings (1) as per DIN or O-rings (ISO). In case of a loose union or a faulty 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 44 High-pressure connections 1 Jacketed pipe 8 Thrust ring 15 Union nut 2 HP line 9 Union nut 16 Thrust ring 3 O-ring 10 Union nut 17 HP line outer tube 4 Union nut 11 Connecting piece 18 HP line inner tube 5 Recess for O-ring 12 Snap ring 19 Ball-type seal area...

  • Page 45: Engine Side And Cylinder Designations

    2.4 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 46: Sensors And Actuators - Overview

    2.5 Sensors and actuators – Overview 12V4000M top view 1 B4.A1 (T-Exhaust cylinder 8 B4.A6 (T-Exhaust cylinder 15 B4.B6 (T-Exhaust cylinder 2 B4.21 (T-Exhaust, A side) 9 B5.2 (P-Lube oil after filter) 16 B4.B5 (T-Exhaust cylinder 3 B4.A2 (T-Exhaust cylinder 10 B48 (P-Fuel in common rail) 11 B34.2 (P-Fuel before filter) 17 B4.B4 (T-Exhaust cylinder...
  • Page 47 12V4000M left side 1 B7 (T-Lube oil) 6 B57.1 (T-Main bearing) 11 B57.6 (T-Main bearing) 2 B50 (P-crankcase) 7 B57.2 (T-Main bearing) 12 B57.7 (T-Main bearing) 3 B3 (T-Intake air) 8 B57.3 (T-Main bearing) 13 B5.1 (P-Lube oil after filter) 4 B44.1 (N-Turbocharger A) 9 B57.4 (T-Main bearing) 5 B10 (P-Charge air)
  • Page 48 12V4000M free end 1 F46 (H-Fuel leakage) 4 B54 (P-Oil refill pump) 7 Connector XD1 – Dialog 2 B33 (T-Fuel, rail) 5 B6.2 (T-Coolant) unit 3 B1 (N-Camshaft) 6 B6 (T-Coolant) 46 | General Information | MS150047/05E 2018-08...
  • Page 49 12V4000M right side 1 B44.2 (N-Turbocharger B) 5 B77.B5 (T-Spray oil (conrod 9 B77.B1 (T-Spray oil (conrod 2 B16 (P-Coolant) bearing)) bearing)) 3 B21 (P-Raw water) 6 B77.B4 (T-Spray oil (conrod 10 B9 (T-Charge-air) 4 B77.B6 (T-Spray oil (conrod bearing)) bearing)) 7 B77.B3 (T-Spray oil (conrod bearing))
  • Page 50 12V4000M driving end 1 B13 (N-Crankshaft) 3 S37.1 (Safety switch) 2 S37.2 (Safety switch) 4 B13.2 (N-Crankshaft) 48 | General Information | MS150047/05E 2018-08...
  • Page 51 16V4000M top view 1 B4.A1 (T-Exhaust cylinder 10 B4.A7 (T-Exhaust cylinder 19 B4.B7 (T-Exhaust cylinder 2 B4.A2 (T-Exhaust cylinder 11 B4.A8 (T-Exhaust cylinder 20 B4.B6 (T-Exhaust cylinder 3 B4.21 (T-Exhaust, A side) 12 B5.2 (P-Lube oil after filter) 21 B4.B5 (T-Exhaust cylinder 4 B4.A3 (T-Exhaust cylinder 13 B5.3 (P-Lube oil before fil- ter)
  • Page 52 16V4000M left side 1 B5.1 (P-Lube oil after filter) 6 B57.1 (T-Main bearing) 11 B57.6 (T-Main bearing) 2 B7 (T-Lube oil) 7 B57.2 (T-Main bearing) 12 B57.7 (T-Main bearing) 3 B50 (P-Crankcase) 8 B57.3 (T-Main bearing) 13 B57.8 (T-Main bearing) 4 B44.1 (N-Turbocharger A) 9 B57.4 (T-Main bearing) 14 B57.9 (T-Main bearing)
  • Page 53 16V4000M free end 1 F46 (H-Fuel leakage) 4 B54 (P-Oil refill pump) 7 Connector XD1 – Dialog 2 B33 (T-Fuel, rail) 5 B6.2 (T-Coolant) unit 3 B1 (N-Camshaft) 6 B6 (T-Coolant) MS150047/05E 2018-08 | General Information | 51...
  • Page 54 16V4000M right side 1 B44.2 (N-Turbocharger B) 5 B77.B7 (T-Spray oil (conrod 9 B77.B3 (T-Spray oil (conrod 2 B16 (P-Coolant) bearing)) bearing)) 3 B21 (P-Raw water) 6 B77.B6 (T-Spray oil (conrod 10 B77.B2 (T-Spray oil (conrod 4 B77.B8 (T-Spray oil (conrod bearing)) bearing)) bearing))
  • Page 55 16V4000M driving end 1 S37.1 (Safety switch) 3 B13 (N-Crankshaft) 2 B13.2 (N-Crankshaft) 4 S37.2 (Safety switch) MS150047/05E 2018-08 | General Information | 53...

  • Page 56: Engine Wiring Harness - Overview

    2.6 Engine wiring harness – Overview Designation Terminal assignment Engine wiring harness Governor ECU-7 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 B5.2 Lube oil pressure after filter B5.3 Lube oil pressure before filter Coolant temperature...
  • Page 57 Designation Terminal assignment Adaption Governor ECU Governor ECU Power EMU Power Start interlock EIM engine box XB19 Starting air pressure Dialog unit Starter Engine wiring harness for sensors 12V 1 B50 11 XG03 21 S37.2 2 B7 12 S37.1 22 B13 3 B5.1 13 B10 23 B16...
  • Page 58 Engine wiring harness for sensors 16V 1 B50 11 B1 21 S37.2 2 B7 12 S37.1 22 B13 3 B5.1 13 B10 23 B16 4 B5.3 14 B4.21 24 B44.2 5 B34.2 15 M8 25 Y27 6 B34.1 16 X2 26 F33 7 F46 17 X37...
  • Page 59 Engine wiring harness for injectors 12V 1 Y39A1 7 X4 13 E4.2 2 Y39A2 8 E4.3 14 E4.1 3 Y39A3 9 E4.4 15 Y39B4 4 Y39A4 10 E4.5 16 Y39B3 5 Y39A5 11 Y39B5 17 Y39B2 6 Y39A6 12 Y39B6 18 Y39B1 MS150047/05E 2018-08 | General Information | 57...
  • Page 60 Engine wiring harness for injectors 16V 1 Y39A1 9 X4 17 Y39B6 2 Y39A2 10 E4.3 18 Y39B5 3 Y39A3 11 E4.4 19 Y39B4 4 Y39A4 12 E4.5 20 Y39B3 5 Y39A5 13 Y39B7 21 Y39B2 6 Y39A6 14 Y39B8 22 Y39B1 7 Y39A7 15 E4.2...
  • Page 61 Engine wiring harness for EIM 1 XD1 4 X52 7 XB19 2 X1 5 XY1 8 X37 3 X3 6 X11 MS150047/05E 2018-08 | General Information | 59...
  • Page 62 Engine wiring harness for electric starter 1 EIM terminals 2 Fuse F1 3 Starter terminals 60 | General Information | MS150047/05E 2018-08...

  • Page 63: Technical Data

    3 Technical Data 3.1 ENGINE DATA 12V4000M93, heat exchanger installed, EPA stage 2 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 changes (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
  • Page 64 RAW WATER CIRCUIT (open circuit) Number of cylinders Raw water pump: Inlet pressure, min. -0.2 Raw water pump: Inlet pressure , max. Pressure loss in external raw water system, max. LUBE OIL SYSTEM Number of cylinders Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C...
  • Page 65 Number of cylinders Longitudinal inclination, continuous max., driving end up (option: max. operat- Degrees ing inclinations) Transverse inclination, constant max. (option: max. operating inclinations) Degrees 22.5 CAPACITIES Number of cylinders Engine coolant, engine-side (with cooler) Liters Engine oil on initial filling (standard oil system) (option: max. operating inclina- Liters tions) Oil change quantity, max.

  • Page 66: Engine Data 12V4000M93, Heat Exchanger Installed, Imo

    3.2 ENGINE DATA 12V4000M93, heat exchanger installed, IMO 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 changes (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
  • Page 67 RAW WATER CIRCUIT (open circuit) Number of cylinders Raw water pump: Inlet pressure, min. -0.2 Raw water pump: Inlet pressure , max. Pressure loss in external raw water system, max. LUBE OIL SYSTEM Number of cylinders Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C...
  • Page 68 Number of cylinders Longitudinal inclination, continuous max., driving end up (option: max. operat- Degrees ing inclinations) Transverse inclination, constant max. (option: max. operating inclinations) Degrees 22.5 CAPACITIES Number of cylinders Engine coolant, engine-side (with cooler) Liters Engine oil on initial filling (standard oil system) (option: max. operating inclina- Liters tions) Oil change quantity, max.

  • Page 69: Engine Data 12V4000M93L, Heat Exchanger Installed, Epa Stage

    3.3 ENGINE DATA 12V4000M93L, heat exchanger installed, EPA stage 2 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 changes (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
  • Page 70 RAW WATER CIRCUIT (open circuit) Number of cylinders Raw water pump: Inlet pressure, min. -0.2 Raw water pump: Inlet pressure , max. Pressure loss in external raw water system, max. LUBE OIL SYSTEM Number of cylinders Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C...
  • Page 71 Number of cylinders Longitudinal inclination, continuous max., driving end up (option: max. operat- Degrees ing inclinations) Transverse inclination, constant max. (option: max. operating inclinations) Degrees 22.5 CAPACITIES Number of cylinders Engine coolant, engine-side (with cooler) Liters Engine oil on initial filling (standard oil system) (option: max. operating inclina- Liters tions) Oil change quantity, max.

  • Page 72: Engine Data 12V4000M93L, Heat Exchanger Installed, Imo

    3.4 ENGINE DATA 12V4000M93L, heat exchanger installed, IMO 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 changes (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
  • Page 73 RAW WATER CIRCUIT (open circuit) Number of cylinders Raw water pump: Inlet pressure, min. -0.2 Raw water pump: Inlet pressure , max. Pressure loss in external raw water system, max. LUBE OIL SYSTEM Number of cylinders Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C...
  • Page 74 Number of cylinders Longitudinal inclination, continuous max., driving end up (option: max. operat- Degrees ing inclinations) Transverse inclination, constant max. (option: max. operating inclinations) Degrees 22.5 CAPACITIES Number of cylinders Engine coolant, engine-side (with cooler) Liters Engine oil on initial filling (standard oil system) (option: max. operating inclina- Liters tions) Oil change quantity, max.

  • Page 75: Engine Data 16V4000M93, Heat Exchanger Installed, Epa Stage

    3.5 ENGINE DATA 16V4000M93, heat exchanger installed, EPA stage 2 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 changes (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
  • Page 76 RAW WATER CIRCUIT (open circuit) Number of cylinders Raw water pump: Inlet pressure, min. -0.2 Raw water pump: Inlet pressure , max. Pressure loss in external raw water system, max. LUBE OIL SYSTEM Number of cylinders Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C...
  • Page 77 Number of cylinders Longitudinal inclination, continuous max., driving end up (option: max. operat- Degrees ing inclinations) Transverse inclination, constant max. (option: max. operating inclinations) Degrees 22.5 CAPACITIES Number of cylinders Engine coolant, engine-side (with cooler) Liters Engine oil on initial filling (standard oil system) (option: max. operating inclina- Liters tions) Oil change quantity, max.

  • Page 78: Engine Data 16V4000M93, Heat Exchanger Installed, Imo

    3.6 ENGINE DATA 16V4000M93, heat exchanger installed, IMO 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 changes (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
  • Page 79 RAW WATER CIRCUIT (open circuit) Number of cylinders Raw water pump: Inlet pressure, min. -0.2 Raw water pump: Inlet pressure , max. Pressure loss in external raw water system, max. LUBE OIL SYSTEM Number of cylinders Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C...
  • Page 80 Number of cylinders Longitudinal inclination, continuous max., driving end up (option: max. operat- Degrees ing inclinations) Transverse inclination, constant max. (option: max. operating inclinations) Degrees 22.5 CAPACITIES Number of cylinders Engine coolant, engine-side (with cooler) Liters Engine oil on initial filling (standard oil system) (option: max. operating inclina- Liters tions) Oil change quantity, max.

  • Page 81: Engine Data 16V4000M93L, Heat Exchanger Installed, Epa Stage

    3.7 ENGINE DATA 16V4000M93L, heat exchanger installed, EPA stage 2 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 changes (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
  • Page 82 RAW WATER CIRCUIT (open circuit) Number of cylinders Raw water pump: Inlet pressure, min. -0.2 Raw water pump: Inlet pressure , max. Pressure loss in external raw water system, max. LUBE OIL SYSTEM Number of cylinders Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C...
  • Page 83 Number of cylinders Longitudinal inclination, continuous max., driving end up (option: max. operat- Degrees ing inclinations) Transverse inclination, constant max. (option: max. operating inclinations) Degrees 22.5 CAPACITIES Number of cylinders Engine coolant, engine-side (with cooler) Liters Engine oil on initial filling (standard oil system) (option: max. operating inclina- Liters tions) Oil change quantity, max.

  • Page 84: Product Data 16V4000M93L

    3.8 Product data 16V4000M93L Explanation: DL Reference value: Continuous power BL Reference value: Fuel stop power I Index A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power setting). N Not yet defined value - Not applicable X Applicable...
  • Page 85 Lube oil system Designation Unit Value Lube oil operating pressure before engine, from Lube oil operating pressure before engine, to Lube oil operating pressure (low idle) (measuring point: before engine) Fuel system Designation Unit Value Fuel pressure at engine supply connection, min. (when engine is started) -0.1 Fuel pressure at engine supply connection , min.
  • Page 86 Capacities Designation Unit Value Engine coolant, engine side (with cooling system) Liters Total engine oil on initial filling (standard oil system) (design: max. operating Liters inclinations) Oil change quantity, max. (standard oil system) (design: max. operating inclina- Liters tions) Oil pan capacity at dipstick mark “min.” (standard oil system) (option: max. op- Liters erating inclinations) Oil pan capacity at dipstick mark “max.”...

  • Page 87: Engine - Main Dimensions

    3.9 Engine – Main dimensions Engine – Main dimensions Engine model Length (A) Width (B) Height (C) 12V4000M73/93 (L) approx. 2991 mm approx. 1463 mm approx. 2368 mm 16V4000M73/93 (L) approx. 3583 mm approx. 1463 mm approx. 2368 mm 20V4000M73/93 (L) approx.

  • Page 88: Firing Order

    3.10 Firing order Firing order Number of cylinders Firing order A1-B4-A4-A2-B3-A3-B2-B1 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 A1-B5-A8-B7-A5-B2-A7-B10-A2-B3-A10-B6-A3-B4-A6-B9-A4-B1-A9-B8 86 | Technical Data | MS150047/05E 2018-08...

  • Page 89: Operation

    4 Operation 4.1 LOP – Controls LOP – Controls Item Color Inscription Meaning / Function White Function keys to control the man-machine interface. Functions vary and are displayed on the LCD screen. White White White DIM ↓ Holding down the button decreases LCD background illumination. White LAMP TEST Pressing the button initiates lamp test.
  • Page 90 Item Color Inscription Meaning / Function White START Pressing the button initiates the automatic engine start sequence. LED (spot) lights up as long as the starting procedure is running. Green LOCAL CONTROL Pressing the button switches between local operation and remote control.

  • Page 91: Putting The Engine Into Operation After Extended Out-Of-Service Periods (>3 Months)

    ☑ Preservation and Represervation Specifications A001070/.. are available. Putting into operation after extended out-of-service periods (>3 months) Item Action Engine Depreserve (→ MTU Preservation and Represervation Specifications A001070/..). Lube oil system Check engine oil level (→ Page 200); Preheat engine oil as necessary.

  • Page 92: Putting The Engine Into Operation After Scheduled Out-Of-Service-Period

    4.3 Putting the engine into operation after scheduled out-of- service-period Preconditions ☑ Engine is stopped and starting disabled. Putting into operation Item Action Lube oil system Check engine oil level (→ Page 200); Preheat engine oil if required. Coolant circuit Check coolant level (→...

  • Page 93: Re-Starting The Engine Following An Automatic Safety Shutdown

    4.4 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 94: Starting The Engine

    4.5 Starting the engine Preconditions ☑ External start interlock is not activated. ☑ Emergency air-shutoff flaps (if applicable) open. DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Before cranking the engine with starter system, make sure that there are no persons in the engine's danger zone.

  • Page 95: Operational Checks

    4.6 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 96: Fuel Treatment System Control Cabinet - Controls

    4.7 Fuel treatment system control cabinet – Controls Item Color Lettering Meaning/function Green Signal lamp Indicates “Pump running” Signal lamp Indicates “Pump fault” Yellow Illuminated Indicates “Water drain” / Press to drain water manually pushbutton Illuminated Indicates “Water alarm” / Press to acknowledge pushbutton Yellow Signal lamp...

  • Page 97: Tasks After Extended Out-Of-Service Periods (>3 Weeks)

    4.8 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 97). Shut down fuel treatment system (→ Page 111). MS150047/05E 2018-08 | Operation | 95...

  • Page 98: 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 99: Fuel Treatment System - Initial Start-Up

    4.10 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 100 Initial start-up: HAT Replace fuel filter on engine (→ Page 180). 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 100). Result: Fuel is drawn from the tank (24).
  • Page 101 Simulating power failure (emergency): SAT Switch on fuel treatment system (→ Page 100). Start engine (→ Page 92). 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 102: Fuel Treatment System - Switching On

    4.11 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 103: Stopping The Engine

    4.12 Stopping the engine Stopping the engine via the automation system Refer to automation system operating instructions MS150047/05E 2018-08 | Operation | 101...

  • Page 104: Emergency Engine Stop At Blueline Automation System (Control Stand)

    4.13 Emergency engine stop at BlueLine automation system (control stand) NOTICE An emergency stop subjects the engine system to an extremely high load. Risk of overheating, damage to components! • Trigger an emergency stop only in emergency situations. Emergency engine stop at BlueLine automation system Item Measure Engine...

  • Page 105: Clutch - Engagement At Lop

    4.14 Clutch – Engagement at LOP Preconditions ☑ Illuminated pushbutton LOCAL OPERATION brightly lit (local control mode is active). ☑ Engine speed is within range for clutch engagement. ☑ No external engagement interlock active. DANGER In Local mode, the propulsion plant is controlled from the engine room. The person controlling the ves- sel has no visual contact with the surrounding area.

  • Page 106: Coupling - Disengaging From Lop

    4.15 Coupling – Disengaging from LOP Preconditions ☑ LOCAL OPERATION illuminated pushbutton lights up brightly (local operating mode is active). ☑ Engine speed in disengagement window. Disengaging coupling without reversing gearbox (CPP, WJ, VS) Item Measure Press COUPLING OUT illuminated pushbutton (→ Page 87). •...

  • Page 107: Waterjet - Flushing From Lop (Optional)

    4.16 Waterjet – Flushing from LOP (optional) Preconditions ☑ LOCAL OPERATION illuminated switch is lit brightly (local operating mode is active). ☑ Waterjet-BucketVessel at standstill and waterjet bucket is below the waterline. ☑ Engine speed is in engagement window. ☑ No external engagement interlock is active. NOTICE Waterjet flushing puts excessive strain on the bearings.

  • Page 108: Stopping The Engine From Lop

    4.17 Stopping the engine from LOP Preconditions ☑ Engine is running in local mode. NOTICE Stopping the engine when it is running at full load causes extreme stress to the engine. Risk of overheating, damage to components! • Before shutting down, disengage gear and run the engine at idle speed for at least 10 minutes until engine temperatures have dropped and constant values are displayed.

  • Page 109: Stopping The Engine At The Blueline Automation System (Control Stand)

    4.18 Stopping the engine at the BlueLine automation system (control stand) NOTICE Stopping the engine when it is running at full load causes extreme stress to the engine. Risk of overheating, damage to components! • Before shutting down, disengage gear and run the engine at idle speed for at least 10 minutes until engine temperatures have dropped and constant values are displayed.

  • Page 110: Emergency Stop From Lop

    4.19 Emergency stop from LOP 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 from LOP Item Action Open cap of illuminated EMERGENCY STOP pushbutton (→ Page 87). Press illuminated pushbutton EMERGENCY STOP.

  • Page 111: Emergency Engine Stop

    4.20 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 112: After Shutting Down The Engine

    Switch off. Air intake and exhaust sys- Out-of-service-period > 1 week: • Seal engine's air and exhaust sides. Engine Out-of-service-period > 1 month: • Carry out engine preservation (→ MTU Preservation and Represervation Specifications A001070/..) 110 | Operation | MS150047/05E 2018-08...

  • Page 113: Fuel Treatment System - Shutdown

    4.22 Fuel treatment system – Shutdown Shutting down fuel treatment system Press the illuminated pushbutton "Water drain" on the switch cabinet until water discharge from the outlet stops. Switch off fuel treatment system. Close ball valve at the inlet to the fuel treatment system. Close ball valve at the outlet of the fuel treatment system.

  • Page 114: Plant - Cleaning

    4.23 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 115: Maintenance

    No longer installed. W1047 Check and clean oil indicator filter. (→ Page 209) W1076 Exhaust turbocharger: Clean compressor (→ Page 190) wheel (MTU-ZR turbocharger). W1207 Check and adjust valve clearance. ATTEN- (→ Page 164) TION! First adjustment after 1,000 operating hours. W1244 Check function of rod electrode.
  • Page 116 Task Option Maintenance tasks W1463 Check general condition of engine mounting (→ Page 224) (visual inspection). W1713 Injector: Reset drift correction (CDC) param- (→ Page 233) eters. Table 2: Maintenance schedule task reference table [QL1] 114 | Maintenance | MS150047/05E 2018-08...

  • Page 117: Fuel Treatment System - Troubleshooting

    6 Troubleshooting 6.1 Fuel treatment system – Troubleshooting Illuminated pushbutton “Water alarm” is lit. Cause Corrective action When the maximum water level is 1. Press illuminated pushbutton “Water alarm” to acknowledge. 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.

  • Page 118: Troubleshooting

    6.2 Troubleshooting Engine does not rotate when starter is actuated. Cause Corrective action Battery discharged or faulty. u Charge or replace (see special documentation). u Check if cable connections for secure seating (see special Battery: Cable connections faulty. documentation). Starter: Incorrect design of power u Check starter power supply and correct the design if necessary supply (battery/cable) (battery/cable resistance).
  • Page 119 Check fans and air supply/ventilation ducts for engine room. Incorrect engine coolant 1. Check engine coolant level (→ Page 214). concentration. 2. Check engine coolant (MTU test kit) (→ Page 221). Intercooler clogged. u Replace (→ Instructions for Exchange of Sub-assemblies). Charge-air pressure too low.
  • Page 120 Black exhaust gas. Cause Corrective action u Reduce load. Overload. Air filter clogged. 1. Check signal ring position of service indicator (→ Page 198). 2. Replace air filter (→ Page 196). Injector defective. u Replace (→ Page 172). Blue exhaust gas Cause Corrective action Too much engine oil in the engine.

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

    6.3 Engine governor ADEC (ECU 7) fault messages for Series 4000 engines, marine application The fault code numbers are generated by the engine governor and transmitted to the display below (if fitted). The fault code (1) comprises 3 digits. Fault messages may also be caused by faulty sensors/actuators. Contact Service to have sensors/actuators tested and replaced as necessary if troubleshooting as described in the table (→...

  • Page 122: Adec Engine Governor - Fault Codes

    6.4 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

    7 Task Description 7.1 SOLAS 7.1.1 SOLAS shielding as per MTN 5233 – Installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Shield A5 735233000101 Shield A6 735233000102 Shield A7 735233000103 Shield A8 735233000104...

  • Page 149: Installation Locations For Solas Shielding

    7.1.2 Installation locations for SOLAS shielding General information Fit SOLAS shielding as per MTN 5233 by way of preference (→ Page 146). Shield unions with adhesive tape if SOLAS shielding as per MTN 5233 is not possible (→ Page 154). When affixing adhesive connections ensure that escaping fluid can flow out without pressure (→...
  • Page 150 Item Type of shielding Installation location Shield A8 Fuel line to HP pump Shield E5 Fuel line to HP pump Lube oil system, oil lines with oil pressure >1.8 bar Item Type of shielding Installation location 2 x shield A5 Actuating cylinder exhaust flap ETC B1 148 | SOLAS | MS150047/05E 2018-08...
  • Page 151 Item Type of shielding Installation location 2 x shield A5 Actuating cylinder air flap ETC B1 3 x shield A5 T adapter for flap control ETC B1 Item Type of shielding Installation location 4 x shield A5 Distributor 3 x shield A5 Oil return MS150047/05E 2018-08 | SOLAS | 149...
  • Page 152 Item Type of shielding Installation location Shield A7 Oil return * This shield must be installed on the assembly line. This position can no longer be accessed as soon as the intake housing is installed. Item Type of shielding Installation location Shield A7 Oil line to ETC Shield A5...
  • Page 153 Item Type of shielding Installation location 2 x shield A5 Air recirculation valve Item Type of shielding Installation location Shield A6 Oil supply line to HP pump: To HP pump MS150047/05E 2018-08 | SOLAS | 151...
  • Page 154 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 A7 ETC oil supply...
  • Page 155 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 156: Adhesive Tape For Solas Shielding - Application

    7.1.3 Adhesive tape for SOLAS shielding – Application Preconditions ☑ Engine shut down and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Adhesive tape X00026424 Note: Use the cable clamp to make a drainage channel. This allows fluid to flow out without pressure in case of leakage.
  • Page 157 Taping plug-in unions, installation locations (→ Page 147) Place adhesive tape flush in position. Wind adhesive tape in three layers until area from screw center to line is covered at least 30 mm. MS150047/05E 2018-08 | SOLAS | 155...

  • Page 158: Engine

    7.2 Engine 7.2.1 Engine – Barring manually Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Barring 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 159: Barring Engine With Starting System

    7.2.2 Barring engine with starting system Barring using the automation system Refer to automation system operating instructions MS150047/05E 2018-08 | Engine | 157...

  • Page 160: Cylinder Liner

    7.3 Cylinder Liner 7.3.1 Cylinder liner – Endoscopic examination Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Rigid endoscope Y20097353 Preparatory steps Remove cylinder head cover (→ Page 168). Remove injector (→...
  • Page 161 Final steps Install injector (→ Page 173). Install cylinder head cover (→ Page 168). MS150047/05E 2018-08 | Cylinder Liner | 159...

  • Page 162: Cylinder Liner - Instructions And Comments On Endoscopic And Visual Examination

    7.3.2 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 163 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 164: Crankcase Breather

    7.4 Crankcase Breather 7.4.1 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 165: Valve Drive

    7.5 Valve Drive 7.5.1 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 168). Fill oil chambers of valve bridges with oil.

  • Page 166: Valve Clearance - Check And Adjustment

    7.5.2 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 Valve setting gauge Y4349603...
  • Page 167 Note: Danger of confusion: There might be an addi- tional OT/A1 mark (1) on the outer perimeter of the flywheel. The additional OT/A1 mark (1) (if applicable) on the outer perimeter of the flywheel must not be used for reference. Diagram for 8V engines –...
  • Page 168 Diagram for 16V engines – Two crankshaft positions Diagram for 20V engines – Two crankshaft positions Checking valve clearance at two crankshaft positions Check TDC position of piston in cylinder A1: • If the rocker arms are unloaded on cylinder A1, the piston is in firing TDC. •...
  • Page 169 Adjusting valve clearance Release locknut (1). Insert valve setting gauge (3) between valve bridge and rocker arm. Note: Replace or rectify adjusting screws and/or locknuts which do not move freely. Using angular screw driver, set adjusting screw (2) so that the specified valve clear- ance is provided.

  • Page 170: Cylinder Head Cover - Removal And Installation

    7.5.3 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 171: Injection Pump / Hp Pump

    7.6 Injection Pump / HP Pump 7.6.1 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 172 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 173: Hp Fuel Pump - Relief Bore Check

    7.6.2 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 174: Injection Valve / Injector

    7.7 Injection Valve / Injector 7.7.1 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 173). 172 | Injection Valve / Injector | MS150047/05E 2018-08...

  • Page 175: Injector - Removal And Installation (Jacketed Fuel System)

    7.7.2 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 176 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 177 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 178 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 179 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 180 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 181 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 182: Fuel Filter

    7.8 Fuel Filter 7.8.1 Fuel filter – Replacement Preconditions ☑ Engine is shut down and starting disabled, or engine is running in lower partial-load operational range. ☑ Positive pressure at inlet to engine (for work on stationary engine). Special tools, Material, Spare parts Designation / Use Part No.
  • Page 183 Replacing fuel filter Note: • The left fuel filter (5) is cut out when the lever is in position (3) • The right fuel filter (4) is cut out when the lever is in position (7) Cut out fuel filter to be replaced. Pull locking pin (1) and turn lever (6) to the left or right stop.

  • Page 184: Fuel Prefilter - Differential Pressure Gage Check And Adjustment

    7.8.2 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 185: Fuel Prefilter - Draining

    7.8.3 Fuel prefilter – Draining Preconditions ☑ Engine is stopped and starting disabled (only in the case of single fuel prefilter). Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel Gasket (→ Spare Parts Catalog) DANGER Components are moving or rotating.
  • Page 186 Fuel prefilter – Draining Note: Only for dual fuel prefilter: Cut out filter to be drained. 1 Left filter cut in 2 Right filter cut in Open threaded vent plug (5) of filter to be drained. Unlock drain valve (6) by pressing toggle and open it.

  • Page 187: Fuel Prefilter - Flushing

    7.8.4 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 188 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 189: Fuel Prefilter With Water Separator - Filter Element Replacement

    7.8.5 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 190 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 191 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 192: Exhaust Turbocharger

    7.9 Exhaust Turbocharger 7.9.1 Compressor wheel – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10–60 Nm F30452769 Ratchet bit F30027340 Cleaner 40377 Engine oil Sealing rings 007603030101 Sealing rings 007603042101...
  • Page 193 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 vent line (2) from compres- sor housing (3).
  • Page 194 Loosen and remove screws (1). Remove compressor housing (2). Compressor wheel – Cleaning Note: Never use a wire brush, scraper or similar ob- ject for cleaning! Clean compressor housing with a smooth paint brush or brush. Clean compressor wheel (2) and bearing housing (1).
  • Page 195 Screw in screws (1) and tighten to specified tightening torque using a torque wrench . Name Size Type Lubricant Value/Standard Screw M10x18 Tightening torque (Engine oil) 44 Nm ± 6.5 Nm Install coolant vent line and coolant lines on compressor housing. Install intake housing (3) with actuating cylin- der (2).

  • Page 196: Charge-Air Cooling

    7.10 Charge-Air Cooling 7.10.1 Intercooler – Checking condensate drain for coolant leakage and obstruction DANGER Moving or rotating parts. Risk of crushing, danger of limbs being caught up or drawn in! • Operate engine in lower load range only. Keep away from the danger zone of the engine. WARNING High level of engine noise when the engine is running.
  • Page 197 Emergency measures prior to engine start for continued operation with leak- ing intercooler Remove injectors (→ Page 173). Bar engine manually (→ Page 156). Bar engine with starting system to blow out combustion chambers (→ Page 156). Install injectors (→ Page 173). MS150047/05E 2018-08 | Charge-Air Cooling | 195...

  • Page 198: Air Filter

    7.11 Air Filter 7.11.1 Air filter – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Air filter (→ Spare Parts Catalog) Replacing air filter Remove old air filter and install new air filter (→ Page 197). Reset signal ring of contamination indicator (→...

  • Page 199: Air Filter - Removal And Installation

    7.11.2 Air filter – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. DANGER Falling from great heights. Risk of serious injury – danger to life! • When working high on the equipment, always use suitable ladders or work platforms. •...

  • Page 200: Air Intake

    7.12 Air Intake 7.12.1 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 201: Starting Equipment

    7.13 Starting Equipment 7.13.1 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 232). MS150047/05E 2018-08 | Starting Equipment | 199...

  • Page 202: Lube Oil System, Lube Oil Circuit

    7.14 Lube Oil System, Lube Oil Circuit 7.14.1 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 203: Engine Oil - Change

    7.14.2 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, 60–320 Nm...
  • Page 204 Tighten drain plugs (1) and (2) to specified torque using a torque wrench: Name Size Type Lubricant Value/Standard Screw M26x1.5 Tightening torque 100 Nm+10 Nm Filling with new oil Open cover (1) on filler neck. Pour oil in at filler neck up to “max.” mark at oil dipstick.

  • Page 205: Engine Oil - Sample Extraction And Analysis

    7.14.3 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 206: Oil Filtration / Cooling

    7.15 Oil Filtration / Cooling 7.15.1 Automatic oil filter – Overview Automatic oil filter DN65 1 Filter housing 9 O-ring 17 Screw 2 Oil filter element 10 Cover 18 Gearbox flange 3 O-ring 11 Screw 19 O-ring 4 Cover 12 Sealing ring 20 Sealing ring 5 Nut 13 Screw-fitting union...
  • Page 207 1 Sealing ring 8 Plug screw 15 Sealing ring 2 Plug screw 9 Sealing ring 16 Sealing ring 3 Sealing ring 10 Plug screw 17 Bypass valve 4 Plug screw 11 Sealing ring 18 O-ring 5 Sealing ring 12 Threaded bushing 19 Cover 6 Plug screw 13 Plug screw...
  • Page 208 1 Screw 8 O-ring 15 Turbine housing 2 Securing bushing 9 Clamping ring 16 Impeller 3 Compression spring 10 Spring washer 17 Washer 4 Scavenge bushing 11 Screw 18 Stud 5 Sight glass 12 Screw 19 Nut 6 Flat gasket 13 Worm gear 7 O-ring 14 Grooved pin...

  • Page 209: Oil Indicator Filter - Cleaning

    7.15.2 Oil indicator filter – Cleaning 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 312) 30390 Engine oil O-ring (→ Spare Parts Catalog) O-ring (→...
  • Page 210 Cleaning strainer Shake coarse contamination out of strainer. Clean all metallic parts with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 312). Use a soft brush to remove stubborn deposits from strainer if required. Ensure that the mesh is not dam- aged.

  • Page 211: Oil Indicator Filter - Cleaning And Check

    7.15.3 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 212 Removing strainer Clean oil indicator filter before disassembling Remove screws (1). Take off cover (2) with O-ring (3). Extract spring (4) and strainer (6) from filter housing. Checking strainer Item Findings Measure Strainer Metallic residues • Clean • Monitor engine operation •...

  • Page 213: Centrifugal Oil Filter - Cleaning And Filter-Sleeve Replacement

    7.15.4 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 Ratchet bit F30027340 Cold cleaner (Hakutex 60) X00056750...
  • Page 214 Centrifugal oil filter – Cleaning and filter-sleeve replacement Remove clamp (14). Loosen cover screw (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). Take off rotor cover (4).

  • Page 215: Coolant Circuit, General, High-Temperature Circuit

    7.16 Coolant Circuit, General, High-Temperature Circuit 7.16.1 Venting points Coolant line on ETC 1 Venting point Vent line – Cross-distribution expansion tank 1 Venting point MS150047/05E 2018-08 | Coolant Circuit, General, High-Temperature Circuit | 213...

  • Page 216: Engine Coolant - Level Check

    7.16.2 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 217 Checking engine coolant level at sight glass Check coolant level (coolant level must be between “min.” and “max.” mark). Top up coolant if necessary (→ Page 218). MS150047/05E 2018-08 | Coolant Circuit, General, High-Temperature Circuit | 215...

  • Page 218: Engine Coolant Change

    7.16.3 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant change Drain engine coolant (→ Page 217). Fill with engine coolant (→ Page 218). 216 | Coolant Circuit, General, High-Temperature Circuit | MS150047/05E 2018-08...

  • Page 219: Engine Coolant Draining

    7.16.4 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 220: Engine Coolant - Filling

    7.16.5 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 221 Filling coolant through filler neck Open vent points on distributor, oil heat ex- changer and exhaust turbochargers (ar- rowed). Fill in coolant in expansion tank via filler neck until coolant level at top edge of filler neck remains constant. When coolant emerges from the vent points, close vent points one by one, proceeding from the lowest point upwards.

  • Page 222: Engine Coolant Pump - Relief Bore Check

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

  • Page 223: 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 224: Raw Water Pump With Connections

    7.17 Raw Water Pump with Connections 7.17.1 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 225: Battery-Charging Generator

    7.18 Battery-Charging Generator 7.18.1 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 156). Guide endoscope optics between guard plate (1) and battery-charging generator car- rier (2) (arrow).

  • Page 226: Engine Mounting / Support

    7.19 Engine Mounting / Support 7.19.1 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 227: Auxiliary Pto

    7.20 Auxiliary PTO 7.20.1 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 228: Fuel Supply System

    7.21 Fuel Supply System 7.21.1 Water drain valve – Check Water drain valve – Check Open water drain valve. Check water outlet for obstructions. Close water drain valve. 226 | Fuel Supply System | MS150047/05E 2018-08...

  • Page 229: Differential Pressure Gage - Alarm Function Check

    7.21.2 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 230: Water Level Probe (3-In-1 Rod Electrode) - Check

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

  • Page 231: Pump Capacity - Check

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

  • Page 232: Coalescer Filter Element - Replacement

    7.21.5 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 233 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 234: Wiring (General) For Engine/Gearbox/Unit

    7.22 Wiring (General) for Engine/Gearbox/Unit 7.22.1 Engine cabling – Check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Solvent (isopropyl alcohol) X00058037 Engine cabling – Check Check securing screws of cable clamps on engine and tighten loose screw connections. Ensure that cables are securely seated in clamps and cannot move freely.

  • Page 235: Accessories For (Electronic) Engine Governor / Control System

    7.23 Accessories for (Electronic) Engine Governor / Control System 7.23.1 CDC parameters – Reset with DiaSys® Preconditions ☑ Engine is stopped and starting disabled. Resetting CDC parameters (DiaSys® is available) Note: The CDC parameters must be reset, otherwise the emission certification of the engine is no longer applica- ble.

  • Page 236: Emu And Connectors - Cleaning

    7.23.2 EMU and connectors – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Solvent (isopropyl alcohol) X00058037 NOTICE Insertion of unsuitable test probe, e.g. test prod. The contacts in the plug connection can be bent! •...

  • Page 237: Limit Switch For Start Interlock - Check

    7.23.3 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 – Check Check whether switches (3) and guard plate (2) with engine support (1) are installed...

  • Page 238: Engine Governor And Connector - Cleaning

    7.23.4 Engine governor and connector – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Solvent (isopropyl alcohol) X00058037 NOTICE Insertion of unsuitable test probe, e.g. test prod. The contacts in the plug connection can be bent! •...

  • Page 239: Engine Control Unit Ecu 7 - Checking Plug Connections

    7.23.5 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 240: Engine Monitoring Unit Emu 8 - Plug Connections Check

    7.23.6 Engine Monitoring Unit EMU 8 – Plug connections check Preconditions ☑ Engine is stopped and starting disabled. Checking EMU plug connections Check both connectors on EMU (2) for firm seating. Ensure that the clips (1) are engag- Check screws (3) of cable clamps on EMU (2) for firm seating.

  • Page 241: Interface Module Eim Plug Connections - Check

    7.23.7 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 242: Engine Governor Ecu 7 - Removal And Installation

    7.23.8 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 243: Engine Monitoring Unit Emu 8 - Removal And Installation

    7.23.9 Engine Monitoring Unit EMU 8 – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. NOTICE Wrong engine governor installed. Engine damage! • When reassembling an engine, make sure that the governor with the data record for the given engine is installed.

  • Page 244: Engine Interface Module Eim 2 - Removal And Installation

    7.23.10 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 245: Engine Interface Module Eim 2 - Diagnostic Features

    7.23.11 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 246 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 247 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 248 7.24 Emergency Instrumentation (Local Operating Panel) 7.24.1 LOP and connectors – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Solvent (isopropyl alcohol) X00058037 Cleaning LOP Wipe LCD screen with dry cloth, without applying excessive pressure. Remove dirt from pushbuttons using solvent.
  • Page 249 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 250 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 251 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 252 9 Appendix B 9.1 Index Crankcase breather  – Oil mist separator   Actuators  – Replacement  162 – Overview  44 Cylinder  ADEC (ECU 7)  – Designation  43 – Fault messages  119 Cylinder head cover  Adhesive tape for SOLAS shielding  – Installation  168 –...
  • Page 253 Engine  Engine oil  – Barring   – Centrifugal oil filter   – With starting system  157 – Cleaning  211 – Barring manually  156 – Change  201 – Emergency stop  109 – Filter sleeve   – Start  92 – Replacement  211 –...
  • Page 254 – Installation   Maintenance schedule  – As per MTN 5233  146 – Maintenance schedule task reference table [QL1]   Spare parts service 249 Starter  MTU contact persons 249 – Condition check  199 Oil indicator filter  Tasks after extended out-of-service periods (>3 weeks) 95 – Check  209...
  • Page 255 9.2 Spare Parts Air filter Part No.: Qty.: Used in: 7.11.1 Air filter – Replacement (→ Page 196) Coalescer filter element Part No.: Qty.: Used in: 7.21.5 Coalescer filter element ‒ Replacement (→ Page 230) Damping ring Part No.: Qty.: Used in: 7.7.2 Injector –...
  • Page 256 O-ring Part No.: Qty.: Used in: 7.4.1 Crankcase breather – Oil mist separator replacement (→ Page 162) Qty.: Used in: 7.7.2 Injector – Removal and installation (jacketed fuel system) (→ Page 173) Qty.: Used in: 7.7.2 Injector – Removal and installation (jacketed fuel system) (→ Page 173) Qty.: Used in: 7.7.2 Injector –...
  • Page 257 Square-section ring Part No.: Qty.: Used in: 7.15.3 Oil indicator filter – Cleaning and check (→ Page 209) Strainer Part No.: Qty.: Used in: 7.15.2 Oil indicator filter – Cleaning (→ Page 207) Qty.: Used in: 7.15.3 Oil indicator filter – Cleaning and check (→ Page 209) MS150047/05E 2018-08 | Spare Parts | 255...
  • Page 258 9.3 Consumables Adhesive tape Part No.: X00026424 Qty.: Used in: 7.1.3 Adhesive tape for SOLAS shielding – Application (→ Page 154) Assembly compound (Kluthe Hakuform 30-15) Part No.: X00067260 Qty.: Used in: 7.7.2 Injector – Removal and installation (jacketed fuel system) (→ Page 173) Assembly compound (Molykote P 37) Part No.: 50564...
  • Page 259 Cold cleaner (Hakutex 60) Part No.: X00056750 Qty.: Used in: 7.15.4 Centrifugal oil filter – Cleaning and filter-sleeve replacement (→ Page 211) Coolant Part No.: Qty.: Used in: 7.16.3 Engine coolant – Change (→ Page 216) Diesel fuel Part No.: Qty.: Used in: 7.8.3 Fuel prefilter –...
  • Page 260 Fuel Part No.: Qty.: Used in: 7.8.1 Fuel filter – Replacement (→ Page 180) Qty.: Used in: 7.21.5 Coalescer filter element ‒ Replacement (→ Page 230) Multi-purpose grease Part No.: 40320 Qty.: Used in: 7.7.2 Injector – Removal and installation (jacketed fuel system) (→ Page 173) Shield A5 Part No.: 735233000101...
  • Page 261 Solvent (isopropyl alcohol) Part No.: X00058037 Qty.: Used in: 7.22.1 Engine cabling – Check (→ Page 232) Qty.: Used in: 7.23.2 EMU and connectors – Cleaning (→ Page 234) Qty.: Used in: 7.23.4 Engine governor and connector – Cleaning (→ Page 236) Solvent (isopropyl alcohol) Part No.: X00058037...
  • Page 262 9.4 Special Tools Angular screw driver Part No.: F30002815 Qty.: Used in: 7.5.2 Valve clearance – Check and adjustment (→ Page 164) Barring tool Part No.: F6555766 Qty.: Used in: 7.2.1 Engine – Barring manually (→ Page 156) Endoscope Part No.: Y20097353 Qty.: Used in:...
  • Page 263 Fuel suction device Part No.: F30378207 Qty.: Used in: 7.6.1 HP fuel pump – Filling with engine oil (→ Page 169) High-pressure cleaner Part No.: Qty.: Used in: 4.23 Plant – Cleaning (→ Page 112) Installation/removal jig Part No.: F6789889 Qty.: Used in: 7.7.2 Injector –...
  • Page 264 MTU test kit Part No.: 5605892099/00 Qty.: Used in: 7.14.3 Engine oil – Sample extraction and analysis (→ Page 203) MTU test kit Part No.: F6798833 Qty.: Used in: 7.16.7 Engine coolant – Sample extraction and analysis (→ Page 221) Oil filter wrench Part No.:...
  • Page 265 Ratchet adapter Part No.: F30027341 Qty.: Used in: 7.14.2 Engine oil ‒ Change (→ Page 201) Ratchet bit Part No.: F30027340 Qty.: Used in: 7.7.2 Injector – Removal and installation (jacketed fuel system) (→ Page 173) Qty.: Used in: 7.9.1 Compressor wheel – Cleaning (→ Page 190) Qty.: Used in: 7.15.4 Centrifugal oil filter –...
  • Page 266 Rigid endoscope Part No.: Y20097353 Qty.: Used in: 7.3.1 Cylinder liner – Endoscopic examination (→ Page 158) Socket wrench, 24 mm Part No.: F30039526 Qty.: Used in: 7.5.2 Valve clearance – Check and adjustment (→ Page 164) Torque wrench, 10–60 Nm Part No.: F30452769 Qty.:...
  • Page 267 Torque wrench, 60–320 Nm Part No.: F30452768 Qty.: Used in: 7.5.2 Valve clearance – Check and adjustment (→ Page 164) Qty.: Used in: 7.7.2 Injector – Removal and installation (jacketed fuel system) (→ Page 173) Qty.: Used in: 7.14.2 Engine oil ‒ Change (→ Page 201) Torque wrench, 8–40 Nm Part No.: F30043446...

This manual is also suitable for:

16v4000m93 series16v4000m93l12v4000m9312v4000m93l16v4000m93

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