MTU 12 V 4000 Mx4 Operating Instructions Manual
  1. Manuals
  2. Brands
  3. MTU Manuals
  4. Engine
  5. 12 V 4000 Mx4
  6. Operating instructions manual

MTU 12 V 4000 Mx4 Operating Instructions Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Operating Instructions

Diesel engine
12 V 4000 Mx4
16 V 4000 Mx4
MS150110/00E

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 12 V 4000 Mx4 and is the answer not in the manual?

Questions and answers

Related Manuals for MTU 12 V 4000 Mx4

Summary of Contents for MTU 12 V 4000 Mx4

  • Page 1: Operating Instructions

    Operating Instructions Diesel engine 12 V 4000 Mx4 16 V 4000 Mx4 MS150110/00E...
  • 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 4.9 Fuel treatment system – Putting into operation 1.1 Important provisions for all products 4.10 Fuel treatment system – Switching on 1.2 Personnel and organizational requirements 4.11 Emergency engine shutdown via 1.3 Safety regulations for startup and operation automation system 1.4 Safety regulations for maintenance and 4.12 Engaging from LOP...
  • Page 4 8 Appendix A 7.14.1 Engine coolant level – Check 8.1 Abbreviations 7.14.2 Engine coolant – Change 8.2 MTU contact persons/service partners 7.14.3 Engine coolant – Draining 7.14.4 Engine coolant – Filling 7.14.5 HT coolant pump – Relief bore check 9 Appendix B 7.14.6 Engine coolant –...

  • Page 5: Safety

    • With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubri- cants Specifications of the manufacturer) • With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU contact/Service partner) •...

  • 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 unattached parts 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 latest version can be found on the website on the "Technical Info" or "Spare Parts and Service" tabs at http://www.mtu-online.com. Consumable fluids and materials may also be hazardous or toxic. When using fluids, lubricants, consum- ables and other chemical substances, follow the safety regulations that apply 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 pastes that contain lead, avoid direct contact with the skin. 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 Safety Notices In The Text

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

  • Page 14: Transport

    Only set down engine on a firm, level surface. Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate. 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 layout Engines with remote heat exchanger The following overviews are also valid for 12 V 4000 Mx4 engines. 1 Engine management and 10 Recirculation line 19 Battery-charging generator monitoring 11 Exhaust manifold (optional) 2 Oil cooler...
  • Page 16 1 Exhaust outlet 10 Oil distribution housing 19 Oil pan 2 Exhaust turbocharger car- 11 Coolant inlet from external 20 Charge-air line rier housing cooling system 21 Cylinder head 3 Dry-type air filter 12 Thermostat housing 22 Exhaust manifold 4 Exhaust turbocharger 13 Coolant pump 23 Charge-air cooler 5 Air flap...
  • Page 17 Engines with engine-mounted heat exchanger 1 Engine management and 10 Air pipe to charge-air cool- 19 Fuel filter monitoring 20 Engine mounts 2 Oil cooler 11 Recirculation line 21 Battery-charging generator 3 Plate-core heat exchanger 12 Exhaust manifold 22 HP fuel pump 4 Coolant expansion tank 13 Charge-air cooler 23 Oil filter...
  • Page 18 1 Exhaust outlet 11 Engine management and 21 Air pipe to charge-air cool- 2 Exhaust turbocharger car- monitoring rier housing 12 Oil distribution housing 22 Oil pan 3 Dry-type air filter 13 Thermostat housing 23 Crankcase 4 Exhaust turbocharger 14 Raw-water inlet 24 Charge-air line 5 Air flap 15 Raw water pump...

  • Page 19: 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 20 • 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 21 SOLAS – Fire protection specifications 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. MS150110/00E 2013-10 | General Information | 21...
  • Page 22 1 SOLAS clip on fuel line: After low- pressure pump 1 SOLAS clip on fuel line: On holder for fuel filter head 1 SOLAS clip on fuel line: On high- pressure pump 2 SOLAS clip on fuel line: After fuel fil- ter head 22 | General Information | MS150110/00E 2013-10...
  • Page 23 1 SOLAS clip on fuel line: On fuel filter head Lube oil system, oil lines with oil pressure >1.8 bar All lines with SOLAS-compliant covers for pipe connections, according to MTU standard MTN5233, are shown. MS150110/00E 2013-10 | General Information | 23...
  • Page 24 1 SOLAS clips on actuating cylinder of ETC B1 exhaust flap 1 SOLAS clips on actuating cylinder of ETC B1 air flap 2 SOLAS clips on T-piece of ETC B1 flap actuation 1 SOLAS clip on distributor piece 2 SOLAS clips on oil return 24 | General Information | MS150110/00E 2013-10...
  • Page 25 1 SOLAS clip on oil return 1 SOLAS clip on oil line to ETC 2 SOLAS clip on oil line to flap actua- tion 3 SOLAS clip on oil line to air recircu- lation valve 4 SOLAS clips on oil line from main gallery 1 SOLAS clips on air recirculation valve...
  • Page 26 1 SOLAS clip on oil supply line for HP pump: on HP pump 1 SOLAS clip on oil supply line for HP pump: On equipment carrier 1 SOLAS clip on ETC oil supply 2 SOLAS clip on ETC oil supply 26 | General Information | MS150110/00E 2013-10...
  • Page 27 1 SOLAS clips for oil line on equip- ment carrier 1 Cover on oil filter cartridge 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. MS150110/00E 2013-10 | General Information | 27...
  • Page 28 Plugs and sensors (a) Screw-in plugs (4) are sealed toward the outside either with a copper sealing ring (1), according to DIN, or an O-ring (ISO). In case of a loose thread or a defective sealing ring (1), the liquid first has to pass the thread. The pressure is so greatly reduced by this and the faulty sealing ring (1) that any leakage is not under pressure.
  • Page 29 HP connections 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 30: Engine Side And Cylinder Designations

    2.3 Engine side and cylinder designations Engine sides are always designated as viewed from the driving end (KS) (4). For designation of the cylinders (to DIN ISO 1204) the letter "A" (1) is used to refer to the cylinders on the left-hand side of the engine and the letter "B"...

  • Page 31: Overview Of Sensors - 12 V Engines

    2.4 Overview of sensors – 12 V engines Engines with remote heat exchanger Left engine side 12V 4000 Mx4 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 fore filter) (only if supple-...
  • Page 32 Free end 12V 4000 Mx4 1 B33 (fuel temperature in 5 B5.1 (lube oil pressure 9 B6.2 (coolant tempera- common rail) downstream of filter) ture) (optional) 2 B7 (lube oil temperature) 6 B48 (fuel pressure in com- 10 B6 (coolant temperature) 3 B5.2 (lube oil pressure af- mon rail) 11 XD1 connector (dialog...
  • Page 33 Right engine side 12V 4000 Mx4 1 B44.2 (turbocharger B 3 B16 (coolant pressure) speed) 4 B9 (charge-air tempera- 2 Y27 (turbocharger control ture) valve) MS150110/00E 2013-10 | General Information | 33...
  • Page 34 Driving end 12V 4000 Mx4 1 B4.21 (exhaust tempera- 3 B13 (crankshaft speed) 5 S37.1 (safety switch) ture, A-side) 4 S37.2 (safety switch) 6 B13.2 (crankshaft speed) 2 B4.22 (exhaust tempera- (optional) ture, B-side) 34 | General Information | MS150110/00E 2013-10...
  • Page 35 Plan view 12 V 4000 Mx4 1 B5.8 (lube oil pressure be- 3 B4 (cylinder exhaust tem- fore turbocharger A) perature A1-A6, B1-B6) 2 B49/Y26 (charge air tem- (optional) perature before air recircu- 4 B5.9 (lube oil pressure be- lation valve/A-air recircu-...
  • Page 36 Engines with engine-mounted heat exchanger Left engine side 12V 4000 Mx4 1 B50 (crankcase pressure) 5 B10 (charge-air pressure) 9 F46 (leak fuel level) 2 B49/Y26 (charge air tem- 6 B34.3 (fuel pressure be- 10 B33 (fuel temperature in perature before air recircu- fore filter) (only if supple- common rail) lation valve/A-air recircu-...
  • Page 37 Free end 12V 4000 Mx4 1 B48 (fuel pressure in com- 5 B5.3 (lube oil pressure be- 9 B6 (coolant temperature) mon rail) fore filter) 10 XD1 connector (dialog 2 B7 (lube oil temperature) 6 B1 (camshaft speed) unit) 3 B5.2 (lube oil pressure af- 7 B54 (oil refill pump pres- ter filter) (option) sure) (optional)
  • Page 38 Right engine side 12V 4000 Mx4 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) 38 | General Information | MS150110/00E 2013-10...
  • Page 39 Driving end 12V 4000 Mx4 1 B4.21 (exhaust tempera- 3 B13 (crankshaft speed) 5 S37.1 (safety switch) ture, A-side) 4 S37.2 (safety switch) 6 B13.2 (crankshaft speed) 2 B4.22 (exhaust tempera- (optional) ture, B-side) MS150110/00E 2013-10 | General Information | 39...
  • Page 40 Plan view 12 V 4000 Mx4 1 B5.8 (lube oil pressure be- 3 F33 (coolant level) fore turbocharger A) 4 B5.9 (lube oil pressure be- 2 B4 (cylinder exhaust tem- fore turbocharger B) perature A1-A6, B1-B6) (optional) 40 | General Information | MS150110/00E 2013-10...

  • Page 41: Overview Of Sensors - 16 V Engines

    2.5 Overview of sensors – 16 V engines Engines with remote heat exchanger Left engine side 16 V 4000 Mx4 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 fore filter) (only if supple-...
  • Page 42 Free end 16 V 4000 Mx4 1 B33 (fuel temperature in 5 B5.1 (lube oil pressure af- 9 B6.2 (coolant tempera- common rail) ter filter) ture) (optional) 2 B7 (lube oil temperature) 6 B48 (fuel pressure in com- 10 B6 (coolant temperature) 3 B5.2 (lube oil pressure af- mon rail) 11 XD1 connector (dialog...
  • Page 43 Right engine side 16 V 4000 Mx4 1 B44.2 (turbocharger B 3 B16 (coolant pressure) speed) 4 B9 (charge-air tempera- 2 Y27 (turbocharger control ture) valve) MS150110/00E 2013-10 | General Information | 43...
  • Page 44 Driving end 16 V 4000 Mx4 1 B4.21 (exhaust tempera- 3 B13 (crankshaft speed) 5 S37.1 (safety switch) ture, A-side) 4 S37.2 (safety switch) 6 B13.2 (crankshaft speed) 2 B4.22 (exhaust tempera- (optional) ture, B-side) 44 | General Information | MS150110/00E 2013-10...
  • Page 45 Plan view 16 V 4000 Mx4 1 B5.8 (lube oil pressure be- 3 B4 (cylinder exhaust tem- fore turbocharger A) perature A1-A6, B1-B6) 2 B49/Y26 (charge air tem- (optional) perature before air recircu- 4 B5.9 (lube oil pressure be- lation valve/A-air recircu- fore turbocharger B) lation valve) MS150110/00E 2013-10 | General Information | 45...
  • Page 46 Engines with engine-mounted heat exchanger Left engine side 16 V 4000 Mx4 1 B50 (crankcase pressure) 5 B10 (charge-air pressure) 9 F46 (leak fuel level) 2 B49/Y26 (charge air tem- 6 B34.3 (fuel pressure be- 10 B33 (fuel temperature in perature before air recircu- fore filter) (only if supple- common rail)
  • Page 47 Free end 16 V 4000 Mx4 1 B48 (fuel pressure in com- 5 B5.3 (lube oil pressure be- 9 B6 (coolant temperature) mon rail) fore filter) 10 XD1 connector (dialog 2 B7 (lube oil temperature) 6 B1 (camshaft speed) unit) 3 B5.2 (lube oil pressure af- 7 B54 (oil refill pump pres- ter filter) (option)
  • Page 48 Right engine side 16 V 4000 Mx4 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) 48 | General Information | MS150110/00E 2013-10...
  • Page 49 Driving end 16 V 4000 Mx4 1 B4.21 (exhaust tempera- 3 B13 (crankshaft speed) 5 S37.1 (safety switch) ture, a bank) 4 S37.2 (safety switch) 6 B13.2 (crankshaft speed) 2 B4.22 (exhaust tempera- (optional) ture, B-side) MS150110/00E 2013-10 | General Information | 49...
  • Page 50 Plan view 16 V 4000 Mx4 1 B5.8 (lube oil pressure be- 3 F33 (coolant level) fore turbocharger A) 4 B5.9 (lube oil pressure be- 2 B4 (cylinder exhaust tem- fore turbocharger B) perature A1-A6, B1-B6) (optional) 50 | General Information | MS150110/00E 2013-10...

  • Page 51: Engine Wiring Harness - Overview

    2.6 Engine wiring harness – Overview Designation Pin assignment Sensors Camshaft speed Intake air temperature B4.21 Exhaust temperature, A side B4.22 Exhaust temperature, B-side B5.1 Lube oil pressure after filter B5.3 Lube oil pressure before filter B5.8 Lube oil pressure before ETC, A-side B5.9 Lube oil pressure before ETC, B-side Coolant temperature...
  • Page 52 Designation Pin assignment Starter Valves Charge-air recirculation Exhaust turbocharger Injectors Y39A1 to Y39AX Engine side A Y39B1 to Y39BX Engine side B Engine wiring harness for sensors 12V 1 XG03 13 B44.2 25 B4.21 2 F46 14 B5.9 26 B3 3 B48 15 B54 27 B5.3...
  • Page 53 Engine wiring harness for sensors 16V 1 XG03 13 B54 25 B4.21 2 F46 14 X37 26 B3 3 B48 15 XF33 27 B5.3 4 B33 16 XXF33 28 B44.1 5 M8 17 F33 29 B34.2 6 B1 18 B4.22 30 B49 7 B6 19 S37.2...
  • Page 54 Engine wiring harness for injectors 12V 1 Y39A1 6 Y39A6 11 Y39B3 2 Y39A2 7 X4 12 Y39B2 3 Y39A3 8 Y39B6 13 Y39B1 4 Y39A4 9 Y39B5 5 Y39A5 10 Y39B4 54 | General Information | MS150110/00E 2013-10...
  • Page 55 Engine wiring harness for injectors 16V 1 Y39A1 7 Y39A7 13 Y39B5 2 Y39A2 8 Y39A8 14 Y39B4 3 Y39A3 9 X4 15 Y39B3 4 Y39A4 10 Y39B8 16 Y39B2 5 Y39A5 11 Y39B7 17 Y39B1 6 Y39A6 12 Y39B6 MS150110/00E 2013-10 | General Information | 55...
  • Page 56 Engine wiring harness for EIM 1 XD1 4 X52 7 X37 2 X1 5 XY1 3 X3 6 XB19 56 | General Information | MS150110/00E 2013-10...
  • Page 57 Engine wiring harness for electric starter 1 EIM terminals 2 Fuse F1 3 Starter terminals MS150110/00E 2013-10 | General Information | 57...

  • Page 58: Technical Data

    3 Technical Data 3.1 Engine data 12V 4000 M54, EPA Tier 3, IMO Tier II Explanation Abbrevia- Meaning tion Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value 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 59 Heat exchanger Heat exchanger engine-mounted remote Cylinder displacement Liters 4.77 4.77 4.77 4.77 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. -0.2 -0.2 -0.2...
  • Page 60 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 61 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) MS150110/00E 2013-10 | Technical Data | 61...

  • Page 62: Engine Data 12V 4000 M64, Epa Tier 3, Imo Tier

    3.2 Engine data 12V 4000 M64, EPA Tier 3, IMO Tier II Explanation Abbrevia- Meaning tion Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value 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 63 Heat exchanger Heat exchanger engine-mounted remote 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. -0.2 -0.2 -0.2 -0.2 Raw water pump: Inlet pressure, max. Pressure loss in off-engine raw water sys- tem, max.
  • Page 64 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 65 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) MS150110/00E 2013-10 | Technical Data | 65...

  • Page 66: Engine Data 16V 4000 M54, Epa Tier 3, Imo Tier

    3.3 Engine data 16V 4000 M54, EPA Tier 3, IMO Tier II Explanation Abbrevia- Meaning tion Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value 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 67 Heat exchanger Heat exchanger engine-mounted remote 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. -0.2 -0.2 -0.2 -0.2 Raw water pump: Inlet pressure, max. Pressure loss in off-engine raw water sys- tem, max.
  • Page 68 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 69 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) MS150110/00E 2013-10 | Technical Data | 69...

  • Page 70: Engine Data - 16V 4000 M64, Epa Tier 3, Imo Tier

    3.4 Engine data – 16V 4000 M64, EPA Tier 3, IMO Tier II Explanation Abbrevia- Meaning tion Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value 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 71 Heat exchanger Heat exchanger engine-mounted remote 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. -0.2 -0.2 -0.2 -0.2 Raw water pump: Inlet pressure, max. Pressure loss in off-engine raw water sys- tem, max.
  • Page 72 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 73 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) MS150110/00E 2013-10 | Technical Data | 73...

  • Page 74: Firing Order

    3.5 Firing order Cylinders Firing order 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 74 | Technical Data | MS150110/00E 2013-10...

  • Page 75: Engine - Main Dimensions

    3.6 Engine – Main dimensions Engines with remote heat exchanger The following overviews also applies to engines in the series 12V4000M54/M64. Engine model Length (A) Width (B) without Width (B) with si- Height (C) silencer lencer 12 V 4000 M54/64 approx. 2638 mm approx.
  • Page 76 Engines with engine-mounted heat exchanger Engine model Length (A) Width (B) without Width (B) with si- Height (C) silencer lencer 12 V 4000 M54/64 approx. 2884 mm approx. 1690 mm approx. 1850 mm approx. 2071 mm 16 V 4000 M54/64 approx. 3393 mm approx.

  • Page 77: Operation

    4 Operation 4.1 LOP controls LOP controls Item Measure Start engine via the automation system (→ Automation system Operating In- structions). MS150110/00E 2013-10 | Operation | 77...

  • Page 78: 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 the engine into operation after extended out-of-service-periods (>3 months) Item...

  • Page 79: 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 Task Lube oil system Check engine oil level (→ Page 211); Preheat engine oil if required. Coolant system Check coolant level (→...

  • Page 80: Starting The Engine Via The Automation System

    4.4 Starting the engine via the automation system Starting the engine via the automation system Item Measure Automation system Start engine via the automation system (→ Automation system Operating In- structions). 80 | Operation | MS150110/00E 2013-10...

  • Page 81: Operational Checks

    4.5 Operational checks DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running. Risk of damage to hearing! •...

  • Page 82: 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 85). Shut down fuel treatment system (→ Page 95). 82 | Operation | MS150110/00E 2013-10...

  • Page 83: 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 84: Fuel Treatment System Control Cabinet - Control Elements

    4.8 Fuel treatment system control cabinet – Control elements Color Inscription Meaning/function Green Signal lamp Indicates "Pump running" Signal lamp Indicates "Pump fault" Yellow Illuminated Indicates "Water drain" / Press to drain water manually. pushbutton Illuminated Indicates "Water alarm" / Press to acknowledge. pushbutton Yellow Signal lamp...

  • Page 85: Fuel Treatment System - Putting Into Operation

    4.9 Fuel treatment system – Putting into operation Overview of fuel treatment system 1 Pressure-free overflow 9 Ball valve, outlet 17 Automatic water drain 2 Bypass 1 10 Check valve 700 mbar 18 Water level electrode 3 Bypass 2 11 Check valve 5 mbar 19 Ball valve, sample extrac- 4 Safety valve, 3 bar 12 Return to overflow con-...
  • Page 86 Initial operation: HAT Replace fuel filter on engine (→ Page 191). Note: Determine the suction pressure upstream of the engine-mounted fuel delivery pump. Install pressure gage in fuel supply line from Yard fuel system to engine. Switch on fuel treatment system and operate it for some minutes (→ Page 88). Result: The fuel is drawn from tank (24), cleaned by the water separator filter (15) and then routed via overflow tank (14) back to tank (24).
  • Page 87 Simulation of power failure (emergency): SAT Switch on fuel treatment system (→ Page 88). Start engine (→ Page 80). Run engine at idling speed. Switch off pump (21) at switchgear cabinet (20). Result: The engine-mounted fuel delivery pump draws fuel via bypass (2) directly from tank (24). Check suction pressure at the engine-mounted fuel delivery pump.

  • Page 88: Fuel Treatment System - Switching On

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

  • Page 89: Emergency Engine Shutdown Via Automation System

    4.11 Emergency engine shutdown via automation system NOTICE An emergency stop causes extreme stress to the engine plant. Risk of overheating, damage to components! • Initiate emergency stop only in emergency situations. Emergency engine shutdown via automation system Item Measure Automation system Emergency shutdown via the automation system (→...

  • Page 90: Engaging From Lop

    4.12 Engaging from LOP DANGER Vessel is sailing blind. In Local Operation mode, the propulsion plant is controlled from the engine room. Risk of accidents! • Only execute vessel movements on the instructions of a person who has visual contact with the area outside the vessel.

  • Page 91: Disengaging From Lop

    4.13 Disengaging from LOP DANGER Vessel is sailing blind. In Local Operation mode, the propulsion plant is controlled from the engine room. Risk of accidents! • Only execute vessel movements on the instructions of a person who has visual contact with the area outside the vessel.

  • Page 92: Waterjet - Flushing From Lop (Optional)

    4.14 Waterjet – Flushing from LOP (optional) Preconditions ☑ LOCAL OPERATION illuminated pushbutton is lit brightly (local operating mode is active). ☑ Vessel is at a standstill and waterjet bucket is below the waterline. ☑ Engine speed is in engagement window. ☑...

  • Page 93: Engine Shutdown Via The Automation System

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

  • Page 94: After Stopping The Engine

    4.16 After stopping the engine Preconditions ☑ MTU Preservation and Re-preservation Specifications (A001070/..) are available. After stopping the engine Item Measure Coolant circuit Drain coolant (→ Page 228) if: freezing temperatures are expected and the engine is to remain out of •...

  • Page 95: 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 96: Plant - Cleaning

    4.18 Plant – Cleaning Preconditions ☑ Engine is stopped and starting disabled. ☑ Operating voltage is not applied. Special tools, Material, Spare parts Designation / Use Part No. Qty. Steam jet cleaner Cleaner (Hakupur 312) 30390 WARNING Compressed air gun ejects a jet of pressurized air. Risk of injury to eyes and damage to hearing, risk of rupturing internal organs! •...

  • Page 97: Maintenance

    5 Maintenance 5.1 Maintenance 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 98: 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' for is reached, the water level acknowledgment. electrode opens the water drain 2.

  • Page 99: Troubleshooting

    6.2 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 100 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 101 White exhaust gas Cause Corrective action Engine is not at operating u Run engine to reach operating temperature. temperature Intercooler leaky u Contact Service. MS150110/00E 2013-10 | Troubleshooting | 101...

  • Page 102: Engine Governor Adec (Ecu 7) Fault Messages For Series 4000 Engines, Marine Application

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

  • Page 103: Engine Governor Adec (Ecu 7) - Fault Codes

    6.4 Engine governor ADEC (ECU 7) – Fault codes 3 – HI T-Fuel ZKP-Number: 2.0122.931 Fuel temperature too high (limit value 1) Yellow alarm; warning Cause Corrective action Fuel tank may be exposed to 1. Reduce power. heat. 2. Contact Service. 4 –...
  • Page 104 9 – HI T-Coolant charge-air cooler ZKP-Number: 2.0124.931 Coolant temperature in charge-air cooler too high (limit value 1) Yellow alarm; warning Cause Corrective action Coolant circuit for charge air 1. Reduce power. defective. 2. Check charge-air cooler and coolant cooler. 3.
  • Page 105 19 – HI T-Exhaust A ZKP-Number: 2.0126.931 Exhaust temperature too high, A-side (limit value 1) Yellow alarm; warning Cause Corrective action Wiring damage. 1. Check air filter and wiring (→ Page 248). 2. Contact Service. 20 – SS T-Exhaust A ZKP-Number: 2.0126.932 Exhaust temperature too high, A-side (limit value 2) Red alarm;...
  • Page 106 25 – HI P-Diff. Lube Oil ZKP-Number: 2.0154.931 Differential oil pressure at oil filter too high (limit value 1) Yellow alarm; warning Cause Corrective action Oil filter not functioning u Replace oil filter (→ Page 216). correctly. 26 – HI P-Diff. Lube Oil ZKP-Number: 2.0154.932 Differential oil pressure at oil filter too high (limit value 2) Red alarm;...
  • Page 107 31 – HI ETC1 Overspeed ZKP-Number: 2.3011.931 Speed of primary turbocharger too high (limit value 1) Yellow alarm; warning Cause Corrective action Clogged charge-air circuit or 1. Reduce power. fault in turbocharger. 2. Check air filter. 3. Contact Service. 32 – SS ETC1 Overspeed ZKP-Number: 2.3012.932 Speed of primary turbocharger too high (limit value 2) Red alarm;...
  • Page 108 37 – SS ETC2 Overspeed ZKP-Number: 2.3013.912 Speed of 1st secondary turbocharger too high (limit value 2) Red alarm; engine shutdown Cause Corrective action Clogged charge-air circuit or u Contact Service. fault in turbocharger. 38 – AL ETC Speed Deviation ZKP-Number: 1.8004.205 Yellow alarm;...
  • Page 109 52 – SS T-Lube Oil ZKP-Number: 2.0125.932 Lube oil temperature too high (limit value 2) Red alarm; engine shutdown Cause Corrective action Insufficient oil. 1. Check engine oil level (→ Page 211). 2. Contact Service. 57 – LO P-Coolant ZKP-Number: 2.0101.921 Coolant pressure too low (limit value 1).
  • Page 110 60 – SS T-Coolant L4 ZKP-Number: 2.0120.934 Coolant temperature too high / low (limit value 4) Red alarm; engine shutdown Cause Corrective action Coolant circuit not functioning 1. Activate fan emergency operating mode if required. correctly (e.g. damage, leaks, 2. Allow engine to cool down. low coolant level).
  • Page 111 66 – SS P-Fuel ZKP-Number: 2.0102.922 Fuel supply pressure too low (limit value 2) Red alarm; engine shutdown Cause Corrective action Leaking or clogged fuel lines or 1. Check fuel lines for leakage. fuel filter. 2. Check filter, fuel low-pressure side. 3.
  • Page 112 82 – HI P-Fuel (Common Rail) ZKP-Number: 2.0104.931 Rail pressure > set value Red alarm - DBR fuel limitation, start of injection retarded; Cause Corrective action Suction restrictor of HP fuel 1. Check wiring (→ Page 248). block jamming or HP fuel control 2.
  • Page 113 90 – SS Starter Speed Not Reached ZKP-Number: 2.1090.925 Idling speed not attained Red alarm; warning Cause Corrective action Various causes possible. 1. Check for additional messages. 2. Contact Service. 91 – SS Release Speed Not Reached ZKP-Number: 2.1090.924 Runup speed was not attained Red alarm;...
  • Page 114 95 – AL Prelubrication Fault ZKP-Number: 2.1090.920 Oil priming fault Yellow alarm; warning Cause Corrective action Priming oil pressure not 1. Check priming system. reached. 2. Contact Service. 102 – AL Fuel Cons. Counter Defect ZKP-Number: 1.8004.624 Error in fuel consumption checksum Yellow alarm;...
  • Page 115 120 – HI ECU Power Supply Voltage ZKP-Number: 2.0140.931 Supply voltage too high (limit value 1) Yellow alarm; warning Cause Corrective action Supply voltage at engine 1. Check Engine Control Unit supply voltage. governor too high. 2. Contact Service. 121 – HIHI ECU Power Supply Voltage ZKP-Number: 2.0140.932 Supply voltage too high (limit value 2) Red alarm - start cancelation of engine stop...
  • Page 116 176 – AL LifeData not available ZKP-Number: 2.4000.004 No (matching) LifeData backup system available Yellow alarm; warning Cause Corrective action After a wait time has elapsed u Contact Service. after ECU reset: Backup system has no LifeData function or CAN bus to backup system disconnected.
  • Page 117 182 – AL CAN Wrong Parameters ZKP-Number: 2.0500.682 Incorrect parameters on CAN Yellow alarm; warning Cause Corrective action Wrong parameter value entered u Contact Service. in data record. 183 – AL CAN No PU-Data ZKP-Number: 2.0500.683 CAN PU data not present or available Yellow alarm;...
  • Page 118 187 – AL CAN1 Error Passive ZKP-Number: 2.0500.687 CAN controller 1 error Yellow alarm; warning Cause Corrective action Missing associated node, minor 1. Check CAN bus for short circuit, rectify short circuit as disruptions or temporary bus necessary. overload. 2. Check shielding, improve shielding as necessary. 3.
  • Page 119 201 – SD T-Coolant ZKP-Number: 1.8004.570 Signal error, coolant temperature sensor Yellow alarm; warning Cause Corrective action Coolant temperature sensor 1. Check sensor and wiring (B6), replace as necessary faulty. (→ Page 248). Short circuit or wire break. 2. Fault is rectified when engine is restarted (→ Page 80). 3.
  • Page 120 205 – SD T-Coolant Charge-Air Cooler ZKP-Number: 1.8004.574 Signal error, coolant temperature sensor Yellow alarm; warning Cause Corrective action Coolant pressure sensor of 1. Check sensor and wiring (B26), replace as necessary charge-air cooler faulty. (→ Page 248). Short circuit or wire break. 2.
  • Page 121 211 – SD P-Lube Oil ZKP-Number: 1.8004.563 Signal error, lube oil pressure sensor Yellow alarm; warning Cause Corrective action Lube-oil pressure sensor faulty. 1. Check sensor and wiring (B5), replace as necessary Short circuit or wire break. (→ Page 248). 2.
  • Page 122 215 – SD P-HD ZKP-Number: 1.8004.567 Signal error, rail pressure sensor Yellow alarm; high-pressure regulator emergency operation Cause Corrective action Rail pressure sensor faulty. ==> 1. Check sensor and wiring (B48), replace as necessary high-pressure regulator (→ Page 248). emergency operation. 2.
  • Page 123 221 – SD P-Diff Lube Oil ZKP-Number: 1.8004.585 Signal error, lube oil differential pressure sensor faulty Yellow alarm; warning Cause Corrective action Lube oil differential pressure 1. Check sensor and cabling (F25), replace as necessary sensor faulty. (→ Page 248). Short circuit or wire break.
  • Page 124 228 – SD P-Fuel before Filter ZKP-Number: 1.8004.595 Signal error, fuel pressure sensor Yellow alarm; warning Cause Corrective action Fuel pressure sensor faulty. 1. Check sensor and wiring (B5.3), replace as necessary Short circuit or wire break. (→ Page 248). 2.
  • Page 125 232 – SD Charger 1 Speed ZKP-Number: 1.3011.128 Signal error, primary turbocharger speed sensor Yellow alarm; warning Cause Corrective action Speed sensor of primary 1. Check sensor and wiring (B44.1), replace as necessary turbocharger faulty. (→ Page 248). Short circuit or wire break. 2.
  • Page 126 241 – SD T-Recirculation ZKP-Number: 1.8004.581 Cause Corrective action Recirculation sensor faulty; u Check sensor and wiring (B49), replace as necessary. Short circuit or wire break. Fault is rectified following engine restart. 242 – SD T-Coolant (R) ZKP-Number: 1.8004.622 Cause Corrective action Redundant coolant pressure u Check sensor and wiring, replace as necessary.
  • Page 127 268 – SD Spinning Value ZKP-Number: 2.8006.591 Skid signal error Yellow alarm; warning Cause Corrective action Analog skid signal faulty. 1. Check sensor and wiring, replace as necessary (→ Page 248). Short circuit or wire break. 2. Fault is rectified when engine is restarted (→ Page 80). 3.
  • Page 128 303 – AL Timing Cylinder A3 ZKP-Number: 1.8004.502 Time-of-flight measuring fault of injector Cause Corrective action Flight time value extremely low u Replace injector if the fault message appears frequently or extremely high. (→ Page 182). 304 – AL Timing Cylinder A4 ZKP-Number: 1.8004.503 Time-of-flight measuring fault of injector Cause...
  • Page 129 309 – AL Timing Cylinder A9 ZKP-Number: 1.8004.508 Time-of-flight measuring fault of injector Cause Corrective action Flight time value extremely low u Replace injector if the fault message appears frequently or extremely high. (→ Page 182). 310 – AL Timing Cylinder A10 ZKP-Number: 1.8004.509 Time-of-flight measuring fault of injector Cause...
  • Page 130 315 – AL Timing Cylinder B5 ZKP-Number: 1.8004.514 Time-of-flight measuring fault of injector Cause Corrective action Flight time value extremely low u Replace injector if the fault message appears frequently or extremely high. (→ Page 182). 316 – AL Timing Cylinder B6 ZKP-Number: 1.8004.515 Time-of-flight measuring fault of injector Cause...
  • Page 131 321 – AL Wiring Cylinder A1 ZKP-Number: 1.8004.520 Wiring fault cylinder A1 Yellow alarm; misfire Cause Corrective action Short circuit fault in injector 1. Check injector solenoid, replace injector if necessary wiring cylinder A1. (→ Page 182). 2. Fault is rectified when engine is restarted (→ Page 80). 3.
  • Page 132 325 – AL Wiring Cylinder A5 ZKP-Number: 1.8004.524 Wiring fault cylinder A5 Yellow alarm; misfire Cause Corrective action Short circuit fault in injector 1. Check injector solenoid, replace injector if necessary wiring cylinder A5. (→ Page 182). 2. Fault is rectified when engine is restarted (→ Page 80). 3.
  • Page 133 329 – AL Wiring Cylinder A9 ZKP-Number: 1.8004.528 Wiring fault cylinder A9 Yellow alarm; misfire Cause Corrective action Short circuit fault in injector 1. Check injector solenoid, replace injector if necessary wiring cylinder A9. (→ Page 182). 2. Fault is rectified when engine is restarted (→ Page 80). 3.
  • Page 134 333 – AL Wiring Cylinder B3 ZKP-Number: 1.8004.532 Wiring fault cylinder B3 Yellow alarm; misfire Cause Corrective action Short circuit fault in injector 1. Check injector solenoid, replace injector if necessary wiring cylinder B3. (→ Page 182). 2. Fault is rectified when engine is restarted (→ Page 80). 3.
  • Page 135 337 – AL Wiring Cylinder B7 ZKP-Number: 1.8004.536 Wiring fault cylinder B7 Yellow alarm; misfire Cause Corrective action Short circuit fault in injector 1. Check injector solenoid, replace injector if necessary wiring cylinder B7. (→ Page 182). 2. Fault is rectified when engine is restarted (→ Page 80). 3.
  • Page 136 341 – AL Open Load Cylinder A1 ZKP-Number: 1.8004.540 Injector wiring fault cylinder A1 Yellow alarm; misfire Cause Corrective action Disruption fault in injector wiring 1. Check injector wiring for open circuit. cylinder A1. 2. Exclude possible injector solenoid fault, replace injector if necessary (→...
  • Page 137 345 – AL Open Load Cylinder A5 ZKP-Number: 1.8004.544 Injector wiring fault cylinder A5 Yellow alarm; misfire Cause Corrective action Disruption fault in injector wiring 1. Check injector wiring for open circuit. cylinder A5. 2. Exclude possible injector solenoid fault, replace injector if necessary (→...
  • Page 138 349 – AL Open Load Cylinder A9 ZKP-Number: 1.8004.548 Injector wiring fault cylinder A9 Yellow alarm; misfire Cause Corrective action Disruption fault in injector wiring 1. Check injector wiring for open circuit. cylinder A9. 2. Exclude possible injector solenoid fault, replace injector if necessary (→...
  • Page 139 353 – AL Open Load Cylinder B3 ZKP-Number: 1.8004.552 Injector wiring fault cylinder B3 Yellow alarm; misfire Cause Corrective action Disruption fault in injector wiring 1. Check injector wiring for open circuit. cylinder B3. 2. Exclude possible injector solenoid fault, replace injector if necessary (→...
  • Page 140 357 – AL Open Load Cylinder B7 ZKP-Number: 1.8004.556 Injector wiring fault cylinder B7 Yellow alarm; misfire Cause Corrective action Disruption fault in injector wiring 1. Check injector wiring for open circuit. cylinder B7. 2. Exclude possible injector solenoid fault, replace injector if necessary (→...
  • Page 141 361 – AL Power Stage Low ZKP-Number: 1.8004.496 Internal electronic fault Red alarm; engine shutdown possible Cause Corrective action Electronics faulty. 1. Start ITS. 2. Replace engine governor if required. 3. Check additional messages if ITS indicates diagnosis "Electronics OK" (e.g. wiring faulty). 4.
  • Page 142 365 – AL Stop MV-Wiring Ground ZKP-Number: 1.8004.561 Injector wiring error Red alarm - engine shutdown via Protection Module possible Cause Corrective action Short circuit of injector positive 1. Check wiring (→ Page 248). connection to ground of one or 2.
  • Page 143 381 – AL Wiring TOP 1 ZKP-Number: 2.8006.638 Line disruption on digital input 1 Yellow alarm; warning Cause Corrective action Short circuit or wire break on u Check wiring to plant. transistor output, plant-side 1 (TOP 1). 382 – AL Wiring TOP 2 ZKP-Number: 2.8006.639 Line disruption on digital input 2 Yellow alarm;...
  • Page 144 390 – AL MCR exceeded ZKP-Number: 1.1085.009 Speed limiter/MCR function: the maximum continuous rate was exceeded Yellow alarm; engine power limited to permissible continuous power Cause Corrective action Engine was overloaded u With a continuous alarm, contact Service. continuously. 392 – HI T-Coolant Red ZKP-Number: 2.0129.931 Limit value 1 Cause...
  • Page 145 397 – TD P-Oil Sensor Deviation ZKP-Number: 1.0480.293 Cause Corrective action Maximum lube oil pressure 1. Check wiring and sensor. deviation. 2. Contact Service. 400 – AL Open Load Digital Input 1 ZKP-Number: 2.8006.625 Line disruption on digital input 1 Yellow alarm;...
  • Page 146 404 – AL Open Load Digital Input 5 ZKP-Number: 2.8006.629 Line disruption on digital input 5 Yellow alarm; warning Cause Corrective action Wiring faulty. 1. Check wiring (→ Page 248). No resistance over switch. 2. Check target device input. 3. Contact Service. 405 –...
  • Page 147 408 – AL Open Load Emerg. Stop Input ESI ZKP-Number: 2.8006.633 Line disruption at input for emergency stop Yellow alarm; warning Cause Corrective action Wiring faulty or no resistance 1. Check wiring (→ Page 248). over switch. 2. Check target device input. 3.
  • Page 148 413 – HIHI U-PDU ZKP-Number: 2.0141.932 Injector voltage too high (limit value 2) Red alarm; engine shutdown Cause Corrective action Wiring damage or faulty current 1. Check wiring (→ Page 248). supply. 2. Check supply. 3. Acknowledge alarm. 4. Contact Service. 414 –...
  • Page 149 419 – SD T-Coolant b.Engine ZKP-Number: 18.004.604 Cause Corrective action Coolant inlet temperature u Check sensor and wiring (B3), replace as necessary. sensor faulty. Short circuit or wire break 420 – AL L1 Aux 1 ZKP-Number: 2.0160.921 Limit value 1 Cause Corrective action Input signal of Aux 1 has...
  • Page 150 440 – AL L1 P-Aux 1 ZKP-Number: 2.0110.921 Limit value 1 Cause Corrective action Pressure signal of Aux 1 has u Determine cause of limit value violation and rectify fault. exceeded / not attained limit value 1, depending on configuration. 442 –...
  • Page 151 446 – SD P-HD2 ZKP-Number: 1.8004.599 Signal error, rail pressure sensor Yellow alarm; high-pressure regulator emergency operation Cause Corrective action Rail pressure sensor faulty. 1. Check sensor and wiring (B48), replace as necessary Short circuit or wire break. (→ Page 248). 2.
  • Page 152 454 – SS Power Reduction Active ZKP-Number: 2.7000.011 Power reduction activated Red alarm - power reduction activated Cause Corrective action Engine operation outside u Check for additional messages. standard limit values. This message has the following possible causes: Intake depression, exhaust back pressure, charge-air coolant temperature or intake air temperature outside the limit...
  • Page 153 461 – LO T-Exhaust EMU ZKP-Number: 2.8006.653 Limit value 1 Cause Corrective action EMU exhaust gas temperature 1. Check wiring. value too low. 2. Contact Service. 462 – HI T-Coolant EMU ZKP-Number: 2.8006.654 Limit value 1 Cause Corrective action EMU coolant temperature value u Check configuration with DiaSys.
  • Page 154 469 – SD AUX 1 ZKP-Number: 1.8004.590 Cause Corrective action Analog input signal for Aux 1 u Check signal sensor and wiring, replace as necessary. faulty; short circuit or wire Fault is rectified following engine restart. break. 470 – SD T-ECU ZKP-Number: 1.8004.587 Signal error, engine governor temperature Yellow alarm;...
  • Page 155 474 – AL Wiring FO ZKP-Number: 2.8006.655 Wiring fault on FO Yellow alarm; warning Cause Corrective action Wire break or short circuit on 1. Check wiring (→ Page 248). channel FO. 2. Contact Service. 475 – AL CR Engine Shutdown Trigger ZKP-Number: 1.8010.009 Crash recorder was triggered by an engine shutdown.
  • Page 156 480 – AL Ext. Engine Protection ZKP-Number: 2.0291.921 External engine protection function active Yellow alarm; warning Cause Corrective action The external engine protection 1. Check plant signal. function is active. 2. Contact Service. Monitoring of plant signal by ECU active (plant side). 482 –...
  • Page 157 486 – HI T-Exhaust D ZKP-Number: 20.134.931 Limit value 1 Cause Corrective action Exhaust gas temperature (D- 1. Reduce power. side) too high. 2. Contact Service. 487 – SS T-Exhaust D ZKP-Number: 20.134.932 Limit value 2 Cause Corrective action Exhaust gas temperature (D- 1.
  • Page 158 491 – SS ETC4 Overspeed ZKP-Number: 2.3015.932 Speed of the 3rd secondary turbocharger too high (limit value 2) Red alarm; engine shutdown Cause Corrective action Clogged charge-air circuit or u Reduce power. fault in turbocharger. 492 – AL ETC4 Cutin Failure ZKP-Number: 18.004.202 Yellow alarm;...
  • Page 159 502 – AL Open Load POM Battery-charging Generator ZKP-Number: 1.4500.902 Power disruption, battery-charging generator connection of POM Yellow alarm; warning Cause Corrective action Wiring faulty or no resistance u Check connection between POM and battery-charging over switch. generator. 503 – AL Battery Not Charging ZKP-Number: 1.4500.903 No battery charge Yellow alarm;...
  • Page 160 508 – AL Incorrect POM ID ZKP-Number: 1.4500.908 POM sends a different ID number than expected Yellow alarm; warning Cause Corrective action If alarm 504 occurs in addition, u Check POM wiring harness. the resistor in the POM wiring is missing.
  • Page 161 532 – AL Wiring PWM1 ZKP-Number: 1.1046.900 Red alarm Cause Corrective action Wire break or short circuit on u Check wiring to mixture throttle on A side, replace mixture channel PWM1. throttle on A side if necessary. 533 – AL Wiring PWM2 ZKP-Number: 1.1047.900 Red alarm Cause...
  • Page 162 Limit value 2 Cause Corrective action Camshaft overspeed. 1. Acknowledge alarm. 2. Attempt engine restart. 555 – AL Call MTU Field Service ZKP-Number: 20.555.001 Cause Corrective action This fault becomes active if a u Request activation code via Internet. maintenance case has been...
  • Page 163 582 – AL Emergency Stop Failure ZKP-Number: 1.1005.006 Emergency stop command was not executed Flashing pre-alarm and alarm Cause Corrective action Engine speed does not come to u Contact Service. a standstill within a configurable period. 584 – AL CAN Start clearance failed Yellow alarm;...
  • Page 164 596 – AL Test Parameters ZKP-Number: 1.8004.645 Yellow alarm; warning Cause Corrective action The parameter set is used for u Contact Service. trials. The alarm remains set until a series parameter set is loaded. 600 – SD T-Exhaust A+B ZKP-Number: 1.8004.646 Signal error, exhaust temperature sensor A- and B-side Yellow alarm;...
  • Page 165 606 – AL Double Nodes Lost CAN 1+2 ZKP-Number: 2.0500.691 ECU does not detect a monitored CAN bus. Red alarm; forced idle Cause Corrective action A node on both CANs has failed. 1. Check wiring and power supply of plant (→ Page 248). Short circuit or wire break.
  • Page 166 690 – AL Oil Level too Low ZKP-Number: 1.0150.921 Cause Corrective action Alarm, lube oil level is too low. 759 – AL L1 T-Fuel b. Engine ZKP-Number: 2.0080.921 Fuel before engine (limit 1) Cause Corrective action Fuel temperature before engine too high.
  • Page 167 850 – SD Alive FIP ZKP-Number: 2.0900.002 Frequency input faulty. Cause Corrective action Short circuit or wire break. Fault in Backup ECU, Alive signal not transmitted 856 – SD P-Lube oil ETC B ZKP-Number: 1.0223.920 Cause Corrective action ETC oil pressure sensor faulty. u Check sensor and wiring, replace as necessary.

  • Page 168: 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 Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...
  • Page 169 Engage barring device (2) in ring gear of fly- wheel and mount on flywheel housing. Fit ratchet (1) onto barring device (2). Note: No resistance other than compression re- sistance must be encountered. Rotate crankshaft in engine direction of ro- tation.

  • Page 170: Engine - Barring With Starting System

    7.1.2 Engine – Barring with starting system Barring using the automation system Refer to automation system operating instructions 170 | Task Description | MS150110/00E 2013-10...

  • Page 171: 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 179). Remove injector (→...
  • Page 172 Final steps Install injector (→ Page 183). Install cylinder head cover (→ Page 179). 172 | Task Description | MS150110/00E 2013-10...

  • Page 173: 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 Explanations/Action Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing products, particles, broken-off burrs).
  • Page 174 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 175: 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 179). Fill oil chambers of valve bridges with oil.

  • Page 176: 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 Y20010128 Torque wrench, 60-320 Nm F30047446...
  • Page 177 Rotate crankshaft with barring tool in en- gine direction of rotation until marking 'TDC-A1' and pointer are aligned. Diagram for 12V 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 16V engines (two crankshaft positions)

  • Page 178: Valve Clearance Adjustment

    Checking valve clearance in two crankshaft positions Check TDC position of piston in cylinder A1: • If the rocker arms are unloaded on cylinder A1, the piston is in firing TDC. • If the rocker arms are loaded on cylinder A1, the piston is in overlap TDC. Check valve clearance with cold engine: •...

  • Page 179: Cylinder Head Cover - Removal And Installation

    7.3.3 Cylinder head cover – Removal and installation Preconditions ☑ Engine stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Grease (Kluthe Hakuform 30-10/emulsifier) X00058061 O-ring (→ Spare Parts Catalog) Removing cylinder head cover Clean very dirty cylinder head covers (1) prior to removal.

  • Page 180: 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 181: Hp Pump - Relief Bore Check

    7.4.2 HP pump – Relief bore check DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running.

  • Page 182: Injector

    7.5 Injector 7.5.1 Injector – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Injector (→ Spare Parts Catalog) Injector – Replacement Remove injector and install new one (→ Page 183). 182 | Task Description | MS150110/00E 2013-10...

  • Page 183: 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. Puller F6790506 Installation device F6790504 Milling cutter F30452739 Torque wrench, 0.5-5 Nm 0015384230 Torque wrench, 10-60 Nm F30452769 Torque wrench, 60-320 Nm F30452768...
  • Page 184 Unscrew union nuts (2, 5) and remove HP line (3) from rail (4) and cylinder head. Note: While the adapter is removed, the injector is drained. Provide suitable container to collect escap- ing fuel. Remove adapter (1). Remove screw (2) from hold-down clamp (1).

  • Page 185: Installing Injector

    Remove sealing ring (4) from injector (1) or cylinder head. Remove O-rings (2) and damper ring (3) from injector (1). Clean all mating and sealing surfaces. If carbon residue is present, clean sealing face on cylinder head and protective sleeve with milling cutter.
  • Page 186 Press in injector (1) and hold-down clamp with force-in tool (2). Remove force-in tool. Coat screw head mating face and thread (2) of hold-down clamp (1) with en- gine oil. Insert screw (2) and use torque wrench to tighten to specified initial tightening torque. Name Size Type...
  • Page 187 Note: Ensure special cleanness. Coat thread and sealing cone of adapter (1) with engine oil. Install adapter (1) and use torque wrench to tighten to the specified initial tightening torque. Name Size Type Lubricant Value/Standard Adapter Preload torque (Engine oil) 5 Nm to 10 Nm Tighten screw on hold-down clamp (Engine oil) to specified tightening torque using a torque wrench.
  • Page 188 Fit connectors on injector. Note: If the CDC parameters are not reset, the emission certification of the engine be- comes invalid. Reset CDC parameters and enter injector code (IIG) (→ Page 249). Final steps Install cylinder head cover (→ Page 179). Open fuel supply to engine.

  • Page 189: 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 MS150110/00E 2013-10 | Task Description | 189...

  • Page 190: Additional Fuel Filter – Replacement

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

  • Page 191: 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 Rotating and moving engine parts.
  • Page 192 Replacing fuel filter with the en- gine running Cut out the filter to be replaced (1): B Left filter cut out C Right filter cut out Remove the cut-out oil filter (1) using an oil filter wrench. Clean sealing surface on filter head. Check sealing ring of new filter (1) and coat with fuel.

  • Page 193: Fuel System – Venting

    7.6.4 Fuel system – Venting Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. •...

  • Page 194: Fuel Prefilter – Differential Pressure Check And Adjustment Of Gauge

    7.6.5 Fuel prefilter – Differential pressure check and adjustment of gauge DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running.

  • Page 195: Draining Fuel Prefilter

    7.6.6 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 Cut out the filter to be replaced (A or B). 1 Filter A cut out 2 Filter B cut out Open vent plug (1) of filter to be drained.
  • Page 196 Connect filling pump to filling connection (1) on the suction side of the filter. Open vent valve (2) and fill with fuel until fuel emerges from the vent pipe (3). Close vent valve (2). Open rotary slide valve (4) a little (by ap- prox.

  • Page 197: Fuel Prefilter – Flushing

    7.6.7 Fuel prefilter – Flushing Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING Fuels are combustible.

  • Page 198: Fuel Prefilter – Filling With Fuel

    Open 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 vent plug (1) and drain valve (2). Fuel prefilter –...

  • Page 199: Fuel Prefilter With Water Separator – Filter Element Replacement

    7.6.8 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 adapter F30027340 Filter element...
  • Page 200 Open vent valve (1) of the filter to be re- placed. Open drain valve (5) and drain fuel. Loosen screws (3) and screw out filter housing (A or B). Remove filter element (4). Insert new filter element in filter housing. Fit O-ring.

  • Page 201: Fuel Prefilter With Water Separator – O-Ring Replacement In Rotary Slide Valve

    7.6.9 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 202: 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 Cleaner 40377 Engine oil Engine coolant Sealing rings (→...
  • Page 203 Remove charge-air pipework (2) from ex- haust turbocharger to charge-air cooler . Remove oil lines (1). Loosen clamp (1). Remove intake housing (3) with actuating cylinder (2). Remove coolant lines (2) from compressor casing (3). Remove coolant ventilation line (1) from compressor casing (3).
  • Page 204 Undo screws (1). Remove compressor casing (2). Cleaning compressor wheel Note: Do not use wire brush, scraper or similar tools for cleaning! Clean compressor casing with a smooth paint brush or brush. Clean compressor wheel (2) and bearing housing (1). Thoroughly remove cleaner from all compo- nents.
  • Page 205 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 casing. Install intake housing (3) with actuating cyl- inder (2).

  • Page 206: Charge-Air Cooling

    7.8 Charge-Air Cooling 7.8.1 Charge-air cooler – Checking condensate drain for water discharge and obstruction DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running.

  • Page 207: 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 208). Reset signal ring of contamination indicator (→...

  • Page 208: Air Filter – Removal And Installation

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

  • Page 209: 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 207). After installation of new filter, press reset button (1).

  • Page 210: Starting Equipment

    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 248). 210 | Task Description | MS150110/00E 2013-10...

  • Page 211: 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. Oil level check prior to engine start Withdraw dipstick from guide tube and wipe it. Insert dipstick into guide tube to stop, withdraw after approx.

  • Page 212: 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 213 Tighten drain plugs (1) and (2) to specified torque using a torque wrench: Name Size Type Lubricant Value/Standard Screw M26x1.5 Tightening torque (Engine oil) 100 Nm+10 Nm Filling with new oil Open cap on filler neck. Pour oil in at filler neck up to 'max.' mark at oil dipstick.

  • Page 214: 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 Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...
  • Page 215 Drain approx. 1 liter engine oil into a clean container. Close screw. Using the equipment and chemicals in the MTU test kit, analyze the engine oil for: • Dispersion capability (spot test); • Water content; • Dilution by fuel. MS150110/00E 2013-10 | Task Description | 215...

  • Page 216: 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 Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...

  • Page 217: Engine Running

    Oil filter with diverter (option): Oil filter replacement with the engine stopped Stop engine (→ Page 93) 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 218: Automatic Oil Filter – Oil Filter Candles Replacement

    7.13.2 Automatic oil filter – Oil filter candles replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Grease (Kluthe Hakuform 30-10/Emulgier) X00058060 Engine oil O-ring (→ Spare Parts Catalog) Oil filter candles (→...
  • Page 219 Pull out oil filter element (1). Remove O-ring. Remove screw (2). Pull out plastic spinner (1) with spring. Remove nut (3). Take off spring washer and washer. Remove screw (4). Remove flushing arm (5) from screen plate (6). Turn filter element by 180° and use appro- priate tool to push out filter candles (1).
  • Page 220 Installing oil filter candles Install in reverse order of removal. Additionally, the following instructions are to be observed: • Replace all seals with new parts • Coat O-rings with grease • Insert O-rings in grooves • Pay attention to installation position of fillister-head screw to slot in shaft. 220 | Task Description | MS150110/00E 2013-10...

  • Page 221: Checking Oil Indicator Filter

    7.13.3 Checking oil indicator filter Preconditions ☑ Engine shut down and secured against being restarted. Special tools, Material, Spare parts Designation / Use Part No. Qty. Cleaner (Snow-White 11-0) 40460 Cleaning agent (Hakupur 312) 30390 Engine oil Strainer (→ Spare Parts Catalog) Square-section ring (→...
  • Page 222 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. When doing so, take care not to damage the mesh.

  • Page 223: Centrifugal Oil Filter – Cleaning And Filter Sleeve Replacement

    7.13.4 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 Filter wrench F30379104 Cleaner Hakutex 60 Grease (Kluthe Hakuform 30-10/emulsifier) X00029933 Filter sleeve...
  • Page 224 Centrifugal oil filter – Cleaning and filter sleeve replacement Remove clamp (14). Release Tommy nut (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 225 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 226: Circuit

    7.14 Coolant Circuit, General, High-Temperature Circuit 7.14.1 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! •...

  • Page 227: Engine Coolant – Change

    7.14.2 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant change Drain engine coolant (→ Page 228). Fill with engine coolant (→ Page 231). MS150110/00E 2013-10 | Task Description | 227...

  • Page 228: Engine Coolant – Draining

    7.14.3 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 229 Open vent valve on exhaust pipework (driv- ing end) (1). Open vent valve on seawater cooler (1) (or remote heat exchanger). Open drain plug (1) and drain coolant at crankcase. MS150110/00E 2013-10 | Task Description | 229...
  • Page 230 Open drain screw (1) and drain coolant on coolant pump elbow. Final steps Seal all open vent and drain points. Set breather valve onto filler neck and close it. 230 | Task Description | MS150110/00E 2013-10...

  • Page 231: Engine Coolant – Filling

    7.14.4 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 232 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 233: Ht Coolant Pump – Relief Bore Check

    7.14.5 HT coolant pump – Relief bore check DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running.

  • Page 234: Engine Coolant – Sample Extraction And Analysis

    7.14.6 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 Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...

  • Page 235: Preheating Unit

    7.14.7 Preheating unit Hotstart preheating unit 1 Plastic cap (drain) 4 Shutoff valve 7 Thermostat 2 On/Off switch 5 Continuous flow heater 8 Circulation pump 3 Plastic cap (supply line) 6 Vent valve Cylinders Nominal voltage / frequency Heating power kW 12 V 230 V / 50 Hz 400 V / 50 Hz...
  • Page 236 Hilzinger preheating unit 1 On/Off switch Cylinders Nominal voltage / frequency Heating power kW 12 V and 16 V 230 V / 50 Hz 400 V / 50 Hz 230 V / 60 Hz 440 V / 60 Hz 236 | Task Description | MS150110/00E 2013-10...
  • Page 237 Hilzinger preheating unit, side view 1 Flange (supply and return) 3 Non-return flap 5 Thermostat 2 Junction box 4 Continuous flow heater 6 Circulation pump Function The preheating unit is intended to warm up the engine coolant. The circulation pump (6) ensures the circulation of the preheated coolant through the engine.

  • Page 238: Raw Water Pump With Connections

    7.15 Raw Water Pump with Connections 7.15.1 Raw water pump – Relief bore check DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running.

  • Page 239: Battery-Charging Generator

    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 screws (1). Remove protective cover (2). Check resilient coupling (3) for cracks and plastic deformation.

  • Page 240: Engine Mounting / Support

    7.17 Engine Mounting / Support 7.17.1 Engine mounting – Check Engine mounting – Check Item Findings Action Damage Visually inspect mounts. • Replace (contact Service). Brittleness • Deformation • • Crack formation Swelling • visible 240 | Task Description | MS150110/00E 2013-10...

  • Page 241: Auxiliary Pto

    7.18 Auxiliary PTO 7.18.1 Bilge pump – Relief bore check DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running.

  • Page 242: 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. 242 | Task Description | MS150110/00E 2013-10...

  • Page 243: 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 88). Set the alarm points at the differential pressure gauge to zero.

  • Page 244: Water Level Probe (3-In-1 Rod Electrode Check

    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 245: 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 at the neck of the intake side of the pump. Check pump pressure.

  • Page 246: Coalescer Filter Element – Replacement

    7.19.5 Coalescer filter element – Replacement Preconditions ☑ System is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 6-50 Nm F30027336 Ratchet F30027339 Diesel fuel Engine oil Coalescer filter element (→ Spare Parts Catalog) Gasket (→...
  • Page 247 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 248: 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 Checking engine wiring 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 249: Governor / Control System

    7.21 Accessories for (Electronic) Engine Governor / Control System 7.21.1 Resetting CDC parameter and entering IIG with DiaSys® Preconditions ☑ Engine is stopped and starting disabled. Note: If the parameters for the drift correction (CDC) are not reset, the emission certification becomes invalid. Resetting parameters for drift correction (CDC) with DiaSys®...

  • Page 250: Limit Switch For Start Interlock ‒ Check

    7.21.2 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 251: Connections

    7.21.3 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 the clips (1) are engaged. Check screws (2) of cable clamps on ECU for firm seating.

  • Page 252: Engine Monitoring Unit Emu 8 – Plug Connections Check

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

  • Page 253: Check

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

  • Page 254: Installation

    7.21.6 Engine Control Unit ECU 7 – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. NOTICE Wrong engine governor installed. Engine damage! • When reassembling an engine, make sure that the governor with the data record for the given engine is installed.

  • Page 255: Emu 8 – Removal And Installation

    7.21.7 EMU 8 – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. NOTICE Wrong engine governor installed. Engine damage! • When reassembling an engine, make sure that the governor with the data record for the given engine is installed. Remove ECU with EMU from en- gine Note or mark assignment of cables and...

  • Page 256: Installation

    7.21.8 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. Unscrew power and starter cable.

  • Page 257: Diagnostic Features Of Eim

    7.21.9 Diagnostic features of EIM Diagnostic lamp (DILA) A diagnostic lamp (LED, blue) is integrated in the housing of the Engine Interface Module (EIM). It indicates the operating status of the EIM. Functions of diagnostic lamp DILA DILA lights Engine Interface Module (EIM) is OK DILA dark EIM supply voltage missing or diagnostic lamp activation is faulty.
  • Page 258 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 259 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 260: Appendix A 8.1 Abbreviations

    American National Standards Institute Governing body for US American standards Exhaust turbocharger Baureihe (Series) Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU Publication No. A01061/.. Controller Area Network Data bus system, bus standard Calibration Drift Compensation Setting for drift correction with DiaSys in engine gov-...
  • Page 261 Abbrevia- Meaning Explanation tion Kraftseite Engine driving end in accordance with DIN ISO 1204 Liquid Crystal Display, Liquid Crystal Device Local Control Unit LOP subassembly Light Emitting Diode Local Monitoring Unit LOP subassembly Alarm: Measured value lower than 1st minimum limit LOLO Low Low Alarm: Measured value lower than 2nd minimum limit...

  • Page 262: 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 263: Special Tools

    9 Appendix B 9.1 Special Tools Barring device Part No.: F6555766 Qty.: Used in: 7.1.1 Engine – Barring manually (→ Page 168) Feeler gauge Part No.: Y20010128 Qty.: Used in: 7.3.2 Valve clearance – Check and adjustment (→ Page 176) Filter wrench Part No.: F30379104...
  • Page 264 7.5.2 Injector – Removal and installation (→ Page 183) Milling cutter Part No.: F30452739 Qty.: Used in: 7.5.2 Injector – Removal and installation (→ Page 183) MTU test kit Part No.: 5605892099/00 Qty.: Used in: 7.12.3 Engine oil – Sample extraction and analysis (→ Page 214) Qty.:...
  • Page 265 Ratchet Part No.: F30027339 Qty.: Used in: 7.19.5 Coalescer filter element – Replacement (→ Page 246) Ratchet adapter Part No.: F30027340 Qty.: Used in: 7.6.8 Fuel prefilter with water separator – Filter ele- ment replacement (→ Page 199) Qty.: Used in: 7.7.1 Compressor wheel –...
  • Page 266 Rigid endoscope Part No.: Y20097353 Qty.: Used in: 7.2.1 Cylinder liner – Endoscopic examination (→ Page 171) Socket wrench, 24 mm Part No.: F30039526 Qty.: Used in: 7.3.2 Valve clearance – Check and adjustment (→ Page 176) Steam jet cleaner Part No.: Qty.: Used in:...
  • Page 267 Torque wrench, 10-60 Nm Part No.: F30452769 Qty.: Used in: 7.5.2 Injector – Removal and installation (→ Page 183) Qty.: Used in: 7.7.1 Compressor wheel – Cleaning (→ Page 202) Torque wrench, 10-60 Nm Part No.: F30510423 Qty.: Used in: 7.6.8 Fuel prefilter with water separator –...
  • Page 268 Torque wrench, 6-50 Nm Part No.: F30027336 Qty.: Used in: 7.19.5 Coalescer filter element – Replacement (→ Page 246) Torque wrench, 60-320 Nm Part No.: F30047446 Qty.: Used in: 7.3.2 Valve clearance – Check and adjustment (→ Page 176) Torque wrench, 60-320 Nm Part No.: F30452768 Qty.:...

  • Page 269: Index

    9.2 Index Disengaging  Preheating unit 235 – From LOP  91 Abbreviations 260 ECU 7  Additional fuel filter  – Installation  254 – Replacement  190 – Removal  254 ADEC (ECU 7)  Emergency engine shutdown   – Fault codes  103 – Via automation system  89 –...
  • Page 270 – Replacing filter candles  218 – Coalescer element   Maintenance Schedule  – Replacement  246 – Maintenance task reference table [QL1]  97 Filter sleeve   MTU contact persons 262 – Replacement  223 Firing order 74 Fuel  Oil indicator filter  – Treatment system  ...
  • Page 271 Safety regulations  – Consumables  11 – Environmental protection  11 – Fire prevention  11 – Fluids and lubricants  11 – Important provisions  5 – Maintenance work  8 – Operation  7 – Organizational requirements  6 – Personnel requirements  6 – Repair work  8 –...

This manual is also suitable for:

16 v 4000 mx4

Table of Contents

Save PDF