MTU 12 V 4000 M63 Operating Instructions Manual
  1. Manuals
  2. Brands
  3. MTU Manuals
  4. Engine
  5. 12 V 4000 M63
  6. Operating instructions manual

MTU 12 V 4000 M63 Operating Instructions Manual

Diesel engine
Hide thumbs
Table of Contents

Advertisement

Quick Links

Operating Instructions

Diesel engine
12 V 4000 M63
16 V 4000 M63
16 V 4000 M63R
MS150066/02E

Advertisement

Table of Contents
loading

Related Manuals for MTU 12 V 4000 M63

Summary of Contents for MTU 12 V 4000 M63

  • Page 1: Operating Instructions

    Operating Instructions Diesel engine 12 V 4000 M63 16 V 4000 M63 16 V 4000 M63R MS150066/02E...
  • 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, mi- crofilming and storage or processing on electronic systems including data bases and online services.

  • Page 3: Table Of Contents

    Table of Contents 1 Safety 4.14 Plant cleaning 1.1 Important provisions for all products 5 Maintenance 1.2 Personnel and organizational requirements 1.3 Safety regulations for startup and operation 5.1 Maintenance task reference table [QL1] 1.4 Safety regulations for maintenance and repair work 6 Troubleshooting 1.5 Fire prevention and environmental...
  • Page 4 7.14.7 Engine coolant – Sample extraction and analysis 8.1 Abbreviations 7.14.8 Engine coolant filter – Replacement 8.2 MTU contact persons/service partners 7.14.9 Preheating unit 7.15 Raw Water Pump with Connections 9 Appendix B 7.15.1 Raw water pump – Relief bore check 9.1 Special Tools...

  • Page 5: Safety

    1 Safety 1.1 Important provisions for all products Nameplate The product is identified by nameplate, model designation or serial number and must match with the information on the title page of this manual. Nameplate, model designation or serial number can be found on the product. General information This product may pose a risk of injury or damage in the following cases: •...

  • Page 6: Personnel And Organizational Requirements

    1.2 Personnel and organizational requirements Organizational measures of the operator This manual must be issued to all personnel involved in operation, maintenance, repair or transporta- tion. Keep this manual handy in the vicinity of the product such that it is accessible to operating, mainte- nance, repair and transport personnel at all times.

  • Page 7: Safety Regulations For Startup And Operation

    1.3 Safety regulations for startup and operation Safety regulations for startup Install the product correctly and carry out acceptance in accordance the manufacturer's specifications before putting the product into service. Before the product is put into operation for the first time, all official authorizations must be available and commissioning preconditions met.

  • Page 8: Safety Regulations For Maintenance And Repair Work

    1.4 Safety regulations for maintenance and repair work Safety regulations prior to maintenance and repair work Have maintenance or repair work carried out by qualified and authorized personnel only. Allow the product to cool down to less than 50°C before starting maintenance work (risk of explosion of oil vapors, fluids and lubricants, risk of burning).
  • Page 9 Ensure particular cleanness during maintenance and repair work on the product. After completion of maintenance and repair work, make sure that no loose objects are in/on the product (e.g. cloths and cable ties) Safety regulations after completion of maintenance and repair work Before barring, make sure that nobody is standing in the danger zone of the product.
  • Page 10 Working on electrical and 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. Do not damage cabling during removal work.

  • Page 11: Fire Prevention And Environmental Protection, Fluids And Lubricants, Auxiliary Materials

    The Fluids and Lubricants Specifications will be amended or supplemented as necessary. Prior to opera- tion, make sure that the latest version is used. The applicable version may be downloaded at: http:// www.mtu-online.com/mtu/mtu-valuecare/mtu-valueservice-Technische-Dokumentation. Auxiliary materials, fluids and lubricants might be hazardous goods or toxic substances.When using flu- ids, lubricants, auxiliary materials and other chemical substances, follow the safety instructions that ap- ply to the product.

  • Page 12: Compressed Air

    Lead • Adopt suitable measures to avoid the formation of lead dust. • Switch on extraction system. • When working with lead or lead-containing compounds, avoid direct contact to the skin and do not inhale lead vapors. • Wash hands after contact with lead or lead-containing substances. Compressed air Observe special safety precautions when working with compressed air: •...

  • Page 13: Standards For Warning Notices In The Text

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

  • Page 14: 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 15: 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 16: Product Description

    2.2 Product description Description of the engine Engine The engine is a liquid-cooled four-stroke diesel engine, rotating counterclockwise (seen from driving end), with direct injection, sequential turbocharging and charge-air cooling. The engine is monitored by an engine control and monitoring system (ADEC). Fuel system Electronically controlled common-rail-injection system with HP pump, pressure accumulator (rail) and single injectors with integrated individual store.
  • Page 17 • Interface to ECU and EMU • MCS5 dialog interface • Control of an MTU lube-oil priming pump (power components in separate MTU PPC Box) • Connection facility for an MTU Local Operating Station (LOS) Serial RS422 interface for diagnosis The engine interface comprises two parts.
  • Page 18 2 Cleaning cycle 3 ditto MTU marine engine models 4000M53R to …M93L may be operated in low-load operation. State-of-the- art design and equipment features, e.g. TE coolant circuit, sequential turbocharging, jacketed, coolant- cooled exhaust lines, Common Rail fuel injection and cylinder cutout allow engine operation at low load.
  • Page 19 100 operating hours in low-load operation, at the latest. SOLAS – Fire safety requirements Fuel system, fuel lines with fuel pressure >1.8 bar All lines with SOLAS-compliant covers for pipe connections, according to MTU standard MTN5233, are shown. MS150066/02E 2013-02 | General Information | 19...
  • Page 20 1 Fuel line after LP pump 1 Fuel line to fuel filter head retainer 20 | General Information | MS150066/02E 2013-02...
  • Page 21 1 Fuel line from fuel filter head 1 Fuel line on HP pump MS150066/02E 2013-02 | General Information | 21...
  • Page 22 1 Fuel line on fuel filter head 1 Fuel line on fuel filter head 22 | General Information | MS150066/02E 2013-02...
  • Page 23 Lube oil system, oil lines with oil pressure >1.8 bar All lines with SOLAS-compliant covers for pipe connections, according to MTU standard MTN5233, are shown. 1 Oil supply for recirculation valve MS150066/02E 2013-02 | General Information | 23...
  • Page 24 1 Oil supply line on HP pump 1 Oil supply line of HP pump on equipment carrier 24 | General Information | MS150066/02E 2013-02...
  • Page 25 1 Oil supply for actuating cylinder of turbocharger B1 exhaust flap 1 Oil supply on equipment carrier MS150066/02E 2013-02 | General Information | 25...
  • Page 26 Engines with horizontal air intake 1 Oil supply for actuating 2 Oil supply for T-piece of cylinder of turbocharger flap control B1 air flap 26 | General Information | MS150066/02E 2013-02...
  • Page 27 1 Oil supply to distributor 2 Oil return 1 Oil return MS150066/02E 2013-02 | General Information | 27...
  • Page 28 1 Oil line to flap control 3 Oil line from main oil gal- 2 Oil line to recirculation lery valve 4 Oil line to ETC 1 ETC oil supply 2 ETC oil supply 28 | General Information | MS150066/02E 2013-02...
  • Page 29 Engines with vertical air intake 1 Oil supply for actuating 2 Oil supply for T-piece of 3 Oil supply for actuating cylinder of turbocharger flap control cylinder of turbocharger B1 air flap B1 air flap MS150066/02E 2013-02 | General Information | 29...
  • Page 30 1 Oil supply to distributor of flap control, B-side 1 Oil lines for B-side flap 2 Oil lines for B-side flap control from main oil gal- control to main oil gallery lery 30 | General Information | MS150066/02E 2013-02...
  • Page 31 1 Oil supply for flap control to main oil gallery in en- gine Vee, engine free end MS150066/02E 2013-02 | General Information | 31...
  • Page 32 1 Turbocharger oil supply connection to main oil gal- lery in engine Vee 32 | General Information | MS150066/02E 2013-02...
  • Page 33 1 Oil supply on distribution point of turbocharger oil supply on engine free end 1 Cover on oil filter cartridge MS150066/02E 2013-02 | General Information | 33...
  • Page 34 Special unions 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 union Design precludes lateral spray as the point of separation is shielded by the sleeve (4). Only leak-off along the line is possible, the pressure is decreased significantly if an O-ring (3) defect occurs.
  • Page 35 High-pressure unions 1 Jacket pipe 8 Thrust ring 15 Union nut 2 HP fuel line 9 Union nut 16 Thrust ring 3 O-ring 10 Union nut 17 HP line outer pipe 4 Union nut 11 Connecting piece 18 Internal pipe of HP line 5 Recess for O-ring 12 Snap ring 19 Ball-type seal area...

  • Page 36: Engine Layout

    2.3 Engine layout Engines with remote heat exchanger and horizontal air intake 1 Dry-type air filter 10 Oil filler neck 19 Bilge pump (option) 2 Exhaust turbocharger 11 Crankcase 20 Coolant outlet to remote 3 Exhaust outlet 12 Fuel filter cooling system 4 Recirculation line 13 Cylinder head...
  • Page 37 Engines with engine-mounted heat exchanger and horizontal air intake 1 Dry-type air filter 10 Oil filler neck 19 Bilge pump (option) 2 Exhaust turbocharger 11 Crankcase 20 Raw-water inlet 3 Exhaust outlet 12 Fuel filter 21 Raw-water outlet 4 Recirculation line 13 Cylinder head 22 Engine management and 5 Air pipe to charge-air cool-...
  • Page 38 Engines with remote heat exchanger and vertical air intake 1 Dry-type air filter 10 Oil filler neck 19 Bilge pump (option) 2 Exhaust turbocharger 11 Crankcase 20 Coolant outlet to remote 3 Exhaust outlet 12 Fuel filter cooling system 4 Recirculation line 13 Cylinder head 21 Coolant inlet from remote 5 Air pipe to charge-air cool-...
  • Page 39 Engines with engine-mounted heat exchanger and vertical air intake 1 Dry-type air filter 10 Oil filler neck 19 Bilge pump (option) 2 Exhaust turbocharger 11 Crankcase 20 Raw-water inlet 3 Exhaust outlet 12 Fuel filter 21 Raw-water outlet 4 Recirculation line 13 Cylinder head 22 Engine management and 5 Air pipe to charge-air cool-...

  • Page 40: Sensors, Actuators And Injectors - Overview

    2.4 Sensors, actuators and injectors – Overview Engines with vertical air intake, remote heat exchanger 12 V 4000 M engine, left engine side 1 B49/Y26 (charge-air tem- 4 B10 (charge-air pressure) 7 B34.1 (fuel pressure after perature before recircula- 5 B34.3 (fuel pressure be- filter) tion valve)/(recirculation fore filter) (only if supple-...
  • Page 41 12 V 4000 M engine, free end 1 B7 (lube oil temperature) 4 B33 (fuel temperature in 7 B54 (oil refill pump pres- 2 B5.3 (lube-oil pressure be- common rail) sure) (optional) fore filter) 5 B48 (fuel pressure in com- 8 B6.2 (coolant tempera- 3 B5.1 (lube-oil pressure af- mon rail)
  • Page 42 12 V 4000 M engine, right engine side 1 B44.2 (turbocharger B 3 B16 (coolant pressure) speed) 4 B9 (charge-air tempera- 2 Y27 (turbocharger control ture) valve) 42 | General Information | MS150066/02E 2013-02...
  • Page 43 12 V 4000 M engine, driving end 1 B4.22 (exhaust tempera- 3 S37.2 (safety switch) 5 B13.2 (crankshaft speed) ture, B bank) 4 S37.1 (safety switch) (optional) 2 B13 (crankshaft speed) 6 B4.21 (exhaust tempera- ture, a bank) MS150066/02E 2013-02 | General Information | 43...
  • Page 44 12 V 4000 M engine, top view 1 B4 (cylinder exhaust tem- 2 B50 (crankcase pressure) 3 B33 (alternatively) (fuel perature A1-A6, B1-B6) temperature in common (optional) rail) 44 | General Information | MS150066/02E 2013-02...
  • Page 45 Engines with vertical air intake, engine-mounted heat exchanger 12 V 4000 M engine, left engine side 1 B49/Y26 (charge-air tem- 4 B10 (charge-air pressure) 7 B34.1 (fuel pressure after perature before recircula- 5 B34.3 (fuel pressure be- filter) tion valve)/(recirculation fore filter) (only if supple- 8 F46 (leak fuel level) valve A)
  • Page 46 12 V 4000 M engine, free end 1 B7 (lube oil temperature) 4 B33 (fuel temperature in 7 B54 (oil refill pump pres- 2 B5.3 (lube-oil pressure be- common rail) sure) (optional) fore filter) 5 B48 (fuel pressure in com- 8 B6.2 (coolant tempera- 3 B5.1 (lube-oil pressure af- mon rail)
  • Page 47 12 V 4000 M engine, right engine side 1 B44.2 (turbocharger B 3 B16 (coolant pressure) 5 B9 (charge-air tempera- speed) 4 B21 (raw-water pressure) ture) 2 Y27 (turbocharger control (optional) valve) MS150066/02E 2013-02 | General Information | 47...
  • Page 48 12 V 4000 M engine, driving end 1 B4.22 (exhaust tempera- 3 S37.2 (safety switch) 5 B13.2 (crankshaft speed) ture, B bank) 4 S37.1 (safety switch) (optional) 2 B13 (crankshaft speed) 6 B4.21 (exhaust tempera- ture, a bank) 48 | General Information | MS150066/02E 2013-02...
  • Page 49 12 V 4000 M engine, top view 1 B4 (cylinder exhaust tem- 3 B33 (alternatively) (fuel perature A1-A6, B1-B6) temperature in common (optional) rail) 2 B50 (crankcase pressure) 4 F33 (coolant level) MS150066/02E 2013-02 | General Information | 49...

  • Page 50: Sensors, Actuators And Injectors On 16V Engines - Overview

    2.5 Sensors, actuators and injectors on 16V engines – Overview Engines with horizontal air intake, remote heat exchanger 16V 4000 M, left engine side 1 B50 (crankcase pressure) 4 B10 (charge-air pressure) 7 B34.1 (fuel pressure after 2 B3 (intake air temperature) 5 B34.3 (fuel pressure be- filter) 3 B44.1 (turbocharger A...
  • Page 51 16 V 4000 M, free end 1 B7 (lube oil temperature) 4 B33 (fuel temperature in 7 B54 (oil refill pump pres- 2 B5.3 (lube oil pressure be- common rail) sure) (optional) fore filter) 5 B48 (fuel pressure in com- 8 B6.2 (coolant tempera- 3 B5.1 (lube oil pressure af- mon rail)
  • Page 52 16V 4000 M, right engine side 1 B44.2 (turbocharger B 3 B16 (coolant pressure) speed) 4 B9 (charge-air tempera- 2 Y27 (turbocharger control ture) valve) 52 | General Information | MS150066/02E 2013-02...
  • Page 53 16 V 4000 M, driving end 1 B4.22 (exhaust tempera- 3 S37.2 (safety switch) 5 B13.2 (crankshaft speed) ture, B bank) 4 S37.1 (safety switch) (optional) 2 B13 (crankshaft speed) 6 B4.21 (exhaust tempera- ture, a bank) MS150066/02E 2013-02 | General Information | 53...
  • Page 54 16 V 4000 M, plan view 1 B49/Y26 (charge-air tem- 2 B4 (cylinder exhaust tem- 3 B33 (alternatively) (fuel perature before recircula- perature A1-A6, B1-B8) temperature in common tion valve)/(recirculation (optional) rail) valve A) 54 | General Information | MS150066/02E 2013-02...
  • Page 55 Engines with horizontal air intake, engine-mounted heat exchanger 16V 4000 M, left engine side 1 B50 (crankcase pressure) 4 B3 (intake air temperature) 7 B34.2 (fuel pressure be- 2 B49/Y26 (charge-air tem- 5 B10 (charge-air pressure) fore filter) perature before recircula- 6 B34.3 (fuel pressure be- 8 B34.1 (fuel pressure after tion valve)/(recirculation...
  • Page 56 16 V 4000 M, free end 1 B7 (lube oil temperature) 4 B33 (fuel temperature in 7 B54 (oil refill pump pres- 2 B5.3 (lube oil pressure be- common rail) sure) (optional) fore filter) 5 B48 (fuel pressure in com- 8 B6.2 (coolant tempera- 3 B5.1 (lube oil pressure af- mon rail)
  • Page 57 16V 4000 M, right engine side 1 B44.2 (turbocharger B 3 B16 (coolant pressure) 5 B9 (charge-air tempera- speed) 4 B21 (raw-water pressure) ture) 2 Y27 (turbocharger control (optional) valve) MS150066/02E 2013-02 | General Information | 57...
  • Page 58 16 V 4000 M, driving end 1 B4.22 (exhaust tempera- 3 S37.2 (safety switch) 5 B13.2 (crankshaft speed) ture, B bank) 4 S37.1 (safety switch) (optional) 2 B13 (crankshaft speed) 6 B4.21 (exhaust tempera- ture, a bank) 58 | General Information | MS150066/02E 2013-02...
  • Page 59 16 V 4000 M, plan view 1 B4 (cylinder exhaust tem- 2 B33 (alternatively) (fuel 3 F33 (coolant level) perature A1-A6, B1-B8) temperature in common (optional) rail) MS150066/02E 2013-02 | General Information | 59...
  • Page 60 Engines with vertical air intake, remote heat exchanger 16V 4000 M, left engine side 1 B50 (crankcase pressure) 4 B44.1 (turbocharger A 7 B34.2 (fuel pressure be- 2 B49/Y26 (charge-air tem- speed) fore filter) perature before recircula- 5 B10 (charge-air pressure) 8 B34.1 (fuel pressure after tion valve)/(recirculation 6 B34.3 (fuel pressure be-...
  • Page 61 16 V 4000 M, free end 1 B7 (lube oil temperature) 4 B33 (fuel temperature in 7 B54 (oil refill pump pres- 2 B5.3 (lube-oil pressure be- common rail) sure) (optional) fore filter) 5 B48 (fuel pressure in com- 8 B6.2 (coolant tempera- 3 B5.1 (lube-oil pressure af- mon rail) ture) (optional)
  • Page 62 16V 4000 M, right engine side 1 B44.2 (turbocharger B 3 B16 (coolant pressure) speed) 4 B9 (charge-air tempera- 2 Y27 (turbocharger control ture) valve) 62 | General Information | MS150066/02E 2013-02...
  • Page 63 16 V 4000 M, driving end 1 B4.22 (exhaust tempera- 3 S37.2 (safety switch) 5 B13.2 (crankshaft speed) ture, B bank) 4 S37.1 (safety switch) (optional) 2 B13 (crankshaft speed) 6 B4.21 (exhaust tempera- ture, a bank) MS150066/02E 2013-02 | General Information | 63...
  • Page 64 16 V 4000 M, plan view 1 B4 (cylinder exhaust tem- 2 B33 (alternatively) (fuel perature A1-A6, B1-B8) temperature in common (optional) rail) 64 | General Information | MS150066/02E 2013-02...
  • Page 65 Engines with vertical air intake, engine-mounted heat exchanger 16V 4000 M, left engine side 1 B50 (crankcase pressure) 4 B44.1 (turbocharger A 7 B34.2 (fuel pressure be- 2 B49/Y26 (charge-air tem- speed) fore filter) perature before recircula- 5 B10 (charge-air pressure) 8 B34.1 (fuel pressure after tion valve)/(recirculation 6 B34.3 (fuel pressure be-...
  • Page 66 16 V 4000 M, free end 1 B7 (lube oil temperature) 4 B33 (fuel temperature in 7 B54 (oil refill pump pres- 2 B5.3 (lube-oil pressure be- common rail) sure) (optional) fore filter) 5 B48 (fuel pressure in com- 8 B6.2 (coolant tempera- 3 B5.1 (lube-oil pressure af- mon rail) ture) (optional)
  • Page 67 16V 4000 M engine, right engine side 1 B44.2 (turbocharger B 3 B16 (coolant pressure) 5 B9 (charge-air tempera- speed) 4 B21 (raw-water pressure) ture) 2 Y27 (turbocharger control (optional) valve) MS150066/02E 2013-02 | General Information | 67...
  • Page 68 16 V 4000 M, driving end 1 B4.22 (exhaust tempera- 3 S37.2 (safety switch) 5 B13.2 (crankshaft speed) ture, B bank) 4 S37.1 (safety switch) (optional) 2 B13 (crankshaft speed) 6 B4.21 (exhaust tempera- ture, a bank) 68 | General Information | MS150066/02E 2013-02...
  • Page 69 16 V 4000 M, plan view 1 B4 (cylinder exhaust tem- 2 B33 (alternatively) (fuel 3 F33 (coolant level) perature A1-A6, B1-B8) temperature in common (optional) rail) MS150066/02E 2013-02 | General Information | 69...

  • Page 70: Technical Data

    3 Technical Data 3.1 12V 4000 M63 engine data, EPA Tier 2, EU Stage IIIA, IMO Tier II Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value up to which the engine can be operated without change, e.g. of power setting. N Not yet defined value - Not applicable X Applicable...
  • Page 71 Heat exchanger Heat exchanger engine-mounted remote Total displacement Liters 57.2 57.2 57.2 57.2 Inlet valves per cylinder Exhaust valves per cylinder RAW WATER CIRCUIT (open circuit) Heat exchanger Heat exchanger engine-mounted remote Raw water pump: Inlet pressure, min. -0.4 -0.4 Raw water pump: Inlet pressure, max.
  • Page 72 STARTER (electric) Heat exchanger Heat exchanger engine-mounted remote Rated starter voltage (standard design) STARTING (with compressed air/hydraulic starter) Heat exchanger Heat exchanger engine-mounted remote Starting-air pressure before starter, min. Starting-air pressure before starter, max. INCLINATIONS, STANDARD OIL SYSTEM (reference: waterline) Heat exchanger Heat exchanger engine-mounted...
  • Page 73 WEIGHTS / MAIN DIMENSIONS Heat exchanger Heat exchanger engine-mounted remote Engine dry weight (with attached standard 7640 7640 7240 7240 accessories, without coupling) ACOUSTICS Heat exchanger Heat exchanger engine-mounted remote Exhaust noise, unsilenced - BL (free-field dB(A) sound pressure level Lp, 1m distance, ISO 6798, +3dB(A) tolerance) Engine surface noise with attenuated in- dB(A)

  • Page 74: 4000 M63 Engine Data, Epa Tier 2, Eu Stage Iiia, Imo Tier

    3.2 16V 4000 M63 engine data, EPA Tier 2, EU Stage IIIA, IMO Tier II Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value up to which the engine can be operated without change, e.g. of power setting. N Not yet defined value - Not applicable X Applicable...
  • Page 75 RAW WATER CIRCUIT (open circuit) Heat exchanger Heat exchanger engine-mounted remote Raw water pump: Inlet pressure, min. -0.4 -0.4 Raw water pump: Inlet pressure, max. Pressure loss in off-engine raw water sys- tem, max. LUBE OIL SYSTEM Heat exchanger Heat exchanger engine-mounted remote Lube oil operating temperature before en-...
  • Page 76 STARTING (with compressed air/hydraulic starter) Heat exchanger Heat exchanger engine-mounted remote Starting-air pressure before starter, min. Starting-air pressure before starter, max. INCLINATIONS, STANDARD OIL SYSTEM (reference: waterline) Heat exchanger Heat exchanger engine-mounted remote Longitudinal inclination, continuous max. Degrees driving end down (Option: max. operating (°) inclinations) Longitudinal inclination, temporary max.
  • Page 77 ACOUSTICS Heat exchanger Heat exchanger engine-mounted remote Exhaust noise, unsilenced - BL (free-field dB(A) sound pressure level Lp, 1m distance, ISO 6798, +3dB(A) tolerance) Engine surface noise with attenuated in- dB(A) take noise (filter) - BL (free-field sound power level Lp, 1 m distance, ISO 6798, +2dB(A) tolerance) MS150066/02E 2013-02 | Technical Data | 77...

  • Page 78: 4000 M63R Engine Data, Imo Tier

    3.3 16V 4000 M63R engine data, IMO Tier II Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value up to which the engine can be operated without change, e.g. of power setting. N Not yet defined value - Not applicable X Applicable...
  • Page 79 RAW WATER CIRCUIT (open circuit) Heat exchanger Heat exchanger engine-mounted remote Raw water pump: Inlet pressure, min. -0.2 -0.2 Raw water pump: Inlet pressure, max. Pressure loss in off-engine raw water sys- tem, max. LUBE OIL SYSTEM Heat exchanger Heat exchanger engine-mounted remote Lube oil operating temperature before en-...
  • Page 80 STARTING (with compressed air/hydraulic starter) Heat exchanger Heat exchanger engine-mounted remote Starting-air pressure before starter, min. Starting-air pressure before starter, max. INCLINATIONS, STANDARD OIL SYSTEM (reference: waterline) Heat exchanger Heat exchanger engine-mounted remote Longitudinal inclination, continuous max. Degrees driving end down (Option: max. operating (°) inclinations) Longitudinal inclination, temporary max.
  • Page 81 ACOUSTICS Heat exchanger Heat exchanger engine-mounted remote Exhaust noise, unsilenced - BL (free-field dB(A) sound pressure level Lp, 1m distance, ISO 6798, +3dB(A) tolerance) Engine surface noise with attenuated in- dB(A) take noise (filter) - BL (free-field sound power level Lp, 1 m distance, ISO 6798, +2dB(A) tolerance) MS150066/02E 2013-02 | Technical Data | 81...

  • Page 82: Firing Order

    3.4 Firing order A1-B4-A4-A2-B3-A3-B2-B1 12 V A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1 16 V A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B7 82 | Technical Data | MS150066/02E 2013-02...

  • Page 83: Engine - Main Dimensions

    3.5 Engine – Main dimensions Engines with horizontal air intake With remote heat exchanger Engine model Length (A) Width (B) without Width (B) with si- Height (C) silencer lencer 16V 4000 approx. 3108 mm approx. 1690 mm approx. 1850 mm approx.
  • Page 84 Engines with vertical air intake With remote heat exchanger Engine model Length (A) Width (B) Height (C) without Height (C) with si- silencer lencer 12V 4000 approx. 2628 mm approx. 1602 mm approx. 2368 mm approx. 2448 mm M23S/23F/33S/ 12V 4000 M53R/ 53/63 16V 4000 approx.

  • Page 85: Operation

    4 Operation 4.1 Controls Automation system controls Refer to automation system operating instructions MS150066/02E 2013-02 | Operation | 85...

  • Page 86: Putting The Engine Into Operation After Extended Out-Of-Service Periods (>3 Months)

    4.2 Putting the engine into operation after extended out-of-service periods (>3 months) Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Preservation and Represervation Specifications (A001070/..) are available. Putting into operation after long out-of-service periods (>3 months) Item Action Engine Depreserve (→...

  • Page 87: Putting The Engine Into Operation After Scheduled Out-Of-Service-Period

    4.3 Putting the engine into operation after scheduled out-of- service-period Preconditions ☑ Engine is stopped and starting disabled. Putting into operation Item Action Lube oil system Check engine oil level (→ Page 178); Preheat engine oil if required. Coolant system Check coolant level (→...

  • Page 88: Starting The Engine

    4.4 Starting the engine Start the engine via the automation system Refer to automation system operating instructions 88 | Operation | MS150066/02E 2013-02...

  • Page 89: Operational Checks

    4.5 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 90: Tasks After Extended Out-Of-Service Periods (>3 Weeks)

    4.6 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 92). Shut down fuel treatment system (→ Page 95). 90 | Operation | MS150066/02E 2013-02...

  • Page 91: 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 92: Fuel Treatment System - Putting Into Operation

    4.8 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 93 Simulation of filter replacement with the engine running: HAT Switch on fuel treatment system (→ Page 94). Start engine (→ Page 88). 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 94: Fuel Treatment System - Switching On

    4.9 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 95: Fuel Treatment System - Shutdown

    4.10 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 96: Stopping The Engine

    4.11 Stopping the engine Stopping the engine via the automation system Refer to automation system operating instructions 96 | Operation | MS150066/02E 2013-02...

  • Page 97: Emergency Engine Stop

    4.12 Emergency engine stop 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 Refer to automation system operating instructions. Follow instructions. MS150066/02E 2013-02 | Operation | 97...

  • Page 98: After Stopping The Engine

    4.13 After stopping the engine Preconditions ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. After stopping the engine Item Measure Coolant circuit Drain coolant (→ Page 196) if: • freezing temperatures are expected and the engine is to remain out of service for an extended period, but engine coolant has no antifreeze addi- tive;...

  • Page 99: Plant Cleaning

    4.14 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 100: Maintenance

    (→ Page 89) charger for leaks and damage. W1036 Replace coolant filter. (→ Page 203) W1076 Exhaust turbocharger: Clean compressor wheel (MTU-ZR tur- (→ Page 165) bocharger). W1207 Check valve clearance, adjust if necessary. Attention!First ad- (→ Page 140) justment after 1,000 operating hours.
  • Page 101 Task Option Maintenance tasks W1495 Replace supplementary fuel filter or filter element of supple- (→ Page 153) mentary fuel filter. W1713 Injector: Reset drift compensation (CDC) parameters. (→ Page 217) W1714 Check and clean oil indicator filter. (→ Page 185) Table 1: Maintenance task reference table [QL1] MS150066/02E 2013-02 | Maintenance | 101...

  • Page 102: Troubleshooting

    6 Troubleshooting 6.1 Troubleshooting Engine does not turn when starter is actuated Cause Corrective action Battery low or faulty u Charge or replace (see separate documentation). Battery: Cable connections u Check firm seating of cable connections (see separate faulty documentation). Engine cabling or starter faulty u Check firm seating of cable connections, contact Service.
  • Page 103 Engine governor defective u Contact Service. Charge-air temperature too high Cause Corrective action Incorrect coolant concentration u Check (MTU test kit). Intercooler dirty u Contact Service. Engine room: Air-intake u Check fans and air supply/ventilation ducts. temperature too high Charge-air pressure too low...
  • Page 104 White exhaust gas Cause Corrective action Engine is not at operating u Run engine to reach operating temperature. temperature Intercooler leaky u Contact Service. 104 | Troubleshooting | MS150066/02E 2013-02...

  • Page 105: Fuel Treatment System - Troubleshooting

    6.2 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 2. In addition to the automatic water drain function, water can electrode opens the water drain also be drained manually.

  • Page 106: Adec (Ecu 7) Fault Codes For Series 4000 Engines, Marine Application

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

  • Page 107: Adec Engine Governor - Fault Codes

    6.4 ADEC engine governor – Fault codes 29 – HI ETC Idle Speed too High ZKP-Number: 18.004.206 Cause Corrective action Idle speed of one of the u Contact Service. secondary turbochargers is too high. 38 – AL ETC Speed Deviation ZKP-Number: 18.004.205 Cause Corrective action...
  • Page 108 141 – AL Power too high ZKP-Number: 11.088.007 Cause Corrective action This alarm occurs if the average u Reduce power. value of power over the last 24 hours exceeded the maximum value specified in PR1.1088.001. 142 – AL MCR exceeded 1 hour ZKP-Number: 11.088.006 Cause Corrective action...
  • Page 109 205 – SD T-Coolant Intercooler ZKP-Number: 18.004.574 Cause Corrective action Intercooler coolant temperature u Check sensor and cabling (B26), replace as necessary. sensor faulty; Short circuit or wire break 206 – SD T-Exhaust A ZKP-Number: 18.004.576 Cause Corrective action Exhaust temperature sensor on u Check sensor and cabling (B4.21), replace as necessary.
  • Page 110 213 – SD P-Coolant Intercooler ZKP-Number: 18.004.569 Cause Corrective action Intercooler coolant pressure 1. Check sensor and cabling (B43), replace as necessary. sensor faulty; Short circuit or 2. Error cleared after restarting the engine. wire break 214 – SD P-Crankcase ZKP-Number: 18.004.568 Cause Corrective action...
  • Page 111 221 – SD P-Diff-Lube Oil ZKP-Number: 18.004.585 Cause Corrective action Lube oil differential pressure 1. Check sensor and cabling (F25), replace as necessary. sensor faulty; Short circuit or 2. Error cleared after restarting the engine. wire break 222 – SD Level Leakage Fuel ZKP-Number: 18.004.582 Cause Corrective action...
  • Page 112 230 – SD Crankshaft Speed ZKP-Number: 18.004.498 Cause Corrective action Crankshaft sensor faulty; Short 1. Check sensor and cabling (B13), replace as necessary. circuit or wire break 2. Error cleared after restarting the engine. 231 – SD Camshaft Speed ZKP-Number: 18.004.499 Cause Corrective action Camshaft sensor faulty;...
  • Page 113 241 – SD T-Umblasen ZKP-Number: 18.004.581 Cause Corrective action Recirculation temperature 1. Check sensor and cabling (B49), replace as necessary. sensor faulty; Short circuit or 2. Error cleared after restarting the engine. wire break 242 – SD T-Coolant (R) ZKP-Number: 18.004.622 Cause Corrective action Redundant coolant temperature...
  • Page 114 303 – AL Timing Cylinder A3 ZKP-Number: 18.004.502 Cause Corrective action Time-of-flight measuring fault of u If alarm occurs frequently, replace solenoid valve of injector injector in cylinder A3: Time-of flight measured value extremely low or extremely high. 304 – AL Timing Cylinder A4 ZKP-Number: 18.004.503 Cause Corrective action...
  • Page 115 308 – AL Timing Cylinder A8 ZKP-Number: 18.004.507 Cause Corrective action Time-of-flight measuring fault of u If alarm occurs frequently, replace solenoid valve of injector injector in cylinder A8: Time-of flight measured value extremely low or extremely high. 309 – AL Timing Cylinder A9 ZKP-Number: 18.004.508 Cause Corrective action...
  • Page 116 313 – AL Timing Cylinder B3 ZKP-Number: 18.004.512 Cause Corrective action Time-of-flight measuring fault of u If alarm occurs frequently, replace solenoid valve of injector injector B3: Time-of flight measured value extremely low or extremely high. 314 – AL Timing Cylinder B4 ZKP-Number: 18.004.513 Cause Corrective action...
  • Page 117 318 – AL Timing Cylinder B8 ZKP-Number: 18.004.517 Cause Corrective action Time-of-flight measuring fault of u If alarm occurs frequently, replace solenoid valve of injector injector B8: Time-of flight measured value extremely low or extremely high. 319 – AL Timing Cylinder B9 ZKP-Number: 18.004.518 Cause Corrective action...
  • Page 118 323 – AL Wiring Cylinder A3 ZKP-Number: 18.004.522 Cause Corrective action Short-circuit in injector cabling 1. Rectify short circuit in injector solenoid valve circuit (positive to to cylinder A3. Result: Misfiring. negative) (e.g. by injector replacement) 2. Error cleared after restarting the engine. 324 –...
  • Page 119 329 – AL Wiring Cylinder A9 ZKP-Number: 18.004.528 Cause Corrective action Short-circuit in injector cabling 1. Rectify short circuit in injector solenoid valve circuit (positive to to cylinder A9. Result: Misfiring. negative) (e.g. by injector replacement) 2. Error cleared after restarting the engine. 330 –...
  • Page 120 335 – AL Wiring Cylinder B5 ZKP-Number: 18.004.534 Cause Corrective action Cabling fault in injector cabling 1. Rectify short circuit in injector solenoid valve circuit (positive to to cylinder B5. Result: Misfiring. negative) (e.g. by injector replacement) 2. Error cleared after restarting the engine. 336 –...
  • Page 121 341 – AL Open Load Cylinder A1 ZKP-Number: 18.004.540 Cause Corrective action Disruption fault in injector 1. Check continuity of injector cabling or exclude open load in cabling to cylinder A1. Result: solenoid valve circuit (e.g. by injector replacement) Misfiring. 2.
  • Page 122 347 – AL Open Load Cylinder A7 ZKP-Number: 18.004.546 Cause Corrective action Disruption fault in injector 1. Check continuity of injector cabling or exclude open load in cabling to cylinder A7. Result: solenoid valve circuit (e.g. by injector replacement) Misfiring. 2.
  • Page 123 353 – AL Open Load Cylinder B3 ZKP-Number: 18.004.552 Cause Corrective action Disruption fault in injector 1. Check continuity of injector cabling or exclude open load in cabling to cylinder B3. Result: solenoid valve circuit (e.g. by injector replacement) Misfiring. 2.
  • Page 124 359 – AL Open Load Cylinder B9 ZKP-Number: 18.004.558 Cause Corrective action Disruption fault in injector 1. Check continuity of injector cabling or exclude open load in cabling to cylinder B9. Result: solenoid valve circuit (e.g. by injector replacement) Misfiring. 2.
  • Page 125 365 – AL Stop MV-Wiring Ground ZKP-Number: 18.004.561 Cause Corrective action Injector cabling fault. If bit u Check wiring, replace wiring harness as necessary. "1.1020.021" (Power Stage Failure: Stop engine) is set, engine is additionally stopped in this case. Possible causes: 1.
  • Page 126 390 – AL MCR exceeded ZKP-Number: 11.085.009 Cause Corrective action DBR/MCR feature: MCR 1. If the alarm occurs temporarily, no action required. (maximum continuous rating) 2. If the alarm is permanently active, contact Service. was exceeded. 396 – TD T-Coolant Sensor Deviation ZKP-Number: 10.480.193 Cause Corrective action...
  • Page 127 445 – SD P-Ambient Air ZKP-Number: 18.004.580 Cause Corrective action Ambient air pressure sensor 1. Check pressure sensor and cabling, replace as necessary. faulty. 2. Replace engine governor. 464 – SD P-AUX 1 ZKP-Number: 18.004.589 Cause Corrective action Analog input signal for Aux 1 u Check pressure sensor and cabling, replace as necessary.
  • Page 128 473 – AL Wiring PWM_CM2 ZKP-Number: 18.004.593 Cause Corrective action Cable break or short circuit on 1. Check cabling. channel PWM_CM2. 2. Contact Service. 475 – AL CR Trigger Engine Stop ZKP-Number: 18.010.009 Cause Corrective action Tripped by crash recorder 1.
  • Page 129 493 – AL ETC3 CutIn Failure ZKP-Number: 18.004.203 Cause Corrective action ETC3 could not be cut in. u Check control valve on ETC 3. 500 – AL Wiring POM Starter 1 ZKP-Number: 14.500.900 Cause Corrective action A wiring fault was detected in u Check connection between POM and starter.
  • Page 130 506 – AL Low Starter Voltage ZKP-Number: 14.500.906 Cause Corrective action The battery voltage is too low for u Check starter battery and cabling. the starting process. 507 – AL POM Error ZKP-Number: 14.500.907 Cause Corrective action A general POM error occurred. u Replace POM.
  • Page 131 527 – TD EngineSpd. Sensor Deviation ZKP-Number: 10.480.093 Cause Corrective action Maximum deviation of speed 1. Check cabling of speed sensors.Observe additional messages. sensors 2. Contact Service. 528 – SD Engine Speed 3rd Sensor ZKP-Number: 12.500.102 Cause Corrective action Redundant crankshaft sensor u Check sensor and cabling, replace as necessary.
  • Page 132 596 – AL Develop PR Set ZKP-Number: 18.004.645 Cause Corrective action The parameter set used is a test u The alarm remains active until a series-production parameter parameter set. set was installed. 600 – SD T-Exhaust A+B ZKP-Number: 18.004.646 Cause Corrective action SD T-Exhaust A and T-Exhaust B u Check sensor and cabling, replace as necessary.

  • Page 133: 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 with extension F30006212 DANGER Unguarded rotating and moving engine components. Risk of serious injury –...

  • Page 134: Engine - Barring With Starting System

    7.1.2 Engine – Barring with starting system Barring using the automation system Refer to automation system operating instructions 134 | Task Description | MS150066/02E 2013-02...

  • Page 135: 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 143). Remove injector (→...
  • Page 136 Final steps Install injector (→ Page 147). Install cylinder head cover (→ Page 143). 136 | Task Description | MS150066/02E 2013-02...

  • Page 137: Instructions And Comments On Endoscopic And Visual Examination Of Cylinder Liners

    7.2.2 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 ex- amination report. Findings Action Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing products, particles, broken-off burrs).
  • Page 138 Evaluation of findings and further measures The findings in the start phase of oxidation discoloration and heat discoloration are similar. A thorough investigation and compliance with the above evaluation criteria allow an unambiguous evaluation. To avoid unnecessary disassembly work, it is recommended that another inspection be carried out after further operation of the engine.

  • Page 139: 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 143). Fill oil chambers of valve bridges with oil.

  • Page 140: 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 gage Y20010128 Torque wrench, 60-320 Nm F30047446...
  • Page 141 Rotate crankshaft with barring gear in di- rection of engine rotation until “OT-A1” mark and pointer are aligned. Two crankshaft positions – 12V 1 Cylinder A1 is in firing TDC 2 Cylinder A1 is in overlap TDC I Inlet valve X Exhaust valve Two crankshaft positions –...

  • Page 142: Adjusting Valve Clearance

    Checking valve clearance in two crankshaft positions Check TDC position of piston in cylinder A1: • The piston is at firing TDC when the rocker arms are unloaded on cylinder A1. • The piston is at overlap TDC when the rocker arms are under load on cylinder A1. Check valve clearance with cold engine: •...

  • Page 143: 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) X00029933 O-ring (→ Spare Parts Catalog) Removing cylinder head cover Clean very dirty cylinder head covers (1) prior to removal.

  • Page 144: Injection Pump / Hp Pump

    7.4 Injection Pump / HP Pump 7.4.1 HP pump – Filling with engine oil Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil WARNING Fuels are combustible. Risk of fire and explosion! •...

  • Page 145: Hp Pump - Relief Bore Check

    7.4.2 HP 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 146: Injection Valve / Injector

    7.5 Injection Valve / Injector 7.5.1 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 147). 146 | Task Description | MS150066/02E 2013-02...

  • Page 147: Injector - Removal And Installation

    7.5.2 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 Ratchet F30027340...
  • Page 148 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 149: Installing Injector

    Installing injector Remove plug before installing the injec- tor. (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 (included in the scope of supply of the injector) with grease on in- jector, observe installation position of seal- ing ring.
  • Page 150 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 speci- fied initial tightening torque. Name Size Type Lubricant Value/Standard Screw Preload torque (Engine oil) 5 Nm to 10 Nm...
  • Page 151 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 152: Fuel Filter

    7.6 Fuel Filter 7.6.1 Supplementary fuel filter – Overview 1 Storage tank 3 Passive standard prefilter 5 Supplementary fuel filter 2 Day tank with water separator 6 Main engine filter 4 LP pump 152 | Task Description | MS150066/02E 2013-02...

  • Page 153: Supplementary Fuel Filter - Replacement

    7.6.2 Supplementary fuel filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Diesel fuel Easy-change filter (→ Spare Parts Catalog) Synthetic ring (→ Spare Parts Catalog) DANGER Unguarded rotating and moving engine components.

  • Page 154: Fuel Filter - Replacement

    7.6.3 Fuel filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Diesel fuel Easy-change filter (→ Spare Parts Catalog) Synthetic ring (→ Spare Parts Catalog) DANGER Unguarded rotating and moving engine components.
  • Page 155 Cut out the filter to be replaced. Unscrew cut-out easy-change filter with filter wrench. Clean sealing surface on filter head. Check seal on new easy-change filter and moisten with fuel. Fit SOLAS shield (→ Page 16). Screw on easy-change filter and tighten by hand. Set three-way cock to normal operating position (both filters cut in).

  • Page 156: Fuel Prefilter - Differential Pressure Gauge Check And Adjustment

    7.6.4 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 157: Fuel Prefilter - Draining

    7.6.5 Fuel prefilter – Draining Preconditions ☑ Engine is stopped and starting disabled. WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Draining fuel prefilter 1 Filter A cut out 2 Filter B cut out Cut out the filter to be drained.
  • Page 158 Connect filling pump to filling connection (1 or 3) on the suction side of the filter. Open vent valve (2 or 4) and fill with fuel until fuel emerges from the vent pipe (7 or Close vent valve (2 or 4). Open rotary slide valve (6) a little (by ap- prox.

  • Page 159: Fuel Prefilter - Flushing

    7.6.6 Fuel prefilter – Flushing Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel 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 160: Fuel Prefilter – Filling With Fuel

    Open threaded vent plug (1) of filter to be flushed. Open drain valve (2) 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 (1) and drain valve (2).

  • Page 161: Fuel Prefilter With Water Separator - Filter Element Replacement

    7.6.7 Fuel prefilter with water separator – Filter element replacement Preconditions ☑ Engine is stopped and starting disabled. ☑ System is at atmospheric pressure. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10-60 Nm F30510423 Ratchet F30027340 Filter element...
  • Page 162 Open vent valve (1 or 2) of the filter to be replaced. Open drain valve (5 or 4) and drain fuel. Undo screws (6 or 3) and screw out filter housing (A or B). Remove filter element (7). Insert new filter element in filter housing. Fit O-ring.
  • Page 163 Connect filling pump to filling connection (1 or 3) on the suction side of the filter. Open vent valve (2 or 4) and fill with fuel until fuel emerges from the vent pipe (7 or Close vent valve (2 or 4). Open rotary slide valve (6) a little (by ap- prox.

  • Page 164: Fuel Prefilter With Water Separator - O-Ring Replacement In Rotary Slide Valve

    7.6.8 Fuel prefilter with water separator – O-ring replacement in rotary slide valve Preconditions ☑ Engine is stopped and starting disabled. ☑ System is at atmospheric pressure. Special tools, Material, Spare parts Designation / Use Part No. Qty. O-ring (→ Spare Parts Catalog) WARNING Tank is pressurized.

  • Page 165: Exhaust Turbocharger

    7.7 Exhaust Turbocharger 7.7.1 Compressor wheel – Cleaning Preconditions ☑ Engine is stopped and starting disabled Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10-60 Nm F30452769 Ratchet adapter F30027340 Cleaning agent 40377 Engine oil Engine coolant Sealing rings (→...
  • Page 166 Remove charge-air pipework (1) from ex- haust turbocharger to intercooler. Remove oil lines (2). Loosen clamp (1). Remove intake housing (3) with actuating cylinder (2). Remove coolant lines (1) from compressor housing (3). Remove coolant ventilation line (2) from compressor housing (3). 166 | Task Description | MS150066/02E 2013-02...
  • Page 167 Undo screws (1). Remove compressor housing (2). Cleaning compressor wheel Note: Do not use wire brush, scraper or similar tools for cleaning! Clean compressor housing with a smooth paint brush or brush. Clean compressor wheel (2) and bearing housing (1). Thoroughly remove cleaner from all compo- nents.
  • Page 168 Tighten screws (1) to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Screw Tightening torque (Engine oil) 20 Nm + 2.5 Nm Install coolant ventilation line and coolant lines on compressor housing. Install intake housing (3) with actuating cyl- inder (2).
  • Page 169 Preparatory steps – Vertical air intake Drain engine coolant (→ Page 196). Remove air filter (→ Page 175). Seal all openings with suitable covers. Remove charge-air pipework (1) from ex- haust turbocharger to intercooler. Remove oil lines (2). Loosen clamp (1). Remove intake housing (3) with actuating cylinder (2).
  • Page 170 Remove coolant lines (1) from compressor housing (3). Remove coolant ventilation line (2) from compressor housing (3). Undo screws (1). Remove compressor housing (2). Cleaning compressor wheel Note: Do not use wire brush, scraper or similar tools for cleaning! Clean compressor housing with a smooth paint brush or brush.
  • Page 171 Final steps – Vertical air intake Install compressor housing (2). Tighten screws (1) to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Screw Tightening torque (Engine oil) 20 Nm + 2.5 Nm Install coolant ventilation line and coolant lines on compressor housing. Install intake housing (3) with actuating cyl- inder (2).
  • Page 172 Install oil lines (2). Tighten threaded adapter at actuating cylinder to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Threaded adapter 10 G 1/4 Tightening torque (Engine oil) 40 Nm + 4 Nm Install charge-air pipework (1) between exhaust turbocharger and intercooler. Install air filter (→...

  • Page 173: Charge-Air Cooling

    7.8 Charge-Air Cooling 7.8.1 Intercooler – Checking condensate drain for water 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).

  • Page 174: Air Filter

    7.9 Air Filter 7.9.1 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 175). Reset signal ring of contamination indicator (→...

  • Page 175: Air Filter – Removal And Installation

    7.9.2 Air filter – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Air filter Release clamp (2). Remove air filter (3) and clamp (2) from flange of intake housing (1). Verify that there are no objects in the flange of the intake housing (1) and clean Attach air filter (3) with clamp (2) onto in- take housing (1).

  • Page 176: Air Intake

    7.10 Air Intake 7.10.1 Service 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 control window (2), replace air filter (→ Page 174). After installation of new filter, press reset button (1).

  • Page 177: Starter – Condition Check

    7.11 Starting Equipment 7.11.1 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 216). MS150066/02E 2013-02 | Task Description | 177...

  • Page 178: Engine Oil – Level Check

    7.12 Lube Oil System, Lube Oil Circuit 7.12.1 Engine oil – Level check Preconditions ☑ Engine is stopped and starting disabled. Checking oil level prior to en- gine start Withdraw oil dipstick from guide tube and wipe it. Insert oil dipstick into guide tube up to stop, withdraw after approx.

  • Page 179: Engine Oil – Change

    7.12.2 Engine oil – Change Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine is at operating temperature. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 40-200 Nm...
  • Page 180 Tighten drain plugs (1) and (2) to specified torque using a torque wrench: Name Size Type Lubricant Value/Standard Tightening torque 100 Nm+10Nm Filling with new oil Open cap on filler neck. Pour oil in at filler neck up to “max.” mark at oil dipstick.

  • Page 181: Engine Oil – Sample Extraction And Analysis

    7.12.3 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 182 Drain approx. 1 liter engine oil into a clean container. Close screw. Using the equipment and chemicals in the MTU test kit, examine engine oil for: • Dispersing capacity (spot test); • Water content; • Dilution by fuel. 182 | Task Description | MS150066/02E 2013-02...

  • Page 183: Engine Oil Filter – Replacement

    7.13 Oil Filtration / Cooling 7.13.1 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 184: Engine Running

    Oil filter with diverter (option): Oil filter replacement with the engine stopped Stop engine (→ Page 96) 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 185: Oil Indicator Filter – Check

    7.13.2 Oil indicator filter – Check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Cleaner (Snow-White 11-0) 40460 Cleaner (Hakupur 312) 30390 Engine oil Strainer (→ Spare Parts Catalog) Square-section ring (→...
  • Page 186 Cleaning strainer Shake coarse contamination out of strainer (5). Clean all metallic parts with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 312). Use a soft brush to remove stubborn deposits from strainer if required. Ensure that the mesh is not damaged.

  • Page 187: Centrifugal Oil Filter – Cleaning And Filter Sleeve Replacement

    7.13.3 Centrifugal oil filter – Cleaning and filter sleeve replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 6-50 Nm F30027336 Filter wrench F30379104 Cleaner Hakutex 60 Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 Filter sleeve...
  • Page 188 Cleaning centrifugal oil filter and replacing filter sleeve Remove clamp (3). Undo hood screw (1) and take off hood (2). Carefully lift rotor (6), allow oil to drain and remove from housing. Holding the rotor (6) firmly, release rotor cover nut (7). Take off rotor cover (8).
  • Page 189 Cleaning centrifugal oil filter and replacing filter sleeve (en- gines with switchable oil filter) Undo and remove screw (1). Remove clamp (3) and take off hood (2). Carefully remove rotor (5) from housing. Hold rotor assembly (5) firmly in position with filter wrench and undo knurled nut (7).

  • Page 190: Circuit

    7.14 Coolant Circuit, General, High-Temperature Circuit 7.14.1 Drain and vent points Coolant lines on ETC 1 Vent point Coolant line to charge-air cooler 1 Vent point 190 | Task Description | MS150066/02E 2013-02...
  • Page 191 1 Vent point Coolant line to raw water cooler 1 Vent point MS150066/02E 2013-02 | Task Description | 191...
  • Page 192 Vent line – Distribution cross 1 Vent point Coolant drain point, engine driving end 1 Drain points 192 | Task Description | MS150066/02E 2013-02...
  • Page 193 Coolant drain point, engine free end 1 Drain point MS150066/02E 2013-02 | Task Description | 193...

  • Page 194: Engine Coolant Level – Check

    7.14.2 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 195: Engine Coolant – Change

    7.14.3 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant – Change Drain engine coolant (→ Page 196). Fill with engine coolant (→ Page 199). MS150066/02E 2013-02 | Task Description | 195...

  • Page 196: Engine Coolant – Draining

    7.14.4 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 a suitable receptacle to catch the coolant.
  • Page 197 Open vent valve on exhaust pipework (driv- ing end) (1). Open vent valve on seawater cooler (1) (or remote heat exchanger). Open drain plugs and drain coolant from crankcase left and right sides (1). MS150066/02E 2013-02 | Task Description | 197...
  • Page 198 Open drain plug and drain coolant on cool- ant pump elbow (1). Final steps Seal all open vent and drain points. Set breather valve onto filler neck and close it. 198 | Task Description | MS150066/02E 2013-02...

  • Page 199: Engine Coolant – Filling

    7.14.5 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 200 Filling coolant through filler neck Open vent points on charge-air cooler, ex- haust turbochargers and on plate-core heat exchanger (arrows). Fill coolant through the filler neck of the expansion tank (for engines with remote heat exchanger: the expansion tank is part of the remote cooling system) until the coolant level at the top edge of the filler neck remains constant.

  • Page 201: Ht Coolant Pump — Relief Bore Check

    7.14.6 HT 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 202: Engine Coolant – Sample Extraction And Analysis

    7.14.7 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 203: Engine Coolant Filter – Replacement

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

  • Page 204: Preheating Unit

    7.14.9 Preheating unit Hotstart preheating unit 1 Plastic cap (outlet) 4 Shut-off valve 7 Thermostat 2 On/Off switch 5 Flow heater 8 Circulating pump 3 Plastic cap (inlet) 6 Vent valve Cylinders Rated voltage / frequency Heat output kW 230V / 50 Hz 400V / 50 Hz 230 V / 60 Hz 440 V / 60Hz...
  • Page 205 Hilzinger preheating unit 1 On/Off switch Cylinders Rated voltage / frequency Heat output kW 12V and 16V 230 V / 50 Hz 400 V / 50 Hz 230 V / 60 Hz 440 V / 60 Hz MS150066/02E 2013-02 | Task Description | 205...
  • Page 206 1 Flange (supply and return) 3 Non-return flap 5 Thermostat 2 Connection box 4 Flow heater 6 Circulating pump Function The preheating unit heats up the engine coolant. The circulating pump (6) ensures the circulation of the preheated engine coolant through the engine. The flow heater (4) comprises a heating element.

  • Page 207: Raw Water Pump – Relief Bore Check

    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 208: Battery-Charging Generator Drive – Coupling Condition Check

    7.16 Battery-Charging Generator 7.16.1 Battery-charging generator drive – Coupling condition check Preconditions ☑ Engine is stopped and starting disabled. Battery-charging generator drive – Coupling condition check Remove protective cover. Check resilient coupling for cracks (arrow) and plastic deformation. In case of severe deformation or cracking: (→...

  • Page 209: Auxiliary Pto

    7.17 Auxiliary PTO 7.17.1 Bilge 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 210: Fuel Supply System

    7.18 Fuel Supply System 7.18.1 Water drain valve – Check Water drain valve – Check Open water drain valve. Check water outlet for obstructions. Close water drain valve. 210 | Task Description | MS150066/02E 2013-02...

  • Page 211: Differential Pressure Gauge – Check

    7.18.2 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 94). Set the alarm points at the differential pressure gauge to zero.

  • Page 212: Check

    7.18.3 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 213: Pump Capacity – Check

    7.18.4 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 at the neck of the intake side of the pump. Check pump pressure.

  • Page 214: Coalescer Filter Element – Replacement

    7.18.5 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 215 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 screws (1), washers (2) and nuts (9). Tighten nuts (9). Open ball valve at the inlet and outlet of the fuel treatment system.

  • Page 216: Wiring (General) For Engine/Gearbox/Unit

    7.19 Wiring (General) for Engine/Gearbox/Unit 7.19.1 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 217: Accessories For (Electronic) Engine Governor / Control System

    7.20 Accessories for (Electronic) Engine Governor / Control System 7.20.1 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 ap- plicable.

  • Page 218: Limit Switch For Start Interlock ‒ Check

    7.20.2 Limit switch for start interlock ‒ Check Preconditions ☑ Engine is stopped and starting disabled. Note: In the OFF position, the limit switch initiates a start interlock, i.e. the engine cannot be started. Checking limit switch for start interlock Check whether switches (3) and guard plate (1) with engine support (4) are instal- led on both sides of flywheel housing (2).

  • Page 219: Engine Control Unit Ecu 7 – Checking Plug Connections

    7.20.3 Engine Control Unit ECU 7 – Checking plug connections Preconditions ☑ Engine is stopped and starting disabled. Check plug connections on ECU Check all connectors on ECU for firm seat- ing. Ensure that clips (3) are engaged. Check screws (2) of cable clamps on ECU for firm seating.

  • Page 220: Engine Monitoring Unit Emu – Plug Connection Check

    7.20.4 Engine monitoring unit EMU – Plug connection check Preconditions ☑ Engine is stopped and starting disabled. Checking EMU plug connections Check both connectors on EMU (2) for firm seating. Make sure that frames (3) are en- gaged. Check screws (1) of cable clamps on EMU (2) for firm seating.

  • Page 221: Interface Module Plug Connections – Check

    7.20.5 Interface module plug connections – Check Preconditions ☑ Engine is stopped and starting disabled. Checking EIM plug connections Check both Tyco plugs (62-pole) (1) on EIM for firm seating. Make sure that the clips (2) are engaged. Check screws (3) of cable clamps on EIM for firm seating.

  • Page 222: Installation

    7.20.6 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 223: Emu 7 – Removal And Installation

    7.20.7 EMU 7 – 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. Removing ECU with EMU from engine Note or mark assignment of cables and...

  • Page 224: Installation

    7.20.8 Engine Interface Module EIM – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Removing EIM from the engine Note or mark assignment of cables and connectors. Unscrew all screws (1). Undo clips (2) on connectors. Disconnect all connectors. Remove screws (3).

  • Page 225: Diagnostic Features Of Eim

    7.20.9 Diagnostic features of EIM Diagnostic lamp A diagnostic lamp (LED DILA, green) is integrated in the housing of the Engine Interface Module. It indicates the operating status of the EIM. The DILA has the following functions: • Diagnostic lamp lit:Engine Interface Module is OK •...
  • Page 226 1 Preamble 6 VSP current path failed 11 ES pushbutton current 2 ECU current path failed (S5) path failed – 24V external (S1) 7 SLD current path failed (S10) 3 MCS current path failed (S6) 12 Key switch current path (S2) 8 DDV current path failed failed (S11)
  • Page 227 Sample flashing sequences A Fuse S5 failure (1/2 sec- B Fuse S1 and fuse S4 fail- ond steps) ure (/1/2 second steps) Note: These bit sequences are transmitted constantly. Information about the status of the current paths of the EIM is also provided in the CAN message “Sta- tus internal power supply“.

  • Page 228: Appendix A 8.1 Abbreviations

    American National Standards Institute Association of American standardization organiza- tions Exhaust turbocharger Series Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU Publication No. A01061/.. Controller Area Network Data bus system, bus standard Controllable Pitch Propeller Controllable pitch propeller Deutsches Institut für Normung e. V.
  • Page 229 Abbrevia- Meaning Explanation tion Light Emitting Diode Light emitting diode Local Monitoring Unit Local monitoring unit (LOP subassembly) Alarm: Measured value lower than 1st minimum limit value LOLO Low Low Alarm: Measured value lower than 2nd minimum limit value Local Operating Panel Control console, control panel Local Operating Station Local operating station...

  • Page 230: 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 231: Special Tools

    9 Appendix B 9.1 Special Tools Barring device Part No.: F6555766 Qty.: Used in: 7.1.1 Engine – Barring manually (→ Page 133) Feeler gage Part No.: Y20010128 Qty.: Used in: 7.3.2 Valve clearance – Check and adjustment (→ Page 140) Filter wrench Part No.: F30379104...
  • Page 232 7.5.2 Injector – Removal and installation (→ Page 147) Milling cutter Part No.: F30452739 Qty.: Used in: 7.5.2 Injector – Removal and installation (→ Page 147) MTU test kit Part No.: 5605892099/00 Qty.: Used in: 7.12.3 Engine oil – Sample extraction and analysis (→ Page 181) Qty.:...
  • Page 233 Ratchet Part No.: F30027341 Qty.: Used in: 7.5.2 Injector – Removal and installation (→ Page 147) Ratchet adapter Part No.: F30027340 Qty.: Used in: 7.7.1 Compressor wheel – Cleaning (→ Page 165) Ratchet adapter Part No.: F30027339 Qty.: Used in: 7.18.5 Coalescer filter element –...
  • Page 234 Rigid endoscope Part No.: Y20097353 Qty.: Used in: 7.2.1 Cylinder liner – Endoscopic examination (→ Page 135) Socket wrench, 24 mm Part No.: F30039526 Qty.: Used in: 7.3.2 Valve clearance – Check and adjustment (→ Page 140) Steam jet cleaner Part No.: Qty.: Used in:...
  • Page 235 Torque wrench, 10-60 Nm Part No.: F30510423 Qty.: Used in: 7.6.7 Fuel prefilter with water separator – Filter ele- ment replacement (→ Page 161) Torque wrench, 10-60 Nm Part No.: F30452769 Qty.: Used in: 7.5.2 Injector – Removal and installation (→ Page 147) Torque wrench, 40-200 Nm Part No.: F30027337...
  • Page 236 Torque wrench, 60-320 Nm Part No.: F30047446 Qty.: Used in: 7.3.2 Valve clearance – Check and adjustment (→ Page 140) Torque wrench, 60-320 Nm Part No.: F30452768 Qty.: Used in: 7.5.2 Injector – Removal and installation (→ Page 147) 236 | Appendix B | MS150066/02E 2013-02...
  • Page 237 9.2 Index Engine  – Barring manually  133 Abbreviations 228 – Barring with starting system  134 Actuators  – Emergency stop  97 – Overview  50 – Main dimensions  83 ADEC (ECU 7) fault codes for Series 4000 engines, marine – Start  88 application 106 –...
  • Page 238  218 – Replacement  153 Maintenance schedule  Tasks  – Maintenance task reference table [QL1]  100 – After extended out-of-service periods  90 MTU contact persons 230 Tasks after extended out-of-service periods (>3 weeks) 90 Transport 14 Troubleshooting 102 Oil indicator filter  – Fuel treatment system  105 –...
  • Page 239 Valve gear  – Lubrication  139 Warning notices, standards 13 Water drain valve  – Check  210 Water level probe (3-in-1 rod electrode)  – Check  212 Wiring - engine  – Check  216 MS150066/02E 2013-02 | Appendix B | 239...

This manual is also suitable for:

16 v 4000 m6316 v 4000 m63r

Table of Contents