MTU 16 V 4000 M63L Manuals

MTU 16 V 4000 M63L Manuals

Manuals and User Guides for MTU 16 V 4000 M63L. We have 1 MTU 16 V 4000 M63L manual available for free PDF download: Operating Instructions Manual

MTU 16 V 4000 M63L Operating Instructions Manual

MTU 16 V 4000 M63L Operating Instructions Manual (262 pages)

Brand: MTU | Category: Engine | Size: 49 MB

Table of Contents

Operating Instructions
1
Table of Contents
5
1 Safety

7
2 Product Summary

16
- Engine Side and Cylinder Designations
  42
- Main Engine Dimensions
  43
  - 4000 M63L Engines - Main Dimensions
    43
- Firing Sequence
  44
  - Firing Order
    44
- Technical Data
  45
  - 4000 M63L Engine Data
    45
  - General Conditions
    45
  - Power-Related Data
    45
  - General Operating Data
    46
  - Lube-Oil System
    46
  - Raw Water Circuit
    46
  - Capacities
    47
  - Inclinations, Standard Oil System
    47
  - Starting
    47
  - Acoustics
    48
  - Weights / Main Dimensions
    48
- Automation System Controls
  49
- Controls
  49
3 Operation

49
5 Troubleshooting

67
- Charge-Air Pressure too Low
  68
- Charge-Air Temperature too High
  68
- Coolant Leaks at Intercooler
  68
- Engine Speed Not Steady
  68
- White Exhaust Gas
  69
- Fuel Treatment System - Troubleshooting
  70
- Engine Governor ADEC (ECU 7) Fault Messages for Series 4000 Engines, Marine Application
  71
  - Engine Governor ADEC (ECU 7) – Fault Codes
    72
  - HI T-Charge Air
    72
  - HI T-Fuel
    72
  - SS T-Fuel
    72
  - HI T-Coolant Charge-Air Cooler
    73
  - LO P-Lube Oil
    73
  - SS P-Lube Oil
    73
  - SS T-Coolant Charge-Air Cooler
    73
  - HI T-Exhaust a
    74
  - HI T-Exhaust B
    74
  - SS T-Exhaust a
    74
  - SS T-Exhaust B
    74
  - HI ETC Idle Speed too High
    75
  - HI Level Leakage Fuel
    75
  - HI P-Diff. Lube Oil
    75
  - SS Engine Overspeed
    75
  - HI ETC1 Overspeed
    76
  - HI P-Diff-Fuel
    76
  - SS ETC1 Overspeed
    76
  - SS P-Diff-Fuel
    76
  - AL ETC Speed Deviation
    77
  - AL ETC2 Cut-In Fault
    77
  - LO Coolant Level Charge-Air Cooler
    77
  - SS ETC2 Overspeed
    77
  - LO P-Coolant
    78
  - SS P-Coolant
    78
  - SS T-Coolant L3
    78
  - SS T-Lube Oil
    78
  - HI P-Crankcase
    79
  - LO P-Fuel
    79
  - SS P-Crankcase
    79
  - SS T-Coolant L4
    79
  - AL Rail Leakage
    80
  - HI T-Coolant
    80
  - SS P-Fuel
    80
  - SS T-Coolant
    80
  - HI P-Fuel (Common Rail)
    81
  - HI T-Recirculation
    81
  - LO P-Fuel (Common Rail)
    81
  - SS T-Recirculation
    81
  - 90 – SS Starter Speed Not Reached
    82
  - 91 – SS Release Speed Not Reached
    82
  - 92 – SS Starter Speed Not Reached
    82
  - 93 – SS T-Preheat
    82
  - 102 – al Fuel Cons. Counter Defect
    83
  - 104 – al Eng Hours Counter Defect
    83
  - 118 – lo ECU Power Supply Voltage
    83
  - 95 – al Prelubrication Fault
    83
  - 120 – HI ECU Power Supply Voltage
    84
  - 121 – HIHI ECU Power Supply Voltage
    84
  - 122 – Hi T-Ecu
    84
  - 141 – al Power too High
    84
  - 176 – al Lifedata Not Available
    85
  - 177 – al Lifedata Restore Incomplete
    85
  - 180 – al CAN1 Node Lost
    85
  - 181 – al CAN2 Node Lost
    85
  - 182 – al CAN Wrong Parameters
    86
  - 183 – al CAN no PU-Data
    86
  - 184 – al CAN PU-Data Flash Error
    86
  - 186 – al CAN1 Bus off
    86
  - 187 – al CAN1 Error Passive
    87
  - 188 – al CAN2 Bus off
    87
  - 189 – al CAN2 Error Passive
    87
  - 190 – al EMU Parameter Not Supported
    87
  - 201 – SD T-Coolant
    88
  - 202 – SD T-Fuel
    88
  - 203 – SD T-Charge Air
    88
  - 204 – SD Level Lube Oil
    88
  - 205 – SD T-Coolant Charge-Air Cooler
    89
  - 206 – SD T-Exhaust a
    89
  - 207 – SD T-Exhaust B
    89
  - 208 – SD P-Charge Air
    89
  - 211 – SD P-Lube Oil
    90
  - 212 – SD P-Coolant
    90
  - 213 – SD P-Coolant Charge-Air Cooler
    90
  - 214 – SD P-Crankcase
    90
  - 215 – Sd P-Hd
    91
  - 216 – SD T-Lube Oil
    91
  - 219 – SD T-Intake Air
    91
  - 220 – SD Level Coolant Water
    91
  - 221 – SD P-Diff Lube Oil
    92
  - 222 – SD Level Leak-Off Fuel
    92
  - 223 – SD Level Coolant Charge-Air Cooler
    92
  - 227 – SD P- Lube Oil before Filter
    92
  - 228 – SD P-Fuel before Filter
    93
  - 229 – al Stop Camshaft Sensor Defect
    93
  - 230 – SD Crankshaft Speed
    93
  - 231 – SD Camshaft Speed
    93
  - 232 – SD Charger 1 Speed
    94
  - 233 – SD Charger 2 Speed
    94
  - 239 – SD P-Diff Fuel
    94
  - 240 – SD P-Fuel
    94
  - 241 – SD T-Recirculation
    95
  - 242 – SD T-Coolant (R)
    95
  - 244 – SD P-Lube Oil (R)
    95
  - 245 – SD ECU Power Supply Voltage
    95
  - 268 – SD Spinning Value
    96
  - 269 – SD Loadp.analog Filt.
    96
  - 270 – SD Frequency Input
    96
  - 301 – al Timing Cylinder A1
    96
  - 303 – al Timing Cylinder A3
    97
  - 304 – al Timing Cylinder A4
    97
  - 305 – al Timing Cylinder A5
    97
  - 306 – al Timing Cylinder A6
    97
  - 309 – al Timing Cylinder A9
    98
  - 310 – al Timing Cylinder A10
    98
  - 311 – al Timing Cylinder B1
    98
  - 312 – al Timing Cylinder B2
    98
  - 315 – al Timing Cylinder B5
    99
  - 316 – al Timing Cylinder B6
    99
  - 317 – al Timing Cylinder B7
    99
  - 318 – al Timing Cylinder B8
    99
  - 321 – al Wiring Cylinder A1
    100
  - 322 – al Wiring Cylinder A2
    100
  - 323 – al Wiring Cylinder A3
    100
  - 324 – al Wiring Cylinder A4
    100
  - 325 – al Wiring Cylinder A5
    101
  - 326 – al Wiring Cylinder A6
    101
  - 327 – al Wiring Cylinder A7
    101
  - 328 – al Wiring Cylinder A8
    101
  - 329 – al Wiring Cylinder A9
    102
  - 330 – al Wiring Cylinder A10
    102
  - 331 – al Wiring Cylinder B1
    102
  - 332 – al Wiring Cylinder B2
    102
  - 333 – al Wiring Cylinder B3
    103
  - 334 – al Wiring Cylinder B4
    103
  - 335 – al Wiring Cylinder B5
    103
  - 336 – al Wiring Cylinder B6
    103
  - 337 – al Wiring Cylinder B7
    104
  - 338 – al Wiring Cylinder B8
    104
  - 339 – al Wiring Cylinder B9
    104
  - 340 – al Wiring Cylinder B10
    104
  - 341 – al Open Load Cylinder A1
    105
  - 342 – al Open Load Cylinder A2
    105
  - 343 – al Open Load Cylinder A3
    105
  - 344 – al Open Load Cylinder A4
    105
  - 345 – al Open Load Cylinder A5
    106
  - 346 – al Open Load Cylinder A6
    106
  - 347 – al Open Load Cylinder A7
    106
  - 348 – al Open Load Cylinder A8
    106
  - 349 – al Open Load Cylinder A9
    107
  - 350 – al Open Load Cylinder A10
    107
  - 351 – al Open Load Cylinder B1
    107
  - 352 – al Open Load Cylinder B2
    107
  - 353 – al Open Load Cylinder B3
    108
  - 354 – al Open Load Cylinder B4
    108
  - 355 – al Open Load Cylinder B5
    108
  - 356 – al Open Load Cylinder B6
    108
  - 357 – al Open Load Cylinder B7
    109
  - 358 – al Open Load Cylinder B8
    109
  - 359 – al Open Load Cylinder B9
    109
  - 360 – al Open Load Cylinder B10
    109
  - 361 – al Power Stage Low
    110
  - 362 – al Power Stage High
    110
  - 363 – al Stop Power Stage
    110
  - 365 – al Stop MV-Wiring Ground
    111
  - 371 – al Wiring to 1
    111
  - 372 – al Wiring to 2
    111
  - 373 – al Wiring to 3
    111
  - 381 – al Wiring TOP 1
    112
  - 382 – al Wiring TOP 2
    112
  - 383 – al Wiring TOP 3
    112
  - 384 – al Wiring TOP 4
    112
  - 390 – al MCR Exceeded
    113
  - 392 – HI T-Coolant Red
    113
  - 393 – SS T-Coolant Red
    113
  - 394 – lo P-Lube Oil Red
    113
  - 397 – TD P-Oil Sensor Deviation
    114
  - 400 – al Open Load Digital Input 1
    114
  - 401 – al Open Load Digital Input 2
    114
  - 402 – al Open Load Digital Input 3
    114
  - 404 – al Open Load Digital Input 5
    115
  - 405 – al Open Load Digital Input 6
    115
  - 406 – al Open Load Digital Input 7
    115
  - 407 – al Open Load Digital Input 8
    115
  - 408 – al Open Load Emerg. Stop Input ESI
    116
  - 410 – lo U-Pdu
    116
  - 411 – Lolo U-Pdu
    116
  - 412 – Hi U-Pdu
    116
  - 413 – Hihi U-Pdu
    117
  - 414 – HI Level Water Fuel Prefilter
    117
  - 415 – lo P-Coolant Charge-Air Cooler
    117
  - 416 – SS P-Coolant Charge-Air Cooler
    117
  - 419 – SD T-Coolant B.engine
    118
  - 420 – al L1 aux 1
    118
  - 421 – al L2 aux 1
    118
  - 428 – al L1 T-Aux 1
    118
  - 440 – al L1 P-Aux 1
    119
  - 442 – al L2 P-Aux 1
    119
  - 444 – Sd U-Pdu
    119
  - 445 – SD P-Ambient Air
    119
  - 446 – Sd P-Hd2
    120
  - 448 – HI P-Charge Air
    120
  - 449 – SS P-Charge Air
    120
  - 450 – SD Idle/End-Torque Input [%]
    120
  - 454 – SS Power Reduction Active
    121
  - 455 – al L1 Aux1 Plant
    121
  - 456 – al L2 Aux1 Plant
    121
  - 460 – HI T-Exhaust EMU
    121
  - 461 – lo T-Exhaust EMU
    122
  - 462 – HI T-Coolant EMU
    122
  - 464 – Sd P-Aux 1
    122
  - 467 – al L2 T-Aux 1
    122
  - 469 – Sd aux 1
    123
  - 470 – Sd T-Ecu
    123
  - 471 – SD Coil Current
    123
  - 472 – al Stop SD
    123
  - 474 – al Wiring FO
    124
  - 475 – al CR Engine Shutdown Trigger
    124
  - 476 – al Crash Rec. Init. Error
    124
  - 478 – al Comb. Alarm Yel (Plant)
    124
  - 480 – al Ext. Engine Protection
    125
  - 482 – SD T-Exhaust C
    125
  - 483 – SD T-Exhaust D
    125
  - 484 – HI T-Exhaust C
    125
  - 486 – HI T-Exhaust D
    126
  - 487 – SS T-Exhaust D
    126
  - 488 – HI ETC3 Overspeed
    126
  - 489 – SS ETC3 Overspeed
    126
  - 491 – SS ETC4 Overspeed
    127
  - 492 – al ETC4 Cutin Failure
    127
  - 493 – al ETC3 Cutin Failure
    127
  - 500 – al Wiring POM Starter 1
    127
  - 502 – al Open Load POM Battery-Charging Generator
    128
  - 503 – al Battery Not Charging
    128
  - 504 – al CAN POM Node Failure
    128
  - 506 – al Low Starter Voltage
    128
  - 508 – al Incorrect POM ID
    129
  - 510 – al Override Applied
    129
  - 515 – al Starter Not Engaged
    129
  - 519 – Oil Level Calibration Error
    129
  - 532 – al Wiring PWM1
    130
  - 543 – al Multiple FDH Slaves
    130
  - 544 – al Configuration Changed
    130
  - AL Wiring PWM2
    130
  - 551 – SS Engine Overspeed Camshaft
    131
  - 555 – al Call MTU Field Service
    131
  - 576 – al ESCM Override
    131
  - 577 – SD T-Lube Oil Pan
    131
  - 582 – al Emergency Stop Failure
    132
  - 584 – al CAN Start Clearance Failed
    132
  - 586 – lo P-Oil Refill Pump
    132
  - 588 – SD P-Oil Refill Pump
    132
  - 596 – al Test Parameters
    133
  - 600 – SD T-Exhaust A+B
    133
  - 601 – Sd Etc1+Etc2
    133
  - 602 – al CAN Engine Start Lock
    133
  - 606 – al Double Nodes Lost CAN 1+2
    134
  - 614 – al L1 P-Fuel Supp. Filt. Diff.
    134
  - 625 – SD P-Fuel B. Supp. Filter
    134
  - 641 – al System Restart by Watchdog
    134
  - 690 – al Oil Level too Low
    135
  - 759 – al L1 T-Fuel B. Engine
    135
  - 760 – al L2 T-Fuel B. Engine
    135
  - 761 – SD T-Fuel B. Engine
    135
  - 850 – SD Alive FIP
    136
  - AL L1 P-Lube Oil ETC a
    136
  - AL L1 P-Lube Oil ETC B
    136
  - SD P-Lube Oil ETC B
    136
  - Barring Engine Manually
    137
  - Engine – Barring Manually
    137
6 Task Description

137
- Barring Using the Automation System
  139
- Engine – Barring with Starting System
  139
- Cylinder Liner - Endoscopic Examination
  140
  - Cylinder Liner – Endoscopic Examination
    140
  - Positioning Crankshaft at BDC
    140
- Instructions and Comments on Endoscopic and Visual Examination of Cylinder Liners
  142
  - Terms Used for Endoscopic Examination
    142
  - Evaluation of Findings and Further Measures
    143
- Crankcase Breather
  144
  - Crankcase Ventilation - Overview
    144
    
    For 16V Engines
    144
    
    Crankcase Breather – Oil Mist Fine Separator Replacement
    145
- Valve Drive
  146
  - Valve Gear - Lubrication
    146
  - Valve Clearance - Check and Adjustment
    147
    
    Checking Valve Clearance at Two Crankshaft Positions
    148
    
    Diagram for 16V Engines
    148
    
    Adjusting Valve Clearance
    149
    
    Cylinder Head Cover – Removal and Installation
    150
    
    Installing Cylinder Head Cover
    150
    
    Removing Cylinder Head Cover
    150
  - Filling HP Pump
    151
  - HP Pump – Filling with Engine Oil
    151
- Injection Pump / HP Pump
  151
- HP Pump – Relief Bore Check
  152
- Injection Valve / Injector
  153
  - Injector - Replacement
    153
  - Replacing Injector
    153
  - Injector - Removal and Installation
    154
  - Removing Injector
    154
- Fuel Filter
  159
- Exhaust Turbocharger
  172
  - Overview of Turbocharger
    172
  - Turbine Housing, Left Turbocharger
    173
  - Impeller Housing, Left
    174
  - Turbine Housing, Right Turbocharger
    175
  - Impeller Housing, Right Turbocharger
    176
  - Bearing Housing
    177
  - Impeller Housing
    177
  - Magnetic Nut
    178
  - Thrust Bearing
    178
  - Compressor Wheel – Cleaning
    179
  - Preparatory Steps – Horizontal Air Intake
    179
  - Cleaning Compressor Wheel
    181
  - Horizontal Air Intake
    181
  - Preparatory Steps – Vertical Air Intake
    183
  - Final Steps – Vertical Air Intake
    185
  - Charge-Air Cooling
    187
  - Checking Condensate Drain for Water Discharge and Obstruction
    187
  - Emergency Measures Prior to Engine Start with a Leaking Intercooler
    187
- Air Filter
  188
  - Air Filter – Replacement
    188
  - Replacing the Air Filter
    188
  - Air Filter with Intake Silencer
    189
  - Air Filter – Removal and Installation
    189
- Air Intake
  190
- Starting Equipment
  191
  - Engine Oil – Level Check
    192
  - Lube Oil System, Lube Oil Circuit
    192
  - Oil Level Check after the Engine Is Stopped
    192
  - Oil Level Check Prior to Engine Start
    192
  - Draining Residual Oil at Gearcase
    193
  - Engine Oil – Change
    193
  - Oil Change with Semirotary Hand Pump: Oil Extraction
    193
  - Filling with New Oil
    194
  - Engine Oil – Sample Extraction and Analysis
    195
  - MTU Test Kit
    195
  - Engine Oil Filter ‒ Replacement
    197
  - Hot Oil
    197
  - Oil Filtration / Cooling
    197
  - Oil Filter Replacement with the Engine Running
    198
  - Oil Filter Replacement with the Engine Stopped
    198
  - Oil Filter with Diverter
    198
  - Oil Indicator Filter – Cleaning and Check
    199
  - Removing Strainer
    199
  - Checking Strainer
    200
  - Cleaning Strainer
    200
  - Installing Strainer
    200
  - Centrifugal Oil Filter – Cleaning and Filter Sleeve Replacement
    201
  - Coolant Circuit, General, High-Temperature Circuit
    204
  - Coolant Line to Intercooler
    204
  - Coolant Lines on ETC
    204
  - Drain and Vent Points
    204
  - Coolant Line to Raw Water Cooler
    205
  - Coolant Drain Point, Engine Driving End
    206
  - Vent Line – Distribution Cross
    206
  - Coolant Drain Point, Engine Free End
    207
  - Checking Engine Coolant Level at External Cooler
    208
  - Checking Engine Coolant Level at Filler Neck
    208
  - Checking Engine Coolant Level by Means of Level Sensor
    208
  - Engine Coolant Level – Check
    208
  - Engine Coolant – Change
    209
  - Engine Coolant – Draining
    210
  - Engine Coolant – Filling
    213
  - Filling Coolant through Filler Neck
    214
  - HT Coolant Pump – Relief Bore Check
    215
  - Engine Coolant – Sample Extraction and Analysis
    216
  - Engine Coolant Filter – Replacement
    217
  - Hotstart Preheating Unit
    218
  - Preheating Unit
    218
    
    Hilzinger Preheating Unit
    219
    
    Hilzinger Preheating Unit, Side View
    220
    
    Overhauling Preheater
    221
    
    Preheater – Overhaul
    221
    
    Checking for Leaks
    222
    
    Checking Operation
    222
    
    Preheater – Function and Leak-Tightness Check
    222
- Raw Water Pump with Connections
  223
- Auxiliary PTO
  226
- Bilge Pump – Relief Bore Check
  226
- Fuel Supply System
  227
- Wiring (General) for Engine/Gearbox/Unit
  233
- 7 Appendix A
  
  251
  - Engine Interface Module EIM – Removal and Installation
    247
  - Installing EIM on the Engine
    247
  - Removing EIM from the Engine
    247
  - 24H Hotline
    253
  - Local Support
    253
  - MTU Contact Persons/Service Partners
    253
- 8 Appendix B
  
  254
  - Barring Device
    254
  - Box Wrench Socket, 24 MM
    254
  - Feeler Gauge
    254
  - Special Tools
    254
  - Filter Wrench
    255
  - Installation/Removal Jig
    255
  - Milling Cutter
    255
  - Ratchet
    256
  - Ratchet Adapter
    256
  - Ratchet with Extension
    256
  - Rigid Endoscope
    257
  - Steam Jet Cleaner
    257
  - Torque Wrench, 0.5-5 Nm
    257
  - Torque Wrench, 10-60 Nm
    257
  - Torque Wrench, 40-200 Nm
    258
  - Torque Wrench, 6-50 Nm
    258
  - Index
    259

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