MTU 12 V 4000 M53 Operating Instructions Manual
  1. Manuals
  2. Brands
  3. MTU Manuals
  4. Engine
  5. 12 V 4000 M53
  6. Operating instructions manual

MTU 12 V 4000 M53 Operating Instructions Manual

Diesel engine mtu 12 v 4000 m53/ 16 v 4000 m53
Hide thumbs
Table of Contents

Advertisement

Quick Links

Operating Instructions

Diesel engine
12 V 4000 M53
16 V 4000 M53
MS150035/01E

Advertisement

Table of Contents
loading

Related Manuals for MTU 12 V 4000 M53

Summary of Contents for MTU 12 V 4000 M53

  • Page 1: Operating Instructions

    Operating Instructions Diesel engine 12 V 4000 M53 16 V 4000 M53 MS150035/01E...
  • 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 3.13 After stopping the engine 3.14 Plant – Cleaning 1.1 Important provisions for all products 1.2 Personnel and organizational requirements 4 Maintenance 1.3 Transport 1.4 Safety regulations for maintenance and 4.1 Maintenance task reference table [QL1] repair work 1.5 Fire prevention and environmental 5 Troubleshooting...
  • Page 4 6.14.8 Engine coolant filter – Replacement 7 Appendix A 6.14.9 Preheating unit 7.1 Abbreviations 6.15 Raw Water Pump with Connections 7.2 MTU contact persons/service partners 6.15.1 Raw water pump – Relief bore check 6.16 Battery-Charging Generator 8 Appendix B 6.16.1 Battery-charging generator drive – Coupling condition check 8.1 Special Tools...

  • 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: 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 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: Product Summary

    2 Product Summary 2.1 Engine Layout 2.1.1 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 15 • 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 16 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 17 100 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. MS150035/01E 2013-11 | Product Summary | 17...
  • Page 18 1 Fuel line after LP pump 1 Fuel line to fuel filter head retainer 18 | Product Summary | MS150035/01E 2013-11...
  • Page 19 1 Fuel line from fuel filter head 1 Fuel line on HP pump MS150035/01E 2013-11 | Product Summary | 19...
  • Page 20 1 Fuel line on fuel filter head 1 Fuel line on fuel filter head 20 | Product Summary | MS150035/01E 2013-11...
  • Page 21 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 MS150035/01E 2013-11 | Product Summary | 21...
  • Page 22 1 Oil supply line on HP pump 1 Oil supply line of HP pump on equipment carrier 22 | Product Summary | MS150035/01E 2013-11...
  • Page 23 1 Oil supply for actuating cylinder of turbocharger B1 exhaust flap 1 Oil supply on equipment carrier MS150035/01E 2013-11 | Product Summary | 23...
  • Page 24 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 24 | Product Summary | MS150035/01E 2013-11...
  • Page 25 1 Oil supply to distributor 2 Oil return 1 Oil return MS150035/01E 2013-11 | Product Summary | 25...
  • Page 26 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 26 | Product Summary | MS150035/01E 2013-11...
  • Page 27 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 MS150035/01E 2013-11 | Product Summary | 27...
  • Page 28 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 28 | Product Summary | MS150035/01E 2013-11...
  • Page 29 1 Oil supply for flap control to main oil gallery in en- gine Vee, engine free end MS150035/01E 2013-11 | Product Summary | 29...
  • Page 30 1 Turbocharger oil supply connection to main oil gal- lery in engine Vee 30 | Product Summary | MS150035/01E 2013-11...
  • Page 31 1 Oil supply on distribution point of turbocharger oil supply on engine free end 1 Cover on oil filter cartridge MS150035/01E 2013-11 | Product Summary | 31...
  • Page 32 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 33 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 34: Engine Layout

    2.1.2 Engine layout Engines with remote heat exchanger and horizontal air intake 1 Engine management and 10 Recirculation line 19 Battery-charging generator monitoring 11 Exhaust manifold 20 HP fuel pump 2 Oil cooler 12 Engine mounts 21 Oil filter 3 Centrifugal oil filter 13 Charge-air line 22 Bilge pump (option) 4 Crankcase breather...
  • Page 35 Engines with engine-mounted heat exchanger and horizontal air intake 1 Raw-water outlet 10 Exhaust outlet 19 Cylinder head 2 Engine management and 11 Air pipe to charge-air cool- 20 Crankcase monitoring 21 Fuel filter 3 Plate-core heat exchanger 12 Recirculation line 22 Battery-charging generator 4 Oil cooler 13 Exhaust manifold...
  • Page 36 Engines with remote heat exchanger and vertical air intake 1 Coolant outlet to remote 10 Exhaust turbocharger 19 Cylinder head cooling system 11 Exhaust outlet 20 Fuel filter 2 Coolant inlet from remote 12 Air pipe to charge-air cool- 21 Oil filter cooling system 22 HP fuel pump 3 Engine management and...
  • Page 37 Engines with engine-mounted heat exchanger and vertical air intake 1 Raw-water outlet 10 Recirculation line 19 Crankcase 2 Engine management and 11 Exhaust turbocharger 20 Cylinder head monitoring 12 Exhaust outlet 21 Fuel filter 3 Oil cooler 13 Air pipe to charge-air cool- 22 Oil filter 4 Plate-core heat exchanger 23 HP fuel pump...

  • Page 38: Sensors, Actuators And Injectors On 12V Engines - Overview

    2.1.3 Sensors, actuators and injectors on 12V engines – 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...
  • Page 39 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 40 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) 40 | Product Summary | MS150035/01E 2013-11...
  • Page 41 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) MS150035/01E 2013-11 | Product Summary | 41...
  • Page 42 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) 42 | Product Summary | MS150035/01E 2013-11...
  • Page 43 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 44 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 45 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) MS150035/01E 2013-11 | Product Summary | 45...
  • Page 46 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) 46 | Product Summary | MS150035/01E 2013-11...
  • Page 47 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) MS150035/01E 2013-11 | Product Summary | 47...

  • Page 48: Sensors, Actuators And Injectors On 16V Engines - Overview

    2.1.4 Sensors, actuators and injectors on 16V engines – Overview Engines with horizontal air intake, remote heat exchanger 16V 4000 M engine, 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 49 16V 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 50 16V 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) 50 | Product Summary | MS150035/01E 2013-11...
  • Page 51 16V 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) MS150035/01E 2013-11 | Product Summary | 51...
  • Page 52 16V 4000 M engine, engine top 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) 52 | Product Summary | MS150035/01E 2013-11...
  • Page 53 Engines with horizontal air intake, engine-mounted heat exchanger 16V 4000 M engine, 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 54 16V 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 55 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) MS150035/01E 2013-11 | Product Summary | 55...
  • Page 56 16V 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) 56 | Product Summary | MS150035/01E 2013-11...
  • Page 57 16V 4000 M engine, engine top 1 B4 (cylinder exhaust tem- 2 B33 (alternatively) (fuel 3 F33 (coolant level) perature A1-A6, B1-B8) temperature in common (optional) rail) MS150035/01E 2013-11 | Product Summary | 57...
  • Page 58 Engines with vertical air intake, remote heat exchanger 16V 4000 M engine, 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 59 16V 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) ture) (optional)
  • Page 60 16V 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) 60 | Product Summary | MS150035/01E 2013-11...
  • Page 61 16V 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) MS150035/01E 2013-11 | Product Summary | 61...
  • Page 62 16V 4000 M engine, engine top 1 B4 (cylinder exhaust tem- 2 B33 (alternatively) (fuel perature A1-A6, B1-B8) temperature in common (optional) rail) 62 | Product Summary | MS150035/01E 2013-11...
  • Page 63 Engines with vertical air intake, engine-mounted heat exchanger 16V 4000 M engine, 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 64 16V 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) ture) (optional)
  • Page 65 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) MS150035/01E 2013-11 | Product Summary | 65...
  • Page 66 16V 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) 66 | Product Summary | MS150035/01E 2013-11...
  • Page 67 16V 4000 M engine, engine top 1 B4 (cylinder exhaust tem- 2 B33 (alternatively) (fuel 3 F33 (coolant level) perature A1-A6, B1-B8) temperature in common (optional) rail) MS150035/01E 2013-11 | Product Summary | 67...

  • Page 68: Engine Side And Cylinder Designations

    2.2 Engine Side and Cylinder Designations 2.2.1 Engine side and cylinder designations Engine sides are always designated as viewed from the driving end (KS) (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 69: Main Engine Dimensions

    2.3 Main Engine Dimensions 2.3.1 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.
  • Page 70 Engine model Length (A) Width (B) without Width (B) with si- Height (C) silencer lencer 16V 4000 M53R/ 53/63R/63/63L 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...

  • Page 71: Firing Sequence

    2.4 Firing Sequence 2.4.1 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 MS150035/01E 2013-11 | Product Summary | 71...

  • Page 72: Technical Data

    2.5 Technical Data 2.5.1 12V 4000 M53 engine data Explanation: DL Referenced value: Continuous power BL Referenced value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value up to which the engine can be operated without changes, e.g. of load setting. N Not defined value - Not applicable X Applicable...
  • Page 73 Engine-mounted heat Remote heat ex- exchanger changer Number of intake valves per cylinder Number of exhaust valves per cylinder RAW WATER CIRCUIT (open circuit) Engine-mounted heat Remote heat ex- exchanger changer Raw water pump: inlet pressure, min. -0.4 -0.4 Raw water pump: Inlet pressure, max. Pressure loss in engine-external raw water system, max.
  • Page 74 STARTING SYSTEM (electric) Engine-mounted heat Remote heat ex- exchanger changer Starter rated voltage (standard design) STARTING SYSTEM (pneumatic/hydraulic) Engine-mounted heat Remote heat ex- exchanger changer Starting air pressure before starter, min. Starting air pressure before starter, max. INCLINATIONS FOR STANDARD OIL SYSTEM (referenced to: water horizontal) Engine-mounted heat Remote heat ex- exchanger...
  • Page 75 WEIGHTS / MAIN DIMENSIONS Engine-mounted heat Remote heat ex- exchanger changer Engine weight dry with standard accesso- 7640 7640 7240 7240 ries without coupling NOISE Engine-mounted heat Remote heat ex- exchanger changer Exhaust noise, unsilenced - BL (free field dB(A) 112* 112* 112*...

  • Page 76: 4000 M53 Engine Data

    2.5.2 16V^4000 M53 engine data Explanation: DL Referenced value: Continuous power BL Referenced value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value up to which the engine can be operated without changes, e.g. of load setting. N Not defined value - Not applicable X Applicable...
  • Page 77 RAW WATER CIRCUIT (open circuit) Engine-mounted heat Remote heat ex- exchanger changer Raw water pump: inlet pressure, min. -0.4 -0.4 Raw water pump: Inlet pressure, max. Pressure loss in engine-external raw water system, max. LUBE OIL SYSTEM Engine-mounted heat Remote heat ex- exchanger changer Lube oil operating temperature before en-...
  • Page 78 STARTING SYSTEM (pneumatic/hydraulic) Engine-mounted heat Remote heat ex- exchanger changer Starting air pressure before starter, min. Starting air pressure before starter, max. INCLINATIONS FOR STANDARD OIL SYSTEM (referenced to: water horizontal) Engine-mounted heat Remote heat ex- exchanger changer Longitudinal inclination, continuous, max. degrees drive end lower (Design: max.
  • Page 79 NOISE Engine-mounted heat Remote heat ex- exchanger changer Exhaust noise, unsilenced - BL (free field dB(A) sound level Lp, 1m distance, ISO 6798, +3dB(A) tolerance) Engine surface noise with attenuated in- dB(A) take noise (filter) - BL (free field sound level Lp, 1m distance, ISO 6798, +2dB(A) tolerance) MS150035/01E 2013-11 | Product Summary | 79...

  • Page 80: Operation

    3 Operation 3.1 Controls Automation system controls Refer to automation system operating instructions 80 | Operation | MS150035/01E 2013-11...

  • Page 81: Putting The Engine Into Operation After Extended Out-Of-Service Periods (>3 Months)

    3.2 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 82: Putting The Engine Into Operation After Scheduled Out-Of-Service-Period

    3.3 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 174); Preheat engine oil if required. Coolant system Check coolant level (→...

  • Page 83: Starting The Engine

    3.4 Starting the engine Start the engine via the automation system Refer to automation system operating instructions MS150035/01E 2013-11 | Operation | 83...

  • Page 84: Operational Checks

    3.5 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 85: Tasks After Extended Out-Of-Service Periods (>3 Weeks)

    3.6 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 87). Shut down fuel treatment system (→ Page 91). MS150035/01E 2013-11 | Operation | 85...

  • Page 86: 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 87: Fuel Treatment System - Putting Into Operation

    3.8 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 88 Initial operation: HAT Replace fuel filter on engine (→ Page 151). 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 90). 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 89 Simulation of power failure (emergency): SAT Switch on fuel treatment system (→ Page 90). Start engine (→ Page 83). 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 90: Fuel Treatment System - Switching On

    3.9 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 91: Fuel Treatment System - Shutdown

    3.10 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 92: Stopping The Engine

    3.11 Stopping the engine Stopping the engine via the automation system Refer to automation system operating instructions 92 | Operation | MS150035/01E 2013-11...

  • Page 93: Emergency Engine Stop

    3.12 Emergency engine stop 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 stop Refer to automation system operating instructions. Follow instructions. MS150035/01E 2013-11 | Operation | 93...

  • Page 94: After Stopping The Engine

    3.13 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 192) if: freezing temperatures are expected and the engine is to remain out of •...

  • Page 95: Plant - Cleaning

    3.14 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 96: Maintenance

    4 Maintenance 4.1 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 97 Task Measures W1713 Injector: reset drift compensation parameters (CDC). (→ Page 229) W1714 Check and clean oil indicator filter (if fitted). (→ Page 179) Table 1: Maintenance task reference table [QL1] MS150035/01E 2013-11 | Maintenance | 97...

  • Page 98: Troubleshooting

    5 Troubleshooting 5.1 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 99 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 100 White exhaust gas Cause Corrective action Engine is not at operating u Run engine to reach operating temperature. temperature Intercooler leaky u Contact Service. 100 | Troubleshooting | MS150035/01E 2013-11...

  • Page 101: Fuel Treatment System - Troubleshooting

    5.2 Fuel treatment system – Troubleshooting Illuminated pushbutton 'water alarm' is lit. Cause Corrective action When the maximum water level 1. Press illuminated pushbutton 'Water alarm' for is reached, the water level acknowledgment. electrode opens the water drain 2. In addition to the automatic water drain function, water can valve and water is discharged.

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

    5.3 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: Adec Engine Governor - Fault Codes

    5.4 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 104 141 – 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 105 205 – 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 106 213 – 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 107 221 – 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 108 230 – 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 109 241 – 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 110 303 – 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 111 308 – 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 112 313 – 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 113 318 – 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 114 323 – 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 115 329 – 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 116 335 – 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 117 341 – 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 118 347 – 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 119 353 – 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 120 359 – 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 121 365 – 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 will be shut down as additional measure. Possible causes: 1.
  • Page 122 390 – 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 123 445 – 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 124 473 – 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 Activated if the crash recorder 1.
  • Page 125 493 – 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 126 506 – AL Low Starter Voltage ZKP-Number: 14.500.906 Cause Corrective action battery voltage is too low to u Check battery-charging generator and cabling. accomplish a starting procedure. 507 – AL POM Error ZKP-Number: 14.500.907 Cause Corrective action A general POM error occurred. u Replace POM.
  • Page 127 527 – 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 128 596 – 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 129: Task Description

    6 Task Description 6.1 Engine 6.1.1 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 130 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 131: Engine - Barring With Starting System

    6.1.2 Engine – Barring with starting system Barring using the automation system Refer to automation system operating instructions MS150035/01E 2013-11 | Task Description | 131...

  • Page 132: Cylinder Liner

    6.2 Cylinder Liner 6.2.1 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 140). Remove injector (→...
  • Page 133 Final steps Install injector (→ Page 144). Install cylinder head cover (→ Page 140). MS150035/01E 2013-11 | Task Description | 133...

  • Page 134: Instructions And Comments On Endoscopic And Visual Examination Of Cylinder Liners

    6.2.2 Instructions and comments on endoscopic and visual examination of cylinder liners Terms used for endoscopic examination Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic 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 135 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 136: Valve Drive

    6.3 Valve Drive 6.3.1 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 140). Fill oil chambers of valve bridges with oil.

  • Page 137: Valve Clearance - Check And Adjustment

    6.3.2 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 138 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 139: 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 140: Cylinder Head Cover - Removal And Installation

    6.3.3 Cylinder head cover – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Gasket (→ Spare Parts Catalog) Removing cylinder head cover Clean very dirty cylinder head covers prior to removal.

  • Page 141: Injection Pump / Hp Pump

    6.4 Injection Pump / HP Pump 6.4.1 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 142: Hp Pump - Relief Bore Check

    6.4.2 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 143: Injection Valve / Injector

    6.5 Injection Valve / Injector 6.5.1 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 144). MS150035/01E 2013-11 | Task Description | 143...

  • Page 144: Injector - Removal And Installation

    6.5.2 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 145 Remove HP fuel line (4). Remove return line (5). Note: While the adapter is removed, the injector is drained. 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 146: 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 retaining 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 147 Coat bolt 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 Note:...
  • Page 148 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 connectors on injector.

  • Page 149: Fuel Filter

    6.6 Fuel Filter 6.6.1 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 MS150035/01E 2013-11 | Task Description | 149...

  • Page 150: Additional Fuel Filter - Replacement

    6.6.2 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 151: Fuel Filter - Replacement

    6.6.3 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 152 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 14). Screw on easy-change filter and tighten by hand. Set three-way cock to normal operating position (both filters cut in).

  • Page 153: Fuel Prefilter - Differential Pressure Check And Adjustment Of Gauge

    6.6.4 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 154: Fuel Prefilter - Draining

    6.6.5 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 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 155 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 156: Fuel Prefilter - Flushing

    6.6.6 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 157: 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 158: Fuel Prefilter With Water Separator - Filter Element Replacement

    6.6.7 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 adapter F30027340 Filter element...
  • Page 159 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 160: Fuel Prefilter With Water Separator - O-Ring Replacement In Rotary Slide Valve

    6.6.8 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 161: Exhaust Turbocharger

    6.7 Exhaust Turbocharger 6.7.1 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 162 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). 162 | Task Description | MS150035/01E 2013-11...
  • Page 163 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 164 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 165 Preparatory steps – Vertical air intake Drain engine coolant (→ Page 192). Remove air filter (→ Page 171). 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 166 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 167 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 168 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 169: Charge-Air Cooling

    6.8 Charge-Air Cooling 6.8.1 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 170: Air Filter

    6.9 Air Filter 6.9.1 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 171). Reset signal ring of contamination indicator (→...

  • Page 171: Air Filter – Removal And Installation

    6.9.2 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 172: Air Intake

    6.10 Air Intake 6.10.1 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 170). After installation of new filter, press reset button (1).

  • Page 173: Starting Equipment

    6.11 Starting Equipment 6.11.1 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 218). MS150035/01E 2013-11 | Task Description | 173...

  • Page 174: Engine Oil – Level Check

    6.12 Lube Oil System, Lube Oil Circuit 6.12.1 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 175: Engine Oil – Change

    6.12.2 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 176 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 177: Engine Oil – Sample Extraction And Analysis

    6.12.3 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 178 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. 178 | Task Description | MS150035/01E 2013-11...

  • Page 179: Checking Oil Indicator Filter

    6.13 Oil Filtration / Cooling 6.13.1 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 (→...
  • Page 180 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 181: Engine Oil Filter – Replacement

    6.13.2 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 182: Engine Running

    Oil filter with diverter (option): Oil filter replacement with the engine stopped Stop engine (→ Page 92) 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 183: Centrifugal Oil Filter – Cleaning And Filter Sleeve Replacement

    6.13.3 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/emulsifier) X00029933 Filter sleeve...
  • Page 184 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 185 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 186: Circuit

    6.14 Coolant Circuit, General, High-Temperature Circuit 6.14.1 Drain and vent points Coolant line on ETC 1 Vent point Coolant line to intercooler 1 Vent point 186 | Task Description | MS150035/01E 2013-11...
  • Page 187 1 Vent point Coolant line to raw water cooler 1 Vent point MS150035/01E 2013-11 | Task Description | 187...
  • Page 188 Vent line – Distribution cross 1 Vent point Coolant drain point, engine driving end 1 Drain point 188 | Task Description | MS150035/01E 2013-11...
  • Page 189 Coolant drain point, engine free end 1 Drain point MS150035/01E 2013-11 | Task Description | 189...

  • Page 190: Engine Coolant Level – Check

    6.14.2 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 191: Engine Coolant – Change

    6.14.3 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant change Drain engine coolant (→ Page 192). Fill with engine coolant (→ Page 195). MS150035/01E 2013-11 | Task Description | 191...

  • Page 192: Engine Coolant – Draining

    6.14.4 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 an appropriate container to drain the coolant into.
  • Page 193 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. MS150035/01E 2013-11 | Task Description | 193...
  • Page 194 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. 194 | Task Description | MS150035/01E 2013-11...

  • Page 195: Engine Coolant – Filling

    6.14.5 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 196 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 197: Ht Coolant Pump – Relief Bore Check

    6.14.6 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 198: Engine Coolant – Sample Extraction And Analysis

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

  • Page 199: Engine Coolant Filter – Replacement

    6.14.8 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 Engine coolant filter (→ Spare Parts Catalog) WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...

  • Page 200: Preheating Unit

    6.14.9 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 201 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 MS150035/01E 2013-11 | Task Description | 201...
  • Page 202 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 203: Raw Water Pump With Connections

    6.15 Raw Water Pump with Connections 6.15.1 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 204: Battery-Charging Generator Drive – Coupling Condition Check

    6.16 Battery-Charging Generator 6.16.1 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 205: Auxiliary Pto

    6.17 Auxiliary PTO 6.17.1 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 206: Engine Mounting / Support

    6.18 Engine Mounting / Support 6.18.1 Engine mounting – Check Engine mounting – Check Item Findings Action Damage Visually inspect mounts. • Replace (contact Service). Brittleness • Deformation • • Crack formation Swelling • visible 206 | Task Description | MS150035/01E 2013-11...

  • Page 207: Fuel Supply System

    6.19 Fuel Supply System 6.19.1 Water drain valve – Check Water drain valve – Check Open water drain valve. Check water outlet for obstructions. Close water drain valve. MS150035/01E 2013-11 | Task Description | 207...

  • Page 208: Differential Pressure Gauge – Check

    6.19.2 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 90). Set the alarm points at the differential pressure gauge to zero.

  • Page 209: Water Level Probe (3-In-1 Rod Electrode Check

    6.19.3 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 210 6.19.4 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 211 6.19.5 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 212 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 213 6.20 Wiring (General) for Engine/Gearbox/Unit 6.20.1 Overview of engine wiring harness Engine wiring harnesses – Terminal assignment Description Terminal assignment Sensors Camshaft speed Intake air temperature B4.21 Exhaust temperature, A side B4.22 Exhaust temperature, B-side B5.1 Oil pressure downstream of filter B5.3 Oil pressure upstream of filter Coolant temperature...
  • Page 214 Description Terminal assignment Injectors Y39A1 to Y39AX Engine A side Y39B1 to Y39BX Engine B side Engine wiring harness for sensors, 12V engine 1 M8 13 B4.22 25 B4.21 2 B1 14 B9 26 B10 3 B6 15 S37.1 27 B13 4 X2 16 B34.3 28 S37.2...
  • Page 215 Engine wiring harness for sensors, 16V engine 1 M8 13 B4.22 25 B4.21 2 B1 14 B9 26 B10 3 B6 15 S37.1 27 B13 4 X2 16 B34.3 28 S37.2 5 Y27 17 B34.2 29 B7 6 B44.2 18 B34.1 30 B5.1 7 X37 19 B50...
  • Page 216 Engine wiring harness for injectors, 12V engine 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 216 | Task Description | MS150035/01E 2013-11...
  • Page 217 Engine wiring harness for injectors, 16V engine 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 MS150035/01E 2013-11 | Task Description | 217...

  • Page 218: Engine Wiring – Check

    6.20.2 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 219: Limit Switch For Start Interlock ‒ Check

    6.21 Accessories for (Electronic) Engine Governor / Control System 6.21.1 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...

  • Page 220: Engine Control Unit Ecu 7 – Checking Plug Connections

    6.21.2 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 221: Engine Monitoring Unit Emu – Plug Connection Check

    6.21.3 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 222: Interface Module Eim Plug Connections Check

    6.21.4 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 223: Installation

    6.21.5 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 224: Emu 7 – Removal And Installation

    6.21.6 EMU 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. Removing ECU with EMU from engine Note or mark assignment of cables and...

  • Page 225: Diagnostic Features Of Eim

    6.21.7 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 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: Installation

    6.21.8 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 229: Cdc Parameters – Reset

    6.21.9 CDC parameters – Reset Preconditions ☑ Engine is stopped and starting disabled. Note: Failure to reset drift compensation (CDC parameters) will void the emissions certification. Resetting CDC parameters with DiaSys® (→ Dialog system DiaSys® E531920/..). Resetting CDC parameters without DiaSys® If no DiaSys®...

  • Page 230: 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 231 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 232: 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 233: Special Tools

    8 Appendix B 8.1 Special Tools Barring device Part No.: F6555766 Qty.: Used in: 6.1.1 Engine – Barring manually (→ Page 129) Feeler gauge Part No.: Y20010128 Qty.: Used in: 6.3.2 Valve clearance – Check and adjustment (→ Page 137) Filter wrench Part No.: F30379104...
  • Page 234 6.5.2 Injector – Removal and installation (→ Page 144) Milling cutter Part No.: F30452739 Qty.: Used in: 6.5.2 Injector – Removal and installation (→ Page 144) MTU test kit Part No.: 5605892099/00 Qty.: Used in: 6.12.3 Engine oil – Sample extraction and analysis (→ Page 177) Qty.:...
  • Page 235 Ratchet Part No.: F30027341 Qty.: Used in: 6.5.2 Injector – Removal and installation (→ Page 144) Ratchet Part No.: F30027339 Qty.: Used in: 6.19.5 Coalescer filter element – Replacement (→ Page 211) Ratchet adapter Part No.: F30027340 Qty.: Used in: 6.6.7 Fuel prefilter with water separator –...
  • Page 236 Ratchet with extension Part No.: F30006212 Qty.: Used in: 6.1.1 Engine – Barring manually (→ Page 129) Rigid endoscope Part No.: Y20097353 Qty.: Used in: 6.2.1 Cylinder liner – Endoscopic examination (→ Page 132) Socket wrench, 24 mm Part No.: F30039526 Qty.: Used in:...
  • Page 237 Torque wrench, 0.5-5 Nm Part No.: 0015384230 Qty.: Used in: 6.5.2 Injector – Removal and installation (→ Page 144) Torque wrench, 10-60 Nm Part No.: F30510423 Qty.: Used in: 6.6.7 Fuel prefilter with water separator – Filter ele- ment replacement (→ Page 158) Torque wrench, 10-60 Nm Part No.: F30452769...
  • Page 238 Torque wrench, 40-200 Nm Part No.: F30027337 Qty.: Used in: 6.12.2 Engine oil – Change (→ Page 175) Torque wrench, 6-50 Nm Part No.: F30027336 Qty.: Used in: 6.13.3 Centrifugal oil filter – Cleaning and filter sleeve replacement (→ Page 183) Torque wrench, 6-50 Nm Part No.: F30027336...
  • Page 239 Torque wrench, 60-320 Nm Part No.: F30452768 Qty.: Used in: 6.5.2 Injector – Removal and installation (→ Page 144) MS150035/01E 2013-11 | Appendix B | 239...

  • Page 240: Index

    8.2 Index Differential pressure gauge  Preheating unit 200 – Check  208 Numerics Drain and vent points 186 Drift compensation  12V 4000 M53 engine data 72 – Reset  229 16V 4000 M53 engine data 76 ECU 7  Abbreviations 230 – Installation  223 Actuators  – Removal  223 –...
  • Page 241 Engine wiring harness  – Overview  213 MTU contact persons 232 Fault messages  Oil indicator filter  – Engine governor ADEC (ECU 7)  102 – Checking  179 Filter  Operational checks 84 – Coalescer element   – Replacement  211 – Engine coolant   Plant  – Replacement  199...
  • Page 242 Valve clearance  – Adjustment  137 – Check  137 Valve gear  – Lubrication  136 Water drain valve  – Check  207 Water level probe (3-in-1 rod electrode)  – Check  209 242 | Appendix B | MS150035/01E 2013-11...

This manual is also suitable for:

16 v 4000 m53

Table of Contents