Page 1 Technical Publication Diesel Engine 8 V 4000 M60 R 12 V 4000 M60 R 16 V 4000 M60 R 16 V 4000 M61 R Operating Instructions M015685/01E...
Page 2 Printed in Germany © 2006 Copyright MTU Friedrichshafen GmbH Diese Veröffentlichung einschließlich aller ihrer Teile ist urheberrechtlich geschützt. Jede Verwertung oder Nutzung bedarf der vorherigen schriftlichen Zustimmung der MTU Friedrichshafen GmbH. Das gilt insbesondere für Vervielfältigung, Verbreitung, Bearbeitung, Übersetzung, Mikroverfilmungen und die Einspeicherung und / oder Verarbeitung in elektronischen Systemen, einschließlich Datenbanken und Online-Diensten. Das Handbuch ist zur Vermeidung von Störungen oder Schäden beim Betrieb zu beachten und daher vom Betreiber dem jeweiligen Wartungs- und Bedienungspersonal zur Verfügung zu stellen.
Page 3 Safety Safety, accident prevention and environmental protection instructions Product Summary Engine layout, technical data Operation Task descriptions Mantenance and Servicing Maintenance schedule Troubleshooting Malfunctions, causes, measures Task Description Inspection and maintenance tasks Annex Abbreviations Index...
Page 5 Wichtig – Important – Importante Bitte die Karte „Inbetriebnahmemeldung“ abtrennen und ausgefüllt an MTU Friedrichshafen GmbH zurücksenden. Die Informationen der Inbetriebnahmemeldung sind Grundlage für den vertraglich vereinbarten Logistik- Support (Gewährleistung, Ersatzteile etc.). Please complete and return the “Commissioning Note” card below to MTU Friedrichshafen GmbH. The Commissioning Note information serves as a basis for the contractually agreed logistic support (warranty, spare parts, etc.).
Page 6 Bitte in Blockschrift ausfüllen! Please use block capitals! Prière de remplir en lettres capitales! ¡A rellenar en letras de imprenta! Scrivere in stampatello! Favor preencher com letras de forma! Motornr.: Auftragsnr.: Inbetriebnahme- Engine No.: MTU works order No.: meldung du moteur: N°...
Page 7: Table Of Contents
Table of Contents Safety ............... . General conditions .
Page 8 Table of Contents Starting the engine at the BlueLine automation system (control stand) ... . Operational checks ............Clutch –...
Page 9 Table of Contents Fuel System ............6.7.1 Fuel system –...
Page 10 Table of Contents 6.21 Auxiliary PTO ............6.21.1 Bilge pump –...
Page 11: Safety
Safety Safety General conditions General In addition to the instructions in this publication, the applicable country-speciﬁc legislation and other compulsory regulations regarding accident prevention must be observed. This engine is a state-of-the art product and conforms with all applicable speciﬁcations and regulations. Nevertheless, persons and property may be at risk in the event of: •...
Page 12: Personnel And Organizational Requirements
Safety Personnel and organizational requirements Personnel Work on the engine must only be carried out by properly qualiﬁed and instructed personnel. The speciﬁed legal minimum age must be observed. Responsibilities of the operating, maintenance and repair personnel must be speciﬁed. Organization This publication must be issued to all personnel involved in operation, maintenance, repair or transportation.
Page 13: Transport
Safety Transport Engine transport Lift the engine only with the lifting eyes provided. The lifting eyes are designed for engine transport only, not for the transport of propulsion units (engine and gearbox). Use only the transport and lifting equipment approved by MTU. The engine must only be transported in installation position, max.
Page 14: Safety Precautions When Working On The Engine
Safety Safety precautions when working on the engine Safety precautions when putting the equipment into operation Prior to initial operation, the product must have been installed correctly and approved according to MTU speciﬁcations. Before putting the device or the system into operation, always ensure •...
Page 15 Safety Ensure that all fuel injection lines and pressurized oil lines have sufﬁcient distance to other components to avoid contact with them. Do not place fuel or oil lines near hot components, except when necessary for design reasons during installation. Elastomers (e.g.
Page 16 Safety Working on electrical/electronic assemblies Always obtain the permission of the person in charge before commencing maintenance and repair work or switching off any part of the electronic system required to do so. De-energize the appropriate areas prior to working on assemblies. Any measures requiring a power supply are expressly deﬁned as such at the appropriate place in the manual.
Page 17: Auxiliary Materials, Fire Prevention And Environmental Protection
Safety Auxiliary materials, ﬁre prevention and environmental protection Fire prevention Rectify any fuel or oil leaks immediately; even splashes of oil or fuel on hot components can cause ﬁres - therefore always keep the engine in a clean condition. Do not leave cloths soaked with ﬂuids and lubricants lying around on the engine.
Page 18 Safety Liquid nitrogen • Store liquid nitrogen only in small quantities and always in regulation containers without ﬁxed covers. • Do not bring liquid nitrogen in contact with the body (eyes, hands), as this causes frostbite and numbing. • Wear protective clothing, gloves, closed shoes and protective goggles! •...
Page 19: Standards For Warning Notices In The Publication
Safety Standards for warning notices in the publication In the event of immediate danger. Consequences: Death or serious injury. DANGER • Preventive measures In the event of possibly dangerous situations. Consequences: Death or serious injury. WARNING • Preventive measures In the event of dangerous situations. Consequences: Slight injury or material damage.
Page 21: Product Summary
Product Summary Product Summary Engine Layout 2.1.1 Product description Description of the engine Engine The engine is a liquid-cooled four-stroke diesel engine, rotating counter-clockwise (seen from driving end), with direct injection, sequential turbocharging and charge air cooling. The engine is monitored by an engine control and monitoring system (MDEC). The monitoring in the engine room is carried out by the engine control and monitoring unit (LOP).
Page 22 Product Summary • Data processing logistics for analog and binary signals; • Interface for data transfer to CAN ﬁeld bus for remote control and ship-side monitoring; • RS 232 Interface for connection of MTU-dialog unit. Electronic engine monitoring unit (EMU), optional Functions: •...
Page 23 Product Summary 1 Return line 3 Non-return valve 5 Fuel line on H.P. fuel pump 2 Fuel line on fuel delivery pump 4 Male connecting nipple 6 Fuel line on vent line Lube oil system, oil lines with oil pressure >1.8 bar All lines ﬁtted with SOLAS-compliant covers for pipe connections, according to MTU standard MTN5233, are shown.
Page 24 Product Summary 1 Seal, oil line to ETC 8 Oil line on control block 13 Connection, oil line to actuating 2 Oil line, ETC 9 Oil lines on T-piece cylinder 3 Connection, oil line to distributor 10 Oil line, valve housing 14 Connection, plug-in pipe to 4 Oil line, ETC 11 Oil line, actuating cylinder to...
Page 25 Product Summary Plug-in pipe connection The sleeve (4) covers the joint to prevent lateral spray. Only leak-off along the line is possible, the pressure decreases signiﬁcantly if an O-ring (3) defect occurs. The connection is conﬁrmed as compliant with SOLAS by DNV and GL. Plug and sensors Screw-in plugs (2) are sealed toward the outside either with a copper sealing ring (1), according to DIN, or an O-ring (ISO).
Page 26 Product Summary H.P. connections 1 Jacketed barrel 7 Leakage-overﬂow bore 13 Thrust ring 2 H.P. fuel line 8 Thrust ring 14 Shims 3 O-ring 9 Union nut 15 Union nut 4 Union nut 10 Union nut 16 Thrust ring 5 Groove for O-ring 11 Connecting piece 17 O-ring 6 Thrust ring...
Page 27 Product Summary Protective cover of fuel ﬁlters and lube oil ﬁlters Protective cover with a plastic ring The plastic ring (1) prevents lateral spray. The liquid is routed into the collector bowl and the pressure is greatly reduced. Protective cover with lip The lip (1) prevents lateral spray.
Page 28: Engine Layout
Product Summary 2.1.2 Engine layout Illustration is applicable to 8V 4000M engines 010 Crankcase and attachments 120 Air intake / air supply 250 Drive systems, driving end and 020 Gear train 140 Exhaust system free end (coupling)* 030 Running gear 170 Starting equipment 360 Auxiliary systems / accessory 040 Cylinder head...
Page 29 Product Summary Engine model designation Key to the engine model designations 8/12/16V 4000 Mxyz 8/12/16 Number of cylinders Cylinder conﬁguration: Vee engine 4000 Series Application Application segment (4,5, 6,7,9) Design index (0, 1, 2,...) Special features M015685/01E 05-11 © MTU...
Page 30: Engine Layout
Product Summary 2.1.3 Engine layout 010 Crankcase and attachments 110 Intercooler 230 Mounting / support 020 Gear train 120 Air intake / air supply 250 Drive systems, drive end and 030 Crank drive 140 Exhaust system free end (coupling) 040 Cylinder head 170 Starting equipment 500 Monitoring and control system, 050 Valve gear...
Page 31: Engine Side And Cylinder Designations
Product Summary Engine Side and Cylinder Designations 2.2.1 Engine side and cylinder designations Engine sides are always designated as viewed from the driving end (KS). The cylinders of the left engine side are designated "A" and those of the right side "B" (as per DIN ISO 1204). The cylinders of each bank are numbered consecutively, starting with No.
Page 32: Main Engine Dimensions
Product Summary Main Engine Dimensions 2.3.1 Main engine dimensions Main engine dimensions Engine model Length (A) Width (B) Height (C) 8V 4000 M60/M60R, approx. 2339 mm approx. 1400 mm approx. 1987 mm engine-mounted heat exchanger 8V 4000 M60/M60R, approx. 1985 mm approx.
Page 33 Product Summary Engine model Length (A) Width (B) Height (C) 16V 4000 M60/M60R, approx. 3692 mm approx. 1520 mm approx. 1836 mm engine-mounted heat exchanger approx. 3232 mm approx. 1520 mm approx. 1836 mm 16V 4000 M60/M60R, separate heat exchanger 16V 4000 M61/M61R, approx.
Page 34: Firing Order
Product Summary Firing Order 2.4.1 Firing order Firing order A1-B4-A4-A2-B3-A3-B2-B1 12 V A1-B2-A5-B4-A3-B1-A6-B5-A2-B3-A4-B6 16 V A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B7 20 V A1-B5-A8-B7-A5-B2-A7-B10-A2-B3-A10-B6-A3-B4-A6-B9-A4-B1-A9-B8 M015685/01E 05-11 © MTU...
Page 35: Technical Data
Product Summary Technical Data 2.5.1 8V 4000 M60R engine data: IMO, engine-mounted heat exchanger Explanation: DL Ref. value: Continuous power (CP) BL Ref. value: Fuel stop power (FSP) 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 36 Product Summary MODEL-RELATED DATA (basic design) Number of cylinders Cylinder conﬁguration: V angle degrees Bore Stroke Cylinder displacement liter 4.06 Total displacement liter 32.5 Number of inlet valves, per cylinder Number of exhaust valves, per cylinder RAW WATER CIRCUIT (open circuit) Number of cylinders Raw water pump: inlet pressure, min.
Page 37 Product Summary STARTING (pneumatic starter) Number of cylinders Starting air pressure before starter motor, min. Starting air pressure before starter motor, max. INCLINATIONS - STANDARD OIL SYSTEM (ref.: waterline) Number of cylinders Longitudinal inclination, continuous max. driving end down (Option: max. operating degrees inclinations) Longitudinal inclination, temporary max.
Page 38: 4000 M60R Engine Data: Imo, Separate Heat Exchanger
Product Summary 2.5.2 8V 4000 M60R engine data: IMO, separate heat exchanger Explanation: DL Ref. value: Continuous power (CP) BL Ref. value: Fuel stop power (FSP) 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 39 Product Summary LUBE OIL SYSTEM Number of cylinders Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C Lube oil operating pressure before engine, from Lube oil operating pressure before engine, to Lube oil operating pressure, low idle (meas. point: before engine) FUEL SYSTEM Number of cylinders Fuel pressure at supply connection to engine, min.
Page 40 Product Summary CAPACITIES Number of cylinders Engine oil capacity, initial ﬁlling (standard oil system) (Option: max. operating liter inclinations) Oil change quantity, max. (standard oil system) (Option: max. operating liter inclinations) Oil pan capacity, dipstick mark min. (standard oil system) (Option: max. operating liter inclinations) Oil pan capacity, dipstick mark max.
Page 41: 4000M 60R Engine Data: Engine-Mounted Heat Exchanger, Imo
Product Summary 2.5.3 8V 4000M 60R engine data: Engine-mounted heat exchanger, IMO - 40% Explanation: DL Ref. value: Continuous power (CP) BL Ref. value: Fuel stop power (FSP) 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 42 Product Summary RAW WATER CIRCUIT (open circuit) Number of cylinders Raw water pump: inlet pressure, min. -0.2 Raw water pump: inlet pressure, max. +0.5 Pressure loss in the 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 43 Product Summary INCLINATIONS - STANDARD OIL SYSTEM (ref.: waterline) Number of cylinders Longitudinal inclination, continuous max. driving end down (Option: max. operating degrees inclinations) Longitudinal inclination, temporary max. driving end down (Option: max. operating degrees 22.5 inclinations) Longitudinal inclination, continuous max. driving end up (Option: max. operating degrees inclinations) Longitudinal inclination, temporary max.
Page 44: 4000 M60R Engine Data: Separate Heat Exchanger, Imo - 40
Product Summary 2.5.4 8V 4000 M60R engine data: Separate heat exchanger, IMO - 40% Explanation: DL Ref. value: Continuous power (CP) BL Ref. value: Fuel stop power (FSP) A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power setting) N Not yet deﬁned value - Not applicable X Applicable...
Page 45 Product Summary LUBE OIL SYSTEM Number of cylinders Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C Lube oil operating pressure before engine, from Lube oil operating pressure before engine, to Lube oil operating pressure, low idle (meas. point: before engine) FUEL SYSTEM Number of cylinders Fuel pressure at supply connection to engine, min.
Page 46 Product Summary CAPACITIES Number of cylinders Engine oil capacity, initial ﬁlling (standard oil system) (Option: max. operating liter inclinations) Oil change quantity, max. (standard oil system) (Option: max. operating liter inclinations) Oil pan capacity, dipstick mark min. (standard oil system) (Option: max. operating liter inclinations) Oil pan capacity, dipstick mark max.
Page 47: 4000 M60R Engine Data: Imo, Engine-Mounted Heat Exchanger
Product Summary 2.5.5 12V 4000 M60R engine data: IMO, engine-mounted heat exchanger Explanation: DL Ref. value: Continuous power (CP) BL Ref. value: Fuel stop power (FSP) A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power setting) N Not yet deﬁned value - Not applicable X Applicable...
Page 48 Product Summary MODEL-RELATED DATA (basic design) Number of cylinders 12V 4000 M60R Cylinder conﬁguration: V angle degrees Bore Stroke Cylinder displacement liter 4.06 Total displacement liter 48.7 Number of inlet valves, per cylinder Number of exhaust valves, per cylinder RAW WATER CIRCUIT (open circuit) Number of cylinders 12V 4000 M60R...
Page 49 Product Summary STARTING (electric) Number of cylinders 12V 4000 M60R Rated starter voltage (standard design) STARTING (pneumatic starter) Number of cylinders 12V 4000 M60R Starting air pressure before starter motor, min. Starting air pressure before starter motor, max. INCLINATIONS - STANDARD OIL SYSTEM (ref.: waterline) Number of cylinders 12V 4000 M60R...
Page 50 Product Summary WEIGHTS / MAIN DIMENSIONS Number of cylinders 12V 4000 M60R Engine dry weight (with attached standard accessories, without coupling) 6800 ACOUSTICS Number of cylinders 12V 4000 M60R Exhaust noise, unsilenced, BL, (free-ﬁeld sound-pressure level Lp, 1m distance, db(A) ISO 6798) Engine surface noise with attenuated intake noise (ﬁlter), BL, (free-ﬁeld db(A)
Page 51: 4000 M60R Engine Data: Imo, Separate Heat Exchanger
Product Summary 2.5.6 12V 4000 M60R engine data: IMO, separate heat exchanger Explanation: DL Ref. value: Continuous power (CP) BL Ref. value: Fuel stop power (FSP) 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 52 Product Summary MODEL-RELATED DATA (basic design) Number of cylinders 12V 4000 M60R Cylinder conﬁguration: V angle degrees Bore Stroke Cylinder displacement liter 4.06 Total displacement liter 48.7 Number of inlet valves, per cylinder Number of exhaust valves, per cylinder LUBE OIL SYSTEM Number of cylinders 12V 4000 M60R...
Page 53 Product Summary STARTING (pneumatic starter) Number of cylinders 12V 4000 M60R Starting air pressure before starter motor, min. Starting air pressure before starter motor, max. INCLINATIONS - STANDARD OIL SYSTEM (ref.: waterline) 12V 4000 Number of cylinders M60R Longitudinal inclination, continuous max. driving end down (Option: max. operating degrees inclinations) Longitudinal inclination, temporary max.
Page 54 Product Summary ACOUSTICS Number of cylinders 12V 4000 M60R Exhaust noise, unsilenced, BL, (free-ﬁeld sound-pressure level Lp, 1m distance, db(A) ISO 6798) Engine surface noise with attenuated intake noise (ﬁlter), BL, (free-ﬁeld db(A) sound-pressure level Lp, 1m distance, ISO 6798) M015685/01E 05-11 ©...
Page 55: 4000 M60R Engine Data: Engine-Mounted Heat Exchanger, Imo - 40
Product Summary 2.5.7 12V 4000 M60R engine data: Engine-mounted heat exchanger, IMO - 40% Explanation: DL Ref. value: Continuous power (CP) BL Ref. value: Fuel stop power (FSP) 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 56 Product Summary MODEL-RELATED DATA (basic design) Number of cylinders 12V 4000 M60R Cylinder conﬁguration: V angle degrees Bore Stroke Cylinder displacement liter 4.06 Total displacement liter 48.7 Number of inlet valves, per cylinder Number of exhaust valves, per cylinder RAW WATER CIRCUIT (open circuit) Number of cylinders 12V 4000 M60R...
Page 57 Product Summary STARTING (electric) Number of cylinders 12V 4000 M60R Rated starter voltage (standard design) STARTING (pneumatic starter) Number of cylinders 12V 4000 M60R Starting air pressure before starter motor, min. Starting air pressure before starter motor, max. INCLINATIONS - STANDARD OIL SYSTEM (ref.: waterline) Number of cylinders 12V 4000 M60R...
Page 58 Product Summary WEIGHTS / MAIN DIMENSIONS Number of cylinders 12V 4000 M60R Engine dry weight (with attached standard accessories, without coupling) 6800 ACOUSTICS Number of cylinders 12V 4000 M60R Exhaust noise, unsilenced, BL, (free-ﬁeld sound-pressure level Lp, 1m distance, db(A) ISO 6798) Engine surface noise with attenuated intake noise (ﬁlter), BL, (free-ﬁeld db(A)
Page 59: 4000 M60R Engine Data: Separate Heat Exchanger, Imo - 40
Product Summary 2.5.8 12V 4000 M60R engine data: Separate heat exchanger, IMO - 40% Explanation: DL Ref. value: Continuous power (CP) BL Ref. value: Fuel stop power (FSP) A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power setting) N Not yet deﬁned value - Not applicable X Applicable...
Page 60 Product Summary MODEL-RELATED DATA (basic design) Number of cylinders 12V 4000 M60R Cylinder conﬁguration: V angle degrees Bore Stroke Cylinder displacement liter 4.06 Total displacement liter 48.7 Number of inlet valves, per cylinder Number of exhaust valves, per cylinder LUBE OIL SYSTEM Number of cylinders 12V 4000 M60R...
Page 61 Product Summary STARTING (pneumatic starter) Number of cylinders 12V 4000 M60R Starting air pressure before starter motor, min. Starting air pressure before starter motor, max. INCLINATIONS - STANDARD OIL SYSTEM (ref.: waterline) 12V 4000 Number of cylinders M60R Longitudinal inclination, continuous max. driving end down (Option: max. operating degrees inclinations) Longitudinal inclination, temporary max.
Page 62 Product Summary ACOUSTICS Number of cylinders 12V 4000 M60R Exhaust noise, unsilenced, BL, (free-ﬁeld sound-pressure level Lp, 1m distance, db(A) ISO 6798) Engine surface noise with attenuated intake noise (ﬁlter), BL, (free-ﬁeld db(A) sound-pressure level Lp, 1m distance, ISO 6798) M015685/01E 05-11 ©...
Page 63: 4000 M60R Engine Data: Engine-Mounted Heat Exchanger
Product Summary 2.5.9 16V 4000 M60R engine data: Engine-mounted heat exchanger Explanation: DL Ref. value: Continuous power (CP) BL Ref. value: Fuel stop power (FSP) 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 64 Product Summary 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 the 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 Product Summary INCLINATIONS - STANDARD OIL SYSTEM (ref.: waterline) Number of cylinders Longitudinal inclination, continuous max. driving end down (Option: max. operating degrees inclinations) Longitudinal inclination, temporary max. driving end down (Option: max. operating degrees 22.5 inclinations) Longitudinal inclination, continuous max. driving end up (Option: max. operating degrees inclinations) Longitudinal inclination, temporary max.
Page 66: 4000 M60R Engine Data: Engine-Mounted Heat Exchanger, Imo - 40
Product Summary 2.5.10 16V 4000 M60R engine data: Engine-mounted heat exchanger, IMO - 40% Explanation: DL Ref. value: Continuous power (CP) BL Ref. value: Fuel stop power (FSP) 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 67 Product Summary MODEL-RELATED DATA (basic design) Number of cylinders Cylinder conﬁguration: V angle degrees Bore Stroke Cylinder displacement liter 4.06 Total displacement liter 65.0 Number of inlet valves, per cylinder Number of exhaust valves, per cylinder RAW WATER CIRCUIT (open circuit) Number of cylinders Raw water pump: inlet pressure, min.
Page 68 Product Summary STARTING (pneumatic starter) Number of cylinders Starting air pressure before starter motor, min. Starting air pressure before starter motor, max. INCLINATIONS - STANDARD OIL SYSTEM (ref.: waterline) Number of cylinders Longitudinal inclination, continuous max. driving end down (Option: max. operating degrees inclinations) Longitudinal inclination, temporary max.
Page 69: 4000 M60R Engine Data: Separate Heat Exchanger
Product Summary 2.5.11 16V 4000 M60R engine data: Separate heat exchanger Explanation: DL Ref. value: Continuous power (CP) BL Ref. value: Fuel stop power (FSP) 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 70 Product Summary LUBE OIL SYSTEM Number of cylinders Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C Lube oil operating pressure before engine, from Lube oil operating pressure before engine, to Lube oil operating pressure, low idle (meas. point: before engine) FUEL SYSTEM Number of cylinders Fuel pressure at supply connection to engine, min.
Page 71 Product Summary CAPACITIES Number of cylinders Engine oil capacity, initial ﬁlling (standard oil system) (Option: max. operating liter inclinations) Oil change quantity, max. (standard oil system) (Option: max. operating liter inclinations) Oil pan capacity, dipstick mark min. (standard oil system) (Option: max. operating liter inclinations) Oil pan capacity, dipstick mark max.
Page 72: 4000 M60R Engine Data: Separate Heat Exchanger, Imo - 40
Product Summary 2.5.12 16V 4000 M60R engine data: Separate heat exchanger, IMO - 40% Explanation: DL Ref. value: Continuous power (CP) BL Ref. value: Fuel stop power (FSP) 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 73 Product Summary LUBE OIL SYSTEM Number of cylinders Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C Lube oil operating pressure before engine, from Lube oil operating pressure before engine, to Lube oil operating pressure, low idle (meas. point: before engine) FUEL SYSTEM Number of cylinders Fuel pressure at supply connection to engine, min.
Page 74 Product Summary CAPACITIES Number of cylinders Engine oil capacity, initial ﬁlling (standard oil system) (Option: max. operating liter inclinations) Oil change quantity, max. (standard oil system) (Option: max. operating liter inclinations) Oil pan capacity, dipstick mark min. (standard oil system) (Option: max. operating liter inclinations) Oil pan capacity, dipstick mark max.
Page 75: 4000 M61R Engine Data: Imo, Intake Air Temperature 45°C, Separate Heat Exchanger
Product Summary 2.5.13 16V 4000 M61R engine data: IMO, Intake air temperature 45°C, separate heat exchanger Explanation: DL Ref. value: Continuous power (CP) BL Ref. value: Fuel stop power (FSP) 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 76 Product Summary MODEL-RELATED DATA (basic design) Number of cylinders Cylinder conﬁguration: V angle degrees Bore Stroke Cylinder displacement liter 4.06 Total displacement liter 65.0 Number of inlet valves, per cylinder Number of exhaust valves, per cylinder LUBE OIL SYSTEM Number of cylinders Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to...
Page 77 Product Summary INCLINATIONS - STANDARD OIL SYSTEM (ref.: waterline) Number of cylinders Longitudinal inclination, continuous max. driving end down (Option: max. operating degrees inclinations) Longitudinal inclination, temporary max. driving end down (Option: max. operating degrees 22.5 inclinations) Longitudinal inclination, continuous max. driving end up (Option: max. operating degrees inclinations) Longitudinal inclination, temporary max.
Page 78: 4000 M61R Engine Data: Imo, Mounted Heat Exchanger
Product Summary 2.5.14 16V 4000 M61R engine data: IMO, mounted heat exchanger Explanation: DL Ref. value: Continuous power (CP) BL Ref. value: Fuel stop power (FSP) 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 79 Product Summary MODEL-RELATED DATA (basic design) Number of cylinders 16V 4000 Cylinder conﬁguration: V angle degrees Bore Stroke Cylinder displacement liter 4.06 Total displacement liter 65.0 Number of inlet valves, per cylinder Number of exhaust valves, per cylinder RAW WATER CIRCUIT (open circuit) Number of cylinders 16V 4000 Raw water pump: inlet pressure, min.
Page 80 Product Summary STARTING (electric) Number of cylinders 16V 4000 Rated starter voltage (standard design) STARTING (pneumatic starter) Number of cylinders 16V 4000 Starting air pressure before starter motor, min. Starting air pressure before starter motor, max. INCLINATIONS - STANDARD OIL SYSTEM (ref.: waterline) Number of cylinders 16V 4000 Longitudinal inclination, continuous max.
Page 81 Product Summary WEIGHTS / MAIN DIMENSIONS Number of cylinders 16V 4000 Engine dry weight (with attached standard accessories, without coupling) 8000 ACOUSTICS Number of cylinders 16V 4000 Exhaust noise, unsilenced, BL, (free-ﬁeld sound-pressure level Lp, 1m distance, db(A) ISO 6798) Engine surface noise with attenuated intake noise (ﬁlter), BL, (free-ﬁeld db(A) sound-pressure level Lp, 1m distance, ISO 6798)
Page 82: 4000 M61R Engine Data: Imo, Separate Heat Exchanger
Product Summary 2.5.15 16V 4000 M61R engine data: IMO, separate heat exchanger Explanation: DL Ref. value: Continuous power (CP) BL Ref. value: Fuel stop power (FSP) 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 83 Product Summary MODEL-RELATED DATA (basic design) Number of cylinders 16V 4000 Cylinder conﬁguration: V angle degrees Bore Stroke Cylinder displacement liter 4.06 Total displacement liter 65.0 Number of inlet valves, per cylinder Number of exhaust valves, per cylinder LUBE OIL SYSTEM Number of cylinders 16V 4000 Lube oil operating temperature before engine, from...
Page 84 Product Summary STARTING (pneumatic starter) Number of cylinders 16V 4000 Starting air pressure before starter motor, min. Starting air pressure before starter motor, max. INCLINATIONS - STANDARD OIL SYSTEM (ref.: waterline) 16V 4000 Number of cylinders Longitudinal inclination, continuous max. driving end down (Option: max. operating degrees inclinations) Longitudinal inclination, temporary max.
Page 85 Product Summary ACOUSTICS Number of cylinders 16V 4000 Exhaust noise, unsilenced, BL, (free-ﬁeld sound-pressure level Lp, 1m distance, db(A) ISO 6798) Engine surface noise with attenuated intake noise (ﬁlter), BL, (free-ﬁeld db(A) sound-pressure level Lp, 1m distance, ISO 6798) M015685/01E 05-11 ©...
Page 87: Operation
Operation Operation LOP controls LOP controls Item Color Inscription Meaning / Function White Function keys for operating the screen. Functions change and are indicated on the display. White White White White White ALARM ACKNOWLEDGE Pressing the button the ﬁrst time stops alarm signalization.
Page 88 Operation Item Color Inscription Meaning / Function TEST OVERSPEED Pressing the button initiates overspeed test. LED (spot) lights up as long as the overspeed test is running. FPP: Pressing the button engages gear ahead. Green (Depending on type of gearbox and propulsion CPP, WJ, VS: Pressing the button engages clutch.
Page 89: Putting The Engine Into Operation After Extended Out-Of-Service Periods (>3 Months)
Operation Putting the engine into operation after extended out-of-service periods (>3 months) Preconditions • Engine is stopped and starting disabled. • MTU Fluids and Lubricants Speciﬁcation (A001061/..) is available. Putting the engine into operation after extended out-of-service-periods (>3 months) Item Task Engine Depreserve (→...
Page 90: Putting The Engine Into Operation After Scheduled Out-Of-Service-Period
Operation Putting the engine into operation after scheduled out-of-service-period Preconditions • Engine is stopped and starting disabled. Putting the engine into operation Item Task Lube oil system Check oil level (→ Page 159); Preheat engine oil, if required. Cooling system Check coolant level (→...
Page 91: Starting The Engine From Lop
Operation Starting the engine from LOP Preconditions • Gearbox is disengaged. • External start interlock is not activated. • Emergency air-shut-off ﬂaps (if provided) are open. Unguarded rotating and moving engine components. Risk of serious injury — danger to life! DANGER •...
Page 92 Operation Starting the engine at the BlueLine automation system (control stand) Unguarded rotating and moving engine components. Risk of serious injury — danger to life! DANGER • Before barring or starting the engine, ensure that nobody is in the danger zone. Engine noise above 85 dB (A).
Page 93 Operation Operational checks Unguarded rotating and moving engine components. Risk of serious injury – danger to life! DANGER • Take special care when working on a running engine. Engine noise above 85 dB (A). Risk of damage to hearing! WARNING •...
Page 94 Operation Clutch – Engaging from LOP Preconditions • LOCAL OPERATION button is illuminated brightly (local operating mode is active) • Engine speed is within range for clutch engagement. • No external clutch engagement interlock is activated. Vessel is sailing blind. In Local Operation mode, the propulsion plant is controlled from the engine room.
Page 95 Operation Clutch – Disengaging from LOP Preconditions • LOCAL OPERATION button is illuminated brightly (local operating mode is active) • Engine speed is within range for clutch disengagement. Disengaging clutch without reversing gearbox (CPP, WJ, VS) Item Task Press CLUTCH OUT button (→ Page 81). •...
Page 96 Operation Waterjet – Flushing from LOP (optional) Preconditions • LOCAL OPERATION button is illuminated brightly (local operating mode is active). • Vessel is stationary and waterjet bucket is below waterline. • Engine speed is within range for clutch engagement. • No external clutch engagement interlock is activated. Waterjet ﬂushing puts excessive strain on the bearings.
Page 97 Operation 3.10 Stopping the engine from LOP Preconditions • Engine is running at local mode. Stopping the engine when it is running at full load causes extreme stress to the engine. Risk of overheating, damage to components! CAUTION • Before stopping the engine, disengage gearbox / transmission and run the engine at idle speed until operating temperatures decrease and stable values are indicated.
Page 98 Operation 3.11 Stopping the engine at the BlueLine automation system (control stand) Stopping the engine when it is running at full load causes extreme stress to the engine. Risk of overheating, damage to components! CAUTION • Before stopping the engine, disengage gearbox / transmission and run the engine at idle speed until operating temperatures decrease and stable values are indicated.
Page 99 Operation 3.12 Emergency stop from LOP An emergency stop causes extreme stress to the engine. Risk of overheating, damage to components! CAUTION • Initiate emergency stop only in emergency situations. Emergency stop from LOP Item Task Open cap of EMERGENCY STOP button (→ Page 81). Press EMERGENCY STOP button.
Page 100 Operation 3.13 Engine emergency stop at BlueLine automation system (control stand) An emergency stop causes extreme stress to the engine. Risk of overheating, damage to components! CAUTION • Initiate emergency stop only in emergency situations. Engine emergency stop at BlueLine automation system (→ BlueLine documentation). M015685/01E 05-11 ©...
Page 101 Operation 3.14 After stopping the engine Preconditions • MTU Fluids and Lubricants Speciﬁcation (A001061/..) is available. After stopping the engine Item Task Cooling system Drain coolant (→ Page 169) if: • freezing temperatures are expected and the engine is to remain out of service for an extended period and engine coolant has no antifreeze additive;...
Page 103 Maintenance Maintenance Preface General Low operating and maintenance costs as well as operational reliability and availability depend on maintenance and servicing being carried out in compliance with MTU’s speciﬁcations and instructions. The overall system, of which the engine is an integral part, must be maintained in such a way as to ensure trouble-free engine operation.
Page 104 Maintenance Load proﬁle Load-proﬁle table Load factor 100 % <15% Corresponding operating time M015685/01E 05-11 © MTU...
Page 105 Maintenance Maintenance schedule matrix 0 - 10,500 operating hours Item Operating hours [hrs] Engine oil ﬁlters Engine operation Air ducting X X X X X X X X X X X X X X X X X X X X X Centrifugal oil ﬁlter X X X X X X X X X X X X X X X X X X X X X Crankcase breather...
Page 106 Maintenance 11,000 - 21,500 operating hours Item Operating hours [hrs] Engine oil ﬁlters Engine operation Air ducting X X X X X X X X X X X X X X X X X X X X X X Centrifugal oil ﬁlter X X X X X X X X X X X X X X X X X X X X X X Crankcase breather Valve gear...
Page 107 Maintenance 22,000 - 30,000 operating hours Item Operating hours [hrs] Engine oil ﬁlters Engine operation Air ducting X X X X X X X X X X X X X X X X X Centrifugal oil ﬁlter X X X X X X X X X X X X X X X X X Crankcase breather Valve gear Fuel ﬁlter...
Page 108 Maintenance Maintenance tasks Interval Item Maintenance tasks Task Qual- iﬁca- code tion [hours] [years] Daily Engine operation Carry out operational checks (→ Page 87). W0500 Engine oil ﬁlter Replace oil ﬁlter when changing engine oil, or when the interval W1008 (years) is reached, at the latest (→...
Page 109 Maintenance Qual- Interval Item Maintenance tasks Task iﬁca- code tion [hours] [years] Disassemble Küsel coupling (if ﬁtted), check parts, replace friction W2019 rings and friction washers (→ Workshop Manual). Check adjustment dimension on central buffer of engine mounts (→ W2020 Workshop Manual).
Page 111 Troubleshooting Troubleshooting Troubleshooting Engine does not turn when starter is actuated Component Probable Cause Task Battery Low or defective Charge or replace (see manufacturer’s documentation). Cable connections defective Check if cable connections are properly secured (see manufacturer’s documentation). Starter Engine wiring or starter defective Check if cable connections are properly secured, contact Service.
Page 112 Troubleshooting Engine does not reach nominal speed Component Probable Cause Task Fuel supply Fuel preﬁlter clogged Replace (→ Page 148). Fuel ﬁlter clogged Replace (→ Page 141). Air supply Air ﬁlter clogged Check signal ring position of service indicator (→ Page 153). Fuel injection equipment Injector defective Replace (→...
Page 113 Troubleshooting Exhaust gas black Component Probable Cause Task Air supply Air ﬁlter clogged Check signal ring position of service indicator (→ Page 153). Fuel injection equipment Injector defective Replace (→ Page 132). Engine Overloaded Contact Service. Exhaust gas blue Component Probable Cause Task Engine oil...
Page 114 Troubleshooting LOP alarms At the LOP, alarm texts and measuring-point messages are indicated on the DIS. Explanation of the displayed texts can be gathered by pressing the help key on the touch screen. Alarms can also be caused by defective sensors / actuators. If troubleshooting in accordance with the following table is not successful, contact Service to have the sensors / actuators checked and, if required, replaced.
Page 115 Troubleshooting Display text Meaning Task AL Transistor Output 1/2 One of the ECU 4 Contact Service: Fail transistor outputs (TAA1 or • Have ECU checked and replaced, if required. TAA2) is defective AL Transistor Output 3/4 One of the ECU transistor Contact Service: Fail outputs (TAA3 or TAA4) is...
Page 116 Troubleshooting Display text Meaning Task DL 211+A004-EMU EMU 1 not detected on 1. Check LOP visually (→ Page 190); default bus 2. Perform LOP test procedures (→ Page 193); 3. Check ECU plug-in connections (→ Page 185); 4. Check engine wiring (→ Page 180); 5.
Page 117 Troubleshooting Display text Meaning Task RL 211+A002-A030 GCU 1 (PIM No. 1. Check LOP visually (→ Page 190); 21.X+A002-A030) not 2. Perform LOP test procedures (→ Page 193); detected on redundant bus 3. Contact Service: • Have GCU/GMU checked and replaced, if required.
Page 118 Troubleshooting Display text Meaning Task SS P-Coolant Safety system detects that Check coolant level and top up, if required (→ Page 170) coolant pressure is too low SS P-Lube Oil (ECU) Safety system detects that 1. Check engine-oil level and top up, if required; engine-oil pressure is too (→...
Page 119 Task Descriptions Task Descriptions Engine 6.1.1 Engine – Barring manually Preconditions • Engine is stopped and starting disabled. Special tools Designation / Use Part No. Qty. Barring tool F6555766 Ratchet F30006212 Unguarded rotating and moving engine components. Risk of serious injury — danger to life! DANGER •...
Page 120 Task Descriptions 6.1.2 Engine – Barring with starting system Special tools Designation / Use Part No. Qty. Connector pliers 0135315483 Unguarded rotating and moving engine components. Risk of serious injury - danger to life! DANGER • Before barring or starting the engine, ensure that nobody is in the danger zone. •...
Page 121 Task Descriptions Cylinder Liner 6.2.1 Cylinder liner – Endoscopic examination Preconditions • Engine is stopped and starting disabled. Special tools Designation / Use Part No. Qty. Rigid endoscope Y20097353 Preparatory steps 1. Remove cylinder-head cover (→ Page 130). 2. Remove injector (→ Page 133). Positioning crankshaft at BDC 1.
Page 122 Task Descriptions 6.2.2 Instructions and comments on endoscopic and visual examination of cylinder liners Terms used for endoscopic examination Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic examination report. Minor dirt scores Light scoring can take place during the assembly of a new engine (honing products, particles, broken-off burrs).
Page 123 Task Descriptions Evaluation of ﬁndings and further measures The ﬁndings in the start phase of oxidation discoloration and heat discoloration are similar. Thorough investigation and compliance with the above evaluation criteria allows a deﬁnite evaluation. To avoid unnecessary disassembly work, it is recommended that another inspection be carried out after further operation of the engine. M015685/01E 05-11 ©...
Page 124 Task Descriptions Crankcase Breather 6.3.1 Crankcase breather – Oil separator replacement, diaphragm check and replacement Preconditions • Engine is stopped and starting disabled. Spare parts Designation / Use Part No. Qty. Filter element Diaphragm Seal Hot oil. Oil can contain combustion residues which are harmful to health. WARNING Risk of injury and poisoning! •...
Page 125 Task Descriptions Replacing oil separator insert (variant B) 1. Remove cover (2) with O-ring (3). 2. Remove ﬁlter element (1) from housing (4). 3. Insert new ﬁlter element in housing (4). 4. Fit cover (2) with new O-ring. 5. Use torque wrench to tighten the screws of cover (2) to speciﬁed torque 6 Nm +2 Nm.
Page 126 Task Descriptions 6.3.2 Crankcase breather – Oil separator replacement, diaphragm check and replacement Preconditions • Engine is stopped and starting disabled. Special tools Designation / Use Part No. Qty. Torque wrench F30027336 Spare parts Designation / Use Part No. Qty. Filter element Diaphragm O-ring...
Page 127 Task Descriptions Checking diaphragm 1. Remove cover (4). 2. Take off spring (5), seal (2) and diaphragm (3). 3. Check diaphragm (3) for damage. 4. Fit new diaphragm if used one is damaged. 5. Mount diaphragm (3) on housing (1). 6.
Page 128 Task Descriptions 6.3.3 Crankcase breather – oil separator replacement Preconditions • Engine is stopped and starting disabled. Material Designation / Use Part No. Qty. Ethanol, denatured Spare parts Designation / Use Part No. Qty. Oil separator Crankcase breather – oil separator replacement 1.
Page 129 Task Descriptions Valve Gear 6.4.1 Valve gear – Lubrication Preconditions • Engine is stopped and starting disabled. Material Designation / Use Part No. Qty. Engine oil Valve gear – Lubrication (valve bridge with guide) 1. Remove cylinder-head covers (→ Page 130). 2.
Page 130 Task Descriptions 6.4.2 Valve clearance – Check and adjustment Preconditions • Engine is stopped and starting disabled. • Engine coolant temperature is max. 40 °C. • Valves are closed. Special tools Designation / Use Part No. Qty. Feeler gauge Y20010128 Torque wrench Allen key Open end spanner...
Page 131 Task Descriptions Checking valve-bridge balance X Valve bridge with guide Y Flying valve bridge Note: Not applicable for engines with ﬂying valve bridge. 1. Prior to adjusting valve clearance, check valve-bridge balance on all valve bridges. 2. Use feeler gauge to determine the distance between valve bridge and rocker arm.
Page 132 Task Descriptions 3. Insert feeler gauge with determined value between valve bridge and valve-stem end (A). 4. At the opposite valve-stem end (B), a feeler gauge thicker by 0.05 mm should not ﬁt, otherwise adjust valve bridge balance. Adjusting valve-bridge balance Note: Not applicable for engines with ﬂying valve bridge.
Page 133 Task Descriptions 7. Tighten locknut (2) to 35 Nm +5 Nm, holding valve bridge (1) in position with open-end spanner. 8. Check valve bridge balance again. M015685/01E 05-11 © MTU...
Page 134 Task Descriptions 1 Cylinder A1 is in ﬁring TDC I Inlet valve 2 Cylinder A1 is in overlap TDC X Exhaust valve Checking valve clearance at two crankshaft positions 1. Check TDC position of piston in cylinder A1: • If the rocker arms are unloaded on cylinder A1, the piston is in ﬁring TDC. •...
Page 135 Task Descriptions Adjusting valve clearance 1. Release locknut (1). 2. Insert feeler gauge between valve bridge and rocker arm. 3. Using Allen key, set adjusting screw (2) so that the speciﬁed valve clearance is provided. 4. Feeler gauge must just pass through the gap. 5.
Page 136 Task Descriptions 6.4.3 Cylinder head cover – Remove and install Preconditions • Engine is stopped and starting disabled. Special tools Designation / Use Part No. Qty. Torque wrench 10–60 Nm F30510423 Spare parts Designation / Use Part No. Qty. Gasket Remove cylinder head cover 1.
Page 137 Task Descriptions Injection Pump / HP Pump 6.5.1 HP fuel pump – Relief bore check Unguarded rotating and moving engine components. Risk of serious injury – danger to life! DANGER • Take special care when working on a running engine. Engine noise above 85 dB (A).
Page 138 Task Descriptions Fuel Injector 6.6.1 Injector replacement Spare parts Designation / Use Part No. Qty. Injector Remove injector and install new one (→ Page 133). M015685/01E 05-11 © MTU...
Page 139 Task Descriptions 6.6.2 Injector – Removal and installation Preconditions • Engine is stopped and starting disabled. Special tools Designation / Use Part No. Qty. Puller for injector F30377769 Puller bracket for injector F6557991 Force-in lever for injector F6557952 Lever for force-in lever F6555197 Injector installation jig F30378403...
Page 140 Task Descriptions Injector removal 1. Release the cable terminal threaded connection on the injector and remove cable terminals. 2. Remove screw (2) and take off hold-down clamp (1). 3. Remove high-pressure fuel line (5). 4. Install puller for injector removal. For this purpose, ﬁt part (4) onto injector (1).
Page 141 Task Descriptions 7. Initial position of part (2) is position a. 8. End position is position b. 9. Install puller bracket (2) for injector removal. 10. Turn nut (1) clockwise and withdraw injector. 11. Remove puller bracket from injector. 12. Remove sealing ring (1) from injector or use a self-made wire hook to take it out of the cylinder head.
Page 142 Task Descriptions Installing injector 1. Prior to installation, remove all plugs. 2. Coat new O-rings (scope of supply of injector) with petroleum jelly and ﬁt on injector. 3. Fit new sealing ring with petroleum jelly on injector, observe installation position of sealing ring. 4.
Page 143 Task Descriptions 11. Use slotted screwdriver to check thrust ring at both line ends for secure seating. 12. Tighten loose thrust ring to 10 Nm. 13. Fit hold-down clamp (1) in correct position and install screw (2) by hand. 14. Use torque wrench to pretighten screw (2) to between 5 Nm and 10 Nm.
Page 144 Task Descriptions Final steps 1. Install cylinder head cover (→ Page 130). 2. Open fuel supply to engine. M015685/01E 05-11 © MTU...
Page 145 Task Descriptions Fuel System 6.7.1 Fuel system – Venting and ﬁlling Preconditions • Engine is stopped and starting disabled. Special tools Designation / Use Part No. Qty. Filling device B80144852 Material Designation / Use Part No. Qty. Diesel fuel Fuels are combustible. Risk of ﬁre and explosion! WARNING •...
Page 146 Task Descriptions 8. Filling is completed if: • Whistling noise is no more audible during pumping; • Bubble-free fuel emerges from the return hose of the ﬁlling device. 9. Disconnect return hose from ﬁlling device at HP pump (1). 10. Connect ﬂushing line (4) to HP pump. 11.
Page 147 Task Descriptions Fuel Filter 6.8.1 Fuel ﬁlter – Replacement Special tools Designation / Use Part No. Qty. Strap wrench F30379104 Material Designation / Use Part No. Qty. Diesel fuel Spare parts Designation / Use Part No. Qty. Easy-change ﬁlter Synthetic ring Unguarded rotating and moving engine components.
Page 148 Task Descriptions Damage to component. Serious damage to plant! CAUTION • For ﬁlter replacement with the engine running, operate the engine at low engine load. • The ﬁlter which is to be exchanged must be cut out for a brief period only. Fuel ﬁlter replacement with the engine stopped 1.
Page 149 Task Descriptions 6.8.2 Fuel preﬁlter – differential pressure check and adjustment of gauge Unguarded rotating and moving engine components. Risk of serious injury – danger to life! DANGER • Take special care when working on a running engine. Engine noise above 85 dB (A). Risk of damage to hearing! WARNING •...
Page 150 Task Descriptions 6.8.3 Fuel preﬁlter – draining Preconditions • Engine is stopped and starting disabled. Material Designation / Use Part No. Qty. Diesel fuel Spare parts Designation / Use Part No. Qty. Gasket M015685/01E 05-11 © MTU...
Page 151 Task Descriptions Fuels are combustible. Risk of ﬁre and explosion! WARNING • Avoid naked ﬂames, electrical sparks and ignition sources. • Do not smoke. Fuel preﬁlter – draining 1. Cut out the ﬁlter to be drained. I Left ﬁlter cut in II Right ﬁlter cut in 2.
Page 152 Task Descriptions 6.8.4 Fuel preﬁlter – ﬂushing Material Designation / Use Part No. Qty. Diesel fuel Spare parts Designation / Use Part No. Qty. Gasket Unguarded rotating and moving engine components. Risk of serious injury – danger to life! DANGER •...
Page 153 Task Descriptions Engine noise above 85 dB (A). Risk of damage to hearing! WARNING • Wear ear protectors. Fuel preﬁlter – ﬂushing 1. Cut out the contaminated ﬁlter. I Left ﬁlter cut in II Right ﬁlter cut in 2. Open vent plug (5) of the ﬁlter to be ﬂushed. 3.
Page 154 Task Descriptions 6.8.5 Fuel preﬁlter – ﬁlter element replacement Preconditions • Engine is stopped and starting disabled. Material Designation / Use Part No. Qty. Diesel fuel Spare parts Designation / Use Part No. Qty. Filter element Gasket M015685/01E 05-11 © MTU...
Page 155 Task Descriptions Fuels are combustible. Risk of ﬁre and explosion! WARNING • Avoid naked ﬂames, electrical sparks and ignition sources. • Do not smoke. Fuel preﬁlter – ﬁlter element replacement 1. Cut out the contaminated ﬁlter. I Left ﬁlter cut in II Right ﬁlter cut in 2.
Page 156 Task Descriptions Charge-air Cooling, General, Left Side 6.9.1 Intercooler – Checking condensate drain line for coolant discharge and obstruction Unguarded rotating and moving engine components. Risk of serious injury – danger to life! DANGER • Take special care when working on a running engine. Engine noise above 85 dB (A).
Page 157 Task Descriptions 6.10 Air Filter 6.10.1 Air ﬁlter replacement Spare parts Designation / Use Part No. Qty. Air ﬁlter Remove air ﬁlter and install new one (→ Page 152). Reset signal ring of service indicator (→ Page 153). M015685/01E 05-11 ©...
Page 158 Task Descriptions 6.10.2 Air ﬁlter removal and installation Preconditions • Engine is stopped and starting disabled. Air ﬁlter removal and installation 1. Loosen clamp (2). 2. Remove air ﬁlter (3) and clamp (2) from ﬂange of intake housing (1). 3. Verify that there are no objects in the ﬂange of the intake housing (1) and clean it.
Page 159 Task Descriptions 6.11 Air Intake 6.11.1 Service indicator – Signal ring position check Preconditions • Engine is stopped and starting disabled. Signal ring position check 1. If the signal ring is completely visible in the control window (2), replace air ﬁlter (→ Page 151). 2.
Page 160 Task Descriptions 6.11.2 Air-ﬂow control ﬂap – check for ease of movement Preconditions • Engine is stopped and starting disabled. Air-ﬂow control ﬂap – check for ease of movement 1. Actuate lever several times to check ease of movement. Result: The spring must push back the air-ﬂow control ﬂap.
Page 161 Task Descriptions 6.12 Exhaust-Flow Control Flap with Controls 6.12.1 Exhaust-ﬂow control ﬂap – check for ease of movement Preconditions • Engine is stopped and starting disabled. Exhaust-ﬂow control ﬂap – check for ease of movement 1. Actuate control linkage several times by hand to check for ease of movement.
Page 162 Task Descriptions 6.13 Starting System 6.13.1 Starter – Condition check Preconditions • Engine is stopped and starting disabled. Starter – Condition check 1. Check starter securing screws for secure seating. 2. Tighten loose screw connections. 3. Check wiring (→ Page 180). M015685/01E 05-11 ©...
Page 163 Task Descriptions 6.14 Lube Oil System / Lube Oil Circuit 6.14.1 Engine oil – Change Preconditions • Engine is stopped and starting disabled. • Engine is at operating temperature. • MTU Fluids and Lubricants Speciﬁcation (A001061/..) is available. Material Designation / Use Part No.
Page 164 Task Descriptions Filling new oil 1. Open cover of ﬁller neck. 2. Pour oil in at ﬁller neck up to "max." mark at oil dipstick. 3. Close cover of ﬁller neck. 4. Check engine oil level (→ Page 159). 5. After oil change and oil ﬁlter replacement, bar engine with starting system (→...
Page 165 Task Descriptions 6.14.2 Engine oil – Level check Preconditions • Engine is stopped and starting disabled. Checking oil level prior to engine start 1. Withdraw dipstick from guide tube and wipe it. 2. Insert dipstick into guide tube up to the stop, withdraw after approx.
Page 166 Task Descriptions 6.14.3 Engine-oil – Sample extraction and analysis Preconditions • MTU Fluids and Lubricants Speciﬁcation (A001061/..) is available. Special tools Designation / Use Part No. Qty. MTU test kit 5605892099/00 Unguarded rotating and moving engine components. Risk of serious injury – danger to life! DANGER •...
Page 167 Task Descriptions 6.15 Oil Filtration / Cooling 6.15.1 Engine oil ﬁlter – Replacement Special tools Designation / Use Part No. Qty. Strap wrench F30379104 Material Designation / Use Part No. Qty. Engine oil Spare parts Designation / Use Part No. Qty.
Page 168 Task Descriptions Damage to component. Serious damage to plant! CAUTION • For ﬁlter replacement with the engine running, operate the engine at low engine load. • The ﬁlter which is to be exchanged must be cut out for a brief period only. Oil ﬁlter replacement with the engine stopped 1.
Page 169 Task Descriptions Oil ﬁlter replacement with the engine running 1. To cut out the ﬁlter to be replaced, set the three-way cock to the corresponding position. • Position A: Lower ﬁlters cut out • Position B: Both ﬁlters cut in (operating position) •...
Page 170 Task Descriptions 6.15.2 Centrifugal oil ﬁlter – Cleaning and ﬁlter-sleeve replacement Preconditions • Engine is stopped and starting disabled. Special tools Designation / Use Part No. Qty. Oil ﬁlter wrench F30379104 Torque wrench 6–50 Nm F30027336 Ratchet adapter F30027339 Material Designation / Use Part No.
Page 171 Task Descriptions Compressed air. Risk of injury! WARNING • Do not direct compressed-air jet at persons. • Wear protective goggles / safety mask and ear protectors. Centrifugal oil ﬁlter – Cleaning and ﬁlter-sleeve replacement 1. Loosen screw (1) and remove. 2.
Page 172 Task Descriptions 6.16 Coolant Circuit, General, HT Circuit 6.16.1 Engine coolant – Change Material Designation / Use Part No. Qty. Engine coolant Drain engine coolant (→ Page 169). Fill engine coolant system (→ Page 167). M015685/01E 05-11 © MTU...
Page 173 Task Descriptions 6.16.2 Engine coolant ﬁlling Preconditions • Engine is stopped and starting disabled. • MTU Fluids and Lubricants Speciﬁcation (A001061/..) is available. Material Designation / Use Part No. Qty. Coolant Coolant is hot and under pressure. Risk of injury and scalding! WARNING •...
Page 174 Task Descriptions Filling coolant with pump 1. Connect appropriate pump with hose to drain valve. 2. Open drain valve and pump treated coolant into engine, until coolant level reaches lower edge of cast-in eye or marking plate on ﬁller neck. 3.
Page 175 Task Descriptions 6.16.3 Engine coolant draining Preconditions • Engine is stopped and starting disabled. Coolant is hot and under pressure. Risk of injury and scalding! WARNING • Let the engine cool down. • Wear protective clothing, gloves, and goggles / safety mask. Preparatory steps 1.
Page 176 Task Descriptions 6.16.4 Engine coolant – Level check Preconditions • Engine is stopped and starting disabled. • MTU Fluids and Lubricants Speciﬁcation (A001061/..) is available. Coolant is hot and under pressure. Risk of injury and scalding! WARNING • Let the engine cool down. •...
Page 177 Task Descriptions 6.16.5 Engine coolant pump – Relief bore check Unguarded rotating and moving engine components. Risk of serious injury – danger to life! DANGER • Take special care when working on a running engine. Engine noise above 85 dB (A). Risk of damage to hearing! WARNING •...
Page 178 Task Descriptions 6.16.6 Engine coolant – Sample extraction and analysis Preconditions • MTU Fluids and Lubricants Speciﬁcation (A001061/..) is available. Special tools Designation / Use Part No. Qty. MTU test kit 5605892099/00 Unguarded rotating and moving engine components. Risk of serious injury – danger to life! DANGER •...
Page 179 Task Descriptions 6.17 Raw Water Pump with Connections 6.17.1 Raw water pump – Relief bore check Unguarded rotating and moving engine components. Risk of serious injury – danger to life! DANGER • Take special care when working on a running engine. Engine noise above 85 dB (A).
Page 180 Task Descriptions 6.18 Battery-charging Generator 6.18.1 Battery-charging generator drive – Coupling condition check Preconditions • Engine is stopped and starting disabled. Battery-charging generator drive – Coupling condition check 1. Remove protective cover. 2. Check resilient coupling for cracks and deformation (arrow).
Page 181 Task Descriptions 6.19 Engine Mounts 6.19.1 Engine mounts – securing screws check Preconditions • Engine is stopped and starting disabled. Engine mounts – securing screws check 1. Check securing screws for secure seating. 2. Tighten loose screw connections. M015685/01E 05-11 ©...
Page 182 Task Descriptions 6.19.2 Engine mounts – Resilient elements check Preconditions • Engine is stopped and starting disabled. • Engine is ﬁlled with coolant and engine oil. Special tools Designation / Use Part No. Qty. Feeler gauge Y20010128 Vernier caliper Box wrench F30379609 Material Designation / Use...
Page 183 Task Descriptions Engine mounts – Buffer clearance check 1. Remove protective cap (2). 2. Check marking (1): • Marking "30" corresponds to a = 3 +0.3 mm. • Marking "40" corresponds to a = 4 +0.3 mm. 3. Check dimension (a) with feeler gauge on measuring groove (4).
Page 184 Task Descriptions 6.20 PTO Systems, KS and KGS (coupling) 6.20.1 Coupling condition check Preconditions • Engine is stopped and starting disabled. Coupling condition check 1. Remove perforated plates(s). 2. Wipe rubber element with dry cloth, do not use organic detergents. 3.
Page 185 Task Descriptions 6.21 Auxiliary PTO 6.21.1 Bilge pump – Relief bore check Unguarded rotating and moving engine components. Risk of serious injury – danger to life! DANGER • Take special care when working on a running engine. Engine noise above 85 dB (A). Risk of damage to hearing! WARNING •...
Page 186 Task Descriptions 6.22 Wiring, General, for Engine / Gearbox / Plant 6.22.1 Engine wiring check Preconditions • Engine is stopped and starting disabled. Material Designation / Use Part No. Qty. Isopropyl alcohol Engine wiring check 1. Check securing screws of cable clamps on the engine and tighten loose screw connections. 2.
Page 187 Task Descriptions 6.23 Accessories for (Electronic) Engine Governor / Control System 6.23.1 ECU and connectors – Cleaning Preconditions • Engine is stopped and starting disabled. Special tools Designation / Use Part No. Qty. Connector pliers 0135315483 Material Designation / Use Part No.
Page 188 Task Descriptions Cleaning severely contaminated connectors on ECU 1. Use connector pliers (2) to disengage bayonet union nut (4) and withdraw connector (3). 2. Clean connector housings, connector socket housings (1) and all contacts with isopropyl alcohol. 3. When connectors, sockets and all contacts are dry: Install connectors and check plug-in connection on ECU (→...
Page 189 Task Descriptions 6.23.2 EMU and connectors – Cleaning Preconditions • Engine is stopped and starting disabled. Special tools Designation / Use Part No. Qty. Connector pliers 0135315483 Material Designation / Use Part No. Qty. Isopropyl alcohol Cleaning EMU and connectors 1.
Page 190 Task Descriptions 6.23.3 Start interlock limit switch check Preconditions • Engine is stopped and starting disabled. Note: In OFF-position, the limit switch initiates start interlock, i.e. the engine cannot be started. Start interlock limit switch check 1. Check if switch housing (1) and cover plate (3) are mounted and the switch (2) is in ON-position.
Page 191 Task Descriptions 6.23.4 ECU – Checking plug-in connections Preconditions • Engine is stopped and starting disabled. Special tools Designation / Use Part No. Qty. Connector pliers 0135315483 ECU – Checking plug-in connections 1. Use connector pliers (3) to make certain that all plug-in connections of ECU are securely seated.
Page 192 Task Descriptions 6.23.5 EMU – Checking plug-in connections Preconditions • Engine is stopped and starting disabled. Special tools Designation / Use Part No. Qty. Connector pliers 0135315483 EMU – Checking plug-in connections 1. Use connector pliers (3) to make certain that all EMU plug-in connections are securely seated.
Page 193 Task Descriptions 6.23.6 ECU – Removal and installation Preconditions • Engine is stopped and starting disabled. Special tools Designation / Use Part No. Qty. Connector pliers 0135315483 Material Designation / Use Part No. Qty. Covering caps for Cannon sockets ECU – Removal 1.
Page 194 Task Descriptions 5. Disconnect grounding strip from ECU grounding pin (7). 6. If the screws (4) are easily accessible: 6.1. Remove screws (4). 6.2. Take off ECU housing (3) from mounting brackets (2). 6.3. Unscrew mounting brackets (2), cable shock absorbers (5) and further securing parts (6) as one unit from engine.
Page 195 Task Descriptions 6.24 Emergency Instrumentation (Control Stand) 6.24.1 LOP and connectors cleaning Preconditions • Engine is stopped and starting disabled. Material Designation / Use Part No. Qty. Isopropyl alcohol LOP cleaning 1. Wipe LCD display with dry cloth, not applying excess pressure. 2.
Page 196 Task Descriptions 6.24.2 LOP – visual inspection Preconditions • Engine is stopped and starting disabled. Preparatory steps 1. If READY FOR OPERATION button is illuminated brightly, press button brieﬂy. Result: READY FOR OPERATION button returns to basic brightness. 2. Switch master power switch to OFF. 3.
Page 197 Task Descriptions Non-assigned bases check 1. Ensure that non-assigned connector bases are protected with covering caps. 2. Make certain that the two securing elements (1) are engaged in the lugs (2) so that the covering cap (3) is held ﬁrmly in place in the base. 3.
Page 198 Task Descriptions Lamp test 1. Connect battery in accordance with battery manufacturer’s instructions. 2. Switch master power switch to ON. 3. Switch on engine control system. 4. Keep LAMP TEST button pressed: Result: Control and indication ﬁelds light up. 5. Have damaged lamps immediately replaced by Service.
Page 199 Task Descriptions 6.24.3 LOP test procedures Preconditions • Engine is stopped and starting disabled. Preparatory steps 1. Connect battery in accordance with battery manufacturer’s instructions. 2. Switch master power switch to ON. 3. Switch on ECS-5. Result: • LOCAL MODE button (1) is illuminated brightly (local control mode is active);...
Page 200 Task Descriptions Overspeed test with the engine at standstill Note: Overspeed test with the engine at standstill can only be carried out if the engine is equipped with EMU. 1. Press OVERSPEED TEST button (3). Observe speed limit and speed simulated by EMU on display.
Page 202 Annex MTU contact person/service partner You will ﬁnd the MTU contact person/service partner for your region at www.mtu-online.com, worldwide, in the left-hand navigation margin. M015685/01E 05-11 © MTU...
Page 203 Annex Abbreviations Abbrevia- Meaning Explanation tion Alarm Alarm (general) ANSI American National Standards Institute Abgasturbolader Turbocharger Baureihe Engine Series Controller Area Network Controllable Pitch Propeller Deutsches Institut für Normung e. V. German Standardization Organization, at the same time identiﬁer of German standards (DIN = "Deutsche Industrie-Norm") Display Unit Default Lost...
Page 204 Annex Abbrevia- Meaning Explanation tion Light Emitting Diode Local Monitoring Unit LOP subassembly Alarm: Measured value lower than 1st minimum limit LOLO Low Low Alarm: Measured value lower than 2nd minimum limit Local Operating Panel Local Operating Station Monitoring and Control System Message Microprocessor Unit, Microprocessing Unit...
Page 205 Annex Index 12V 4000 M60R engine data: Engine-mounted Air-ﬂow control ﬂap – check for ease of heat exchanger, IMO - 40% ....movement ..... . . Service indicator –...
Page 206 Annex Engine Side and Cylinder Designations ..Cylinder liner – Endoscopic examina Engine side and cylinder designa tion ......tions .
Page 207 Annex Intercooler – Checking condensate drain line for coolant discharge and obstruction ..Safety precautions when working on the engine ....... Service indicator –...
Page 208 Annex Valve gear – Lubrication ....Valve clearance – Check and adjustment ..Valve Gear ......Cylinder head cover –...

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