MTU 20 V 4000 M93 Operating Instructions Manual
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MTU 20 V 4000 M93 Operating Instructions Manual

MTU 20 V 4000 M93 Operating Instructions Manual

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Operating Instructions

Diesel Engine
20 V 4000 M93
20 V 4000 M93L
MS150048/03E

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Summary of Contents for MTU 20 V 4000 M93

  • Page 1: Operating Instructions

    Operating Instructions Diesel Engine 20 V 4000 M93 20 V 4000 M93L MS150048/03E...
  • Page 2 This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, micro‐ filming and storage or processing on electronic systems including data bases and online services.

  • Page 3: Table Of Contents

    Table of Contents 1 Safety 4.5 Starting the engine 4.6 Fuel treatment system – Switching on 1.1 General conditions 4.7 Starting the engine 1.2 Personnel and organizational requirements 4.8 Engine emergency stop at BlueLine 1.3 Transport automation system (control stand) 1.4 Crankshaft transport locking device 4.9 Operational checks 1.5 Safety regulations for startup and operation...
  • Page 4 7.13.4 Engine coolant draining 7.13.5 Engine coolant – Filling 8.1 Abbreviations 7.13.6 Engine coolant pump – Relief bore check 8.2 MTU contact persons/service partners 7.13.7 Engine coolant – Sample extraction and analysis 7.13.8 Coolant filter – Replacement 7.14 Low-Temperature Circuit 9 Appendix B 7.14.1 Charge-air coolant –...

  • Page 5: Safety

    Correct use also includes observation of and compliance with the maintenance specifications. Modifications or conversions Unauthorized modifications to the engine represent a safety risk. MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or conversions. Spare parts Only genuine MTU spare parts must be used to replace components or assemblies.

  • Page 6: Personnel And Organizational Requirements

    1.2 Personnel and organizational requirements Personnel requirements All work on the engine shall be carried out by trained and qualified personnel only. The specified legal minimum age must be observed. The operator must specify the responsibilities of the operating, maintenance and repair personnel. Organizational measures This publication must be issued to all personnel involved in operation, maintenance, repair or transporta‐...

  • Page 7: 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 so.

  • Page 8: Crankshaft Transport Locking Device

    1.4 Crankshaft transport locking device Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10-60 Nm F30510423 Torque wrench, 60-320 Nm F30047446 Engine oil Transport locking device Note: The locking device protects the crankshaft bearings from shocks and vibration damage during engine transport.
  • Page 9 Fitting the transport locking device on driving end (KS) Note: Attach plates (2) only to the upper part of the openings. Secure the two plates (2) with screws (6) and washers (5) at the bores on both sides of the flywheel housing and tighten to the specified tightening torque.
  • Page 10 Installing guard plates and engine mounting brackets (if applicable) on driving end (KS) Note: Always use the screws supplied with the or removed from the guard plates and engine mounting brackets to secure them on the engine. Install engine mounting brackets (2) on both sides with guard plates (1) washers (3), and screws (4).

  • Page 11: Safety Regulations For Startup And Operation

    Safety precautions when putting the equipment into operation Prior to initial operation of the assembly or plant, install the assembly or unit according to the specifica‐ tions and check the installation according to the MTU specifications. Before putting the device or plant into operation, always ensure: •...

  • Page 12: Explosion Hazard When Removing Inspection Port Cover On Engine

    1.6 Explosion hazard when removing inspection port cover on engine DANGER Explosion hazard due to oil vapors. Risk of serious injury – danger to life! • Allow the engine to cool down before opening the crankcase! • Avoid open flames, electrical sparks and ignition sources. Safety instructions Before starting maintenance work, allow the engine to cool down for at least 10 min.

  • Page 13: Safety Regulations For Maintenance And Repair Work

    1.7 Safety regulations for maintenance and repair work Safety regulations for maintenance and repair work Have maintenance and repair work carried out by qualified and authorized personnel only. Allow the engine to cool down before starting maintenance work (risk of explosion of oil vapors). Before starting work, relieve pressure in systems and compressed-air lines which are to be opened.
  • Page 14 Do not use the assembly or system as ground terminal. Do not route the welding lead over or near the wiring harnesses of MTU systems. The welding current may otherwise induce an interference voltage in the wiring harnesses which could conceivably damage the electrical system.
  • Page 15 For conducting light-beam procedures and measurement work, only the following laser devices must be used: • Laser devices of classes 1, 2 or 3A. • Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700 nm), a maximum output of 5 mW, and in which the beam axis and surface are designed to prevent any risk to the eyes.

  • Page 16: Auxiliary Materials, Fluids And Lubricants

    Use only fuel of prescribed quality to comply with emission limit values. Dispose of used fluids, lubricants and filters in accordance with local regulations. Within the EU, batteries can be returned free of charge to MTU FN / MTU Onsite Energy where they are subjected to proper recycling procedures.
  • Page 17 Lead • When working with lead or lead-containing compounds, avoid direct contact to the skin and do not inhale lead vapors. • Adopt suitable measures to avoid the formation of lead dust. • Switch on extraction system. • Wash hands after contact with lead or lead-containing substances. Compressed air Observe special safety precautions when working with compressed air: •...

  • Page 18: Conventions For Safety Instructions In The Text

    1.9 Conventions for safety instructions in the text DANGER In the event of immediate danger. Consequences: Death or serious injury • Remedial action WARNING In the event of potentially dangerous situations. Consequences: Death or serious injury • Remedial action CAUTION In the event of dangerous situations.

  • Page 19: General Information

    2 General Information 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).

  • Page 20: Product Description

    2.2 Product description Description of the engine Engine The engine is a liquid-cooled four-stroke cycle diesel engine, rotating counterclockwise (seen from driv‐ ing end), with direct injection, sequential exhaust turbocharging and charge-air cooling. The engine is monitored by an engine control and monitoring system (ADEC). The monitoring in the engine room is carried out by the engine control and monitoring unit (LOP).
  • Page 21 • Interface to CAN field bus for connected, communicating monitoring system components. SOLAS – Fire protection specifications Fuel system, fuel lines with fuel pressures exceeding 1.8 bar All lines with SOLAS-compliant covers for pipe connections, according to MTU standard MTN5233, are shown. 1 Fuel line to fuel filter head...
  • Page 22 1 Fuel line from fuel filter head 1 Fuel line to HP pump Lube oil system, oil lines with oil pressures exceeding 1.8 bar All lines with SOLAS-compliant covers for pipe connections, according to MTU standard MTN5233, are shown. 22 | General Information | MS150048/03E 2012-07...
  • Page 23 1 Parting line ETC oil supply free end 1 Parting line ETC oil supply driving 1 Oil line to equipment carrier MS150048/03E 2012-07 | General Information | 23...
  • Page 24 1 Oil supply to HP pump 1 Oil supply to flap control free end 1 ETC oil supply on main oil gallery 24 | General Information | MS150048/03E 2012-07...
  • Page 25 1 Switching cylinder air flap A2 1 Oil line connection 2 Switching cylinder exhaust flap tur‐ bocharger A2 3 T piece flap control 1 Connection oil line to turbocharger 2 Switching cylinder exhaust flap tur‐ bocharger B1 3 T piece flap control turbocharger B1 MS150048/03E 2012-07 | General Information | 25...
  • Page 26 1 Switching cylinder air flap turbo‐ charger B1 1 Connection oil line to turbocharger 2 Switching cylinder exhaust flap tur‐ bocharger B2 3 Switching cylinder air flap turbo‐ charger B2 4 T piece flap control turbocharger B2 1 Flap control distributor 26 | General Information | MS150048/03E 2012-07...
  • Page 27 Special connections The following types of union are spray-proof in case of leakage even without covers and have been con‐ firmed as being SOLAS-compliant by GL and DNV. Plug-in pipe connection Design precludes lateral spray as the point of separation is shielded by the sleeve (4). Only seepage along the pipeline is possible whereby the pressure is greatly reduced by a faulty O-ring (3).
  • Page 28 HP connections 1 Jacket tube 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 pipe 4 Union nut 11 Connecting piece 18 HP line inner 5 Recess for O-ring 12 Circlip 19 Ball retaining area...

  • Page 29: Engine Overview

    2.3 Engine overview 1 Oil cooler 6 Charge-air pipework 11 Automatic oil filter 2 Crankcase breather 7 Cylinder head 12 HP fuel pump 3 Air filter 8 Oil filler neck 13 Fuel filter 4 Exhaust turbocharger 9 Engine mounting 14 Centrifugal oil filter(s) 5 Intercooler 10 Oil pan 15 Coolant cooler...

  • Page 30: Sensors, Actuators And Injectors - Overview

    2.4 Sensors, actuators and injectors – Overview Top view 20V 4000 M 1 B4.A1 (exhaust temper‐ 10 B4.A10 (exhaust tem‐ 19 B4.B7 (exhaust temper‐ ature cyl. A1) perature cyl. A10) ature cyl. B7) 2 B4.A2 (exhaust temper‐ 11 B5.2 (lube oil pressure 20 B4.B6 (exhaust temper‐...
  • Page 31 20V 4000 M left side 1 B7 (lube oil tempera‐ 8 B10 (charge-air pres‐ 15 B57.7 (main bearing ture) sure) temperature) 2 B50 (crankcase pres‐ 9 B57.1 (main bearing 16 B57.8 (main bearing sure) temperature) temperature) 3 B44.3 (turbocharger C 10 B57.2 (main bearing 17 B57.9 (main bearing speed)
  • Page 32 20V 4000 M free end 1 B6 (coolant tempera‐ 3 B33 (fuel temperature) 5 B54 (oil refill pump ture) 4 B1 (camshaft speed) pressure) 2 F46 (leak fuel level) 6 B6.2 (coolant tempera‐ ture) 32 | General Information | MS150048/03E 2012-07...
  • Page 33 20V 4000 M right side 1 B44.2 (turbocharger B 7 B21 (raw water pres‐ 13 B77.B5 (spray oil temp. speed) sure) conrod bearing) 2 B4.22 (temperature, tur‐ 8 B77.B10 (spray oil temp. 14 B77.B4 (spray oil temp. bocharger B) conrod bearing) conrod bearing) 3 B49 (charge-air temper‐...
  • Page 34 20 V 4000 M driving end 1 B13.2 (crankshaft 3 S37.2 (safety switch) speed) 4 S37.1 (safety switch) 2 B13 (crankshaft speed) 34 | General Information | MS150048/03E 2012-07...

  • Page 35: Technical Data

    3 Technical Data 3.1 20V 4000 M93 engine data: IMO, engine-mounted heat exchanger, intercooler made of copper-based alloy EXPLANATION Abbr. Meaning Reference value: Continuous power (CP) Reference value: Fuel stop power (FSP) Design value Guaranteed value Benchmark Limit value up to which the engine can be operated without change, e.g. of power setting. Not yet defined value Not applicable Applicable...
  • Page 36 Number of cylinders Cylinder displacement Liters 4.31 Total displacement Liters 86.2 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. -0.2 Raw water pump: Inlet pressure, max. Pressure loss in off-engine raw water system, max.
  • Page 37 INCLINATIONS, STANDARD OIL SYSTEM (Reference: Waterline) Number of cylinders Longitudinal inclination, continuous max., driving end down (Option: max. Degrees operating inclinations) Longitudinal inclination, temporary max., driving end down (Option: max. Degrees 22.5 operating inclinations) Longitudinal inclination, continuous max., driving end up (Option: max. op‐ Degrees erating inclinations) Longitudinal inclination, temporary max., driving end up (Option: max.

  • Page 38: 4000 M93 Engine Data: Epa 2, Engine-Mounted Heat Exchanger

    3.2 20V 4000 M93 engine data: EPA 2, engine-mounted heat exchanger EXPLANATION Abbr. Meaning Reference value: Continuous power (CP) Reference value: Fuel stop power (FSP) Design value Guaranteed value Benchmark Limit value up to which the engine can be operated without change, e.g. of power setting. Not yet defined value Not applicable Applicable...
  • Page 39 Number of cylinders 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. -0.2 Raw water pump: Inlet pressure, max. Pressure loss in off-engine raw water system, max. LUBE OIL SYSTEM Number of cylinders Lube oil operating temperature before engine, from...
  • Page 40 INCLINATIONS, STANDARD OIL SYSTEM (Reference: Waterline) Number of cylinders Longitudinal inclination, continuous max., driving end down (Option: max. Degrees operating inclinations) Longitudinal inclination, temporary max., driving end down (Option: max. Degrees 22.5 operating inclinations) Longitudinal inclination, continuous max., driving end up (Option: max. op‐ Degrees erating inclinations) Longitudinal inclination, temporary max., driving end up (Option: max.

  • Page 41: 4000 M93L Engine Data: Imo, Engine-Mounted Heat Exchanger, Intercooler Made Of Copper-Based Alloy

    3.3 20V 4000 M93L engine data: IMO, engine-mounted heat exchanger, intercooler made of copper-based alloy EXPLANATION Abbr. Meaning Reference value: Continuous power (CP) Reference value: Fuel stop power (FSP) Design value Guaranteed value Benchmark Limit value up to which the engine can be operated without change, e.g. of power setting. Not yet defined value Not applicable Applicable...
  • Page 42 Number of cylinders 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. -0.2 Raw water pump: Inlet pressure, max. Pressure loss in off-engine raw water system, max. LUBE OIL SYSTEM Number of cylinders Lube oil operating temperature before engine, from...
  • Page 43 INCLINATIONS, STANDARD OIL SYSTEM (Reference: Waterline) Number of cylinders Longitudinal inclination, continuous max., driving end down (Option: max. Degrees operating inclinations) Longitudinal inclination, temporary max., driving end down (Option: max. Degrees 22.5 operating inclinations) Longitudinal inclination, continuous max., driving end up (Option: max. op‐ Degrees erating inclinations) Longitudinal inclination, temporary max., driving end up (Option: max.

  • Page 44: 4000 M93L Engine Data: Epa 2, Engine-Mounted Heat Exchanger

    3.4 20V 4000 M93L engine data: EPA 2, engine-mounted heat exchanger EXPLANATION Abbr. Meaning Reference value: Continuous power (CP) Reference value: Fuel stop power (FSP) Design value Guaranteed value Benchmark Limit value up to which the engine can be operated without change, e.g. of power setting. Not yet defined value Not applicable Applicable...
  • Page 45 Number of cylinders 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. -0.2 Raw water pump: Inlet pressure, max. Pressure loss in off-engine raw water system, max. LUBE OIL SYSTEM Number of cylinders Lube oil operating temperature before engine, from...
  • Page 46 INCLINATIONS, STANDARD OIL SYSTEM (Reference: Waterline) Number of cylinders Longitudinal inclination, continuous max., driving end down (Option: max. Degrees operating inclinations) Longitudinal inclination, temporary max., driving end down (Option: max. Degrees 22.5 operating inclinations) Longitudinal inclination, continuous max., driving end up (Option: max. op‐ Degrees erating inclinations) Longitudinal inclination, temporary max., driving end up (Option: max.

  • Page 47: Firing Order

    3.5 Firing order Firing order Num‐ Firing order ber of cylin‐ ders A1-B4-A4-A2-B3-A3-B2-B1 A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1 16 V A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B7 20 V A1-B5-A8-B7-A5-B2-A7-B10-A2-B3-A10-B6-A3-B4-A6-B9-A4-B1-A9-B8 MS150048/03E 2012-07 | Technical Data | 47...

  • Page 48: Operation

    4 Operation 4.1 Controls Automation system controls Refer to automation system operating instructions 48 | Operation | MS150048/03E 2012-07...

  • Page 49: Tasks After Extended Out-Of-Service Periods (>3 Weeks)

    4.2 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 51). Shut down fuel treatment system (→ Page 65). MS150048/03E 2012-07 | Operation | 49...

  • Page 50: Checks Prior To Start-Up

    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 51: Fuel Treatment System - Putting Into Operation

    4.4 Fuel treatment system – Putting into operation Overview of fuel treatment system 1 Pressure-free overflow 2 Bypass 1 3 Bypass 2 4 Safety valve, 3 bar 5 Ball valve, inlet 6 Pressure gage 7 Ventilation, sample extraction 8 Differential pressure gage 9 Ball valve, outlet 10 Check valve 700 mbar 11 Check valve 5 mbar...
  • Page 52 Simulation of filter replacement with the engine running: HAT Switch on fuel treatment system (→ Page 54). Start engine (→ Page 53). Run engine at idling speed. Close ball valve (5) at inlet to fuel treatment system. Result: The pressure upstream of the fuel treatment system increases until the overflow valve at the pump unit opens and fuel flows through bypass (3) and bypass (2).

  • Page 53: Starting The Engine

    4.5 Starting the engine Preconditions ☑ External start interlock is not active. ☑ Emergency air shut-off flaps (if fitted) are open. DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Before barring or starting the engine, make sure that nobody is in the danger zone. WARNING Engine noise above 85 dB (A).

  • Page 54: Fuel Treatment System - Switching On

    4.6 Fuel treatment system – Switching on Preconditions ☑ The on-board power supply is switched on. CAUTION Damage to engine/plant. Major material damage! • Before switching on, ensure that the engine/plant is ready for operation. • Before switching on, ensure that all housings are closed. •...

  • Page 55: Starting The Engine

    4.7 Starting the engine BlueLine automation system Starting the engine at LOS or at LOP 8 (with display) (→ BlueLine Operating Instructions) Starting the engine at LOP 6 (without display) (→ BlueLine Operating Instructions) Starting the engine at control stand (→...

  • Page 56: Engine Emergency Stop At Blueline Automation System (Control Stand)

    4.8 Engine emergency stop at BlueLine automation system (control stand) CAUTION An emergency stop causes extreme stress to the engine. Risk of overheating, damage to components! • Initiate emergency stop only in emergency situations. Engine emergency stop at BlueLine automation system Item Measure Engine...

  • Page 57: Operational Checks

    4.9 Operational checks DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...

  • Page 58: Coupling - Engaging From Lop

    4.10 Coupling – Engaging from LOP Preconditions ☑ LOCAL OPERATION illuminated pushbutton lights up brightly (local operating mode is active). ☑ Engine speed in engagement window. ☑ No external engagement interlock active. DANGER Vessel is sailing blind. In Local Operation mode, the propulsion plant is controlled from the engine room. Risk of accidents! •...

  • Page 59: Coupling - Disengaging From Lop

    4.11 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 48). •...

  • Page 60: Waterjet - Flushing From Lop (Optional)

    4.12 Waterjet – Flushing from LOP (optional) Preconditions ☑ LOCAL OPERATION illuminated pushbutton lights up brightly (local operating mode is active). ☑ Vessel at a standstill and Waterjet bucket below the waterline. ☑ Engine speed in engagement window. ☑ No external engagement interlock active. CAUTION Waterjet flushing puts excessive strain on the bearings.

  • Page 61: Stopping The Engine From Lop

    4.13 Stopping the engine from LOP Preconditions ☑ Engine is running in local mode. CAUTION 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 mins. until engine temperatures have dropped and constant values are displayed.

  • Page 62: Stopping The Engine At The Blueline Automation System (Control Stand)

    4.14 Stopping the engine at the BlueLine automation system (control stand) CAUTION 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 mins. until engine temperatures have dropped and constant values are displayed.

  • Page 63: Emergency Stop From Lop

    4.15 Emergency stop from LOP CAUTION An emergency stop causes extreme stress to the engine. Risk of overheating, damage to components! • Initiate emergency stop only in emergency situations. Emergency stop from LOP Item Measure Open cap of illuminated EMERGENCY STOP pushbutton (→ Page 48). Press EMERGENCY STOP illuminated pushbutton.

  • Page 64: After Stopping The Engine

    4.16 After stopping the engine Preconditions ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. After stopping the engine Item Action Coolant circuit Drain coolant (→ Page 123) if: • freezing temperatures are expected and the engine is to remain out of service for an extended period, but engine coolant has no antifreeze additive;...

  • Page 65: Fuel Treatment System - Shutdown

    4.17 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 66: Plant Cleaning

    4.18 Plant cleaning Preconditions ☑ Engine is stopped and starting disabled. ☑ Operating voltage is not present. Special tools, Material, Spare parts Designation / Use Part No. Qty. Steam jet cleaner Cleaner (Hakupur 312) 30390 WARNING Compressed air Risk of injury! •...

  • Page 67: Maintenance

    5 Maintenance 5.1 Maintenance schedule task reference table [QL1] The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Maintenance Schedule is a stand-alone publication. The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance Schedule.

  • Page 68: 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 1. Press illuminated pushbutton “Water alarm” to acknowledge. is reached, the water level elec‐ 2. In addition to the automatic water drain function, water can also trode opens the water drain be drained manually.

  • Page 69: Troubleshooting

    6.2 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 whether cable connections are properly secured (see manufacturer's documentation). Starter Engine wiring or starter defective Check whether cable connections are properly secured, contact Service.
  • Page 70 Contact Service. Defective Contact Service. Charge-air temperature too high Component Probable cause Task Engine coolant Incorrect engine coolant concentration Check (MTU test kit). Intercooler Contaminated Contact Service. Engine room Air-intake temperature too high Check fans and air supply / ventilation ducts.
  • Page 71 Exhaust gas white Component Probable cause Task Engine Not at operating temperature Run engine to reach operating temper‐ ature. Intercooler Leaking Contact Service. MS150048/03E 2012-07 | Troubleshooting | 71...

  • Page 72: Task Description

    7 Task Description 7.1 Engine 7.1.1 Engine – Barring manually Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Barring device F6555766 Ratchet head with extension F30006212 DANGER Unguarded rotating and moving engine components. Risk of serious injury –...

  • Page 73: Engine - Barring With Starting System

    7.1.2 Engine – Barring with starting system Barring using the automation system Refer to automation system operating instructions MS150048/03E 2012-07 | Task Description | 73...

  • Page 74: Cylinder Liner

    7.2 Cylinder Liner 7.2.1 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 83). Remove injector (→...
  • Page 75 Final steps Install injector (→ Page 85). Install cylinder head cover (→ Page 83). MS150048/03E 2012-07 | Task Description | 75...

  • Page 76: Cylinder Liner - Instructions And Comments On Endoscopic And Visual Examination

    7.2.2 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 exami‐ nation report. Findings Measure Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing prod‐...
  • Page 77 Findings Measure Burn mark This is caused by a malfunction in the liner / ring tribosystem. Usually they run over the whole ring-travel area (TDC/BDC), starting at the first TDC-ring and becoming more visible from the second TDC-ring 2 onwards and less pro‐ nounced from TDC-ring 1.

  • Page 78: Valve Drive

    7.3 Valve Drive 7.3.1 Valve gear – Lubrication Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil Valve gear – Lubrication Remove cylinder head covers (→ Page 83). Fill oil chambers of valve bridges with oil.

  • Page 79: Valve Clearance - Check And Adjustment

    7.3.2 Valve clearance – Check and adjustment Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine coolant temperature is max. 40 °C. ☑ Valves are closed. Special tools, Material, Spare parts Designation / Use Part No. Qty. Feeler gauge Y20098771 Torque wrench, 60-320 Nm F30452768...
  • Page 80 Rotate crankshaft with barring device in di‐ rection of engine rotation until TDC-A1 marking and pointer are aligned. Diagram for 8V engines (two crankshaft positions) 1 Cylinder A1 is in firing TDC 2 Cylinder A1 is in overlap TDC I Inlet valve X Exhaust valve Diagram for 12V engines (two crankshaft positions)
  • Page 81 Diagram for 16V engines (two crankshaft positions) 1 Cylinder A1 is in firing TDC 2 Cylinder A1 is in overlap TDC I Inlet valve X Exhaust valve Diagram for 20V engines (two crankshaft positions) 1 Cylinder A1 is in firing TDC 2 Cylinder A1 is in overlap TDC I Inlet valve X Exhaust valve...
  • Page 82 Adjusting valve clearance Release locknut (1). Insert feeler gauge between valve bridge and rocker arm. Use Allen key to set adjusting screw (2) so that the specified valve clearance is estab‐ lished. Feeler gauge must just pass through the gap. Tighten locknut (1) with torque wrench to the specified tightening torque, holding the adjusting screw (2) to prevent it from turning.

  • Page 83: Cylinder Head Cover - Removal And Installation

    7.3.3 Cylinder head cover – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Grease (Kluthe Hakuform 30-10/Emulgier) X00058061 O-ring (→ Spare Parts Catalog) Removing cylinder head cover Clean very dirty cylinder head covers (3) prior to removal.

  • Page 84: Injection Valve / Injector

    7.4 Injection Valve / Injector 7.4.1 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 85). 84 | Task Description | MS150048/03E 2012-07...

  • Page 85: Injector - Removal And Installation

    7.4.2 Injector – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Installation/removal tool F6789889 Milling cutter F30452739 Torque wrench, 0.5-5 Nm 0015384230 Torque wrench, 10-60 Nm F30452769 Torque wrench, 60-320 Nm F30452768...
  • Page 86 Remove HP fuel line (4). Remove return line (5). Note: The injector accumulator will be emptied when removing the adapter. Remove adapter (3). Remove screw (2) and take off hold-down clamp (1). Install installation/removal tool on cylinder head. Remove injector with installation/removal tool.

  • Page 87: Installing Injector

    Installing injector Remove plug before installing the injector. (Do not remove the plug from the HP line before installing the adapter.) Coat injector with assembly paste at the seat of the nozzle clamping nut. Fit new sealing ring (4) (included in the scope of supply of the injector) with grease on injector, observe installation position of sealing ring (4).
  • Page 88 Coat screw head mating face (2) and thread with engine oil. Fit hold-down clamp (1) in the correct position and use torque wrench to tighten screw (2) to the specified initial tightening torque. Name Size Type Lubricant Value/Standard Screw Preload torque (Engine oil) 5 Nm to 10 Nm Note:...
  • Page 89 Mount double-walled HP line (5) and use torque wrench to tighten to the specified torque. Tightening sequence: 1 Adapter (4) 2 Rail (6) Name Size Type Lubricant Value/Standard Union nut / thrust Tightening torque 40 Nm + 5 Nm screw Fit cable connector onto injector.

  • Page 90: Fuel Filter

    7.5 Fuel Filter 7.5.1 Fuel filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Oil filter wrench F30379104 Diesel fuel Easy-change filter (→ Spare Parts Catalog) Synthetic ring (→...

  • Page 91: Engine Running

    Fuel filter replacement with the engine stopped A Both filters operating B Left filter cut out C Right filter cut out 1 Fuel vent 2 Fuel filter Cut out the filter to be replaced. Remove cut-out easy-change filter using the oil filter wrench. Clean the sealing face of the filter head.
  • Page 92 7.5.2 Fuel prefilter – Differential pressure gauge check and adjustment DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...

  • Page 93: Fuel Prefilter – Draining

    7.5.3 Fuel prefilter – Draining Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel Gasket (→ Spare Parts Catalog) WARNING Fuels are combustible. Risk of fire and explosion! •...

  • Page 94: Fuel Prefilter ‒ Flushing

    7.5.4 Fuel prefilter ‒ Flushing Special tools, Material, Spare parts Designation / Use Part No. Qty. Fuel Gasket (→ Spare Parts Catalog) DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Fuels are combustible.
  • Page 95 Open threaded vent plug (5) of filter to be flushed. Unlock drain valve (6) by pressing valve toggle, open it and drain fuel. Result: Fuel flows from filtered side back to the un‐ filtered side, flushing the filter deposits downwards out of the filter. Close threaded vent plug (5) and drain valve (6).

  • Page 96: Fuel Prefilter – Filter Element Replacement

    7.5.5 Fuel prefilter – Filter element replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel Filter element (→ Spare Parts Catalog) Gasket (→ Spare Parts Catalog) WARNING Fuels are combustible.
  • Page 97 Open threaded vent plug (5) of contaminat‐ ed filter. Unlock drain valve (6) by pressing toggle and open it. Drain water and dirt from filter. Close drain valve (6). Remove screws securing the cover and take off cover (2). Remove spring housing (4) and filter ele‐ ment (3).

  • Page 98: Charge-Air Cooling

    7.6 Charge-Air Cooling 7.6.1 Compressor wheel – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Cold cleaner X00056750 WARNING Compressed air Risk of injury! • Do not direct compressed-air jet at persons. •...
  • Page 99 Final steps Install air intake. Install exhaust flap with actuators. Install exhaust system after exhaust turbocharger. Install air filter.(→ Page 102) Fill with engine coolant.(→ Page 124) MS150048/03E 2012-07 | Task Description | 99...
  • Page 100 7.6.2 Intercooler – Check water drain for coolant discharge and obstruction DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...

  • Page 101: Air Filter

    7.7 Air Filter 7.7.1 Air filter – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Air filter (→ Spare Parts Catalog) Replacing the air filter Remove old air filter and install new air filter (→ Page 102). Reset signal ring of contamination indicator (→...

  • Page 102: Air Filter – Removal And Installation

    7.7.2 Air filter – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Removing and installing air filter Release clamp (2). Remove air filter (3) and clamp (2) from connecting flange of intake housing (1). Verify that there are no objects in the con‐ necting flange of the intake housing (1) and clean it.

  • Page 103: Air Intake

    7.8 Air Intake 7.8.1 Contamination indicator – Signal ring position check (optional) Preconditions ☑ Engine is stopped and starting disabled. Checking signal ring position If the signal ring is completely visible in the observation window (2), replace air filter (→ Page 101). After installation of new filter, press reset button (1).

  • Page 104: Air Flap – Check For Ease Of Movement

    7.8.2 Air flap – Check for ease of movement Preconditions ☑ Engine is stopped and starting disabled. DANGER Unguarded rotating and moving engine components. Risk of serious injury — danger to life! • Before working on the engine, disable engine start. Checking air flap for ease of movement Open air flap by moving the lever in the di‐...

  • Page 105: Exhaust Flap With Actuator

    7.9 Exhaust Flap with Actuator 7.9.1 Exhaust flap – Check for easy movement Preconditions ☑ Engine is stopped and starting disabled. Checking exhaust flap for easy movement Actuate control linkage and actuating cylin‐ der several times by hand to check for easy movement.

  • Page 106: Starting Equipment

    7.10 Starting Equipment 7.10.1 Starter – Condition check Preconditions ☑ Engine is stopped and starting disabled. Checking starter condition Check securing screws of starter for secure seating and tighten if required. Check wiring (→ Page 143). 106 | Task Description | MS150048/03E 2012-07...

  • Page 107: Lube Oil System, Lube Oil Circuit

    7.11 Lube Oil System, Lube Oil Circuit 7.11.1 Engine oil level – Check Preconditions ☑ Engine shut down and starting disabled. Checking oil level prior to engine start Withdraw oil dipstick from guide tube and wipe it. Insert oil dipstick into guide tube up to stop, withdraw after approx.

  • Page 108: Engine Oil – Change

    7.11.2 Engine oil – Change Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine is at operating temperature. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench...
  • Page 109 Tighten drain plugs (1) and (2) with torque wrench to the specified torque: Name Size Type Lubricant Value/Standard Tightening torque 100 Nm+10Nm Filling new oil Open cover of filler neck. Pour oil in at filler neck up to "max." mark at oil dipstick.

  • Page 110: Engine Oil – Sample Extraction And Analysis

    7.11.3 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 Unguarded rotating and moving engine components.

  • Page 111: Oil Filtration / Cooling

    7.12 Oil Filtration / Cooling 7.12.1 Engine oil filter – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Engine oil Oil filter (→ Spare Parts Catalog) DANGER Unguarded rotating and moving engine components. Risk of serious injury –...
  • Page 112 Oil filter with diverter (option): Oil filter replacement with the engine stopped Stop engine (→ Page 61) and disable en‐ gine start. Unscrew oil filter using oil filter wrench. Clean sealing surface on connecting piece. Check condition of new oil filter sealing ring and moisten it with oil.
  • Page 113 7.12.2 Automatic oil filter – Oil filter candle replacement Preconditions ☑ Engine shut down and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 Engine oil O-ring (→ Spare Parts Catalog) Oil filter candles (→...
  • Page 114 Withdraw filter insert (1). Remove O-ring. Remove screw (2). Withdraw plastic spinner (1) with spring. Unscrew nut (3). Take off spring washer and washer. Remove screw (4). Remove flushing arm (5) from screen plate (6). Turn filter element through 180° and use appropriate tool to push out filter can‐...
  • Page 115 Installing oil filter candles For installation follow reverse sequence of working steps. Additionally, the following instructions are to be observed: • Replace all sealing elements with new parts • Coat O-rings with grease • Insert O-rings in grooves • Pay attention to installation position of fillister-head screw to elongated hole in shaft MS150048/03E 2012-07 | Task Description | 115...

  • Page 116: Oil Indicator Filter – Check

    7.12.3 Oil indicator filter – Check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Strainer (→ Spare Parts Catalog) Square-section ring (→ Spare Parts Catalog) O-ring (→ Spare Parts Catalog) WARNING Hot oil.
  • Page 117 Checking strainer Item Findings Task Strainer Metallic residues • Clean • Monitor engine operation • Check strainer daily • Contact Service. Strainer Damaged Replace Square-section ring Damaged Replace O-ring Damaged Replace Cleaning strainer Wash strainer (5) with cleaner. Remove stubborn deposits with soft brush. Blow out strainer (5) with compressed air from inside.
  • Page 118 7.12.4 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, 6-50 Nm F30027336 Cold cleaner (Hakutex 60) X00056750 Filter sleeve (→...
  • Page 119 Centrifugal oil filter cleaning and filter sleeve replacement Remove clamp (14). Release cover screw (2) and take off cov‐ er (1). Carefully lift rotor (11), allow oil to drain and remove from housing. Holding the rotor (11) firmly, release rotor cover nut (3).

  • Page 120: Coolant Circuit, General, High Temperature Circuit

    7.13 Coolant Circuit, General, High-Temperature Circuit 7.13.1 Ventilation points Coolant lines on exhaust turbocharger 1 Ventilation point 120 | Task Description | MS150048/03E 2012-07...

  • Page 121: Engine Coolant – Level Check

    7.13.2 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 122: Engine Coolant – Change

    7.13.3 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant – Change Drain engine coolant (→ Page 123). Fill with engine coolant (→ Page 124). 122 | Task Description | MS150048/03E 2012-07...

  • Page 123: Engine Coolant Draining

    7.13.4 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 124: Engine Coolant – Filling

    7.13.5 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 125 Filling with coolant using a pump Connect appropriate pump with hose to fill‐ ing connection (arrow) on A side or B side. Alternatively: Connect a suitable pump with a hose to drain valve (arrowed). Pump coolant into engine at 0.5 bar mini‐ mum until coolant emerges from the loos‐...
  • Page 126 Filling with coolant through filler neck Alternatively: Fill coolant through filler neck on expansion tank until coolant emerges from the loosened unions at the coolant distribution. Tighten the union for coolant line at the coolant distributor (→ Page 120). Continue to fill until coolant level remains constant at top edge of filler neck. Tighten the coolant line union on both turbochargers (→...

  • Page 127: Engine Coolant Pump – Relief Bore Check

    7.13.6 Engine coolant pump – Relief bore check DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...
  • Page 128 7.13.7 Engine coolant – Sample extraction and analysis Preconditions ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. MTU test kit 5605892099/00 DANGER Unguarded rotating and moving engine components.

  • Page 129: Coolant Filter – Replacement

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

  • Page 130: Low-Temperature Circuit

    7.14 Low-Temperature Circuit 7.14.1 Charge-air coolant – Draining Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Sealing ring (→ Spare Parts Catalog) WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...

  • Page 131: Raw Water Pump With Connections

    7.15 Raw Water Pump with Connections 7.15.1 Raw water pump – Relief bore check DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A).
  • Page 132 7.16 Battery-Charging Generator 7.16.1 Battery-charging generator drive – Coupling condition check Preconditions ☑ Engine shut down and starting disabled. Checking condition of battery- charging generator drive coupling Remove protective cover. Check resilient coupling for cracks and de‐ formation (arrow). Contact Service in case of severe deforma‐ tion or cracking.

  • Page 133: Engine Mounting / Support

    7.17 Engine Mounting / Support 7.17.1 Engine mounts – Checking securing screws for firm seating Preconditions ☑ Engine is stopped and starting disabled. Engine mounts – Checking securing screws for firm seating Check securing screws for firm seating. Tighten loose threaded connections. MS150048/03E 2012-07 | Task Description | 133...

  • Page 134: Engine Mounts – Resilient Element Check

    7.17.2 Engine mounts – Resilient element check Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine is filled with coolant and engine oil. Special tools, Material, Spare parts Designation / Use Part No. Qty. Feeler gauge Y20010128 Calipers Y20001743 Box wrench F30379609 Engine oil...
  • Page 135 Engine mounts – Checking buffer clearance Take off protective cap (2). Check marking (1): • With marking 30: a = 3 mm +0,3 mm. • With marking 40: a = 4 mm +0,3 mm. Check dimension (a) with feeler gauge on measuring groove (4).
  • Page 136 7.18 Drive Systems, Driving End and Free End (Coupling) 7.18.1 Coupling – Condition check Preconditions ☑ Engine is stopped and starting disabled. Coupling condition check Remove perforated plate(s). Wipe rubber element with dry cloth, do not use organic detergents. Check condition of coupling through assembly hole(s) using an inspection lamp. Hair cracks in the rubber elements are permissible.

  • Page 137: Fuel Supply System

    7.19 Fuel Supply System 7.19.1 Water drain valve – Check Water drain valve – Check Open water drain valve. Check water outlet for obstructions. Close water drain valve. MS150048/03E 2012-07 | Task Description | 137...

  • Page 138: Differential Pressure Gauge – Check

    7.19.2 Differential pressure gauge – Check WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Checking differential pressure gauge Switch on fuel treatment system (→ Page 54). Set the alarm points at the differential pressure gauge to zero.
  • Page 139 7.19.3 Water level probe (3-in-1 rod electrode) – Check Preconditions ☑ System is put out of operation and emptied. WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Checking water level probe (3-in-1 rod electrode) Disconnect connector from water level probe.

  • Page 140: Pump Capacity – Check

    7.19.4 Pump capacity – Check WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Pump capacity – Check Install suitable pressure gauge in the intake connection of the pump. Check pump pressure.

  • Page 141: Coalescer Filter Element – Replacement

    7.19.5 Coalescer filter element – Replacement Preconditions ☑ System is switched off and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 6-50 Nm F30027336 Ratchet adapter F30027339 Diesel fuel Engine oil Coalescer filter element (→...
  • Page 142 Tighten nut (3) to specified tightening torque using a torque wrench. Name Size Type Lubricant Value/Standard Tightening torque (Engine oil) 30 Nm +3 Nm Fit gasket (10). Install cover. Install screw (1), washer (2) and nut (9). Tighten nut (9). Open ball valve at the inlet and outlet of the fuel treatment system.

  • Page 143: Wiring (General) For Engine/Gearbox/Unit

    7.20 Wiring (General) for Engine/Gearbox/Unit 7.20.1 Engine wiring – Check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Isopropyl alcohol X00058037 Engine wiring – Check Check securing screws of cable clamps on engine and tighten loose threaded connections. Ensure that cables are fixed in their clamps and cannot swing freely.

  • Page 144: Accessories For (Electronic) Engine Governor / Control System

    7.21 Accessories for (Electronic) Engine Governor / Control System 7.21.1 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 appli‐ cable.

  • Page 145: Engine Governor And Connectors – Cleaning

    7.21.2 Engine governor and connectors – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Isopropyl alcohol X00058037 Note: Always use test connectors to enter the connectors. Never use test leads for this purpose.Otherwise the contacts could be bent.

  • Page 146: Emu And Connectors – Cleaning

    7.21.3 EMU and connectors – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Isopropyl alcohol EMU and connectors – Cleaning Remove coarse dirt from housing surface using a cloth moistened with isopropyl alcohol. Remove dirt from connector and cable surfaces with isopropyl alcohol.
  • Page 147 7.21.4 Engine Monitoring Unit EMU 7 – Plug connection check Preconditions ☑ Engine is stopped and starting disabled. Checking EMU plug connections Check both connectors on EMU (2) for firm seating. Ensure that clips (3) are engaged. Check screws (1) of cable clamps on EMU (2) for firm seating.
  • Page 148 7.21.5 Engine governor – Checking plug-in connections Preconditions ☑ Engine is stopped and starting disabled. Note: Always use test connectors to enter the connectors. Never use test leads for this purpose.Otherwise the contacts could be bent. Checking plug-in connections on engine governor Check all plug-in connections for secure seating.
  • Page 149 7.21.6 ECU 7 engine governor – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. CAUTION 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 150 7.22 Emergency Instrumentation (Local Operating Panel) 7.22.1 LOP and connectors – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Isopropyl alcohol X00058037 Cleaning LOP Wipe LCD display with dry cloth, without applying excessive pressure. Remove dirt from keys using isopropyl alcohol.

  • Page 151: Appendix A 8.1 Abbreviations

    ANSI American National Standards Institute Association of American standardization organiza‐ tions Exhaust turbocharger Series Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU Publica‐ tion No. A01061/.. Controller Area Network Data bus system, bus standard Controllable Pitch Propeller Controllable pitch propeller Deutsches Institut für Normung e. V.
  • Page 152 Abbrevia‐ Meaning Explanation tion Driving end Engine driving end in accordance with DIN ISO 1204 Liquid Crystal Display, Liquid Crystal Liquid-crystal display Device Local Control Unit Local control unit (LOP subassembly) Light Emitting Diode Light emitting diode Local Monitoring Unit Local monitoring unit (LOP subassembly) Alarm: Measured value lower than 1st minimum limit value...

  • Page 153: Mtu Contact Persons/Service Partners

    Local support Experienced and qualified specialists place their knowledge and expertise at your disposal. For locally available support, go to the MTU Internet site: http://www.mtu-online.com 24h hotline With our 24h hotline and the outstanding flexibility of our service staff, we are always ready to assist you –...

  • Page 154: Appendix B 9.1 Special Tools

    9 Appendix B 9.1 Special Tools Barring device Part No.: F6555766 Qty.: Used in: 7.1.1 Engine – Barring manually (→ Page 72) Box wrench Part No.: F30379609 Qty.: Used in: 7.17.2 Engine mounts – Resilient element check (→ Page 134) Box wrench socket, 24 mm Part No.: F30039526...
  • Page 155 Calipers Part No.: Y20001743 Qty.: Used in: 7.17.2 Engine mounts – Resilient element check (→ Page 134) Feeler gauge Part No.: Y20098771 Qty.: Used in: 7.3.2 Valve clearance – Check and adjustment (→ Page Feeler gauge Part No.: Y20010128 Qty.: Used in: 7.17.2 Engine mounts –...
  • Page 156 7.4.2 Injector – Removal and installation (→ Page 85) Milling cutter Part No.: F30452739 Qty.: Used in: 7.4.2 Injector – Removal and installation (→ Page 85) MTU test kit Part No.: 5605892099/00 Qty.: Used in: 7.11.3 Engine oil – Sample extraction and analysis (→ Page 110) Qty.:...
  • Page 157 Ratchet adapter Part No.: F30027341 Qty.: Used in: 7.3.2 Valve clearance – Check and adjustment (→ Page Qty.: Used in: 7.11.2 Engine oil – Change (→ Page 108) Ratchet adapter Part No.: F30027339 Qty.: Used in: 7.19.5 Coalescer filter element – Replacement (→ Page 141) Ratchet head with extension Part No.:...
  • Page 158 Steam jet cleaner Part No.: Qty.: Used in: 4.18 Plant cleaning (→ Page 66) Torque wrench Part No.: F30027337 Qty.: Used in: 7.11.2 Engine oil – Change (→ Page 108) Torque wrench, 0.5-5 Nm Part No.: 0015384230 Qty.: Used in: 7.4.2 Injector –...
  • Page 159 Torque wrench, 6-50 Nm Part No.: F30027336 Qty.: Used in: 7.19.5 Coalescer filter element – Replacement (→ Page 141) Torque wrench, 6-50 Nm Part No.: F30027336 Qty.: Used in: 7.12.4 Centrifugal oil filter – Cleaning and filter sleeve replacement (→ Page 118) Torque wrench, 60-320 Nm Part No.: F30047446...
  • Page 160 Torque wrench, 60-320 Nm Part No.: F30452768 Qty.: Used in: 7.4.2 Injector – Removal and installation (→ Page 85) 160 | Appendix B | MS150048/03E 2012-07...

  • Page 161: Index

    9.2 Index 20V 4000 M93 engine data: EPA 2, engine-mounted Cylinder liner heat exchanger 38 – Endoscopic examination  74 20V 4000 M93 engine data: IMO, engine-mounted heat – Instructions and comments on endoscopic and visual exchanger, intercooler made of copper-based alloy 35 examination  76 20V 4000 M93L engine data: EPA 2, engine-mounted...
  • Page 162 Environmental protection 16 Exhaust flap Maintenance work – Check for easy movement  105 – Safety regulations  13 MTU contact persons 153 Filter – Automatic oil filter   Oil indicator filter – Check 116 – Filter candles - Replacement  113 Operation – Coalescer Element  ...
  • Page 163 Ventilation points 120 Water drain valve – Check  137 Water level probe (3-in-1 rod electrode) – Check  139 Waterjet – Flushing   – From LOP (option)  60 Wiring - engine – Check  143 MS150048/03E 2012-07 | Appendix B | 163...

This manual is also suitable for:

20 v 4000 m93l

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