MTU 12 V 4000 M33F Operating Instructions Manual
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MTU 12 V 4000 M33F Operating Instructions Manual

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Operating Instructions

Diesel Engine
12 V 4000 M33F
12 V 4000 M33S
16 V 4000 M33F
16 V 4000 M33S
16 V 4000 M43S
MS150069/02E

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Summary of Contents for MTU 12 V 4000 M33F

  • Page 1: Operating Instructions

    Operating Instructions Diesel Engine 12 V 4000 M33F 12 V 4000 M33S 16 V 4000 M33F 16 V 4000 M33S 16 V 4000 M43S MS150069/02E...
  • Page 2 This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, mi- crofilming and storage or processing on electronic systems including data bases and online services.

  • Page 3: Table Of Contents

    Table of Contents 1 Safety 3.6 Tasks after extended out-of-service periods (>3 weeks) 1.1 Important provisions for all products 3.7 Checks prior to start-up 1.2 Personnel and organizational requirements 3.8 Fuel treatment system – Putting into 1.3 Transport operation 1.4 Safety regulations for startup and operation 3.9 Fuel treatment system –...
  • Page 4 6.15.2 Engine coolant level – Check 6.15.3 Engine coolant – Change 7.1 Abbreviations 6.15.4 Engine coolant – Draining 7.2 MTU contact persons/service partners 6.15.5 Engine coolant – Filling 6.15.6 HT coolant pump – Relief bore check 8 Appendix B 6.15.7 Engine coolant – Sample extraction and analysis 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

    Place the engine only on an even, firm surface. Ensure appropriate consistency and load-bearing capacity of the ground or support surface. Never place an engine on the oil pan, unless expressively authorized by MTU on a case-to-case basis to do so.

  • Page 8: Safety Regulations For Startup And Operation

    1.4 Safety regulations for startup and operation Safety regulations for startup Install the product correctly and carry out acceptance in accordance with the manufacturer's specifica- tions 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 9: Safety Regulations For Maintenance And Repair Work

    1.5 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 below 50°C before starting maintenance work (risk of explosion of oil vapors, fluids and lubricants, risk of burning).
  • Page 10 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 11 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 12: 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 13: 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 14: Standards For Safety Notices In The Text

    1.7 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 15: 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 16 • 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 17 2 Cleaning cycle 3 ditto MTU marine engine Series 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 18 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. 18 | Product Summary | MS150069/02E 2014-03...
  • Page 19 1 SOLAS clip on the fuel line: after LP pump 1 SOLAS clip on the fuel line: on fuel filter head retainer 1 SOLAS clip on the fuel line: on HP pump 2 SOLAS clip on the fuel line: after fuel filter head MS150069/02E 2014-03 | Product Summary | 19...
  • Page 20 1 SOLAS clips on the 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. 20 | Product Summary | MS150069/02E 2014-03...
  • Page 21 1 SOLAS clips on exhaust flap switch- ing cylinder ETC B1 1 SOLAS clips on air flap switching cylinder ETC B1 2 SOLAS clips on flap control T adapt- er ETC B1 1 SOLAS clips on distributor element 2 SOLAS clips on oil return MS150069/02E 2014-03 | Product Summary | 21...
  • Page 22 1 SOLAS clip on oil return 1 SOLAS clip on oil line to ETC 2 SOLAS clip on oil line to flap control 3 SOLAS clip on oil line to recircula- tion valve 4 SOLAS clips on oil line from main gallery 1 SOLAS clips on recirculation valve 22 | Product Summary | MS150069/02E 2014-03...
  • Page 23 1 SOLAS clip on HP pump oil supply: on HP pump 1 SOLAS clip on HP pump oil supply: on equipment carrier 1 SOLAS clip on ETC oil supply 2 SOLAS clip on ETC oil supply MS150069/02E 2014-03 | Product Summary | 23...
  • Page 24 1 SOLAS clips of oil line on equipment 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. 24 | Product Summary | MS150069/02E 2014-03...
  • Page 25 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 26 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 27: 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 28 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 intercooler 20 Crankcase monitoring 12 Recirculation line 21 Fuel filter 3 Plate-core heat exchanger 13 Exhaust manifold 22 Battery-charging generator 4 Oil cooler...
  • Page 29 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 intercooler 21 Oil filter cooling system 13 Intercooler 22 HP fuel pump...
  • Page 30 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 intercooler 22 Oil filter 4 Plate-core heat exchanger 14 Intercooler...

  • Page 31: Overview Of Sensors And Actuators

    2.1.3 Overview of sensors and actuators Top view of 12V 4000 M with external cooling 1 B49 (charge-air temp., air 2 B4.A1-B4.B6 (single ex- 3 B33 (fuel temperature in recirculation valve) haust temp., A1-A6, B1- common rail) Y26 (air recirculation valve MS150069/02E 2014-03 | Product Summary | 31...
  • Page 32 Aux. PTO end, 12V 4000 M, external cooling 1 B7 (engine oil temp.) 4 B33 (fuel temperature in 7 B54 (oil refill pump pres- 2 B5.3 (oil pressure up- common rail) sure) stream of filter) 5 B48 (fuel pressure in com- 8 B6.2 (coolant tempera- 3 B5.1 (oil pressure down- mon rail)
  • Page 33 Main PTO end, 12V 4000 M, external cooling 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- ture, B bank) MS150069/02E 2014-03 | Product Summary | 33...
  • Page 34 Left side of engine, 12V 4000 M, external cooling 1 B50 (crankcase pressure) 4 B10 (charge-air pressure) 7 B34.1 (fuel pressure down- 2 B3 (intake air temperature) 5 B34.3 (fuel pressure up- stream of filter) 3 B44.1 (turbocharger A stream of filter) 8 F46 (fuel overflow level) speed) 6 B34.2 (fuel pressure up-...
  • Page 35 Right side of engine, 12V 4000 M, external cooling 1 B44.2 (turbocharger B 3 B16 (coolant pressure) speed) 4 B9 (charge-air tempera- 2 Y27 (turbocharger control ture) valve) MS150069/02E 2014-03 | Product Summary | 35...
  • Page 36 Top view, 12V 4000 M, integral cooling 1 B4.A1-B4.B6 (single ex- 2 B33 (fuel temperature in 3 F33 (coolant level) haust temp., A1-A6, B1- common rail) 36 | Product Summary | MS150069/02E 2014-03...
  • Page 37 Aux. PTO end, 12V 4000 M, integral cooling 1 B7 (engine oil temp.) 4 B33 (fuel temperature in 7 B54 (oil refill pump pres- 2 B5.3 (oil pressure up- common rail) sure) stream of filter) 5 B48 (fuel pressure in com- 8 B6.2 (coolant tempera- 3 B5.1 (oil pressure down- mon rail)
  • Page 38 Main PTO end, 12V 4000 M, integral cooling 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- ture, B bank) 38 | Product Summary | MS150069/02E 2014-03...
  • Page 39 Left side of engine, 12V 4000 M, integral cooling 1 B50 (crankcase pressure) 4 B44.1 (turbocharger A 7 B34.2 (fuel pressure up- 2 B49 (charge-air temp., air speed) stream of filter) recirculation valve) 5 B10 (charge-air pressure) 8 B34.1 (fuel pressure down- Y26 (air recirculation valve 6 B34.3 (fuel pressure up- stream of filter)
  • Page 40 Right side of engine, 12V 4000 M, integral cooling 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 valve) 40 | Product Summary | MS150069/02E 2014-03...
  • Page 41 Top view of 16V 4000 M with external cooling 1 B49 (charge-air temp., air 2 B4.A1-B4.B8 (single ex- 3 B33 (fuel temperature in recirculation valve) haust temp., A1-A8, B1- common rail) Y26 (air recirculation valve MS150069/02E 2014-03 | Product Summary | 41...
  • Page 42 Aux. PTO end, 16V 4000 M, external cooling 1 B7 (engine oil temp.) 4 B33 (fuel temperature in 7 B54 (oil refill pump pres- 2 B5.3 (oil pressure up- common rail) sure) stream of filter) 5 B48 (fuel pressure in com- 8 B6.2 (coolant tempera- 3 B5.1 (oil pressure down- mon rail)
  • Page 43 Main PTO end, 16V 4000 M, external cooling 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- ture, B bank) MS150069/02E 2014-03 | Product Summary | 43...
  • Page 44 Left side of engine, 16V 4000 M, external cooling 1 B50 (crankcase pressure) 4 B10 (charge-air pressure) 7 B34.1 (fuel pressure down- 2 B3 (intake air temperature) 5 B34.3 (fuel pressure up- stream of filter) 3 B44.1 (turbocharger A stream of filter) 8 F46 (fuel overflow level) speed) 6 B34.2 (fuel pressure up-...
  • Page 45 Right side of engine, 16V 4000 M, external cooling 1 B44.2 (turbocharger B 3 B16 (coolant pressure) speed) 4 B9 (charge-air tempera- 2 Y27 (turbocharger control ture) valve) MS150069/02E 2014-03 | Product Summary | 45...
  • Page 46 Top view, 16V 4000 M, integral cooling 1 B4.A1-B4.B8 (single ex- 2 B33 (fuel temperature in 3 F33 (coolant level) haust temp., A1-A8, B1- common rail) 46 | Product Summary | MS150069/02E 2014-03...
  • Page 47 Aux. PTO end, 16V 4000 M, integral cooling 1 B7 (engine oil temp.) 4 B33 (fuel temperature in 7 B54 (oil refill pump pres- 2 B5.3 (oil pressure up- common rail) sure) stream of filter) 5 B48 (fuel pressure in com- 8 B6.2 (coolant tempera- 3 B5.1 (oil pressure down- mon rail)
  • Page 48 Main PTO end, 16V 4000 M, integral cooling 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- ture, B bank) 48 | Product Summary | MS150069/02E 2014-03...
  • Page 49 Left side of engine, 16V 4000 M, integral cooling 1 B50 (crankcase pressure) 4 B44.1 (turbocharger A 7 B34.2 (fuel pressure up- 2 B49 (charge-air temp., air speed) stream of filter) recirculation valve) 5 B10 (charge-air pressure) 8 B34.1 (fuel pressure down- Y26 (air recirculation valve 6 B34.3 (fuel pressure up- stream of filter)
  • Page 50 Right side of engine, 16V 4000 M, integral cooling 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 valve) 50 | Product Summary | MS150069/02E 2014-03...

  • Page 51: 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). The cylinders of the left engine side are designated “A” and those of the right side “B" (as per DIN ISO 1204).

  • Page 52: 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 53 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 54: Firing Sequence

    2.4 Firing Sequence 2.4.1 Firing order A1-B4-A4-A2-B3-A3-B2-B1 12 V A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1 16 V A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B7 54 | Product Summary | MS150069/02E 2014-03...

  • Page 55: Technical Data

    2.5 Technical Data 2.5.1 ENGINE DATA 12V 4000 M33F, RheinSchUO Stage II, IMO Tier II Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
  • Page 56 Heat exchanger Heat exchanger installed separate Inlet valves per cylinder Exhaust valves per cylinder RAW WATER CIRCUIT (open circuit) Heat exchanger Heat exchanger installed separate 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 57 STARTER (electric) Heat exchanger Heat exchanger installed separate Rated starter voltage (standard design) STARTING (with compressed air/hydraulic starter) Heat exchanger Heat exchanger installed separate Starting-air pressure before starter motor, min. Starting-air pressure before starter, max. CAPACITIES Heat exchanger Heat exchanger installed separate Engine coolant, engine side (with cooling...

  • Page 58: Engine Data 12V 4000 M33S, Rheinschuo Stage Ii, Imo Tier

    2.5.2 ENGINE DATA 12V 4000 M33S, RheinSchUO Stage II, IMO Tier II Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...

  • Page 59: Starter (Electric)

    RAW WATER CIRCUIT (open circuit) Heat exchanger Heat exchanger installed separate 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 Heat exchanger Heat exchanger installed separate Lube oil operating temperature before en-...

  • Page 60: Starting (With Compressed Air/Hydraulic Starter)

    STARTING (with compressed air/hydraulic starter) Heat exchanger Heat exchanger installed separate Starting-air pressure before starter motor, min. Starting-air pressure before starter, max. CAPACITIES Heat exchanger Heat exchanger installed separate Engine coolant, engine side (with cooling Liters system) Total engine oil capacity at initial filling Liters (standard oil system) (option: max.

  • Page 61: Engine Data 12V 4000 M33S, Imo Tier Ii, Epa Tier

    2.5.3 ENGINE DATA 12V 4000 M33S, IMO Tier II, EPA Tier 2 Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
  • Page 62 RAW WATER CIRCUIT (open circuit) Heat exchanger Heat exchanger installed separate 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 Heat exchanger Heat exchanger installed separate Lube oil operating temperature before en-...

  • Page 63: Starting-Air Pressure Before Starter Motor, Min

    STARTING (with compressed air/hydraulic starter) Heat exchanger Heat exchanger installed separate Starting-air pressure before starter motor, min. Starting-air pressure before starter, max. CAPACITIES Heat exchanger Heat exchanger installed separate Engine coolant, engine side (with cooling Liters system) Total engine oil capacity at initial filling Liters (standard oil system) (option: max.

  • Page 64: Engine Data 16V 4000 M33F, Rheinschuo Stage Ii, Imo Tier

    2.5.4 ENGINE DATA 16V 4000 M33F, RheinSchUO Stage II, IMO Tier II Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...

  • Page 65: R V

    RAW WATER CIRCUIT (open circuit) Heat exchanger Heat exchanger installed separate 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 Heat exchanger Heat exchanger installed separate Lube oil operating temperature before en-...

  • Page 66: R Bar

    STARTING (with compressed air/hydraulic starter) Heat exchanger Heat exchanger installed separate Starting-air pressure before starter motor, min. Starting-air pressure before starter, max. CAPACITIES Heat exchanger Heat exchanger installed separate Engine coolant, engine side (with cooling Liters system) Total engine oil capacity at initial filling Liters (standard oil system) (option: max.

  • Page 67: Engine Data 16V 4000 M33S, Rheinschuo Stage Ii, Imo Tier

    2.5.5 ENGINE DATA 16V 4000 M33S, RheinSchUO Stage II, IMO Tier II Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...

  • Page 68: Heat Exchanger Heat Exchanger Installed Separate

    RAW WATER CIRCUIT (open circuit) Heat exchanger Heat exchanger installed separate 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 Heat exchanger Heat exchanger installed separate Lube oil operating temperature before en-...
  • Page 69 STARTING (with compressed air/hydraulic starter) Heat exchanger Heat exchanger installed separate Starting-air pressure before starter motor, min. Starting-air pressure before starter, max. CAPACITIES Heat exchanger Heat exchanger installed separate Engine coolant, engine side (with cooling Liters system) Total engine oil capacity at initial filling Liters (standard oil system) (option: max.

  • Page 70: Engine Data 16V 4000 M33S, Imo Tier Ii, Epa Tier

    2.5.6 ENGINE DATA 16V 4000 M33S, IMO Tier II, EPA Tier 2 Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
  • Page 71 RAW WATER CIRCUIT (open circuit) Heat exchanger Heat exchanger installed separate 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 Heat exchanger Heat exchanger installed separate Lube oil operating temperature before en-...
  • Page 72 STARTING (with compressed air/hydraulic starter) Heat exchanger Heat exchanger installed separate Starting-air pressure before starter motor, min. Starting-air pressure before starter, max. CAPACITIES Heat exchanger Heat exchanger installed separate Engine coolant, engine side (with cooling Liters system) Total engine oil capacity at initial filling Liters (standard oil system) (option: max.

  • Page 73: Engine Data 16V 4000 M43S, Imo Tier Ii, Epa Tier

    2.5.7 Engine data 16V 4000 M43S, IMO Tier II, EPA Tier 2 Explanation: DL Reference value: Continuous power (CP) BL Reference value: Fuel stop power (FSP) A Design value G Guaranteed value R Guideline value L Limit value up to which the engine can be operated without change, e.g. of power setting. N Not yet defined value - Not applicable X Applicable...
  • Page 74 RAW WATER CIRCUIT (open circuit) Heat exchanger Heat exchanger engine-mounted remote Raw water pump: Inlet pressure, min. -0.4 -0.4 Raw water pump: Inlet pressure, max. Pressure loss in off-engine raw water sys- tem, max. LUBE OIL SYSTEM Heat exchanger Heat exchanger engine-mounted remote Lube oil operating temperature before en-...
  • Page 75 STARTER (compressed air/hydraulic starter motor) Heat exchanger Heat exchanger engine-mounted remote Starting-air pressure before starter motor, min. Starting-air pressure before starter, max. CAPACITIES Heat exchanger Heat exchanger engine-mounted remote Engine coolant, engine side (with cooling Liters system) Engine oil on initial filling (standard oil sys- Liters tem) (option: max.

  • Page 76: Operation

    3 Operation 3.1 Controls Automation system controls Refer to automation system operating instructions 76 | Operation | MS150069/02E 2014-03...

  • Page 77: 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 Task Engine Depreserve (→...

  • Page 78: 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 213); Preheat engine oil if required. Coolant system Check coolant level (→ Page 229). Coolant system Preheat coolant with preheating unit.

  • Page 79: Starting The Engine

    3.4 Starting the engine Start the engine via the automation system Refer to automation system operating instructions MS150069/02E 2014-03 | Operation | 79...

  • Page 80: 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 81: 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 83). Shut down fuel treatment system (→ Page 87). MS150069/02E 2014-03 | Operation | 81...

  • Page 82: 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 83: 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 84 Initial operation: HAT Replace fuel filter on engine (→ Page 189). 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 86). 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 85 Simulation of power failure (emergency): SAT Switch on fuel treatment system (→ Page 86). Start engine (→ Page 79). 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 86: 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. • Before switching on, ensure that all housings are closed. •...

  • Page 87: 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 88: Stopping The Engine

    3.11 Stopping the engine Stopping the engine via the automation system Refer to automation system operating instructions 88 | Operation | MS150069/02E 2014-03...

  • Page 89: 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. MS150069/02E 2014-03 | Operation | 89...

  • Page 90: After Stopping The Engine

    Switch off. Out-of-service-period > 1 week Air intake and exhaust sys- • Seal engine on air and exhaust sides. Out-of-service-period > 1 month • Preserve engine (→ MTU Preservation and Re-preservation specifica- tions A001070/..). 90 | Operation | MS150069/02E 2014-03...

  • Page 91: 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 92: 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 93 Task Maintenance tasks W1675 Replace fuel prefilter or fuel prefilter element. (→ Page 197) W1713 Injector: Reset drift correction parameter (CDC). (→ Page 261) Table 1: Maintenance task reference table [QL1] MS150069/02E 2014-03 | Maintenance | 93...

  • Page 94: Troubleshooting

    5 Troubleshooting 5.1 Troubleshooting Engine does not turn when starter is actuated Cause Corrective action u Charge or replace (see separate documentation). Battery low or faulty u Check firm seating of cable connections (see separate Battery: Cable connections faulty documentation). Engine cabling or starter faulty u Check firm seating of cable connections, contact Service.
  • Page 95 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. u Check fans and air supply/ventilation ducts. Engine room: Air-intake temperature too high Charge-air pressure too low...
  • Page 96 White exhaust gas Cause Corrective action Engine is not at operating u Run engine to reach operating temperature. temperature Intercooler leaky u Contact Service. 96 | Troubleshooting | MS150069/02E 2014-03...

  • Page 97: 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 also valve and water is discharged.

  • Page 98: 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 99: Engine Governor Adec (Ecu 7) - Fault Codes

    5.4 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 100 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 101 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 260). 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 102 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 u Replace oil filter (→ Page 218). Oil filter not functioning 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 103 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 104 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 u Contact Service. Clogged charge-air circuit or fault in turbocharger. 38 – AL ETC Speed Deviation ZKP-Number: 1.8004.205 Yellow alarm;...
  • Page 105 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 213). 2. Contact Service. 57 – LO P-Coolant ZKP-Number: 2.0101.921 Coolant pressure too low (limit value 1).
  • Page 106 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 107 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 108 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 260). block jamming or HP fuel control 2.
  • Page 109 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 110 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 111 120 – 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 112 176 – AL LifeData not available ZKP-Number: 2.4000.004 No (matching) LifeData backup system available Yellow alarm; warning Cause Corrective action u Contact Service. After a wait time has elapsed after ECU reset: Backup system has no LifeData function or CAN bus to backup system disconnected.
  • Page 113 182 – AL CAN Wrong Parameters ZKP-Number: 2.0500.682 Incorrect parameters on CAN Yellow alarm; warning Cause Corrective action u Contact Service. Wrong parameter value entered in data record. 183 – AL CAN No PU-Data ZKP-Number: 2.0500.683 CAN PU data not present or available Yellow alarm;...
  • Page 114 187 – 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 115 201 – 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 260). Short circuit or wire break. 2. Fault is rectified when engine is restarted (→ Page 79). 3.
  • Page 116 205 – 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 260). Short circuit or wire break. 2.
  • Page 117 211 – 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 260). 2.
  • Page 118 215 – 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 260). emergency operation. 2.
  • Page 119 221 – 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 260). Short circuit or wire break.
  • Page 120 228 – 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 260). 2.
  • Page 121 232 – 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 260). Short circuit or wire break. 2.
  • Page 122 241 – SD T-Recirculation ZKP-Number: 1.8004.581 Cause Corrective action u Check sensor and wiring (B49), replace as necessary. Recirculation sensor faulty; Short circuit or wire break. Fault is rectified following engine restart. 242 – SD T-Coolant (R) ZKP-Number: 1.8004.622 Cause Corrective action u Check sensor and wiring, replace as necessary.
  • Page 123 268 – 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 260). Short circuit or wire break. 2. Fault is rectified when engine is restarted (→ Page 79). 3.
  • Page 124 303 – AL Timing Cylinder A3 ZKP-Number: 1.8004.502 Time-of-flight measuring fault of injector Cause Corrective action u Replace injector if the fault message appears frequently Flight time value extremely low or extremely high. (→ Page 181). 304 – AL Timing Cylinder A4 ZKP-Number: 1.8004.503 Time-of-flight measuring fault of injector Cause...
  • Page 125 309 – AL Timing Cylinder A9 ZKP-Number: 1.8004.508 Time-of-flight measuring fault of injector Cause Corrective action u Replace injector if the fault message appears frequently Flight time value extremely low or extremely high. (→ Page 181). 310 – AL Timing Cylinder A10 ZKP-Number: 1.8004.509 Time-of-flight measuring fault of injector Cause...
  • Page 126 315 – AL Timing Cylinder B5 ZKP-Number: 1.8004.514 Time-of-flight measuring fault of injector Cause Corrective action u Replace injector if the fault message appears frequently Flight time value extremely low or extremely high. (→ Page 181). 316 – AL Timing Cylinder B6 ZKP-Number: 1.8004.515 Time-of-flight measuring fault of injector Cause...
  • Page 127 321 – 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 181). 2. Fault is rectified when engine is restarted (→ Page 79). 3.
  • Page 128 325 – 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 181). 2. Fault is rectified when engine is restarted (→ Page 79). 3.
  • Page 129 329 – 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 181). 2. Fault is rectified when engine is restarted (→ Page 79). 3.
  • Page 130 333 – 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 181). 2. Fault is rectified when engine is restarted (→ Page 79). 3.
  • Page 131 337 – 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 181). 2. Fault is rectified when engine is restarted (→ Page 79). 3.
  • Page 132 341 – 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 133 345 – 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 134 349 – 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 135 353 – 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 136 357 – 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 137 361 – 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 138 365 – 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 260). connection to ground of one or 2.
  • Page 139 381 – AL Wiring TOP 1 ZKP-Number: 2.8006.638 Line disruption on digital input 1 Yellow alarm; warning Cause Corrective action u Check wiring to plant. Short circuit or wire break on 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 140 390 – 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 u With a continuous alarm, contact Service. Engine was overloaded continuously. 392 – HI T-Coolant Red ZKP-Number: 2.0129.931 Limit value 1 Cause...
  • Page 141 397 – 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 142 404 – 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 260). No resistance over switch. 2. Check target device input. 3. Contact Service. 405 –...
  • Page 143 408 – 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 260). over switch. 2. Check target device input. 3.
  • Page 144 413 – 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 260). supply. 2. Check supply. 3. Acknowledge alarm. 4. Contact Service. 414 –...
  • Page 145 419 – SD T-Coolant b.Engine ZKP-Number: 18.004.604 Cause Corrective action u Check sensor and wiring (B3), replace as necessary. Coolant inlet temperature 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 146 440 – AL L1 P-Aux 1 ZKP-Number: 2.0110.921 Limit value 1 Cause Corrective action u Determine cause of limit value violation and rectify fault. Pressure signal of Aux 1 has exceeded / not attained limit value 1, depending on configuration. 442 –...
  • Page 147 446 – 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 260). 2.
  • Page 148 454 – SS Power Reduction Active ZKP-Number: 2.7000.011 Power reduction activated Red alarm - power reduction activated Cause Corrective action u Check for additional messages. Engine operation outside 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 149 461 – 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 u Check configuration with DiaSys. EMU coolant temperature value too high / low.
  • Page 150 469 – SD AUX 1 ZKP-Number: 1.8004.590 Cause Corrective action u Check signal sensor and wiring, replace as necessary. Analog input signal for Aux 1 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 151 474 – 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 260). 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 152 480 – 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 153 486 – 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 154 491 – 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 u Reduce power. Clogged charge-air circuit or fault in turbocharger. 492 – AL ETC4 Cutin Failure ZKP-Number: 18.004.202 Yellow alarm;...
  • Page 155 502 – 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 u Check connection between POM and battery-charging Wiring faulty or no resistance over switch. generator. 503 – AL Battery Not Charging ZKP-Number: 1.4500.903 No battery charge Yellow alarm;...
  • Page 156 508 – AL Incorrect POM ID ZKP-Number: 1.4500.908 POM sends a different ID number than expected Yellow alarm; warning Cause Corrective action u Check POM wiring harness. If alarm 504 occurs in addition, the resistor in the POM wiring is missing.
  • Page 157 532 – AL Wiring PWM1 ZKP-Number: 1.1046.900 Red alarm Cause Corrective action u Check wiring to mixture throttle on A side, replace mixture Wire break or short circuit on channel PWM1. throttle on A side if necessary. 533 – AL Wiring PWM2 ZKP-Number: 1.1047.900 Red alarm Cause...
  • Page 158 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 u Request activation code via Internet. This fault becomes active if a maintenance case has been...
  • Page 159 582 – AL Emergency Stop Failure ZKP-Number: 1.1005.006 Emergency stop command was not executed Flashing pre-alarm and alarm Cause Corrective action u Contact Service. Engine speed does not come to a standstill within a configurable period. 584 – AL CAN Start clearance failed Yellow alarm;...
  • Page 160 596 – AL Test Parameters ZKP-Number: 1.8004.645 Yellow alarm; warning Cause Corrective action u Contact Service. The parameter set is used for 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 161 606 – 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 260). Short circuit or wire break.
  • Page 162 690 – 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 163 850 – 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 164: 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 165 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 166: Engine - Barring With Starting System

    6.1.2 Engine – Barring with starting system Barring using the automation system Refer to automation system operating instructions 166 | Task Description | MS150069/02E 2014-03...

  • Page 167: 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 178). Remove injector (→ Page 182). Positioning crankshaft at BDC Using barring gear, turn crankshaft until crankshaft journal of the cylinder to be inspected has reached BDC.
  • Page 168 Final steps Install injector (→ Page 182). Install cylinder head cover (→ Page 178). 168 | Task Description | MS150069/02E 2014-03...

  • Page 169: 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 170 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 171: Crankcase Breather

    6.3 Crankcase Breather 6.3.1 Crankcase breather – Overview For 12V engines 1 Vent pipe 5 Bracket 9 Spigot pipe 2 Plug 6 Oil line 10 Drain pipe 3 Oil separator 7 Service block 11 Bracket 4 Impactor carrier 8 Vent housing 12 Connection MS150069/02E 2014-03 | Task Description | 171...
  • Page 172 For 16V engines 1 Vent pipe 5 Service block 9 Bracket 2 Impactor carrier 6 Vent housing 10 Plug 3 Bracket 7 Spigot pipe 11 Oil separator 4 Oil line 8 Drain pipe 172 | Task Description | MS150069/02E 2014-03...

  • Page 173: Crankcase Breather - Oil Mist Fine Separator Replacement

    6.3.2 Crankcase breather – Oil mist fine separator replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil Oil mist fine separator (→ Spare Parts Catalog) O-ring (→ Spare Parts Catalog) WARNING Hot oil.

  • Page 174: Valve Drive

    6.4 Valve Drive 6.4.1 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 178). Fill oil chambers of valve bridges with oil. Fill oil chambers of rocker arms and adjust- ing screws with oil.

  • Page 175: Valve Clearance - Check And Adjustment

    6.4.2 Valve clearance – Check and adjustment Preconditions ☑Engine is stopped and starting disabled. ☑Engine coolant temperature is max. 40 °C. ☑Valves are closed. Special tools, Material, Spare parts Designation / Use Part No. Qty. Feeler gage Y20010128 Torque wrench, 60-320 Nm F30452768 Socket wrench, 24 mm F30039526...
  • Page 176 Rotate crankshaft with barring tool in en- gine direction of rotation until marking “OT- 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...

  • Page 177: Adjusting Valve Clearance

    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 adjustment with engine cold: •...

  • Page 178: Cylinder Head Cover - Removal And Installation

    6.4.3 Cylinder head cover – Removal and installation Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Assembly compound (Kluthe Hakuform 30-11C/Emulgier) X00059351 O-ring (→ Spare Parts Catalog) Removing cylinder head cover Clean very dirty cylinder head covers (1) prior to removal.

  • Page 179: Injection Pump / Hp Pump

    6.5 Injection Pump / HP Pump 6.5.1 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 180: Hp Pump - Relief Bore Check

    6.5.2 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 181: Injector

    6.6 Injector 6.6.1 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 182). MS150069/02E 2014-03 | Task Description | 181...

  • Page 182: Injector - Removal And Installation

    6.6.2 Injector – Removal and installation Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Installation/removal jig F6789889 Milling cutter F30452739 Torque wrench, 0.5-5 Nm 0015384230 Torque wrench, 10-60 Nm F30452769 Ratchet adapter F30027340 Torque wrench, 60-320 Nm...
  • Page 183 Remove HP fuel line 4). 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 jig on cylinder head. Remove injector with installation/removal jig. Remove installation/removal jig. Remove sealing ring (4) from injector or use a self-made hook to take it out of the cylinder head.

  • Page 184: 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 delivery of the injector) with assembly compound on injector, observe installation position of sealing ring.
  • Page 185 Coat screw head mating face (2) and thread with engine oil. Fit hold-down clamp (1) in the correct position and use torque wrench to tighten screw (2) to the speci- fied initial tightening torque. Name Size Type Lubricant Value/Standard Screw Preload torque (Engine oil) 5 Nm to 10 Nm...
  • Page 186 Fit connectors on injector. Note: Failure to reset drift compensation (CDC) will void the emissions certification. Reset drift compensation (CDC) with Dia- Sys® (→ E531920/...). If DiaSys® is not available, contact Service. Final steps Install cylinder head cover (→ Page 178). Open fuel supply to engine.

  • Page 187: Fuel Filter

    6.7 Fuel Filter 6.7.1 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 MS150069/02E 2014-03 | Task Description | 187...
  • Page 188 6.7.2 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 189 6.7.3 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 190 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 191 6.7.4 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 192: Fuel Prefilter – Differential Pressure Check

    6.7.5 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 193: Draining Fuel Prefilter

    6.7.6 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 194 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 195 6.7.7 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 196: 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 197: Fuel Prefilter With Water Separator – Filter

    6.7.8 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 F30452769 Ratchet adapter F30027340 Filter element (→...
  • Page 198 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 199: Fuel Prefilter With Water Separator – O-Ring

    6.7.9 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 200: Exhaust Turbocharger

    6.8 Exhaust Turbocharger 6.8.1 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 201 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). MS150069/02E 2014-03 | Task Description | 201...
  • Page 202 Undo screws (1). Remove compressor housing (2). Cleaning compressor wheel Note: Do not use wire brushes, scrapers or simi- lar 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 203 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 204 Preparatory steps – Vertical air intake Drain engine coolant (→ Page 231). Remove air filter (→ Page 210). 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 205 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 brushes, scrapers or simi- lar tools for cleaning! Clean compressor housing with a smooth paint brush or brush.
  • Page 206 Final steps – Vertical air intake Install compressor casing (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 207 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 208: Intercooler – Checking Condensate Drain For

    6.9 Charge-Air Cooling 6.9.1 Intercooler – 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 209: Air Filter

    6.10 Air Filter 6.10.1 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 210). Reset signal ring of contamination indicator (→...
  • Page 210 6.10.2 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 211: Air Intake

    6.11 Air Intake 6.11.1 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 209). After installation of new filter, press reset button (1).

  • Page 212: Starting Equipment

    6.12 Starting Equipment 6.12.1 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 260). 212 | Task Description | MS150069/02E 2014-03...

  • Page 213: Lube Oil System, Lube Oil Circuit

    6.13 Lube Oil System, Lube Oil Circuit 6.13.1 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 214 6.13.2 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 215 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 216 6.13.3 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 217 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. MS150069/02E 2014-03 | Task Description | 217...

  • Page 218: Oil Filtration / Cooling

    6.14 Oil Filtration / Cooling 6.14.1 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 219: Engine Running

    Oil filter with diverter (option): Oil filter replacement with the engine stopped Stop engine (→ Page 88) 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 220 6.14.2 Oil indicator filter – Cleaning and check Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Cleaning agent (Snow-White 11-0) 40460 Cleaning agent (Hakupur 312) 30390 Engine oil Strainer (→ Spare Parts Catalog) Square-section ring (→...
  • Page 221 Checking strainer Item Findings Action • Clean Strainer Metallic residues • Monitor engine operation • Check strainer daily • Contact Service Strainer Damaged Fit new part Square-section ring Damaged Fit new part O-ring Damaged Fit new part Cleaning strainer Wash strainer (5) with cleaner. Remove stubborn deposits with soft brush.

  • Page 222: Centrifugal Oil Filter – Cleaning And Filter

    6.14.3 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 223 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 224 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 225: Coolant Circuit, General, High-Temperature

    6.15 Coolant Circuit, General, High-Temperature Circuit 6.15.1 Drain and vent points Coolant lines on ETC 1 Vent point Coolant line to intercooler 1 Vent point MS150069/02E 2014-03 | Task Description | 225...
  • Page 226 1 Vent point Coolant line to raw water cooler 1 Vent point 226 | Task Description | MS150069/02E 2014-03...
  • Page 227 Vent line – Distribution cross 1 Vent point Coolant drain point, engine driving end 1 Drain point MS150069/02E 2014-03 | Task Description | 227...
  • Page 228 Coolant drain point, engine free end 1 Drain point 228 | Task Description | MS150069/02E 2014-03...
  • Page 229 6.15.2 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. • Wear protective clothing, gloves, and goggles / safety mask.
  • Page 230 6.15.3 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant change Drain engine coolant (→ Page 231). Fill with engine coolant (→ Page 234). 230 | Task Description | MS150069/02E 2014-03...
  • Page 231 6.15.4 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 232 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. 232 | Task Description | MS150069/02E 2014-03...
  • Page 233 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. MS150069/02E 2014-03 | Task Description | 233...
  • Page 234 6.15.5 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 235 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 236 6.15.6 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 237: Engine Coolant – Sample Extraction And

    6.15.7 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 238 6.15.8 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 239: Preheating Unit

    6.15.9 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 240 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 240 | Task Description | MS150069/02E 2014-03...
  • Page 241 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 242: Preheater – Overhaul

    6.15.10 Preheater – Overhaul Preconditions ☑Engine is stopped and starting disabled. DANGER Electric voltage supply for operation. Danger of burns and fatal electric shock! • Make certain that the power supply to the product is switched off before starting work. Secure against unintentional switching on! WARNING Coolant is hot and under pressure.

  • Page 243: Preheater – Function And Leak-Tightness Check

    6.15.11 Preheater – Function and leak-tightness check Preconditions ☑Preheater is switched on. WARNING Coolant is hot and highly pressurized. Risk of injury! Risk of scalding! • Allow engine to cool down. • Wear protective clothing, protective gloves, and safety glasses / facial protection. Checking operation Note: The coolant temperature must correlate to the control range of the thermostat when the preheater is...

  • Page 244: Raw Water Pump With Connections

    6.16 Raw Water Pump with Connections 6.16.1 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 245: Engine Mounting / Support

    6.17 Engine Mounting / Support 6.17.1 Engine mounting – Check Engine mounting – Check Item Findings Action • Damage Visually inspect mounts. Replace (contact Service). • Brittleness • Deformation • Crack formation • Swelling visible MS150069/02E 2014-03 | Task Description | 245...

  • Page 246: Battery-Charging Generator

    6.18 Battery-Charging Generator 6.18.1 Battery-charging generator drive – Coupling condition check Preconditions ☑Engine is stopped and starting disabled. Battery-charging generator drive – Coupling condition check Remove screws (1). Remove protective cover (2). Check resilient coupling (3) for cracks and plastic deformation. If there is serious deformation or crack for- mation, contact Service.

  • Page 247: Auxiliary Pto

    6.19 Auxiliary PTO 6.19.1 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 248: Fuel Supply System

    6.20 Fuel Supply System 6.20.1 Water drain valve – Check Water drain valve – Check Open water drain valve. Check water outlet for obstructions. Close water drain valve. 248 | Task Description | MS150069/02E 2014-03...

  • Page 249: Differential Pressure Gauge – Check

    6.20.2 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 86). Set the alarm points at the differential pressure gauge to zero.

  • Page 250: Water Level Probe (3-In-1 Rod Electrode

    6.20.3 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 251: Pump Capacity – Check

    6.20.4 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 252: Coalescer Filter Element – Replacement

    6.20.5 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 253 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 254: Wiring (General) For Engine/Gearbox/Unit

    6.21 Wiring (General) for Engine/Gearbox/Unit 6.21.1 Engine wiring harness – Overview 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 255 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 256 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 257 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 MS150069/02E 2014-03 | Task Description | 257...
  • Page 258 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 258 | Task Description | MS150069/02E 2014-03...
  • Page 259 Engine wiring harness for electric starter 1 Connection terminals, EIM 2 Fuse F1 3 Connection terminals, starter MS150069/02E 2014-03 | Task Description | 259...

  • Page 260: Engine Wiring – Check

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

  • Page 261: Accessories For (Electronic) Engine

    6.22 Accessories for (Electronic) Engine Governor / Control System 6.22.1 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®...

  • Page 262: Limit Switch For Start Interlock ‒ Check

    6.22.2 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 263: Engine Control Unit Ecu 7 – Checking Plug

    6.22.3 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 264: Engine Monitoring Unit Emu 7 – Plug

    6.22.4 Engine Monitoring Unit EMU 7 – Plug connection check Preconditions ☑Engine is stopped and starting disabled. Checking EMU plug connections Check both connectors on EMU (2) for firm seating. Make sure that frames (3) are en- gaged. Check screws (1) of cable clamps on EMU (2) for firm seating.

  • Page 265: Interface Module Eim Plug Connections

    6.22.5 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 266: Engine Control Unit Ecu 7 – Removal And

    6.22.6 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 267: Emu 7 – Removal And Installation

    6.22.7 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 268: Engine Interface Module Eim – Removal And

    6.22.8 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 269: Diagnostic Features Of Eim

    6.22.9 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 270 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 271 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 272: Appendix A

    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 273 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 274: 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 275: Appendix B

    8 Appendix B 8.1 Special Tools Barring device Part No.: F6555766 Qty.: Used in: 6.1.1 Engine – Barring manually (→ Page 164) Feeler gage Part No.: Y20010128 Qty.: Used in: 6.4.2 Valve clearance – Check and adjustment (→ Page 175) Filter wrench Part No.: F30379104...
  • Page 276 6.6.2 Injector – Removal and installation (→ Page 182) Milling cutter Part No.: F30452739 Qty.: Used in: 6.6.2 Injector – Removal and installation (→ Page 182) MTU test kit Part No.: 5605892099/00 Qty.: Used in: 6.13.3 Engine oil – Sample extraction and analysis (→ Page 216) Qty.:...
  • Page 277 Ratchet adapter Part No.: F30027340 Qty.: Used in: 6.6.2 Injector – Removal and installation (→ Page 182) Qty.: Used in: 6.7.8 Fuel prefilter with water separator – Filter ele- ment replacement (→ Page 197) Qty.: Used in: 6.8.1 Compressor wheel – Cleaning (→ Page 200) Ratchet adapter Part No.: F30027341...
  • Page 278 Socket wrench, 24 mm Part No.: F30039526 Qty.: Used in: 6.4.2 Valve clearance – Check and adjustment (→ Page 175) Steam jet cleaner Part No.: Qty.: Used in: 3.14 Plant – Cleaning (→ Page 91) Torque wrench, 0.5-5 Nm Part No.: 0015384230 Qty.: Used in:...
  • Page 279 Torque wrench, 40-200 Nm Part No.: F30027337 Qty.: Used in: 6.13.2 Engine oil – Change (→ Page 214) Torque wrench, 6-50 Nm Part No.: F30027336 Qty.: Used in: 6.14.3 Centrifugal oil filter – Cleaning and filter sleeve replacement (→ Page 222) Torque wrench, 6-50 Nm Part No.: F30027336...

  • Page 280: Index

    8.2 Index Preheating unit 239 Differential pressure gauge  – Check  249 Abbreviations 272 Drain and vent points 225 Actuators  Drift compensation  – Overview  31 – Reset  261 Additional fuel filter  – Replacement  188 ADEC (ECU 7)  ECU 7  – Fault codes  99 – Installation  266 –...
  • Page 281 – Engine governor ADEC (ECU 7)  98 Filter  Maintenance schedule  – Coalescer element   – Maintenance task reference table [QL1]  92 – Replacement  252 MTU contact persons 274 – Engine coolant   – Replacement  238 Filter sleeve   Oil indicator filter  – Replacement  222 –...
  • Page 282 Safety regulations  – Auxiliary materials  12 – Environmental protection  12 – Fire prevention  12 – Fluids and lubricants  12 – Important provisions  5 – Maintenance work  9 – Operation  8 – Organizational requirements  6 – Personnel requirements  6 – Repair work  9 –...

This manual is also suitable for:

12 v 4000 m33s16 v 4000 m33s16 v 4000 m43s16 v 4000 m33f

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