MTU 8V4000M53, 8V4000M53R, 8V4000M63 Operating Instructions Manual

Operating Instructions

Diesel engine

8V4000Mx3x

MS15034/00E

Engine model

8V4000M53

8V4000M63

8V4000M53R

Table 1: Applicability kW/cyl.

115 kW/cyl.

125 kW/cyl.

93 kW/cyl.

rpm

1800

1800

1600

Application group

1A, continuous operation, unrestricted



© 2018 Copyright MTU Friedrichshafen GmbH

This publication is protected by copyright and may not be used in any way, whether in whole or in part, without the prior written consent of MTU Friedrichshafen GmbH. This particularly applies to its reproduction, distribution, editing, translation, microfilming and storage or processing in electronic systems including databases and online services.

All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen GmbH reserves the right to change, delete or supplement the information provided as and when required.

Table of Contents

1 Safety

1.1 Important provisions for all products

1.2 Correct use of all products

1.3 Personnel and organizational requirements

1.4 Initial start-up and operation – Safety regulations

1.5 Assembly, maintenance, and repair work –

Safety regulations

1.6 Fire and environmental protection, fluids and lubricants

1.7 Standards for warning notices in the text and highlighted information

2 Transport

2.1 Transport

2.2 Lifting requirements

3 General Information

3.1 Engine layout

3.2 Product description

3.3 Tightening specifications for screws, nuts and bolts

3.4 Engine side and cylinder designations

3.5 Sensors and actuators – Overview

4 Technical Data

4.1 ENGINE DATA 8V4000M53R (provisional)

4.2 Product data 8V4000M53


4.4 Firing order

4.5 Engine – Main dimensions

18

19

5 Operation

5.1 Controls

5.2 Putting the engine into operation after

79

extended out-of-service periods (>3 months) 80

5.3 Putting the engine into operation after scheduled out-of-service-period

5.4 Re-starting the engine following an

81

automatic safety shutdown

5.5 Starting the engine

5.6 Operational checks

5.7 Tasks after extended out-of-service periods

(>3 weeks)

5.8 Checks prior to start-up

5.9 Fuel treatment system – Initial start-up

82

83

84

85

86

87

63

67

72

77

78

21

25

39

52

53

9

11

5

7

8

15

17

5.10 Fuel treatment system – Switching on

5.11 Fuel treatment system – Shutdown

5.12 Stopping the engine

5.13 Emergency engine stop

5.14 After shutdown

5.15 Plant – Cleaning

6 Maintenance

6.1 Maintenance task reference table [QL1] for

EPA regions

6.2 Maintenance task reference table [QL1] for

Non EPA regions

7 Troubleshooting

7.1 Troubleshooting

7.2 Control cabinet of fuel treatment system –

Troubleshooting

7.3 Engine governor ADEC (ECU 7) fault messages for Series 4000 engines, marine application

7.4 ADEC engine governor – Fault codes

100

103

104

105

8 Task Description

8.1 SOLAS

8.1.1 SOLAS shielding as per MTN 5233 –

Installation

8.1.2 SOLAS shielding – Installation

8.1.3 Installation locations for SOLAS shielding

8.1.4 Adhesive tape for SOLAS shielding –

Application

8.2 Engine

8.2.1 Engine – Barring manually

8.2.2 Barring engine with starting system

8.3 Cylinder Liner

8.3.1 Cylinder liner – Endoscopic examination

8.3.2 Cylinder liner – Instructions and comments on endoscopic and visual examination

8.4 Crankcase Breather

8.4.1 Crankcase breather – Oil mist fine separator replacement

8.5 Valve Drive

8.5.1 Valve gear – Lubrication

8.5.2 Valve clearance – Check and adjustment

8.5.3 Cylinder head cover – Removal and installation


131

131

132

133

140

141

141

143

144

144

146

148

148

149

149

150

153

154

96

98

90

91

92

93

94

95

MS15034/00E 2018-08 | Table of Contents | 3

8.6 Injection Pump / HP Pump

8.6.1 HP fuel pump – Filling with engine oil

8.6.2 HP fuel pump – Relief bore check

8.7 Injection Valve / Injector

8.7.1 Injector – Replacement

8.7.2 Injector – Removal and installation (jacketed fuel system)

8.8 Fuel Filter

8.8.1 Additional fuel filter – Overview

8.8.2 Additional fuel filter – Replacement

8.8.3 Fuel filter – Replacement

8.8.4 Fuel prefilter – Differential pressure gage check and adjustment

8.8.5 Fuel prefilter – Draining

8.8.6 Fuel prefilter – Flushing

8.8.7 Fuel prefilter with water separator – Filter element replacement

8.8.8 Fuel prefilter with water separator – O-ring replacement in rotary slide valve

8.9 Exhaust Turbocharger

8.9.1 Compressor wheel – Cleaning

8.10 Charge-Air Cooling

8.10.1 Intercooler – Check water drain for coolant leakage and obstruction

8.11 Air Filter

8.11.1 Air filter – Replacement

8.11.2 Air filter – Removal and installation

8.12 Air Intake

8.12.1 Contamination indicator – Signal ring position check

8.13 Starting Equipment

8.13.1 Starter – Condition check

8.14 Lube Oil System, Lube Oil Circuit

8.14.1 Engine oil level – Check

8.14.2 Engine oil – Change

8.14.3 Engine oil – Sample extraction and analysis

8.15 Oil Filtration / Cooling

8.15.1 Engine oil filter – Replacement

8.15.2 Oil indicator filter – Cleaning and check

8.15.3 Centrifugal oil filter – Cleaning and filter sleeve replacement

8.16 Coolant Circuit, General, High-Temperature

Circuit

8.16.1 Drain and vent points

8.16.2 Engine coolant level – Check

8.16.3 Engine coolant – Change

8.16.4 Engine coolant – Draining

8.16.5 Engine coolant, filling

8.16.6 HT coolant pump – Relief bore check

8.16.7 Engine coolant – Sample extraction and analysis

155

155

157

158

158

159

166

166

167

168

170

171

173

175

178

179

179

184

184

185

185

186

187

187

188

188

189

189

190

192

194

194

196

199

202

202

205

206

207

208

210

211

8.16.8 Engine coolant filter – Replacement 212

8.16.9 Preheater – Function and leak-tightness check 213

8.16.10 Preheating unit

8.16.11 Preheater – Overhaul

214

217

8.17 Raw Water Pump with Connections

8.17.1 Raw water pump – Relief bore check

8.18 Battery-Charging Generator

8.18.1 Battery-charging generator drive – Coupling condition check

218

218

219

219

8.19 Engine Mounting / Support 220

8.19.1 Engine mounting – Checking resilient element 220

8.20 Auxiliary PTO

8.20.1 Bilge pump – Relief bore check

8.21 Fuel Supply System

8.21.1 Water drain valve – Check

8.21.2 Differential pressure gage – Alarm function check

8.21.3 Water level probe (3-in-1 rod electrode) –

Check

8.21.4 Pump capacity – Check

8.21.5 Coalescer filter element ‒ Replacement

223

224

225

226

8.22 Wiring (General) for Engine/Gearbox/Unit 228

8.22.1 Engine wiring harness and mounts – Overview 228

8.22.2 Engine cabling – Check 234

221

221

222

222

8.23 Accessories for (Electronic) Engine

Governor / Control System

8.23.1 Limit switch for start interlock – Check

8.23.2 Engine Control Unit ECU 7 – Checking plug connections

8.23.3 Engine Monitoring Unit EMU 7 – Plug connection check

8.23.4 Interface module EIM plug connections –

Check

8.23.5 Engine governor ECU 7 – Removal and installation

8.23.6 Engine Interface Module EIM 2 – Removal and installation

8.23.7 Engine Interface Module EIM 2 – Diagnostic features

8.23.8 EMU 7 – Removal and installation

8.23.9 CDC parameters – Reset

235

235

236

237

238

239

240

241

244

245

9 Appendix A

9.1 List of abbreviations

9.2 MTU Contact/Service Partners

10 Appendix B

10.1 Special Tools

10.2 Index

246

248

249

256

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1 Safety

1.1 Important provisions for all products

General

This product may pose a risk of injury or damage in the following cases:

• Incorrect use

• Operation, maintenance and repair by unqualified personnel

• Changes or modifications which are neither made nor authorized by the manufacturer

• Noncompliance with the safety instructions and warning notices

Nameplates

The product is identified by nameplate, model designation or serial number. This data must match the specifications in these instructions.

Nameplates, model designation or serial number can be found on the product.

All EU-certified engines delivered by MTU come with a second nameplate. This second nameplate is delivered "loosely" with the engine. If the nameplate secured to the engine after installation in the vehicle/system is not visible without the removal of components, the system integrator must install the second nameplate in a clearly visible area on the vehicle/system.

Emission specifications and emission label

Responsibility for compliance with emission regulations

Modification or removal of any mechanical/electronic components or the installation of additional components including the execution of calibration processes that might affect the emission characteristics of the product are prohibited by emission regulations. Emission-related components must only be serviced, exchanged or repaired if the components used for this purpose are approved by the manufacturer.

Noncompliance with these specifications will invalidate the design type approval or certification issued by the emissions regulation authorities. The manufacturer does not accept any liability for violations of the emission regulations.

The product must be operated over its entire life cycle according to the conditions defined as "Intended use"

(→ Page 7).

Emission certification applicable to engines with EPA Nonroad Tier 4 emission certification in accordance with 40 CFR 1039

Extract from the standard:

Failing to follow these instructions when installing a certified engine in a piece of nonroad equipment violates federal law (40 CFR 1068.105(b)), subject to fines or other penalties as described in the Clean Air Act.

Extract from the standard:

If you install the engine in a way that makes the engine's emission control information label hard to read during normal engine maintenance, you must place a duplicate label on the equipment, as described in 40

CFR 1068.105.

When fitting the second label, the requirements of 40 CFR 1068.105(c) must be followed and observed. This paragraph describes the process for requesting and fitting the label, the documentation obligations and storage obligations for the required documents.

MS15034/00E 2018-08 | Safety | 5

Replacing components with emission labels

On all MTU engines fitted with emission labels, these labels must remain on the engine throughout its operational life.

Exception: Engines used exclusively in land-based, military applications other than by US government agencies.

Please note the following when replacing components with emission labels:

• The relevant emission labels must be affixed to the spare part.

• Emission labels shall not be transferred from the replaced part to the spare part.

• The emission labels must be removed from the replaced part and destroyed.

6 | Safety | MS15034/00E 2018-08

1.2 Correct use of all products

Correct use

The product is intended for use in accordance with its contractually-defined purpose as described in the relevant technical documents only.

Intended use entails operation:

• Within the permissible operating parameters in accordance with the (→ Technical data)

• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubricants

Specifications of the manufacturer)

• With preservation approved by the manufacturer in accordance with the (→ Preservation and Represervation Specifications of the manufacturer)

• With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU contact/Service partner)

• In the original as-delivered configuration or in a configuration approved by the manufacturer in writing (also applies to engine control/parameters)

• In compliance with all safety regulations and in adherence with all warning notices in this manual

• In compliance with the maintenance work and intervals specified in the (→ Maintenance Schedule) throughout the useful life of the product

• In compliance with the maintenance and repair instructions contained in this manual, in particular with regard to the specified tightening torques

• With the exclusive use of technical personnel trained in commissioning, operation, maintenance and repair

The product must not be operated in explosive atmospheres unless the engine fulfills the conditions for such use and approval has been granted.

Any other use, particularly misuse, is considered as being contrary to the intended purpose. Such improper use increases the risk of injury and damage when working with the product. The manufacturer shall not be held liable for any damage resulting from improper, non-intended use.

The specifications of the manufacturer will be amended or supplemented as necessary. Prior to operation, make sure that the latest version is used. The latest version can be found on the websites:

• For drive systems: http://www.mtu-online.com

• For power generation: http://www.mtuonsiteenergy.com

Modifications or conversions

Unauthorized changes to the product represent a contravention of its intended use and compromise safety.

Changes or modifications shall only be considered to comply with the intended use when expressly authorized by the manufacturer. The manufacturer shall not be held liable for any damage resulting from unauthorized changes or modifications.

MS15034/00E 2018-08 | Safety | 7

1.3 Personnel and organizational requirements

Organizational measures of the user/manufacturer

This manual must be issued to all personnel involved in operation, maintenance, repair, assembly, installation, or transportation.

Keep this manual handy in the vicinity of the product such that it is accessible to operating, maintenance, repair, assembly, installation, and transport personnel at all times.

Personnel must receive instruction on product handling and repair based on this manual. In particular, personnel must have read and understood the safety requirements and warnings before starting work.

This is important in the case of personnel who only occasionally perform work on or around the product.

Such personnel must be instructed repeatedly.

Personnel requirements

All work on the product must be carried out by trained, instructed and qualified personnel only:

• Training at the Training Center of the manufacturer

• Qualified personnel from the areas mechanical engineering, plant construction, and electrical engineering and also for work with live parts

The operator must define the responsibilities of the personnel involved in operation, maintenance, repair, assembly, installation, and transport in writing.

Personnel shall not report for duty under the influence of alcohol, drugs or strong medication.

Clothing and personal protective equipment

Always wear appropriate personal protective equipment, e.g. safety shoes, ear protectors, protective gloves, goggles, breathing mask. Follow the instructions concerning personal protective equipment in the descriptions of the individual activities.

Safe handling of Substances of Very High Concern pursuant to the REACH regulation (Registration, Evaluation, Authorization and restriction of Chemicals): We recommend wearing protective gloves at all times in order to reduce risk when working.

8 | Safety | MS15034/00E 2018-08

1.4 Initial start-up and operation – Safety regulations

Safety regulations for initial start-up

Install the product correctly and carry out acceptance in accordance with the manufacturer's specifications before putting the product into service. All necessary approvals must be granted by the relevant authorities and all requirements for initial startup must be fulfilled.

Whenever the product is subsequently taken into operation ensure that:

• All personnel is clear of the danger zone surrounding moving parts of the machine.

Electrically-actuated linkages may be set in motion when the Engine Control Unit (governor) is switched on.

• All maintenance and repair work has been completed.

• All loose parts have been removed from rotating machine components.

• All safeguards are in place.

• All components must be properly grounded. Ground separately by means of a grounding stake as necessary.

• No persons wearing pacemakers or any other technical body aids are present.

• The service room is adequately ventilated.

• In the first few hours of operation, the product emits gases as a result of smoldering e.g. lacquers or oil.

These gases may be hazardous to health. Always wear respiratory protection in the operating room during this period.

• The exhaust system is leak-tight and that the gases are vented to atmosphere.

• The product must be free of any damage, this applies in particular to lines and cabling.

• Protect battery terminals, generator terminals or cables against accidental contact.

• Check that all connections have been correctly allocated e.g. +/- polarity, fuel line/reduction agent line, supply/return.

Immediately after putting the product into operation, make sure that all control and display instruments as well as the monitoring, signaling and alarm systems work properly.

Smoking is prohibited in the area of the product.

Safety regulations during operation

The operator must be familiar with the control and display elements.

The operator must be familiar with the consequences of any operations performed.

During operation, the display instruments and monitoring units must be permanently observed with regard to present operating status, violation of limit values and warning or alarm messages.

Malfunctions and emergency stop

Practice emergency procedures, especially emergency stopping, at regular intervals.

Take the following steps if any system malfunctions are detected or signaled by the system:

• Inform supervisor(s) in charge.

• Analyze the message.

• Respond by taking any necessary emergency action, e.g. emergency stop.

After a safety shutdown, the engine must only be started after the cause of the shutdown has been eliminated.

Contact Service if the root cause of the malfunction cannot be clearly identified.

Operation

Do not remain in the operating room when the product is running unless absolutely necessary. Keep your stay as short as possible.

Keep a safe distance away from the product if possible. Do not touch the product unless expressly instructed to do so following a written procedure.

MS15034/00E 2018-08 | Safety | 9

Do not inhale the exhaust gases of the product.

The following requirements must be fulfilled before the product is started:

• Wear ear protectors.

• Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binding agent.

Operation of electrical equipment

When electrical equipment is in operation, certain components of these appliances are electrically live.

Follow the applicable operating and safety instructions when operating the devices and heed warnings at all times.

10 | Safety | MS15034/00E 2018-08

1.5 Assembly, maintenance, and repair work – Safety regulations

Safety regulations for work prior to assembly, maintenance, and repair

Have assembly, maintenance, or repair work carried out by qualified and authorized personnel only.

Allow the product to cool down to less than 50 °C (risk of explosion from oil vapors, fluids and lubricants, risk of burning).

Relieve pressure in fluid and lubricant systems and compressed-air lines which are to be opened. Use suitable containers of adequate capacity to catch fluids and lubricants.

Release residual pressure before removing or replacing a component in the supply line. To depressurize pressurized lines, shut off the lines first, then release the residual pressure.

Work must only be carried out on lines when they are free of fluids and lubricants.

When changing the oil or working on the fuel system, ensure that the service room is adequately ventilated.

Never carry out assembly, maintenance, or repair work with the product in operation, unless:

• It is expressly permitted to do so following a written procedure.

Lock-out the product to preclude undesired starting, e.g.

• Start interlock

• Key switch

• Close supply line for hydraulic starting.

Attach “Do not operate” sign in the operating area or to control equipment.

Disconnect the battery cables or actuate the battery isolating switch, if fitted. Lock circuit breakers.

Before starting work on CaPoS, if used:

• Switch off the charging system (DC/DC converter).

• Discharge the UltraCap modules using the appropriate discharger.

• Short-circuit the UltraCap modules with a suitable wire jumper.

Close the main valve on the compressed-air system and vent the compressed-air line when air starters are fitted.

Before working on the exhaust gas aftertreatment system, close the shutoff valve on the reducing agent tank. Note that the reducing agent pumps continue to run for a certain period when the engine is stopped.

Disconnect the control equipment from the product.

Use the recommended special tools or suitable equivalents when instructed to do so.

Safety regulations when performing assembly, maintenance, and repair work

Special tools and lifting equipment

Use only proper and calibrated tools. Observe the specified tightening torques during assembly or disassembly.

Setting down, lifting and climbing

Carry out work only on assemblies or plants which are properly secured.

Use appropriate lifting equipment for all components. Use all specified attachment points and observe the center of gravity.

Never work on engines or components when they are held in place by lifting equipment.

Make sure components or assemblies are placed on stable surfaces. Adopt suitable measures to prevent components/tools from falling down.

Assume a safe standing position when performing assembly work.

Never use the product as a climbing aid.

MS15034/00E 2018-08 | Safety | 11

When working high on the equipment, always use suitable ladders and work platforms. Special instructions for outdoor areas: There must be no risk of slipping e.g. due to icing.

Removing, installing and cleanliness

Pay particular attention to cleanliness at all times.

Completely wipe up escaped fluids and lubricants due to the risk of slipping.

Take special care when removing ventilation or plug screws from the product.

Ensure that O-rings are not installed in a slanted/twisted condition.

Carry out appropriate cleaning procedures to clean and inspect components requiring special cleanness

(e.g. components carrying oil, fuel, or air).

Note cooling time for components which are heated for installation or removal (risk of burning).

Ensure that all mounts and dampers are installed correctly.

Remove any accumulation of condensate after assembling chilled components. Coat the components with a suitable corrosion inhibitor as necessary.

Lines

Ensure that lines for all fluids and lubricants and their connections are clean.

Always seal connections with caps or covers if a line is removed or opened.

Fit new seals when re-installing lines.

Never bend lines and avoid damaging lines, particularly the fuel lines.

Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent contact with other components. Do not place fuel or oil lines near hot components.

Miscellaneous

Sufficient ventilation must be guaranteed during the work.

Wear a breathing mask offering protection against soot, dust, and mineral fibers (filter class P3) when working on exhaust components. Clean the work area with a dust extraction machine of class H. Wear protective gloves and goggles for protection against acidic condensate.

Do not touch elastomeric seals (e.g. Viton sealing rings) with your bare hands if they have a carbonized or resinous appearance.

Elastomer components (e.g. engine mounts, damping elements, couplings and V-belts) must not be painted.

Only install them after painting the engine or mask them prior to painting.

The following applies to starters with copper-beryllium alloy pinions:

• Wear a respirator mask (filter class P3). Do not blow out the interior of the flywheel housing or the starter with compressed air. Clean the flywheel housing inside with a class H dust extraction device.

• Observe the safety data sheet.

Safety regulations after performing assembly, maintenance, and repair work

Before barring the engine, make sure no one is in the danger zone of the engine.

Check that all access ports/apertures which have been opened to facilitate working are closed again.

Check that all safeguards have been installed and that all tools and loose parts have been removed (especially the barring tool).

Ensure that no unattached parts have been left in/on the product (e.g. including rags and cable straps).

Ensure that the grounding system is properly connected.

12 | Safety | MS15034/00E 2018-08

Welding work

Welding operations on the product or mounted units are not permitted. Cover the product when welding in its vicinity.

Before starting welding work:

• Switch off the power supply master switch.

• Disconnect the battery cables or actuate the battery isolating switch.

• Separate the electrical ground of electronic equipment from the ground of the unit.

No other assembly, maintenance, or repair work must be carried out in the vicinity of the product while welding is in progress. There is a risk of explosion or fire due to oil vapors or highly flammable fluids and lubricants.

Do not use product as ground terminal.

Never position the welding power supply cable adjacent to, or crossing wiring harnesses of the product. The welding current can induce interfering voltages in the wiring harnesses which may damage the electrical system.

Remove components (e.g. exhaust pipe) from the product before performing necessary welding work.

Hydraulic installation and removal

Check the function and safe operating condition of tools and fixtures to be used. Use only the specified devices for hydraulic removal/installation procedures.

Observe the max. permissible push-on pressure specified for the equipment.

Do not attempt to bend or apply force to lines which are under pressure.

Before starting work, pay attention to the following:

• Vent the installation/removal jig, the pumps and the pipework at the relevant designated points.

• For hydraulic installation, screw on the jig with the piston retracted.

• For hydraulic removal, screw on the jig with the piston extended.

For a hydraulic installation/removal jig with central expansion pressure supply, screw spindle into shaft end until correct sealing is established.

During hydraulic installation and removal of components, ensure that nobody is standing in the immediate vicinity of the component to be installed/removed.

Working with batteries

Observe the safety instructions of the manufacturer when working on batteries.

Gases released from the battery are explosive. Avoid sparks and naked flames.

Do not allow battery acids to come into contact with skin or clothing.

Wear protective clothing, goggles and protective gloves.

Do not place objects on the battery.

Before connecting the cable to the battery, check the battery polarity. The battery may explode and spray acid if the battery terminals are connected incorrectly.

Working on electrical and electronic assemblies

Always obtain the permission of the person in charge before commencing assembly, maintenance, and repair work or switching off any part of the electronic system required to do so.

De-energize the relevant areas prior to working on assemblies.

ESD (Electrostatic Discharge): Work on components which could be damaged by electrostatic discharge must always be carried out with appropriate equipment. Appropriate equipment is e.g. electrically conductive work surfaces or antistatic wristbands.

MS15034/00E 2018-08 | Safety | 13

Do not damage wiring during removal work. When reconnecting, ensure that cabling cannot be damaged during operation by:

• Contact with sharp edges

• Chafing on components

• Contact with hot surfaces.

Do not secure cables on lines carrying fluids.

Do not use cable ties to secure lines.

Always use connector pliers to tighten union nuts on connectors.

Subject the device as well as the product to functional testing on completion of all repair work. The emergency stop function must be tested in particular. The functional check of the emergency stop, during which the voltage supply of the ECU is switched off, must only be carried out when the product is cold.

Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Package faulty electronic components or assemblies properly before dispatching for repair:

• Moisture-proof

• Shock-proof

• Wrapped in antistatic foil (as necessary)

Working with laser equipment

Work with laser devices shall be carried out by trained and qualified personnel only. Follow the safety instructions in the manufacturer's user manual when working with laser equipment.

Wear special laser safety glasses when working with laser equipment (danger of concentrated radiation).

Laser equipment must be fitted with the protective devices necessary for safe operation according to type and application.

Measuring component dimensions

Workpieces, components and measuring equipment lie in the specified tolerance range at a reference temperature of 20 °C.

14 | Safety | MS15034/00E 2018-08

1.6 Fire and environmental protection, fluids and lubricants

Fire prevention and fire

Fire, naked light and smoking are prohibited.

In case of a fire, stop the fuel supply if this is possible without endangering personnel.

The product has hot surfaces that can ignite combustible gases and other substances in the immediate area.

The operating company must install and operate the product a safe distance away from danger sources and observe any relevant safety regulations or recommendations. Products that comply with the SOLAS Convention do not constitute such as danger.

After working with combustible fluids and lubricants (e.g. cleaning agents), ensure the area is well ventilated.

The resultant steam/air mixture must be sufficiently diluted to prevent a potentially explosive atmosphere.

Eliminate leaks of fluids and lubricants immediately. Fluids and lubricants on hot components can cause fires, so keep the product clean at all times. Do not leave rags saturated with fluids and lubricants on the product. Do not store combustible materials near the product.

Incorrect refueling of the reducing agent system with fuel can result in fire.

Before welding, clean the area to be welded with a nonflammable fluid. Do not carry out welding work on pipes and components carrying oil or fuel.

When starting the engine with an external power source, connect the ground lead last and remove it first. To avoid sparks in the vicinity of the battery, connect the ground cable from the external power source to the ground cable of the engine or to the ground terminal of the starter.

Ensure that suitable extinguishing agents (fire extinguishers) are always available and that staff are familiar with their correct handling.

A fire can result in the creation of toxic substances. Always wear protective gloves when handling components and wear additional personal protective equipment is necessary.

Noise

Wear ear protectors in workplaces with a sound pressure level in excess of 85 dB (A).

Noise can lead to an increased risk of accidents if acoustic signals, warning shouts or sounds indicating danger are compromised.

Environmental protection and disposal

Dispose of used fluids, lubricants and components in accordance with local regulations.

Within the EU, batteries can be returned free of charge to the manufacturer where they will be properly recycled.

Fluids and lubricants/auxiliary materials (process materials)

Process materials can also be or contain hazardous or toxic substances. When using process materials and other chemical substances, observe the associated safety data sheet. The safety data sheet may be obtained from the relevant manufacturer or from MTU.

Only process materials approved by the manufacturer in accordance with the Fluids and Lubricants Specifications must be used. The most recent respective version must be requested from the manufacturer.

Contamination of process materials with reducing agent (e.g. AdBlue ® , DEF): Store process materials in separate containers and their own drip trays. Even extremely small amounts of reducing agent contamination can result in malfunctions in sensors and other components.

Used oil contains combustion residues that are harmful to health.

When handling used oil, protective gloves must be used.

Wash relevant areas after contact with used oil.

MS15034/00E 2018-08 | Safety | 15

Registration, evaluation, approval and restriction of chemicals (REACH ordinance)

Particularly hazardous substances used with our products are named in a list: www.mtu-online.com/mtu/technische-info → SVHC as per REACH in MTU products

Compressed air

• Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII and B) out of containers, risks causing an explosion.

• Wear goggles when blowing dirt off workpieces or blowing away chips.

• Blowing compressed air into thin-walled containers (e.g. containers made of sheet metal, plastic or glass) for drying purposes or to check for leaks risks bursting them.

• Pay special attention to the pressure in the compressed air system or pressure vessel.

• Assemblies or products which are to be connected must be designed to withstand this pressure. Install pressure-reducing or safety valves set to the admissible pressure if this is not the case.

• Hose couplings and connections must be securely attached.

• Provide the snout of the air nozzle with a protective disk (e.g. rubber disk).

• Release residual pressure before removing a compressed air device from the supply line. To depressurize compressed-air lines, shut off the lines first, then release the residual pressure.

• Carry out a leak test in the specified manner.

Painting

• Observe the relevant safety data sheet for all materials.

• When carrying out painting work outside the spray stands provided with fume extraction systems, ensure that the area is well ventilated. Make sure that neighboring work areas are not adversely affected.

• Avoid open flames in the surrounding area.

• No smoking.

• Observe fire-prevention regulations.

• Always wear a mask providing protection against paint and solvent vapors.

Liquid nitrogen


• Work with liquid nitrogen may be carried out only by qualified personnel.

• Store liquid nitrogen only in small quantities and always in specified containers without fixed covers.

• Avoid body contact (eyes, hands).

• Wear protective clothing, protective gloves, closed shoes and safety goggles.

• Make sure that the working area is well ventilated.

• Avoid knocking or jolting the containers, valves and fittings or workpieces in any way.

Acids/alkalines/reducing agents (e.g. AdBlue

®

, DEF)


• When working with acids and alkaline solutions, wear goggles or face mask, gloves and protective clothing.

• Do not inhale vapors.

• If reducing agent is swallowed, rinse out mouth and drink plenty of water.

• Remove any wet clothing immediately.

• After skin contact, wash affected body areas with plenty of water.

• Rinse eyes immediately with eyedrops or clean mains water. Consult a doctor as soon as possible.

Contamination of reducing agent with other process materials: Store reducing agent in separate containers and use separate drip trays. Even extremely slight contamination can lead to malfunctions in the exhaust aftertreatment system.

Mistakenly filling the tank of the reducing agent system with fuel can cause leakage at the seals and in the hoses.

16 | Safety | MS15034/00E 2018-08

1.7 Standards for warning notices in the text and highlighted information

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!


CAUTION

In the event of a situation involving potential danger.

Consequences: Minor or moderate injuries!


NOTICE

In the event of a situation involving potentially adverse effects on the product.

Consequences: Material damage!


• Additional product information.

Warning notices

1.

This manual with all safety instructions and warning notices must be issued to all personnel involved in operation, maintenance, repair, assembly, installation, or transportation.

2.

The highest level warning notice is used if several hazards apply at the same time. Warnings related to personal injury shall be considered to include a warning of potential damage.

Highlighted information

Important

This field contains product information which is important or useful for the user.

This information must not refer to hazards related to personal injury or material damage.

MS15034/00E 2018-08 | Safety | 17

2 Transport

2.1 Transport

Transport

Attach the engine at the lifting eyes provided only.

The lifting eyes are designed for engine transport only, not for the transport of propulsion units (engine and gearbox).

Use only the transport and lifting gear approved by MTU.

The engine must only be transported in installation position, max. permissible diagonal pull 10°.

Take note of the engine center of gravity.

In the case of special packaging with aluminum foil, suspend the engine on the lifting eyes of the transport pallet or transport with equipment for heavy loads (forklift truck).

Prior to transporting the engine, it is imperative to install transportation locking devices for crankshaft and engine mounts.

Secure the engine against tilting during transportation. The engine must be especially secured against slipping or tilting when going up or down inclines and ramps.

Setting the engine down after 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.

18 | Transport | MS15034/00E 2018-08

2.2 Lifting requirements

DANGER

Suspended load.

Danger to life!

• Use suitable equipment and lifting devices.

• Never stand beneath a suspended load and keep a safe distance.

• Wear personal protective equipment (e.g. protective helmet, safety shoes).

Lifting requirements for installed heat exchanger

1 Maximum permissible diagonal pull 10° (*)

2 Center of gravity

(*) Max. permissible diagonal pull must be observed:

• Max. permissible diagonal pull in longitudinal direction is 10 degrees; simultaneous diagonal pull in transverse direction is impermissible.

• Max. permissible diagonal pull in transverse direction is 10 degrees; simultaneous diagonal pull in longitudinal direction is impermissible.

MS15034/00E 2018-08 | Transport | 19

Lifting requirements for remote heat exchanger

1 Maximum permissible diagonal pull 10° (*)

2 Center of gravity

(*) Max. permissible diagonal pull must be observed:

• Max. permissible diagonal pull in longitudinal direction is 10 degrees; simultaneous diagonal pull in transverse direction is impermissible.

• Max. permissible diagonal pull in transverse direction is 10 degrees; simultaneous diagonal pull in longitudinal direction is impermissible.

Take note of the engine center of gravity

Refer to the installation/arrangement drawings for details of the center of gravity of the system or engine.

20 | Transport | MS15034/00E 2018-08

3 General Information

3.1 Engine layout

Overview with remote heat exchanger, free end

1 Centrifugal oil filter

2 Dry-type air filter

3 Exhaust manifold

4 Cylinder head

5 Fuel filter

6 Oil filter

7 Battery-charging generator

(option)

8 HP fuel pump

9 Bilge pump (option)

10 Raw water pump (option for engines with remote heat exchanger)

11 Engine management and monitoring

KGS Free end

MS15034/00E 2018-08 | General Information | 21

Overview with remote heat exchanger, driving end

1 Exhaust outlet

2 Recirculation line

3 Crankcase breather coolant expansion tank

4 Oil cooler

5 Coolant pump

6 Engine mounting

7 Oil filler neck

8 Oil pan

9 Crankcase

10 Charge-air line

11 Compressor housing

12 Charge-air cooler

13 Exhaust turbocharger carrier housing

14 Air pipe to charge-air cooler

KS Driving end

22 | General Information | MS15034/00E 2018-08

Overview with engine-mounted heat exchanger, free end

1 Raw-water outlet

2 Coolant expansion tank

3 Centrifugal oil filter

4 Dry-type air filter

5 Exhaust manifold

6 Cylinder head

7 Fuel filter

8 Oil filter

9 Battery-charging generator

(option)

10 HP fuel pump

11 Raw water pump

12 Heat exchanger

13 Engine management and monitoring

KGS Free end


Overview with engine-mounted heat exchanger, driving end

1 Exhaust outlet

2 Crankcase breather

3 Oil cooler

4 Coolant pump

5 Engine mounting

6 Oil filler neck

7 Oil pan

8 Crankcase

9 Charge-air line

10 Compressor housing

11 Charge-air cooler

12 Air pipe to charge-air cooler

13 Exhaust turbocharger carrier housing

KS Driving end

Engine model designation

x y z

Key to engine model designation 8V 4000 Mxyz

8 Number of cylinders

V Cylinder arrangement: V-engine

4000

M

Series

Application (M= Marine)

Application load profile (0, 1, 2, 3...9)

Design status (0, 1, 2, 3...9)

R (reduced power/speed)

L (enhanced power/speed)

S (60 Hz)

F (50 Hz)


3.2 Product description

Engine description

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.

The electronic control unit controls

• Injection start

• Injection quantity

• Injection pressure

Exhaust system

The exhaust system is equipped with triple-walled, water-cooled exhaust lines.

The triple-walled design offers

• low surface temperature,

• reduced amount of heat to be dissipated by the coolant,

• absolute gas-tightness.

Turbocharging system

Sequential turbocharging with internal, engine-coolant-controlled charge air cooling. The left-hand exhaust turbocharger is cut-in and cut-out with electronically controlled, hydraulically actuated flaps.

Cooling system

Split-circuit engine cooling system with remote or engine-mounted heat exchanger.

Heating of the charge-air in idle and low-load operation prevents white smoke formation.

Seawater only flows through engine coolant and fuel heat exchanger as well as the raw water pump (if applicable)..

Service block

The service components are mounted on the auxiliary PTO end.

The arrangement permits easy access for maintenance.

Service components:

• Raw water pump (if fitted), coolant pump

• Centrifugal lube oil filter

• Coolant expansion tank (only on engines with engine-mounted heat exchanger)

• Coolant filter

Intermittent oil priming for on-board power generating engines (M23-M43)

The engines are equipped with intermittent oil priming as standard.

Oil priming is activated every 30 minutes. The oil priming process ends as soon as oil pressure in the main oil gallery reaches 0.4 bar or after 180 seconds, at the latest.

If at least 0.2 bar has not been reached in 180 seconds, an alarm is issued.


To prevent engine damage through hydraulic impact due to excessive oiling of the combustion chamber, the engine must be started at least once a month as a countermeasure.

Electronic system

Electronic control and monitoring system with integrated safety and test system, providing interfaces to Remote Control System (RCS) and Monitoring and Control System (MCS).

Engine Interface Module (EIM)

The Engine Interface Module (EIM) is the central connection box on the engine. It covers the complete minimum scope of a marine engine. It does not have any controls or components requiring maintenance.

Functions:

• Starter control (start repetition, tooth alignment, starter protection)

• Battery-charging generator monitoring

• Open bus interface to the plant (SAE J1939)

• Emergency stop function with wire break monitoring

• Redundant power supply

• Optional control of emergency-air shutoff flaps

• Key switch logic

• 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. The first section is integrated in the engine cable harness via a

Tyco male connector X52, 62-pin. The second part refers to signals associated with higher currents. These signals are guided out via M-threaded pins and are also integrated in the engine wiring harness.

Functions

• Power supply of ECU

• Power supply of EMU

• Plant signals (ECU7 connector X1)

• Bus interface (2x MCS5 CAN)

• CAN dialog output (1xMCS5 CAN)

• Emergency stop from EMU and ECU

• Electric starter

• Terminal 45 starter A/B (engaged)

• Pneumatic starter

• Starting-air pressure valve

• Starting-air pressure sensor

• Barring gear (Barring Gear 1 and 2)

• Battery-charging generator (with exciter control)

• Optional emergency air-shutoff flaps

• Activation of emergency-air shutoff flaps 1+2

• Feedback from emergency-air shutoff flaps 1+2

Electronic engine governor (Engine Control Unit, ECU)

Functions:

• Engine speed control with fuel and speed limitation according to engine status and operating conditions

• Control of sequential turbocharging, cylinder bank cut-out and air recirculation function

• Data processing logistics for analog and binary signals

• Interface for data transfer to CAN field bus for remote control and ship-side monitoring


Electronic Engine Monitoring Unit (EMU)

Functions:

• Data processing logistics for analog and binary signals

• Interface for data transfer to CAN field bus for remote control and ship-side monitoring

Low-load operation

8V4000M53/M53R/M63 engines

1 Low-load operation 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.

Nevertheless, low-load operation at engine load below 15% of the nominal rating is permitted for max. 100 hours. In order to avoid inadmissible oil carbon and/or carbon particle deposits in the engine, it is recommended to carry out a cleaning cycle for at least 20 minutes after extended low-load operation periods. During the cleaning cycle, engine speed (power) must be increased step by step until all exhaust turbochargers are running. The figure shows the basic speed/power run-up procedure for the cleaning cycle to be carried out.


8V4000M23/M33/M43 engines

A Engine power B Engine speed ETC Exhaust turbocharger

MTU marine genset engine Series 4000M23/M33/M43 may be operated in low-load operation. State-of-theart design and equipment features e.g. TE coolant circuit, jacketed, coolant-cooled exhaust lines, Common

Rail fuel injection and cylinder cutout allow engine operation at low load.

Low-load operation (engine power up to approx. 20% of rated power) takes place in single-ETC mode (with only one exhaust turbocharger running). To ensure the functionality of the control mechanism and of the exhaust flap of the turbocharger which does not run in low-load operation, it is recommended to operate the engine with both exhaust turbochargers running after 100 operating hours in low-load operation, at the latest.

SOLAS – Fire protection specifications

Fuel system, fuel lines with fuel pressure >1.8 bar

All lines with SOLAS-compliant covers for pipe joints, according to MTU standard MTN5233, are shown.


1 Fuel line after LP pump

1 Fuel line to fuel filter head retainer


1 Fuel line from fuel filter head

1 Fuel line on HP pump


1 Fuel line on fuel filter head

1 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 joints, according to MTU standard MTN5233, are shown.


1 Oil supply to actuating cylinder and air flap - Turbocharger A1

1 Actuating cylinder of exhaust flap -

Turbocharger A1

2 Oil line to actuating cylinder of exhaust flap - Turbocharger A1

3 4/2-way valve

4 From distributor

5 Oil return from 4/2-way directional control valve

1 Oil return from 4/2-way directional control valve

2 Oil supply for 4/2-way directional control valve and exhaust turbocharger

3 Oil from main oil gallery

4 Oil return to crankcase

5 Air recirculation valve


Item

1

2

Type of shielding

Shields (A4)

Shields (A5) (2 x)

1 Oil supply for exhaust turbocharger

Comments

Exhaust turbocharger oil supply, A side

Exhaust turbocharger oil supply, A side


Item

1

Type of shielding

Shields (A6)

Comments

Oil supply to HP pump


1 Oil supply line of HP pump on equipment carrier

1 Oil supply on equipment carrier


1 Cover on oil filter cartridge

Special connections

The following types of connections are spray-proof in case of leakage even without covers and have been confirmed as being SOLAS-compliant by GL and DnV.


Plug-in pipe connection

The sleeve (4) covers the joint to prevent lateral spray.

Only leak-off along the line is possible, the pressure is decreased significantly if an O-ring (3) defect occurs.

The union is confirmed as being SOLAS-compliant by DnV and GL.

Plugs and sensors

Screwed-in plugs (2) are either sealed with copper sealing rings (1) as per DIN or O-rings (ISO).

The fluid must first pass the thread in case of a loose threaded union or faulty sealing ring (2).

The pressure is so greatly reduced by this and the faulty sealing ring (2) that any leakage is not under pressure.


High-pressure connections

1 Jacket pipe

2 HP line

3 O-ring

4 Union nut

5 Recess for O-ring

6 Thrust ring

7 Leakage overflow bore

8 Thrust ring

9 Union nut

10 Union nut

11 Connecting piece

12 Snap ring

13 Thrust ring

14 Compensating disks

The HP fuel line is sealed by the thrust ring (8).

15 Union nut

16 Thrust ring

17 Outer high-pressure line pipe

18 Internal pipe of HP line

19 Ball-type seal area

20 Leak fuel connection

In case of leakage around the thrust ring (8) or the HP line (5) fuel escapes into the leakage chamber.

The leaking fuel is drained off without pressure via the leakage overflow-bore (7). The leakage chamber is sealed toward the outside by the O-rings (3).

This prevents leakage egress.

The union is confirmed as being SOLAS-compliant by DnV and GL.


3.3 Tightening specifications for screws, nuts and bolts

Tightening torques for setscrew and connections as per MTN 5008 standard

This standard applies to setscrews not subject to dynamic loads and the associated nuts according to:

• MMN 384

• ISO 4762 (DIN 912)

• ISO 4014 (DIN 931-1)

• ISO 4017 (DIN 933)

• DIN EN ISO 8765 (EN 28765; DIN 960)

• DIN EN ISO 8676 (EN 28676; DIN 961)

• DIN 6912

This standard applies to studs not subject to dynamic loads and the associated nuts according to:

• DIN 833

• DIN 835

• DIN EN ISO 5395 (DIN 836)

• DIN 938

• DIN 939

This standard applies to screws with hexalobular heads according to:

• DIN 34800

• DIN 34801

The standard does not apply to heat-resistant screws in the hot component zone.

Tightening torques M

A

are specified for screws of strength class 8.8 (surface condition bare, phosphatized or galvanized) and 10.9 (surface condition bare or phosphatized).

The values in the table are based on a friction coefficient µtot = 0.125.

Threads and mating faces of screws and nuts must be coated with engine oil prior to assembly.

When hand-tightening (defined torque), an assembly tolerance of -5+15% of the figures in the table is permitted.

When machine-tightening, the permissible assembly tolerance is ±15%.

M6

M8

M8 x 1

M10

M10 x 1.25

M12

M12 x 1.25

M12 x 1.5

M14

M14 x 1.5

M16

M16 x 1.5

M18

M18 x 1.5

M20

Tightening torques for setscrews

Thread

Hand-tightening

8.8 M

A

(Nm) 10.9 M

A

(Nm)

9

21

23

42

12

31

32

60

115

125

180

190

45

74

80

76

250

280

350

350

400

500

160

180

250

270

63

100

110

105

Machine-tightening

8.8 M

A

(Nm) 10.9 M

A

(Nm)

8

20

21

40

11

28

30

57

110

120

170

180

42

70

75

72

240

270

330

330

380

475

150

170

235

255

60

92

105

100


Thread

M20 x 1.5

M22

M22 x 1.5

M24

M24 x 1.5

M24 x 2

M27

M27 x 2

M30

M30 x 2

M

A

= tightening torques

Tightening torques for studs

Hand-tightening

8.8 M

A

(Nm) 10.9 M

A

(Nm)

390

480

520

600

550

680

730

850

680

660

900

960

1200

1350

950

900

1250

1350

1700

1900

Thread

M6

M8

M10

M12

M14

M16

M

A


Steel M

A

(Nm)

9

11

17

27

37

55 screwed into

Gray cast iron M

A

(Nm)

6

9

13

23

33

45

8.8 M

Machine-tightening

A

(Nm) 10.9 M

A

(Nm)

350

450

490

570

520

650

700

810

640

620

850

900

1100

1250

900

850

1175

1275

1600

1800

AI alloy M

A

(Nm)

6

10

13

18

33

–

Tightening torques for setscrews and nuts made of stainless steel

The values in the table are based on a friction coefficient µtot = 0.12, lubricated with Molykote on the thread and under the screw head.

Strength class

Basic size

M5

M6

M8

M10

M12

M16

M20

M

A


70

M

A

(Nm)

3.7

6.4

15.3

31

52

126

254

80

M

A

(Nm)

4.9

8.5

20.4

41

70

167

326

Material

A2 / A4

A2 / A4

A2 / A4

A2 / A4

A2 / A4

A2 / A4

A2 / A4


Tightening torque for self-locking hex nuts

Thread

M6

M8

M10

M12

M14

M16

M20

M

A


M

A

(Nm)

7.5 +1

17 +2

35 +4

59 +6

100 +10

140 +14

290 +29

Lubricants

–

–

–

–

–

–

–

M14 x 1.5

M16

M16 x 1.5

M18

M18 x 1.5

M20

M20 x 1.5

M22

M22 x 1.5

M24

M24 x 2

M27

M27 x 2

Thread

M6

M8

M8 x 1

M10

M10 x 1.25

M12

M12 x 1.5

M14

Tightening torque for stress bolt connections as per MTN 5007 standard

This standard applies to stress pin bolts and stress bolts which are subjected to static and dynamic load of strength class 10.9 as well as to the associated nuts.

Shaft and transition dimensions as per MMN 209 standard and material and machining as per MMN 389 standard (bright surface or phosphatized).

The values in the table are based on a friction coefficient µtot = 0.125.

Threads and mating faces of screws and nuts must be coated with engine oil prior to assembly.

An assembly tolerance of +10% of the figures in the table is permitted due to unavoidable deviations during the tightening process.

The values in the tables are for manual tightening using a torque wrench.

Not torsion-protected M

A

(Nm)

9

21

24

42

46

75

200

250

300

350

78

120

135

180

430

500

560

640

700

900

1000

Torsion-protected M

A

(Nm)

12

28

30

55

60

93

245

315

360

450

99

150

160

225

495

620

675

790

850

1170

1230


M30

Thread Not torsion-protected M

A

(Nm)

1250

*Protect screw shaft from torsion when tightening.

M

A

= tightening torques.

Torsion-protected M

A

(Nm)

1575

Tightening torques for plug screws as per MTN 5183-1 standard

This standard applies to plug screws to DIN 908, DIN 910 and DIN 7604 with threaded end to DIN 3852

Form A (sealed with sealing ring to DIN 7603-Cu).


M10 x 1

M12 x 1.5

M14 x 1.5

M16 x 1.5

M18 x 1.5

M20 x 1.5

M22 x 1.5

M24 x 1.5

M26 x 1.5

M27 x 2

M30 x 1.5

M30 x 2

M33 x 2

M36 x 1.5

M38 x 1.5

M42 x 1.5

M45 x 1.5

M48 x 1.5

M52 x 1.5

M56 x 2


A

are given for screw plugs made of steel (St) with surface protected by a phosphate coating and oiled or galvanized.

Threads and mating faces beneath heads must be coated with engine oil prior to assembly.


Tightening torques for plug screws to DIN 908, DIN 910 and DIN 7604A (with short threaded end).

Thread screwed into

Steel/gray cast iron M

A

(Nm)

15

25

35

40

50

100

110

120

160

60

70

85

100

190

220

260

290

310

325

380

120

160

180

200

240

80

100

100

110

270

300

320

360

AI alloy M

A

(Nm)

15

25

30

35

40

50

70


Thread Steel/gray cast iron M

A

(Nm)

400 screwed into

AI alloy M

A

(Nm)

400 M64 x 2

M

A


Tightening torque for plug screws DIN 7604C (with long screwed end)

Thread

M8 x 1

M22 x 1.5

M26 x 1.5

M30 x 1.5

M38 x 1.5

M45 x 1.5

M

A

= tightening torques screwed into


A

(Nm)

10

80

105

130

140

160

AI alloy M

A

(Nm)

10

65

90

130

120

140

Tightening torque for banjo screws as per MTN 5183-2 standard

This standard applies to banjo screws to MMN 223 and N 15011 sealed with sealing ring to DIN 7603-Cu.


The stated tightening torques M

A

apply to steel (St) banjo screws with a phosphatized surface and oiled or galvanized and for copper-aluminum alloy.



Tightening torques for steel banjo screws

Thread

M8 x 1

M10 x 1

M12 x 1.5

M14 x 1.5

M16 x 1.5

M18 x 1.5

M22 x 1.5

M26 x 1.5

M30 x 1.5

M38 x 1.5

M45 x 1.5

M

A

= tightening torques inserted in steel/gray cast iron/aluminum alloy

M

A

(Nm)

10

15

20

25

25

30

60

90

130

140

160

Tightening torques for copper-aluminum alloy banjo screws

Thread

M10 x 1

M16 x 1.5

M

A

= tightening torques inserted in steel/gray cast iron/aluminum alloy

M

A

(Nm)

15

30


Tightening torques for male connectors as per MTN 5183-3 standard

This standard applies to male unions to DIN 2353 Series L with threaded end to DIN 3852 Form A (sealed by sealing ring to DIN 7603-Cu).


A

are given for male unions made of steel (St) with phosphatized surface coating and oiled, or galvanized.



M10 x 1

M12 x 1.5

M14 x 1.5

M16 x 1.5

M18 x 1.5

M22 x 1.5

M26 x 1.5

M32 x 2

M42 x 2

M48 x 2

Thread

M

A

= tightening torques inserted in steel/gray cast iron M

A

(Nm)

15

20

35

50

60

70

100

160

260

320


Tightening torques for union nuts as per DIN 3859-2

1 Union nut

2 Screw fixture

3 O-ring

4 Linear ball bearing

Union nut: On installing the ball-type union, after tightening the union nut firmly by hand (noticeable increase in force), it should be tightened another 1/4 turn (90°) past this point.

Tightening torques for spigot unions with O-ring to ISO 6149-2

M8 x 1

M10 x 1

M12 x 1.5

M14 x 1.5

M16 x 1.5

M18 x 1.5

M20 x 1.5

1)

M22 x 1.5

Thread Torque (Nm) +10%

10

20

35

45

55

70

80

100


M27 x 2

M33 x 2

M42 x 2

M48 x 2

M60 x 2

Thread Torque (Nm) +10%

170

310

330

420

500

1) Only for sealing off installation spaces for screw-in valves (see ISO 6149-47 and ISO 7789)

Tightening torques for screwed plugs with O-ring as per ISO 6149-3

M8 x 1

M10 x 1

M12 x 1.5

M14 x 1.5

M16 x 1.5

M18 x 1.5

M22 x 1.5

M27 x 2

M33 x 2

M42 x 2

M48 x 2

M60 x 2

Thread


Torque (Nm) +10%

8

15

25

35

40

45

60

100

160

210

260

315

Tightening torques for plug screw joints as per MTN 5183-6

Thread

M10 x 1

M12 x 1.5

M14 x 1.5

M16 x 1.5

M18 x 1.5

M22 x 1.5

M27 x 2

M33 x 2

M42 x 2

M48 x 2

M60 x 2

M

A

= tightening torques screwed into


A

(Nm)

20

35

45

55

70

100

170

310

330

420

–

AI alloy M

A

(Nm)

10 +2

14 +2

15 +3

18 +3

23 +3

33 +4

57 +5

103 +10

110 +11

140 +14

200 +20

Assembly instructions and tightening torque for hose fittings with union nuts

These instructions do not apply to ORFS fittings. In contrast to the instructions for pipe unions, hose fittings with sealing heads and the matching adapters must be fitted and connected as follows.

Hose fitting, metallic sealing with union nut: tighten union nut by hand then tighten a further max. 1/4 of a turn with a wrench.

Hose fitting with O-ring and union nut: tighten union nut by hand then tighten a further max. 1/2 of a turn with a wrench.

Hoses must be properly aligned before tightening the union nuts.

Metric thread

M12 x 1.5

M14 x 1.5

Sealing head/sealing cone with metric union nut

Pipe outer dia.

6

8

Torque (Nm)

20

38


Metric thread

M16 x 1.5

M18 x 1.5

M20 x 1.5

M22 x 1.5

M24 x 1.5

M26 x 1.5

M30 x 2

M36 x 2

M42 x 2

M45 x 2

M52 x 2

BSPP thread

G1/4

G3/8

G1/2

G5/8

G3/4

G1

G1.1/4

G1.1/2

G2

7/16–20

1/2–20

9/16–18

3/4–16

7/8–14

1.1/16–12

1.3/16–12

1.5/16–12

UNF thread

1.5/8–12

1.7/8–12

2.1/2–12

Sealing head/sealing cone with metric union nut

Pipe outer dia.

8

10

10

12

12

14

15

16

18

20

22

25

28

30

35

38

42

Torque (Nm)

45

51

58

74

74

105

135

166

240

290

330

Sealing head with BSP union nut

SAE sealing cone with union nut JIC 37°

Size

–4

–5

–6

–8

–10

–12

–14

–16

–20

–24

–32

Torque (Nm)

20

34

60

69

115

140

210

290

400

Torque (Nm)

15

20

30

50

69

98

118

140

210

290

450


UNF thread

9/16–18

11/16–16

13/16–16

1–14

1.3/16–12

1.3/16–12

1.7/16–12

1.11/16–12

2–12

2–1/2–20

ORFS – flat sealing with union nut

Size

–4

–6

–8

–10

–12

–14

–16

–20

–24

–32

Torque (Nm)

14 +2

24 +3

43 +4

60 +8

90 +5

90 +5

125 +10

170 +20

200 +25

460 +30


3.4 Engine side and cylinder designations

1 Left engine side (A-side)

2 Engine free end in accordance with DIN ISO 1204

(KGS = Kupplungsgegenseite)

3 Right engine side (B-side)

4 Engine driving end in accordance with

DIN ISO 1204 (KS = Kupplungsseite)

Engine sides are always designated (in accordance with DIN ISO 1204) as viewed from driving end (4).

For cylinder designation (in accordance with DIN ISO 1204), the letter "Ax" refers to the cylinders on the lefthand side of the engine (1) and letter "Bx" refers to the cylinders on the right-hand side (3). The cylinders of each bank are numbered consecutively, starting with x=1 at driving end (4).

The numbering of other engine components also starts with 1 at driving end (4).


3.5 Sensors and actuators – Overview

Remote heat exchanger

Left engine side 8V4000Mx3

1 B44.2 (N-Turbocharger B)

2 B4.21 (T-Exhaust, A side)

3 B10 (P-Charge air)

4 B34.2 (P-Fuel before filter)


6 B34.1 (P-Fuel after filter)

7 F46 (H fuel leakage)


Engine free end (KGS) 8V4000Mx3

1 B33 (T-Fuel, rail)

2 B7 (T-Lube oil)

3 B5.2 (P-Lube oil after filter), only with switchable oil filter

4 B5.1 (P-Lube oil after filter)

5 B5.3 (P-Lube oil before filter)

6 B48 (P-Fuel in common rail)

7 B1 (N-Camshaft)

8 B54 (P-Oil refill pump)

9 B6.2 (T-Coolant)

10 B6 (T-Coolant)

11 Connector XD1 – Dialog unit


Right engine side 8V4000Mx3

1 B16 (P-Coolant)

2 B9 (T-Charge Air)

3 B4.22 (T-Exhaust, B bank)

4 B44.1 (N-Turbocharger A)


Driving end (KS) 8V4000Mx3

1 S37.1 (S-Safety switch)

2 B13.2 (N-Crankshaft)

3 B13 (N-Crankshaft)

4 S37.2 (safety switch)


Plan view 8V4000Mx3

1 Y27 (turbocharger control valve)

2 Y26 (A-Air recirculation valve)

3 B50 (P-Crankcase)

4 B4.A1-B4B4 (T-Individual exhaust A1-A4, B1-B4)

5 B49 (T-Charge-air, air recirculation valve)

6 B3 (T-Intake air)


Engine-mounted heat exchanger

Left engine side 8V4000Mx3

1 B44.2 (N-Turbocharger B)

2 B4.21 (T-Exhaust, A side)

3 B10 (P-Charge air)



6 B34.1 (P-Fuel after filter)

7 F46 (H-Fuel leakage)

8 B33 (T-Fuel in common rail)


Engine free end (KGS) 8V4000Mx3

1 B48 (P-Fuel in common rail)

2 B7 (T-Lube oil)

3 B5.2 (P-Lube oil after filter), only with switchable oil filter

4 B5.1 (P-Lube oil after filter)

5 B5.3 (P-Lube oil before of filter)

6 B1 (N-Camshaft)

7 B54 (P-Oil refill pump)

8 B6.2 (T-Coolant)

9 B6 (T-Coolant)

10 Connector XD1 – Dialog unit


Right engine side 8V4000Mx3

1 F33 (H-Coolant)

2 B16 (P-Coolant)

3 B21 (P-Raw water)

4 B9 (T-Charge Air)

5 B4.22 (T-Exhaust, B bank)

6 B44.1 (N-Turbocharger A)


Driving end (KS) 8V4000Mx3


2 B13.2 (N-Crankshaft)

3 B13 (N-Crankshaft)



Plan view 8V4000Mx3

1 Y27 (turbocharger control valve)

2 B50 (P-Crankcase)

3 B4.A1-B4B4 (T-Individual exhaust A1-A4, B1-B4)

4 Y26 (A-Air recirculation valve)

5 B49 (T-Charge-air, air recirculation valve)

6 B3 (T-Intake air)


4 Technical Data

4.1 ENGINE DATA 8V4000M53R (provisional)

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 settings).

N Value not yet defined

- Not applicable

X Applicable

Engine model

Application group

Intake air temperature

Charge-air coolant temperature

Raw water inlet temperature

Barometric pressure

Site altitude above sea level

°C

°C

°C mbar m


1A 1A

25 45

25

-

1000

100

32

1000

100

-


1A 1A

25 45

25

-

1000

100

32

1000

100

-

POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)

Number of cylinders

Rated engine speed

Fuel stop power ISO 3046

A rpm

A kW


1600 1600

746 746


1600 1600

746 746

GENERAL CONDITIONS (for maximum power)

Number of cylinders

Intake depression (new filter)

Intake depression, max.

A mbar

L mbar


15 15

30 30

MODEL RELATED DATA (basic design)

Number of cylinders

Cylinder arrangement: V-angle

Bore

Stroke

Cylinder displacement

Total displacement

Degrees

(°) mm mm

Liters

Liters


90 90

170

210

4.77

38.1

170

210

4.77

38.1


15 15

30 30


90 90

170

210

4.77

38.1

170

210

4.77

38.1

MS15034/00E 2018-08 | Technical Data | 63

Number of cylinders

Inlet valves per cylinder

Number of exhaust valves per cylinder

RAW WATER CIRCUIT (open circuit)

Number of cylinders


2 2

2 2

Raw water pump: Inlet pressure, min.

Raw water pump: Inlet pressure, max.

Pressure loss in engine-external raw water system, max.

L bar

L bar

L bar

LUBE-OIL SYSTEM

Number of cylinders


-0.4

-0.4

1.0

1.0

1.0

1.0

Firing speed, from

Firing speed, to

R rpm

R rpm


80** 81** Lube oil operating temperature before engine, from

Lube-oil operating temperature before engine, to

Lube-oil operating pressure before engine, from

Lube oil operating pressure before engine, to

Lube oil operating pressure (low idle)

(meas. point: before engine)

R °C

R °C

R bar

R bar

R bar

88**

6.3

5.3

2.2

89**

6.3

5.3

2.2

FUEL SYSTEM

Number of cylinders

Fuel pressure at engine inlet connection, min. (when engine is starting)

Fuel pressure at supply connection to engine, min. (when engine is running),

Fuel pressure at supply connection to engine (when engine is starting), max.

Fuel supply flow, max.

L bar

L bar

L bar

A Liters/mi n


-0.1

-0.1

-0.3

1.5

-0.3

1.5

GENERAL OPERATING DATA

Number of cylinders Engine-mounted heat exchanger

80 80

120 120


2 2

2 2


---

---

---


80** 81**

88**

6.3

5.3

2.2

89**

6.3

5.3

2.2


-0.1

-0.1

-0.3

1.5

-0.3

1.5


80 80

120 120

64 | Technical Data | MS15034/00E 2018-08

STARTING SYSTEM (electric)

Number of cylinders

Rated starter voltage (standard design) R V=


24 24

STARTING (with compressed air/hydraulic starter)


8 8 Starting-air pressure before starter motor, min.

R bar

Starting-air pressure before starter, max.

R bar 9 9

INCLINATIONS, STANDARD OIL SYSTEM (reference: waterline)

Number of cylinders

Longitudinal inclination, continuous max.

driving end down (Option: max. operating inclinations)

Longitudinal inclination, temporary max.

driving end down (Option: max. operating inclinations)


driving end up (Option: max. operating inclinations)

Longitudinal inclination, temporary max., driving end up (Option: max. operating inclinations)

Transverse inclination, continuous max.

(option: max. operating inclinations)

Transverse inclination, temporary max.


L Degrees

(°)

L Degrees

(°)

L Degrees

(°)

L Degrees

(°)

L Degrees

(°)

L Degrees

(°)


15 15

22.5

10

22.5

22.5

10

22.5

CAPACITIES


230 230 Engine coolant, engine side (with cooling system)

Engine oil, total, for initial filling (standard oil system) (option: max. operating inclinations)

Oil change quantity, max. (standard oil system) (Option: max. operating inclinations)

Oil pan capacity at dipstick mark “min.”

(standard oil system) (Option: max. operating inclinations)

Oil pan capacity at dipstick mark “max.”

(standard oil system) (Option: max. operating inclinations)

R Liters

R Liters

R Liters

L Liters

L Liters

190

120*

160*

190

120*

160*


24 24


8 8

9


15 15

22.5

10

22.5


---

190

120*

160*

9

22.5

10

22.5

190

120*

160*


WEIGHTS / MAIN DIMENSIONS

Number of cylinders

Engine dry weight (with attached standard accessories, without coupling)

R kg

ACOUSTICS

Number of cylinders

Exhaust noise, unsilenced - BL (free-field sound pressure level Lp, 1m distance, ISO

6798, +3dB(A) tolerance)

Engine surface noise with attenuated intake noise (filter) - BL (free-field sound power level Lp, 1 m distance, ISO 6798,

+2dB(A) tolerance)

R dB(A)

R dB(A)


5875


5875 5505* 5505*


108* 108*


108* 108*

103* 103* 103* 103*



Legend

DL Reference value: Continuous power. Continuous driving performance under standard conditions

BL Reference value: Fuel stop power. Maximum engine power. With some applications, not drivable on continuous basis (adjustment reserve)

A Design value. Value required to design an external system (plant)

R Guideline value. Typical average value for information, only conditionally suitable for design

L Limit value. Value which must not be undershot (lower limit value, min. value) or exceeded (upper limit value, max. value), not suitable for design

N Not yet defined value. Value not yet named/will not be named

- Not applicable

X Applicable

> Actual value must be greater than the specified value.

< Actual value must be smaller than the specified value.

* Insufficiently guaranteed value (tolerance +/- 10%).

** Insufficiently guaranteed value (tolerance +/- 5%).

ID Product type Application

1 8V4000M53 Marine / ship main propulsion

1A continuous power, unlimited

Engine speed Listed output

1800 rpm 920 kW

1234 bhp



1800 rpm 920 kW

1234 bhp

Ref. 25 °C/25 °C; heat exchanger installed on the engine

IMO Tier II (Marpol convention)

EU Nonroad St IIIA

(97/68/EC)

IMO Tier I Marpol

Comp

IMO Tier II Marpol

Comp

EPA Marine T2 Comp

(40CFR94)

Ref. 25 °C/25 °C;

Heat exchanger separate from engine


EU Nonroad St IIIA

(97/68/EC)

IMO Tier I Marpol

Comp

IMO Tier II Marpol

Comp

EPA Marine T2 Comp

(40CFR94)






1800 rpm 920 kW

1234 bhp



1800 rpm 920 kW

1234 bhp

Ref. 45 °C/32; heat exchanger installed on engine


EU Nonroad St IIIA

(97/68/EC)

IMO Tier I Marpol

Comp

IMO Tier II Marpol

Comp

EPA Marine T2 Comp

(40CFR94)

Ref. 45 °C/32 °C;



EU Nonroad St IIIA

(97/68/EC)

IMO Tier I Marpol

Comp

IMO Tier II Marpol

Comp

EPA Marine T2 Comp

(40CFR94)

Reference conditions

ID



Barometric pressure



Performance data

ID

Rated engine speed


°C

°C mbar m

°C

A rpm

A kW

1

25

-

1000

100

25

1

1800

920

2

25

-

1000

100

25

2

1800

920

3

45

-

1000

100

32

3

1800

920

4

45

-

1000

100

32

4

1800

920

General conditions (for max. power)

ID



Exhaust overpressure

Exhaust overpressure, max.

A mbar

L mbar

A mbar

L mbar

1

15

30

30

85

2

15

30

30

85

3

15

30

30

85

4

15

30

30

85


ID

Fuel temperature at engine inlet connection

Fuel temperature at engine supply connection, max.

R °C

L °C

Model related data (basic design)

ID

Cylinder arrangement: V angle

Bore

Stroke

Displacement of a cylinder

Total displacement

Raw-water circuit (open circuit)

ID


Raw water pump: inlet pressure, max.

Pressure loss in off-engine raw water system, max.

L bar

L bar

L bar

Degrees

(°) mm mm

Liters

Liters

1

25

55

1

90

Lube oil system

ID

Lube oil operating pressure before engine, from





ID

Firing speed, from

Firing speed, to

R bar

R bar

R bar

Fuel system

ID


L bar

1

-0.1

Fuel pressure at engine inlet connection, min. (when engine is running)

Fuel pressure at engine inlet connection, max. (when engine is starting)

L

L bar bar

-0.3

1.5

Fuel supply flow, max. normal operation R liters/min 5.5

R rpm

R rpm

1

6.5

5.5

2.2

1

80

120

1

-0.2

1.0

1.0

170

210

4.77

38.1

2

2

80

120

2

25

55

2

6.5

5.5

2.2

2

-0.1

-0.3

1.5

7.5

3

25

55

2

90

170

210

4.77

38.1

3

90

170

210

4.77

38.1

3

-0.2

1.0

1.0

3

80

120

3

6.5

5.5

2.2

3

-0.1

-0.3

1.5

5.5

4

25

55

4

90

170

210

4.77

38.1

4

4

6.5

5.5

2.2

4

-0.1

-0.3

1.5

7.5

4

80

120


Starter (electric)

ID

Rated starter voltage (standard rating) R V=

Starter (with air/hydraulic starter motor)

ID

Starting-air pressure before starter motor, min.

Starting-air pressure before starter motor, max.

R bar

R bar

1

8

1

24

10

2

8

2

24

10

Inclinations, standard oil system (reference: waterline)

ID


driving end down (option: max. operating inclinations)




driving end up (option: max. operating inclinations)

Longitudinal inclination, temporary max., driving end up (option: max. operating inclinations)





L Degrees

(°)

L Degrees

(°)

L Degrees

(°)

L Degrees

(°)

L Degrees

(°)

L Degrees

(°)

1

20

22.5

15

17.5

15

22.5

2

20

22.5

15

17.5

15

22.5

Capacities

ID

Engine coolant, engine side (with cooling system)

Engine oil capacity, initial filling (standard oil system) (option: max. operating inclinations)


(standard oil system) (option: max. operating inclinations)



R Liters

R Liters

L Liters

L Liters

1

230

190

100

130

-

2

190

100

130

Weights / main dimensions

ID

Engine dry weight (with standard accessories installed, w/o coupling)

R kg

1

6030

2

5610


3

24

3

8

10

3

20

22.5

15

17.5

15

22.5

3

230

190

100

130

4

24

-

4

190

4

8

10

4

20

22.5

15

17.5

15

22.5

100

130

3

6030

4

5610

Sound

ID

Exhaust noise, unsilenced - BL (free-field sound pressure level Lp, 1m distance,

ISO 6798, +3dB(A) tolerance)


+2dB(A) tolerance)

R dB(A)

R dB(A)

1

107

104

2

107

104

3

107

104

4

107

104



Legend

DL Reference value: Continuous power. Continuous driving performance under standard conditions

BL Reference value: Fuel stop power. Maximum engine power. With some applications, not drivable on continuous basis (adjustment reserve)

A Design value. Value required to design an external system (plant)

R Guideline value. Typical average value for information, only conditionally suitable for design

L Limit value. Value which must not be undershot (lower limit value, min. value) or exceeded (upper limit value, max. value), not suitable for design

N Not yet defined value. Value not yet named/will not be named

- Not applicable

X Applicable

> Actual value must be greater than the specified value.

< Actual value must be smaller than the specified value.

* Insufficiently guaranteed value (tolerance +/- 10%).

** Insufficiently guaranteed value (tolerance +/- 5%).





1800 rpm 1000 kW

1341 bhp



1800 rpm 1000 kW

1341 bhp



EU Nonroad St IIIA

(97/68/EC)

IMO Tier I Marpol

Comp

IMO Tier II Marpol

Comp

EPA Marine T2 Comp

(40CFR94)

Ref. 25 °C/25 °C;



EU Nonroad St IIIA

(97/68/EC)

IMO Tier I Marpol

Comp

IMO Tier II Marpol

Comp

EPA Marine T2 Comp

(40CFR94)






1800 rpm 1000 kW

1341 bhp



1800 rpm 1000 kW

1341 bhp



EU Nonroad St IIIA

(97/68/EC)

IMO Tier I Marpol

Comp

IMO Tier II Marpol

Comp

EPA Marine T2 Comp

(40CFR94)

Ref. 45 °C/32 °C;



EU Nonroad St IIIA

(97/68/EC)

IMO Tier I Marpol

Comp

IMO Tier II Marpol

Comp

EPA Marine T2 Comp

(40CFR94)

Reference conditions

ID



Barometric pressure



Performance data

ID

Rated engine speed


°C

°C mbar m

°C

A rpm

A kW

1

25

-

1000

100

25

1

1800

1000

2

25

-

1000

100

25

2

1800

1000

3

45

-

1000

100

32

3

1800

1000

4

45

-

1000

100

32

4

1800

1000

General conditions (for max. power)

ID



A mbar

L mbar

1

15

30

2

15

30

3

15

30

4

15

30


Model related data (basic design)

ID

Cylinder arrangement: V angle

Bore

Stroke

Displacement of a cylinder

Total displacement

Raw-water circuit (open circuit)

ID


Raw water pump: inlet pressure, max.

Pressure loss in off-engine raw water system, max.

L bar

L bar

L bar

Lube oil system

ID

Lube oil operating pressure before engine, from




Degrees

(°) mm mm

Liters

Liters

R bar

R bar

R bar

1

90

1

6.5

5.5

2.2

Fuel system

ID


L bar

1

-0.1

Fuel pressure at engine inlet connection, min. (when engine is running)

Fuel pressure at engine inlet connection, max. (when engine is starting)

L

L bar bar

-0.3

1.5

Fuel supply flow, max. normal operation R liters/min 5.8


ID

Firing speed, from

Firing speed, to

R rpm

R rpm

1

80

120

Starter (electric)

ID

Rated starter voltage (standard rating) R V=

1

24

1

-0.2

1.0

1.0

170

210

4.77

38.1

2

2

80

120

2

24

2

6.5

5.5

2.2

2

-0.1

-0.3

1.5

7.8

2

90

170

210

4.77

38.1

3

90

170

210

4.77

38.1

4

90

170

210

4.77

38.1

3

-0.1

-0.3

1.5

5.8

3

6.5

5.5

2.2

3

-0.2

1.0

1.0

3

80

120

3

24

4

4

6.5

5.5

2.2

4

80

120

4

24

4

-0.1

-0.3

1.5

7.8


Starter (with air/hydraulic starter motor)

ID

Starting-air pressure before starter motor, min.

Starting-air pressure before starter motor, max.

R bar

R bar

1

8

10

2

8

10

Inclinations, standard oil system (reference: waterline)

ID






driving end up (option: max. operating inclinations)

Longitudinal inclination, temporary max., driving end up (option: max. operating inclinations)





L Degrees

(°)

L Degrees

(°)

L Degrees

(°)

L Degrees

(°)

L Degrees

(°)

L Degrees

(°)

1

20

22.5

15

17.5

15

22.5

2

20

22.5

15

17.5

15

22.5

Capacities

ID

Engine coolant, engine side (with cooling system)

Engine oil capacity, initial filling (standard oil system) (option: max. operating inclinations)





R Liters

R Liters

L Liters

L Liters

1

230

190

100

130

2

190

100

130

Weights / main dimensions

ID

Engine dry weight (with standard accessories installed, w/o coupling)

R kg

1

6120

2

5710

3

8

10

3

20

22.5

15

17.5

15

22.5

3

230

190

100

130

3

6120

4

8

10

4

4

5710

190

100

130

4

20

22.5

15

17.5

15

22.5


22. Sound

ID

Exhaust noise, unsilenced - BL (free-field sound pressure level Lp, 1m distance,

ISO 6798, +3dB(A) tolerance)


+2dB(A) tolerance)

R dB(A)

R dB(A)

1

107

104

2

107

104

3

107

104

4

107

104


4.4 Firing order

8V

12 V

16 V

A1-B4-A4-A2-B3-A3-B2-B1

A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1

A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B7


4.5 Engine – Main dimensions

Main engine dimensions

Engines with remote heat exchanger

Engine model

8V4000 M23S/23F/33S/33S/53/53R/63

Length (A) approx. 2386 mm

Engines with engine-mounted heat exchanger

Engine model

8V4000 M23S/23F/33S/33S/53/53R/63

Length (A) approx. 2590 mm

Width (B) approx. 1613 mm

Height (C) approx. 1959 mm

Width (B) approx. 1613 mm

Height (C) approx. 2060 mm


5 Operation

5.1 Controls

Automation system controls

Refer to automation system operating instructions

MS15034/00E 2018-08 | Operation | 79

5.2 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

Engine

Valve drive

Lube oil system

Coolant circuit

Coolant circuit

Engine control system

ECU

EMU

EIM

Task

Depreserve (→ Preservation and Represervation Specifications A001070/..).

Lubricate valve gear every ≥ 6 months (→ Page 149).

Check engine oil level (→ Page 189);

Preheat engine oil if required.

Prime with fuel (→ Page 175)

Align adjustable pointer with position of pressure indicator (→ Page 170).

Fuel prefilter

Fuel prefilter, pressure gauge

HP fuel pump

Raw water pump (if located above waterline (only applicable to engines with engine-mounted heat exchanger or with optional remote heat exchanger))

Coolant circuit

Only for engines without oil priming pump:

Fill HP fuel pump with fresh engine oil (→ Page 155).

Prime with water (approx. 3 to 4 liters).

If engine is out of service for more than one year, change engine coolant

(→ Page 206).

Check coolant level (→ Page 205).

Preheat coolant with preheating unit.

Refer to automation system operating instructions.

Check plug connections (→ Page 236).

Check plug connections (→ Page 237)


80 | Operation | MS15034/00E 2018-08

5.3 Putting the engine into operation after scheduled out-ofservice-period

Preconditions


Putting into operation

Item

Lube oil system

Coolant system

Coolant system

Fuel prefilter


ECU

EIM

EMU

Task

Check engine oil level (→ Page 189);

Preheat engine oil if required.


Preheat coolant with preheating unit.

Drain (→ Page 171);

Check that suction-side pressure indicated at the fuel prefilter pressure

gauge is within the limit (→ Page 170).





MS15034/00E 2018-08 | Operation | 81

5.4 Re-starting the engine following an automatic safety shutdown

NOTICE

Re-starting the engine following an automatic safety shutdown.

Risk of severe engine damage!

• Before starting the engine, make sure the root cause of the safety shutdown was eliminated.

• If the root cause cannot be identified or eliminated, contact Service.

Note: • If an engine has been shutdown by a fault (red alarm), the engine may only be re-started when the fault has been identified and eliminated.

Procedure following an automatic safety shutdown

1.

Eliminate fault.

2.

If the root cause cannot be identified or eliminated, contact Service.

Important

The function "Overdrive safety system" (if fitted), which is only used in emergency situations, is not affected.

82 | Operation | MS15034/00E 2018-08

5.5 Starting the engine

Start the engine via the automation system


MS15034/00E 2018-08 | Operation | 83

5.6 Operational checks

DANGER

Components are moving or rotating.

Risk of crushing, danger of parts of the body being caught or pulled in!

• Operate the engine at low load only. Keep clear of the danger zone of the engine.

WARNING

High level of engine noise when the engine is running.

Risk of damage to hearing!


Operational checks

Item

Engine under load

Engine at nominal speed

Air filter

HP fuel pump

HT coolant pump

Fuel prefilter (optional)

Raw water pump (only on engines with engine-mounted or optional remote heat exchanger)

Bilge pump (optional)

Task

Check engine visually for leaks and general condition; Check air pipework between air filter and exhaust turbocharger for leaks and damage.

Check for abnormal running noise, vibration, and exhaust color (→ Page 100).

Check signal ring position of service indicator (→ Page 187).

Replace air filter (→ Page 185), if the signal ring is completely visible in the

service indicator control window.

Check relief bores for fuel discharge (→ Page 157).

Check relief bore for oil and coolant discharge and obstructions

(→ Page 210).

Check reading on differential pressure gage (→ Page 170);

Drain water and contaminants (→ Page 171).


(→ Page 218).


(→ Page 221).

84 | Operation | MS15034/00E 2018-08

5.7 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.

1.

Start up fuel treatment system (→ Page 87).

2.

Shut down fuel treatment system (→ Page 91).

MS15034/00E 2018-08 | Operation | 85

5.8 Checks prior to start-up

Checks prior to start-up

1.

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/..).

2.

Close drain valves on housing.

3.

Open all supply and discharge valves.

4.

Switch on fuel treatment system (→ Page 90).

5.

Check direction of rotation of pump.

6.

Vent bypass and fuel lines of the system.

a) Open ball valve for pressure tank.

b) Open ball valve for overflow tank.

c) Close ball valve at the inlet to the fuel treatment system.

Bypass line is vented via the overflow tank.

Result: d) Open ball valve at the inlet to the fuel treatment system.

7.

Check the fuel treatment system for leaks.

Result: The fuel treatment system is ready for operation.

86 | Operation | MS15034/00E 2018-08

5.9 Fuel treatment system – Initial start-up

Overview of fuel treatment system

1 Pressure-free overflow

2 Bypass 1

3 Bypass 2

4 Safety valve, 3 bar

5 Ball valve, inlet

6 Pressure gage

7 Ventilation, sample extraction

8 Differential pressure gage

9 Ball valve, outlet

10 Check valve 700 mbar

11 Check valve 5 mbar

12 Return to overflow tank

13 Engine

14 Overflow tank

15 Filter water separator

16 Drain ball valve

17 Automatic water drain

18 Water level electrode

19 Ball valve, sample extraction, inlet

20 Switchgear cabinet

21 Pump

22 Coarse filter

23 Fuel supply from tank

24 Tank

Switching on fuel treatment system

1.


2.

Check differential pressure at differential pressure gage (8). Differential pressure in a new system: 0.1 bar to

0.3 bar.

Result: If no differential pressure is measured, the coalescer filter element is probably being bypassed.

1. Remove coalescer filter element (→ Page 226).

2. Check sealing surfaces on coalescer filter element and in the pressure tank.

MS15034/00E 2018-08 | Operation | 87

Initial start-up: HAT

1.

Replace fuel filter on engine (→ Page 168).

Note: Determine the suction pressure upstream of the engine-mounted fuel delivery pump.

2.

Install pressure gage in fuel supply line from Yard fuel system to engine.

3.

Switch on fuel treatment system and operate it for some minutes (→ Page 90).

Result: Fuel is drawn from the tank (24). It is then cleaned and dewatered via the filter water separator (15). It is then returned to the tank (24) via the overflow tank (14). Water settled in the tank is separated.

4.

Start engine (→ Page 83).

5.

Run engine at idling speed.

6.

Check suction pressure (see technical data of the engine) at the engine-mounted fuel delivery pump.

Note: If the suction pressure is within the admissible limits and engine operation is satisfactory.

7.

Increase engine speed to 1000 rpm and monitor suction pressure.

8.

Check suction pressure at the engine-mounted fuel delivery pump.

Result: If the values are within the limits specified by the manufacturer, the system is ready to start filter replacement simulation with the engine running as part of the Harbor Acceptance Tests.

Simulating filter replacement with the engine running: HAT

1.


2.


3.


4.

Close ball valve (5) at inlet to fuel treatment system.

Result: The pressure upstream of the fuel treatment system increases until the overflow valve at the pump unit opens and fuel flows through bypass (3) and bypass (2).

5.

Open ball valve (19) .

Result: Fuel emerges. If no fuel emerges:

• Open ball valve (5) at inlet to fuel treatment system.

• No function of bypasses (2) and (3); carry out functional test of bypasses (2) and (3) .

6.

Check suction pressure (see technical data of the engine) at the fuel delivery pump.


7.


Result: If all engine operating values are within the specified limits, open ball valve (5) at inlet to fuel treatment system.

Simulating power failure (emergency): HAT

1.


2.


3.


4.

Switch off pump (21) at switchgear cabinet (20).

Result: The engine-mounted fuel delivery pump draws fuel via bypass (2) directly from tank (24).

5.



6.


Result: Simulation was successful if the suction pressure is within the specified limits.

88 | Operation | MS15034/00E 2018-08

Simulating power failure (emergency): SAT

1.


2.


3.


4.

Switch off pump (21) at switchgear cabinet (20).

Result: The engine-mounted fuel delivery pump draws fuel via bypass (2) directly from tank (24).

5.



6.

Operate engine at full load and monitor suction pressure.

Result: Simulation was successful if the suction pressure is within the specified limits.

MS15034/00E 2018-08 | Operation | 89

5.10 Fuel treatment system – Switching on

Preconditions

☑ The on-board power supply is switched on.

NOTICE

Risk of damage to engine/system.

Risk of severe damage to property!

• Before switching on, ensure that the engine/system is ready for operation.

• Before switching on, ensure that all housings are closed.

• Before switching on, ensure that no work is in progress anywhere on the entire system.

Fuel treatment system – Switching on

1.

Carry out checks prior to start-up (→ Page 86).

2.

Switch on master switch on switchgear cabinet.

Result: Signal lamp “Control voltage present” lights up.

3.

Switch on switch for pump.

Result: Signal lamp “Pump running” lights up.

90 | Operation | MS15034/00E 2018-08

5.11 Fuel treatment system – Shutdown

Shutting down fuel treatment system

1.

Press the illuminated pushbutton "Water drain" on the switch cabinet until water discharge from the outlet stops.

2.

Switch off fuel treatment system.

3.

Close ball valve at the inlet to the fuel treatment system.

4.

Close ball valve at the outlet of the fuel treatment system.

5.

Open drain valve until pressure has escaped from fuel treatment system.

MS15034/00E 2018-08 | Operation | 91

5.12 Stopping the engine

Stopping the engine via the automation system


92 | Operation | MS15034/00E 2018-08

5.13 Emergency engine stop

NOTICE

An emergency stop subjects the engine system to an extremely high load.

Risk of overheating, damage to components!

• Trigger an emergency stop only in emergency situations.

Emergency stop

1.


2.

Follow instructions.

MS15034/00E 2018-08 | Operation | 93

5.14 After shutdown

Preconditions

☑ MTU Preservation and Represervation Specifications (A001070/..) are available.

After shutdown

Item

Coolant circuit

Raw water (only on engines with engine-mounted heat exchanger)


Air intake and exhaust system

Task

Drain coolant (→ Page 207) if:

• freezing temperatures are to be expected and the engine is to remain out of service for an extended period but the coolant has no antifreeze additive;

• engine room is not heated;

• coolant is not kept at a suitable temperature;

• antifreeze concentration is insufficient for the engine-room temperature;

• antifreeze concentration is 50% and engine-room temperature is below

-40 °C.

Drain

• if freezing temperatures are to be expected and the engine is to remain out of service for an extended period.

Switch off.

Out-of-service-period > 1 week

• Seal engine on air and exhaust sides.

Out-of-service-period > 1 month

• Carry out engine preservation (→ MTU Preservation and Represervation

Specifications A001070/..).

94 | Operation | MS15034/00E 2018-08

5.15 Plant – Cleaning

Preconditions


☑ No operating voltage applied.

Special tools, Material, Spare parts

Designation / Use

High-pressure cleaner

Cleaner (Hakupur 50/136)

WARNING

Part No.

(→ Tools Catalog)

X00056700

Compressed air gun ejects a jet of pressurized air.

Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!

• Never direct air jet at people.

• Always wear safety goggles/face mask and ear defenders.

WARNING

Water jet from high-pressure cleaning unit.

Risk of eye injury, risk of scalding!

• Do not direct water jet at persons.

• Wear protective clothing, protective gloves, and goggles/safety mask.

NOTICE

Cleaning agents should not be left to take effect for too long.

Damage to components is possible!

• Observe manufacturer's instructions.

Qty.

1

1

NOTICE

Blowing down product with compressed air.

Entry of dirt and damage to components is possible!

• Do not aim compressed air gun directly at seals or electronic components such as connectors or

ECUs.

Cleaning the plant

1.

Carry out plant cleaning only in areas where an appropriate oil separator is provided (environmental protection).

2.

Prior to putting the cleaning unit into operation, read the operating instructions of the high-pressure cleaning units carefully and observe the safety precautions.

3.

The following requirements apply for cleaning the plant outside with a high-pressure cleaning unit:

• The pressure of the high-pressure jet (cleaning jet) must not exceed 50 bar.

• A minimum distance between spray nozzle and plant of 1 m must be observed.

• The temperature of the cleaning medium must not exceed 80 °C.

4.

For external cleaning with high-pressure jet, use a fan jet nozzle only.

Note: Never direct compressed air directly at electronic components.

5.

Carry out external cleaning as follows: a) Seal all openings in a suitable way.

b) Remove coarse dirt.

c) Spray on cleaner sparingly and leave it for 1 to 5 minutes.

d) Use high-pressure jet to remove loosened dirt.

e) Dry engine with compressed air.

MS15034/00E 2018-08 | Operation | 95

6 Maintenance

6.1 Maintenance task reference table [QL1] for EPA regions

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.

Task Maintenance tasks

W0500

W0501

Check engine oil level.

Carry out visual inspection of engine for general condition and leaks.

Inspect service indicator of air filter.

W0503

W0504

W0505

W0506

Check the inspection bores of the HP fuel pump.

Check relief bores of coolant pump(s).

Check for abnormal running noises, exhaust gas color and vibration.

W0507 Drain off water and contamination from fuel prefilter.

W0508 X Check differential pressure gauge of fuel prefilter.

W1001 Fit new fuel filter or new fuel filter insert.

W1005 X Fit new air filters.

W1006 Replace fuel injectors.

W1008 X Fit new engine oil filters each time the engine oil is changed or, at the latest, on expiry of the time limit (given in years).

W1009

W1011

Check thickness of oil residue layer. Clean. Fit new sleeve, at the latest, each time the engine oil is changed.

Inspect cylinder chambers using endoscope.

W1016 X Check condition of coupling.

W1055 X Fit new oil separators.

W1076 Clean compressor wheel.

W1207 Check valve clearance, adjust if required. ATTENTION! Initial adjustment after 1,000 operating hours and subsequently

1,000 operating hours after each cylinder-head overhaul..

W1244 X Check function of bar electrode.

W1245 X Check alarm function of differential pressure gauge.

W1246 X Check pump capacity.

W1463 Carry out visual inspection of engine mounts for general condition.

W1477 X Overhaul preheater / jacket water heater.

W1481 Replace intermediate fuel filter of filter element of intermediate fuel filter.

W1675 X Fit new fuel prefilter or new fuel prefilter insert.

(→ Page 189)

(→ Page 84)

(→ Page 187)

(→ Page 84)

(→ Page 210)

(→ Page 84)

(→ Page 84)

(→ Page 84)

(→ Page 168)

(→ Page 185)

(→ Page 158)

(→ Page 194)

(→ Page 199)

(→ Page 144)

(→ Page 219)

(→ Page 148)

(→ Page 179)

(→ Page 150)

(→ Page 224)

(→ Page 223)

(→ Page 225)

(→ Page 220)

(→ Page 217)

(→ Page 167)

(→ Page 175)

96 | Maintenance | MS15034/00E 2018-08


W1713 Injector: reset drift compensation parameters (CDC).

W1864 X Check and clean oil indicator filter.

Table 2: Maintenance task reference table [QL1]

(→ Page 245)

(REFDM TARGET NOT FOUND)

MS15034/00E 2018-08 | Maintenance | 97

6.2 Maintenance task reference table [QL1] for Non EPA regions

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.


W0500

W0501

W0502

W0503

W0504

Check engine oil level.

Carry out visual inspection of engine for general condition and leaks.

Inspect intercooler drain system.

Inspect service indicator of air filter.

Check the inspection bores of the HP fuel pump.

W0505

W0506

Check relief bores of coolant pump(s).

Check for abnormal running noises, exhaust gas color and vibration.

W0507 Drain off water and contamination from fuel prefilter.

W0508 X Check differential pressure gauge of fuel prefilter.

W1001 Fit new fuel filter or new fuel filter insert.

W1005 X Fit new air filters.

W1006 Replace fuel injectors.

W1008 X Fit new engine oil filters each time the engine oil is changed or, at the latest, on expiry of the time limit (given in years).

W1009 Check thickness of oil residue layer. Clean. Fit new sleeve, at the latest, each time the engine oil is changed.

W1011 Inspect cylinder chambers using endoscope.

W1016 X Check condition of coupling.

W1047 X Check and clean oil indicator filter.

W1076 Clean compressor wheel.

W1207 Check valve clearance, adjust if required. ATTENTION! Initial adjustment after 1,000 operating hours and subsequently

1,000 operating hours after each cylinder-head overhaul..

W1244 X Check function of bar electrode.

W1245 X Check alarm function of differential pressure gauge.

W1246 X Check pump capacity.

W1463 Carry out visual inspection of engine mounts for general condition.

W1477 X Overhaul preheater / jacket water heater.

W1481 Replace intermediate fuel filter of filter element of intermediate fuel filter.

W1581 X Replace impactor.

(→ Page 189)

(→ Page 84)

(→ Page 184)

(→ Page 187)

(→ Page 84)

(→ Page 210)

(→ Page 84)

(→ Page 84)

(→ Page 84)

(→ Page 168)

(→ Page 185)

(→ Page 158)

(→ Page 194)

(→ Page 199)

(→ Page 144)

(→ Page 219)

(REFDM TARGET NOT FOUND)

(→ Page 179)

(→ Page 150)

(→ Page 224)

(→ Page 223)

(→ Page 225)

(→ Page 220)

98 | Maintenance | MS15034/00E 2018-08


W1675 X Fit new fuel prefilter or new fuel prefilter insert.

W1713 Injector: reset drift compensation parameters (CDC).

Table 3: Maintenance task reference table [QL1]

(→ Page 245)

MS15034/00E 2018-08 | Maintenance | 99

7 Troubleshooting

7.1 Troubleshooting

Engine does not turn when starter is actuated

Cause Corrective action

Battery low or faulty u Charge or replace (see separate documentation).

Battery: Cable connections faulty u Check firm seating of cable connections (see separate documentation).

Engine cabling or starter faulty

Engine cabling faulty

Loose plug connections on Engine

Control Unit u Check firm seating of cable connections, contact Service.

u

Check (→ Page 234).

u


Loose plug connections on Engine

Interface Module (EIM) u


Fuse F1 (→ Page 228)in engine

wiring harness faulty (fuse lamp on EIM flashes with relevant flashing code) u Check fuse (replace as necessary) and re-start the system by actuating the key switch.

Engine blocked (engine cannot be barred manually) u Contact Service.

Engine turns on starting but does not fire

Cause

Poor rotation by starter: Battery low or faulty


Engine Control Unit faulty

Corrective action u Charge or replace battery (see separate documentation).

u


u Contact Service.

Engine fires unevenly

Cause

Injector faulty



Corrective action u

Replace (→ Page 158).

u


u Contact Service.

Engine does not reach nominal speed

Cause

Fuel filter clogged

Air supply: Air filter clogged

Fuel injection: Injector faulty


Engine: Overload

Corrective action u


u


u


u


u Contact Service.

100 | Troubleshooting | MS15034/00E 2018-08

Engine speed not steady

Cause


Speed transmitter faulty


Corrective action u


u Contact Service.

u Contact Service.

Charge-air temperature too high

Cause

Incorrect coolant concentration

Intercooler dirty

Engine room: Air-intake temperature too high

Corrective action u Check (MTU test kit).

u Contact Service.

u Check fans and air supply/ventilation ducts.

Charge-air pressure too low

Cause


Intercooler dirty

Exhaust turbocharger faulty

Corrective action u


u Contact Service.

u Contact Service.

Coolant leaks at intercooler

Cause

Intercooler leaking, major coolant discharge

Corrective action u Contact Service.

Black exhaust gas

Cause



Engine: Overload

Blue exhaust gas

Cause

Too much oil in engine

Oil separator or oil-preseparator of crankcase breather clogged

Exhaust turbocharger, cylinder head, piston rings, cylinder liner faulty

Corrective action u


u


u Contact Service.

Corrective action u

Drain engine oil (→ Page 190).

u Replace.

u Contact Service.

MS15034/00E 2018-08 | Troubleshooting | 101

White exhaust gas

Cause

Engine is not at operating temperature

Intercooler leaking

Corrective action u Run engine to reach operating temperature.

u Contact Service.


7.2 Control cabinet of fuel treatment system – Troubleshooting

Water alarm

Cause

When the maximum water level is reached, the water level electrode opens the water drain valve and water is discharged. If the opening period of the valve exceeds a preset limit (4 minutes), the pump will switch off and an alarm is initiated.

Corrective action

1. Press illuminated pushbutton 'Water alarm' for acknowledgment.

2. In addition to the automatic water drain function, water can also be drained manually: Press illuminated pushbutton 'Water drain'.

The water drain valve opens.

Pump fault

Cause

The drive motor is equipped with an overload protection. If the maximum permissible current consumption is exceeded, e.g. in case of a blockage or dry-running, the motor protection relay triggers and the pump is switched off.

Corrective action u Reset motor protection relay.

Pre-alarm

Cause

The differential pressure exceeded 1.3 bar.

Corrective action u

Replace coalescer filter element (→ Page 226).

Replace filter element

Cause

The max. permissible differential pressure exceeded 1.5 bar. If the coalescer filter element is not replaced, pressure will increase further and the safety valve will open. Fuel will be led via the bypass directly into the overflow tank.

Corrective action

1. Replace coalescer filter element (→ Page 226).

2. Press illuminated pushbutton 'Water alarm' for acknowledgment.


7.3 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 104) proves unsuc-

cessful.

For explanations of alarm configuration parameters, refer to PR 2.8008.100.

Fault code list (→ Page 104).


7.4 ADEC engine governor – Fault codes

29 – HI ETC Idle Speed too High

ZKP-Number: 1.8004.206

Cause

Idle speed of one of the secondary turbochargers is too high.


38 – AL ETC Speed Deviation


Cause

Speeds of one of the secondary turbochargers deviates from primary turbocharger speed.

Corrective action

1. Reduce power.

2. Contact Service.

39 – AL ETC2 CutIn Failure


Cause

ETC2 could not be cut in.

Corrective action

1. Reduce power.

2. Contact Service.

81 – AL Rail Leakage


Cause

Pressure gradient in rail is too low during starting or too high during stopping (HP system leaky or air in the system)


102 – AL Cons. Counter Defect


Cause

Consumption meter faulty.


104 – AL Eng Hours Counter Defect


Cause

Hourmeter faulty.



141 – AL Power too high

Cause

This alarm occurs if the average value of power over the last 24 hours exceeded the maximum value specified in PR1.1088.001.


Corrective action u Reduce power.

142 – AL MCR exceeded 1 hour


Cause

This alarm occurs if the MCR was exceeded for more than 1 hour within the last 12 hours.


201 – SD T-Coolant

Cause

Coolant temperature sensor faulty; Short circuit or wire break


Corrective action

1. Check sensor and cabling (B6), replace as necessary.

2. Error cleared after restarting the engine.

202 – SD T-Fuel

Cause

Coolant temperature sensor faulty; Short circuit or wire break


Corrective action



203 – SD T-Charge Air

Cause

Charge-air temperature sensor faulty; Short circuit or wire break


Corrective action



204 – SD Level Lube Oil

Cause lube oil level sensor faulty; Short circuit or wire break


Corrective action u Check sensor and cabling, replace as necessary.


205 – SD T-Coolant Intercooler


Cause

Charge-air cooler coolant temperature sensor faulty; Short circuit or wire break

Corrective action u Check sensor and cabling (B26), replace as necessary.

206 – SD T-Exhaust A


Cause

Exhaust temperature sensor on Aside faulty; Short circuit or wire break

Corrective action u Check sensor and cabling (B4.21), replace as necessary.

207 – SD T-Exhaust B


Cause

Exhaust temperature sensor on Bside faulty; Short circuit or wire break


208 – SD P-Charge Air


Cause

Charge-air pressure sensor faulty;

Short circuit or wire break

Corrective action



211 – SD P-Lube Oil

Cause

Lube oil pressure sensor faulty;


212 – SD P-Coolant


Corrective action



Cause

Coolant pressure sensor faulty;



Corrective action




213 – SD P-Coolant charge-air cooler


Cause

Charge-air cooler coolant pressure sensor faulty; Short circuit or wire break

Corrective action



214 – SD P-CrankCase


Cause

Crankcase pressure sensor faulty;


Corrective action



215 – SD P-HD

Cause

Rail pressure sensor faulty; highpressure regulator emergency mode; Short circuit or wire break


Corrective action



216 – SD T-Lube Oil

Cause

Lube oil temperature sensor faulty; Short circuit or wire break


Corrective action



219 – SD T-Intake Air

Cause

Intake air temperature sensor faulty; Short circuit or wire break


Corrective action



220 – SD Level Coolant Water


Cause

Coolant level sensor faulty; Short circuit or wire break

Corrective action

1. Check sensor and cabling (F33), replace as necessary.



221 – SD P-Diff-Lube Oil


Cause

Lube oil differential pressure sensor faulty; Short circuit or wire break

Corrective action



222 – SD Level Leakage Fuel


Cause

Leak-off fuel level sensor faulty;


Corrective action



223 – SD Level Coolant Intercooler


Cause

Coolant level sensor of charge-air cooler faulty; Short circuit or wire break

Corrective action



227 – SD P-Lube Oil before Filter


Cause

Sensor for lube oil pressure before filter faulty; Short circuit or wire break

Corrective action

1. Check sensor and cabling (B5.3), replace as necessary.


228 – SD P-Fuel before Filter


Cause

Fuel pressure sensor faulty; Short circuit or wire break

Corrective action



229 – AL Stop Camshaft Sensor Defect


Cause

Engine shutdown due to camshaft sensor fault (and a prior crankshaft sensor fault in the same operating cycle).

Corrective action

1. Check connector and cabling to sensor B1, replace as necessary.



230 – SD Crankshaft Speed

Cause

Crankshaft sensor faulty; Short circuit or wire break


Corrective action



231 – SD Camshaft Speed

Cause

Camshaft sensor faulty; Short circuit or wire break


Corrective action



232 – SD Charger 1 Speed

Cause

Speed sensor of primary turbocharger faulty; Short circuit or wire break


Corrective action



233 – SD Charger 2 Speed

Cause

Speed sensor of secondary turbocharger faulty; Short circuit or wire break


Corrective action



239 – SD P-Diff Fuel


Cause

Fuel differential pressure sensor faulty; occurs only in combination with alarm "SD P-Fuel before

Filter" or "SD P-Fuel after Filter".

Corrective action u Note further fault messages. Pressure sensor before or after filter is faulty.

240 – SD P-Fuel


Cause

Fuel pressure sensor faulty; Short circuit or wire break

Corrective action




241 – SD T-Circulating air

Cause

Recirculation temperature sensor faulty; Short circuit or wire break


Corrective action



242 – SD T-Coolant (R)


Cause

Redundant coolant temperature sensor faulty; Short circuit or wire break

Corrective action

1. Check sensor and cabling, replace as necessary.


244 – SD P-Lube Oil (R)


Cause

Redundant lube oil pressure sensor faulty; Short circuit or wire break

Corrective action



301 – AL Timing Cylinder A1


Cause

Time-of-flight measuring fault of injector in cylinder A1: Time-of flight measured value extremely low or extremely high.

Corrective action u If alarm occurs frequently, replace solenoid valve of injector



Cause





Cause






Cause





Cause





Cause





Cause





Cause






Cause





Cause



311 – AL Timing Cylinder B1


Cause

Time-of-flight measuring fault of injector B1: Time-of flight measured value extremely low or extremely high.




Cause





Cause

Time-of-flight measuring fault of injector B3: Time-of-flight measurement value is extremely small or extremely large.





Cause





Cause





Cause





Cause





Cause






Cause





Cause



321 – AL Wiring Cylinder A1


Cause

Short-circuit in injector cabling to cylinder A1. Result: Misfiring

Corrective action

1. Rectify injector solenoid valve short circuit (positive to negative)

(e.g.by exchanging injectors).




Cause


Corrective action


(e.g. by exchanging injectors).




Cause


Corrective action






Cause


Corrective action







Cause


Corrective action






Cause


Corrective action






Cause


Corrective action






Cause


Corrective action






Cause


Corrective action






Cause


Corrective action





331 – AL Wiring Cylinder B1


Cause

Cabling fault in injector cabling to cylinder B1. Result: Misfiring

Corrective action






Cause


Corrective action






Cause


Corrective action






Cause


Corrective action






Cause


Corrective action






Cause


Corrective action







Cause


Corrective action






Cause


Corrective action






Cause


Corrective action






Cause


Corrective action




341 – AL Open Load Cylinder A1


Cause

Disruption fault in injector cabling to cylinder A1. Result: Misfiring

Corrective action

1. Check continuity of injector cabling or exclude open load in solenoid valve circuit (e.g. by injector replacement)

2. Error clearance: After each working cycle.



Cause


Corrective action






Cause


Corrective action





Cause


Corrective action





Cause


Corrective action





Cause


Corrective action





Cause


Corrective action

1. Check injector wiring for disruption or rule out any discontinuity in the solenoid valve (e.g. by replacing the injector)




Cause


Corrective action






Cause


Corrective action





Cause


Corrective action



351 – AL Open Load Cylinder B1


Cause

Disruption fault in injector cabling to cylinder B1. Result: Misfiring

Corrective action





Cause


Corrective action





Cause


Corrective action





Cause


Corrective action






Cause


Corrective action





Cause


Corrective action





Cause


Corrective action





Cause


Corrective action





Cause


Corrective action





Cause


Corrective action




361 – AL Power Stage Low

Cause

Internal electronic fault

(electronics possibly faulty). If bit

"1.1020.021" (Power Stage

Failure: Stop Engine) is set, engine will be shut down as additional measure.


Corrective action u Start ITS. If the ITS diagnosis result is "electronics OK", note further fault messages (e.g. cabling faults).

362 – AL Power Stage High


Cause






363 – AL Stop Power Stage

Cause







365 – AL Stop MV-Wiring Ground


Cause

Injector cabling fault. If bit


Failure: Stop Engine) is set, engine will be shut down as additional measure. Possible causes:

1. Short circuit of positive connection of one or more injectors to ground

2. Short circuit of negative connection of one or more injectors to ground.

Corrective action u Check wiring, replace wiring harness as necessary.


371 – AL Wiring TO 1

Cause

Short circuit or wire break on transistor output 1 (TO 1).



Corrective action

1. Check charger valve/cabling, repair as necessary.

2. Replace engine governor

Cause




Corrective action

1. Check air recirculation valve/cabling, repair as necessary.

2. Replace engine governor

Cause




Corrective action u Check wiring of charger valve 2 (marine engine)

Cause



Corrective action u Check wiring of charger valve 3 (marine engine)

390 – AL MCR exceeded


Cause

DBR/MCR feature: MCR

(maximum continuous rating) was exceeded.

Corrective action

1. If the alarm occurs temporarily, no action required.

2. If the alarm is permanently active, contact Service.

396 – TD T-Coolant

Cause

Maximum deviation of coolant temperature values from sensors


Corrective action


2. Contact Service.


397 – TD P-Lube Oil

Cause

Maximum deviation of lube oil pressure values from sensors


Corrective action


2. Contact Service.

417 – SD Level Water Fuel Prefilter


Cause

Water level sensor in fuel prefilter faulty; Short circuit or wire break


419 – SD T-Coolant b.Engine


Cause

Coolant inlet temperature sensor faulty; Short circuit or wire break

Corrective action u Check sensor and cabling (B3), replace as necessary.

444 – SD U-PDU

Cause

Injector power stage sensor defect; Internal fault in ECU7

445 – SD P-Ambient Air


Corrective action u Replace ECU7.

Cause

Ambient air pressure sensor faulty.

464 – SD P-AUX 1


Corrective action

1. Check pressure sensor and cabling, replace as necessary.

2. Replace engine governor.

Cause

Analog input signal for Aux 1 pressure faulty; Short circuit or wire break


Corrective action u Check pressure sensor and cabling, replace as necessary.


468 – SD T-AUX 1

Cause

Analog input signal for Aux 1 temperature faulty;.


Corrective action

1. Check signal transmitter and cabling, replace as necessary.

2. Replace engine governor.

469 – SD AUX 1

Cause

Analog input signal for Aux 1 faulty; Short circuit or wire break


Corrective action u Check signal transmitter and cabling, replace as necessary.

470 – SD T-ECU

Cause

Temperature sensor for ECU faulty; Short circuit or wire break



471 – SD Coil Current

Cause

Control of HP fuel control block faulty; Short circuit or wire break



473 – AL Wiring PWM_CM2


Cause

Cable break or short circuit on channel PWM_CM2.

Corrective action

1. Check cabling.

2. Contact Service.

475 – AL CR Trigger Engine Stop


Cause

Activated if the crash recorder was triggered due to an engine stop.

Corrective action

1. Determine cause of trigger/engine stop and rectify.

2. Contact Service.


476 – AL Crash Rec. Init. Error


Cause Corrective action

Crash recorder initialization error.

1. Check setting with DiaSys.

2. Contact Service.

482 – SD T-Exhaust C


Cause



483 – SD T-Exhaust D


Cause





Cause


Corrective action u Check control valve on ETC 4.



Cause


Corrective action u Check control valve on ETC 3.

500 – AL Wiring POM Starter 1


Cause

A wiring fault was detected in the connection between starter 1 and

POM. This may be a missing consumer, a wire break, or a short circuit.

Corrective action u Check connection between POM and starter.


501 – AL Wiring POM Starter 2


Cause

A wiring fault was detected in the connection between starter 2 and

POM. This may be a missing consumer, a wire break, or a short circuit.


502 – AL Open Load POM Alternator


Cause

Open load was detected at the connection of the batterycharging generator on the POM.


503 – AL Battery not Charging


Cause

The battery-charging generator does not charge the battery.

Corrective action u Check battery-charging generator and cabling.

504 – AL CAN POM node Lost


Cause

POM missing on CAN bus.

Corrective action u Check connection and POM. If alarm occurs in combination with alarm 508, the resistor in the POM cabling is missing.

506 – AL Low Starter Voltage


Cause battery voltage is too low to accomplish a starting procedure.

Corrective action u Check battery-charging generator and cabling.

507 – AL POM Error

Cause

A general POM error occurred.


Corrective action u Replace POM.


508 – AL Wrong POM-ID

Cause

POM transmits an unexpected ID number. If alarm occurs in combination with alarm 504, the resistor in the POM cabling is missing.


Corrective action u Check POM wiring harness.

519 – Oillevel Calibration Error


Cause

Error when writing the calibration value into the Flash or SD memory of the level sensor; associated PV:

AL Group 6 Mot Bit 11

Corrective action


2. Contact Service.

525 – SD P-Lube Oil (R2)


Cause

Redundant lube oil pressure sensor faulty; Short circuit or wire break


526 – SD T-Coolant (R2)


Cause

Redundant coolant temperature sensor faulty; Short circuit or wire break


527 – TD EngineSpd. Sensor Deviation


Cause

Maximum deviation of speed sensors

Corrective action

1. Check cabling of speed sensors. Observe additional messages.

2. Contact Service.

528 – SD Engine Speed 3rd Sensor


Cause

Redundant crankshaft sensor faulty; Short circuit or wire break



576 – AL ESCM Override


Cause

Violation of corrected MCR or

DBR/MCR curve. Engine overload!


577 – SD T-Lube Oil Pan

Cause

Temperature sensor in oil pan defective; Short circuit or wire break



582 – AL Emergency Stop Failed


Cause

This alarm occurs if the engine fails to come to a standstill within a specified (by parametrization) period of time after the emergency stop signal was output.

Corrective action u The delay between the emergency stop signal and this alarm signal is set in parameter 1.1005.4.

588 – SD P-Oil Refill Pump

Cause

Pressure sensor faulty; Short circuit or wire break



596 – AL Develop PR Set

Cause

The parameter set used is a test parameter set.


Corrective action u The alarm remains active until a series-production parameter set was installed.

600 – SD T-Exhaust A+B

Cause

SD T-Exhaust A and T-Exhaust B




601 – SD ETC1+ETC2

Cause

SD ETC1 and ETC2



625 – SD P-Fuel before Prefilter


Cause

Analog input signal for pressure before prefilter faulty; Short circuit or wire break

Corrective action

1. Check pressure sensor and cabling, replace as necessary.



8 Task Description

8.1 SOLAS

8.1.1 SOLAS shielding as per MTN 5233 – Installation

Preconditions



Designation / Use

Shield A4

Shield A5

Shield A6

Shield A7

Shield A8

Shield B2

Shield B4

Shield B6

Shield E5

Installing SOLAS shielding

1.

Pinpoint installation location

(REFDM TARGET NOT FOUND) .

2.

Install suitable shielding.

3.

Press shielding until locked.

Part No.

735233000100

735233000101

735233000102

735233000103

735233000104

735233000200

735233000202

735233000204

735233000500

Qty.

1

2

4

2

4

4

3

2

18

MS15034/00E 2018-08 | Task Description | 131

8.1.2 SOLAS shielding – Installation

Preconditions


☑ Engine is cooled down to ambient temperature.


Designation / Use

Oil filter shield

Shield for switchable oil filter

Installing SOLAS shield

1.

Pinpoint installation location.

2.

Install suitable shielding.

Part No.

X00040625

X00040625

Qty.

5

4

132 | SOLAS | MS15034/00E 2018-08

8.1.3 Installation locations for SOLAS shielding

General information

Primarily fit SOLAS shielding as per MTN 5233 (→ Page 131).

Shield unions with adhesive tape if SOLAS shielding as per MTN 5233 is not possible (→ Page 140).

When affixing adhesive connections ensure that escaping fluid can flow out without pressure (→ Page 140).

Fuel system, fuel lines with fuel pressures exceeding >1.8 bar

Item

1 *

Type of shielding

Shield A8

Installation location

After LP fuel pump

* This shield must be installed on the assembly line. This location is no longer accessible, or only with great difficulty, following assembly of the air pipework and/or fuel filters.

MS15034/00E 2018-08 | SOLAS | 133

Item

1 *

Type of shielding

Shield A8


Fuel filter head holder

* This shield must be installed on the assembly line. This location is no longer accessible, or only with great difficulty, following assembly of the air pipework and/or fuel filters.

Item

1

2

Type of shielding Installation location

Shield E5 Fuel line on HP pump

Shield E5 Fuel line downstream of fuel filter head

Item

1


2 x shielding A8 Fuel line at fuel filter head holder

134 | SOLAS | MS15034/00E 2018-08

Item

1 *

Type of shielding

2 x shielding B6


Fuel line at fuel filter head

* This shield must be installed on the assembly line. This location is no longer accessible, or only with great difficulty, following assembly of the air pipework.

Lube oil system, oil lines with oil pressures exceeding 1.8 bar

Item

1


2 x shielding A5 Actuating cylinder air flap ETC A1

MS15034/00E 2018-08 | SOLAS | 135

2

3

Item

1


2 x shielding A5 Actuating cylinder exhaust flap turbocharger A1

2 x shielding A5

4 x shielding A5

Actuating cylinder air flap turbocharger A1

4/2-way directional control valve

Item

1

2

3

136 | SOLAS | MS15034/00E 2018-08

Type of shielding

2 x shielding A5

2 x shielding A5

1 x shielding A6

3 x shielding A6


Air recirculation valve

Oil drain into crankcase

Oil from main oil gallery at distributor piece

Item

1

2


Shield A4 ETC oil supply

2 x shielding A5 ETC oil supply

Item

1


Shield A4 ETC oil supply

MS15034/00E 2018-08 | SOLAS | 137

Item

1


Shield A6 Oil supply line to HP pump: To HP pump

Item

1


Shield B4 Oil supply line to HP pump: On equipment carrier

138 | SOLAS | MS15034/00E 2018-08

Item

1

2


Shield B2 Oil line on equipment carrier

Shield B2 Oil line on pressure reducing valve

Item

1


Cover Oil/easy-change fuel filter

MS15034/00E 2018-08 | SOLAS | 139

8.1.4 Adhesive tape for SOLAS shielding – Application

Preconditions



Designation / Use

Adhesive tape

Applying adhesive tape – general information

Note: Use the cable clamp to make a drainage channel. This allows fluid to flow out without pressure in case of leakage.

1.

Place cable clamp (3) on union.

2.

Affix adhesive tape (1) such that lettering (2) faces out.

3.

Wrap adhesive tape without tensioning.

4.

Pull out cable clamp (3) after affixing adhesive tape.

Part No.

Qty.

Sealing cone unions

Note: For installation positions of sealing cone unions, see (REFDM TARGET NOT FOUND) .

1.

Wrap three layers of adhesive tape from the middle of the sealing cone union to area (A) for at least 30 mm, ensuring that the adhesive tape overlaps at least half its own width.

2.

Wrap three layers of adhesive tape from the middle of the sealing cone union to area (B) for at least 30 mm, ensuring that the adhesive tape overlaps at least half its own width.

Plug-in connections

Note: For installation positions of plug-in connections, see (REFDM TARGET NOT FOUND) .

1.

Apply adhesive tape flush.

2.

Apply three layers of adhesive tape such that at least 30 mm are covered from the middle of the screw to the line.

140 | SOLAS | MS15034/00E 2018-08

8.2 Engine

8.2.1 Engine – Barring manually

Preconditions



Designation / Use

Barring tool

Ratchet with extension

DANGER

Part No.

F6555766

F30006212

Rotating and moving engine parts.


• Before barring the engine, make sure that there are no persons in the engine's danger zone.

• After finishing work on the engine, make sure that all safety devices are put back in place and all tools are removed from the engine.

Qty.

1

1

Engine – Barring manually

1.

Release screws (1) and remove end cover (2) from flywheel housing.

MS15034/00E 2018-08 | Engine | 141

Note: Use barring device F6555766.

2.

Engage barring device (2) in ring gear of flywheel and install it on flywheel housing.

3.

Fit ratchet (1) onto barring device (2).

Note: No resistance other than compression resistance must be encountered.

4.

Rotate crankshaft in engine direction of rotation.

Result: If the resistance exceeds the normal compression resistance, contact Service.

5.

For removal, follow the reverse sequence of work steps.

142 | Engine | MS15034/00E 2018-08

8.2.2 Barring engine with starting system

Barring using the automation system


MS15034/00E 2018-08 | Engine | 143

8.3 Cylinder Liner


Preconditions

☑ Engine is stopped and starting disabled


Designation / Use

Barring tool


Endoscope

Part No.

F6555766

F30006212

Y20097353

Qty.

1

1

1

Preparatory steps

1.

Remove cylinder head cover (→ Page 154).

2.

Remove injector (→ Page 159).

Positioning crankshaft at BDC

1.

Using barring tool, turn crankshaft until crankshaft journal of the cylinder to be tested has reached BDC.

2.

Insert endoscope into cylinder liner through injector seat.

Endoscopic examination of cylinder liner

Findings

• Thin carbon coating around carbon scraper ring

• Slight localized additive deposits at top edge

• Localized smooth areas at bottom edge

• Carbon deposits on entire circumference between top piston ring and bottom edge of carbon scraper ring

• First signs of marks left by top piston ring

• Bright mark on entire circumference

• Faultless, even honing pattern

• First signs of marks left by lower cooling bores

• Running pattern seems darker

• Dark areas with even or varying degrees of discoloration

• Beginning and end of the discoloration are not sharply defined and do not cover the entire stroke area

• Dark areas in the upper section of the cooling bore, remaining circumference are faultless

• Piston rings are faultless

• On the entire circumference, apart from light areas of discoloration (do not impair operation) clearly darker stripes that start at the top piston ring

• Heat discoloration in the direction of stroke and honing pattern damage

• Heat discoloration of piston rings

Measure

No actions required.

Further endoscopic examination required as part of maintenance work.

Cylinder liner must be replaced, contact Service.

144 | Cylinder Liner | MS15034/00E 2018-08

1.

Compile endoscopic report using the table.

2.

Use technical terms to describe the liner surface (→ Page 146).

3.

Depending on findings:

• Do not take any action or

• carry out a further endoscopic examination as part of maintenance work or

• contact Service; cylinder liner must be replaced.

Final steps

1.

Install injector (→ Page 159).

2.

Install cylinder head cover (→ Page 154).

MS15034/00E 2018-08 | Cylinder Liner | 145

8.3.2 Cylinder liner – Instructions and comments on endoscopic and visual examination

Terms used for endoscopic examination

Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic examination report.

Findings

Minor dirt scores

Single scores

Scored area

Polished area

Bright area

Discoloration

Corrosion fields / spots

Black lines

Burn mark

Seizure marks, scuffing

Explanations/Action

Minor dirt scores can occur during the assembly of a new engine (honing products, particles, broken-off burrs). Removed cylinders clearly show such scoring on the running surface under endoscope magnification. Cannot be felt with the fingernail.

Findings not critical

Clearly visible scores caused by hard particles. They usually start in the TDC area and cross through the honing pattern in the direction of stroke.


These areas consist of scores of different length and depth next to one another. In most cases, they are found at the 6-o'clock and 12-o'clock positions (inlet/ exhaust) along the transverse engine axis.


Polished areas are on the running surface but almost the whole honing pattern is still visible. Polished areas appear brighter and more shiny than the surrounding running surface.


Bright areas are on the running surface and show local removal of the honing pattern. Grooves from the honing process are not visible any more.

This is caused by oxidation (surface discoloration through oil or fuel) and temperature differences around the liner. It appears rather darker within the honed structure in contrast to the bright metallic running surface. The honing pattern is undisturbed. Discolorations extend in stroke direction and may be interrupted.


Corrosion fields / spots result from moisture (condensate) with the valves in the overlap (open) position. They are clearly visible due to the dark color of the honing groove bottom.

This corrosion is not critical unless there is corrosion pitting.

Black lines are a preliminary stage of burn marks. They are visible as a clear discoloration from TDC to BDC in the running surface and the start of localized damage to the honing pattern.

Cylinder liners with a large number of black lines around the running surface have limited service life and should be replaced.

These are caused by a disturbance in the liner / ring tribo system. Usually they run over the whole ring-travel area (TDC/BDC), starting at the first TDC-ring and becoming more visible from the second TDC-ring 2 onwards and less pronounced from TDC-ring 1. The honing pattern is usually no longer visible and displays a clearly defined (straight) edge to the undisturbed surface. The damaged surface is usually discolored. The circumferential length varies.

Liners with burn marks starting in TDC ring 1 have to be replaced.

Irregular circumference lengths and depths. Can be caused either by the piston skirt or the piston crown. Material deposits on the liner (smear), heavy discoloration. Severe, visible scoring.

Replace liner.

Table 4: Endoscopic examination – Terms used

146 | Cylinder Liner | MS15034/00E 2018-08

Evaluation of findings and further measures

The findings in the start phase of oxidation discoloration and burn marks 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.

MS15034/00E 2018-08 | Cylinder Liner | 147

8.4 Crankcase Breather

8.4.1 Crankcase breather – Oil mist fine separator replacement

Preconditions



Designation / Use

Engine oil

Oil mist fine separator

O-ring

Part No.

(→ Spare Parts Catalog)


WARNING

Oil is hot.

Oil can contain residue/substances which are harmful to health.

Risk of injury and poisoning!

• Allow the product to cool to below 50 °C before beginning work.

• Wear protective clothing, protective gloves and goggles/safety mask.

• Avoid contact with skin.

• Do not inhale oil vapor.

Replacing oil mist fine separator

1.

Remove screws (1) and washer (2) and take off together with plug (6).

2.

Remove both retainers (3).

3.

Replace oil mist fine separator (4).

4.

Replace O-ring (5) as necessary.

5.

Replace other oil mist fine separators in the same way.

Qty.

148 | Crankcase Breather | MS15034/00E 2018-08

8.5 Valve Drive

8.5.1 Valve gear – Lubrication

Preconditions



Designation / Use

Engine oil

Valve gear – Lubrication

1.

Remove cylinder head covers (→ Page 153).

2.

Fill oil chambers of valve bridges with oil.

3.

Fill oil chambers of rocker arms and adjusting screws with oil.

4.

Install cylinder head covers (→ Page 153).

Part No.

Qty.

MS15034/00E 2018-08 | Valve Drive | 149


Preconditions


☑ Engine coolant temperature is max. 40 °C.

☑ Valves are closed.


Designation / Use

Feeler gauge

Torque wrench, 60–320 Nm

Socket wrench, 24 mm

Engine oil


1.


2.

Install barring device (→ Page 141).

Note: The pointer (1) is in the lower opening of the flywheel housing (arrow).

3.

Use barring device to turn crankshaft in engine direction of rotation until marking

OT/A1 on the rear side of the flywheel and pointer (1) are aligned.

Part No.

Y20098771

F30452768

F30039526

Qty.

1

1

1

150 | Valve Drive | MS15034/00E 2018-08

Note: Danger of interchanging: Additional marking

OT/A1 (1) on outer circumference, if applicable.

4.

Additional OT/A1 (1) marking on the outer circumference of flywheel must not be used.

Diagram for 8V engines (two crankshaft positions)

Checking valve clearance at two crankshaft positions

1.

Check TDC position of piston in cylinder A1:

• The piston is in firing TDC when the rocker arms on cylinder A1 are unloaded.

• The piston is in overlap TDC when the rocker arms on cylinder A1 are loaded.

2.

Check valve clearance setting with engine cold:

• Inlet (long rocker arm) = 0.2 ±0.05 mm

• Exhaust (short rocker arm) = 0.5 ±0.0 5mm

3.

Check all valve clearances in two crankshaft positions (firing TDC and overlap TDC of cylinder A1) as per diagram:

1 Cylinder A1 is in firing TDC

2 Cylinder A1 is in overlap TDC

I Inlet valve

X Exhaust valve

4.

Use feeler gauge to determine the distance between valve bridge and rocker arm.

5.

Adjust valve clearance if the deviation from the set value exceeds 0.1 mm.

MS15034/00E 2018-08 | Valve Drive | 151

Adjusting valve clearance

1.

Release locknut (1).

2.

Insert feeler gauge (3) between valve bridge and rocker arm.

Note: Replace or loosen stiff adjusting screws and/or locknuts.

3.

Using Allen key, set adjusting screw (2) so that the specified valve clearance is provided.

Note: Feeler gauge must just pass through the gap.

4.

Pull feeler gauge (3) between valve bridge and rocker arm.

5.

Tighten locknut (1) with torque wrench to the specified tightening torque, holding the adjusting screw (2) to prevent it from turning.

Name

Locknut

Size Type

Tightening torque

Lubricant Value/Standard

90 Nm + 9 Nm

6.

Check valve clearance, adjust if necessary.

Final steps

1.

Remove barring device (→ Page 141).

2.


152 | Valve Drive | MS15034/00E 2018-08


Preconditions



Designation / Use

Gasket

Removing cylinder head cover

1.

Clean very dirty cylinder head covers (3) prior to removal.

2.

Undo screws (1) and remove with washers (2).

3.

Remove cylinder head cover (3) with gasket (4) from cylinder head.

4.

Remove other cylinder head covers in the same way.

Part No.


Qty.

Installing cylinder head cover

1.

Clean mating faces.

2.

Check gasket (4) for damage, replace if necessary.

3.

Place gasket (4) and cylinder head cover (3) onto cylinder head.

4.

Install cylinder head cover (3) with screws (1) and washers (2).

5.

Install other cylinder head covers in the same way.

MS15034/00E 2018-08 | Valve Drive | 153


Preconditions



Designation / Use


Ratchet bit

Assembly compound (Kluthe Hakuform 30-15)

Engine oil

O-ring

Removing cylinder head cover

1.

Clean very dirty cylinder head covers (1) prior to removal.

2.

Remove screws (3, 4) with washers (2, 5).

3.

Take off cylinder head cover with O-ring (6) from cylinder head (7).

Part No.

F30510423

F30027341

X00067260


Qty.

1

Installing cylinder head cover

1.

Clean installation surface.

2.

Check O-ring (6) for damage, replace as necessary.

3.

Coat O-ring (6) with assembly compound.

4.

Insert O-ring (6) in groove on cylinder head cover (1).

5.

Place cylinder head cover (7) on cylinder head.

6.

Install cylinder head cover with screws (3, 4) and washers (2, 5).

7.

Tighten screws (3), (4) to specified tightening torque using a torque wrench.

Name

Screw

Size

M10

Type

Tightening torque

Lubricant

(Engine oil)

Value/Standard

42 Nm

154 | Valve Drive | MS15034/00E 2018-08

8.6 Injection Pump / HP Pump

8.6.1 HP fuel pump – Filling with engine oil

Preconditions



Designation / Use


Fuel suction device

Engine oil

WARNING

Part No.

F30452769

F30378207

Fuels are combustible and explosive.

Risk of fire and explosion!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

• Wear protective clothing, protective gloves, and safety glasses / facial protection.

WARNING

Liquid or gaseous media, e.g. fuel, are poisonous.

Escaping vapors of highly volatile media, e.g. fuel or ether.

Risk of fatal injury through swallowing; risk of poisoning through inhalation; irritation to eyes and skin!

• Seek medical attention immediately; do not induce vomiting.

• Do not inhale vapors or mist.

• Wear protective clothing, protective gloves, and safety glasses.

• If contact is made with skin, wash off with water and soap.

Qty.

1

1

WARNING

Oils/oil vapors are combustible/explosive.


• Avoid open flames, electric sparks and ignition sources.

• Do not smoke.

NOTICE

HP fuel pump not filled with engine oil.

Damage to components, major material damage!

• Ensure that th HP fuel pump is filled with engine oil before it is installed or put into operation.

NOTICE

Contaminated components.

Risk of damage to component!

• Check components for special cleanliness and clean if necessary.

MS15034/00E 2018-08 | Injection Pump / HP Pump | 155


u Loosen nut (2) and remove oil line (1) from

HP pump.

HP pump – Filling

1.

Remove union (1).

Note: Excess engine oil runs into gear box.

2.

Use fuel suction device to fill HP pump with

2 liters of clean engine oil.

3.

Screw in union (1) and use torque wrench to tighten to specified tightening torque.

Name

Neck

Size

M16x1.5

Type

Tightening torque

Lubricant

Final steps

u Install oil line.

Value/Standard

40 Nm

156 | Injection Pump / HP Pump | MS15034/00E 2018-08

8.6.2 HP fuel pump – Relief bore check

DANGER




WARNING




HP fuel pump, checking relief bore

1.

Visually inspect relief bore (1) for fuel discharge.

2.

If fuel discharge is found or indicated, contact Service.

MS15034/00E 2018-08 | Injection Pump / HP Pump | 157

8.7 Injection Valve / Injector

8.7.1 Injector – Replacement


Designation / Use

Injector

Replacing injector

u

Remove injector and install new injector (→ Page 159).

Part No.


Qty.

158 | Injection Valve / Injector | MS15034/00E 2018-08

8.7.2 Injector – Removal and installation (jacketed fuel system)

Preconditions



Designation / Use

Installation/removal jig

Milling cutter


Ratchet bit


Ratchet bit

Assembly compound (Molykote P 37)


Multi-purpose grease

Engine oil

Damping ring

O-ring

O-ring

Sealing ring

O-ring

Part No.

F6789889

F30452739

F30452769

F30027340

F30452768

F30027342

50564

X00067260

40320






WARNING




• Do not smoke.


WARNING








1

1

1

2

1

Qty.

1

1

1

1

1

1

1

1

1

WARNING

Hot components/surfaces.

Risk of burns!

• Allow the engine to cool down to below 50 °C before beginning work.

• Wear suitable protective equipment/thermal gloves.

• Avoid unprotected contact with hot surfaces.

MS15034/00E 2018-08 | Injection Valve / Injector | 159

WARNING

Internal load and residual pressure in the HP fuel system. Parts may be expelled at high speed on release.

Fuel may spurt out.

Risk of injury by flying parts and sprayed fuel!

• Only use specified tools and devices.

• Always wear protective goggles / safety mask.

NOTICE

Contamination of components.

Damage to component!


• Check components for special cleanliness.


1.

Allow HP system to cool down.

2.

Shut off fuel supply to engine.

3.


Removing injector

1.

Disconnect cable connector on injector.

Note: When the plug screw (1) is removed, fuel emerges.

2.

Place a suitable collecting vessel underneath.

3.

Remove plug screw (1).


Note: Observe system pressure.

4.

Slowly loosen union on HP line (4).

5.

Remove HP line (4).

Note: The fuel stored in the injector drains out when the adapter (3) is unscrewed.

6.

Unscrew adapter (3).

Note: Components are sensitive.

7.

Protect contact surfaces of HP line (4) and adapter (3) on cylinder head and the HP line

(4) itself against damage.

8.

Unscrew screw (2).

9.

Install installation/removal jig on cylinder head.

10.

Remove injector with installation/removal jig and take off hold-down clamp.

11.

Remove installation/removal jig.

Note: The sealing ring (4) for sealing the combustion chamber must only be used once.

12.

Remove sealing ring (4) from injector or use a self-made wire hook or magnet to take it out of the cylinder head and dispose properly.

Note: For new assembly:

13.

Dispose of injector with O-rings in place.

Note: For repeated assembly:

14.

Remove O-rings (3), O-ring (2) and damper ring (1) from injector.

15.

Clean all mating and sealing surfaces.

16.

Cover all connections and bores, or seal with suitable plugs.


Installing injector

Note: • The new sealing ring is included in the scope of supply of the injector (new part).

• Use a multi-purpose grease without solids content.

1.

Install new sealing ring (1) with multi-purpose grease and ensure that the installation position is correct.

Note: If the milling cutter is pressed with excessive force into the seat of the injector, this can cause damage to the cylinder head.

2.

Remove oil carbon from sealing face on cylinder head and protective sleeve by using the milling cutter with little force.

Note: Remove seal plugs on HP line only before installation of the adapter.

3.

Remove seal plug.

Note: The damper ring is already in place for new assembly. Coat damper ring with assembly compound.

4.

Fit damper ring (1) on injector and coat with assembly compound (Molykote P 37).

Note: The O-rings are already in place for new assembly. Coat O-rings with assembly compound.

5.

Fit new O-rings (3) and (2) on injector and coat with assembly compound (Kluthe Hakuform 30-15).

Note: Make sure that the sealing ring does not fall into the water sleeve.

6.

Ensure that the sealing ring (4) is correctly seated.

7.

Insert injector with hold-down clamp into cylinder head, ensuring that the HP line connection is correctly aligned.


8.

Press in injector with installation/removal jig.

9.

Remove installation/removal jig.

10.

Coat screw mating face (2) and thread with engine oil.

11.

Fit hold-down clamp (1) in correct position, fit screw (2) and tighten by hand.

Note: Make sure parts are perfectly clean.

12.

Apply engine oil to thread, sealing taper and thrust ring of adapter (3).

13.

Coat O-ring on adapter (3) with assembly compound (Kluthe Hakuform 30-15).

14.

Install adapter (3).

15.

Use torque wrench to tighten screw (2) to specified tightening torque.

Name

Screw

Size

M12

Type

Tightening torque

Lubricant

(Engine oil)

16.

Use torque wrench to tighten adapter (3) to specified tightening torque.

Name

Adapter

Size Type

Tightening torque

Lubricant

(Engine oil)

Note: Make sure parts are perfectly clean.

17.

Coat thread and sealing cone of HP line (5) with engine oil.

18.

Coat O-rings with assembly compound (Kluthe Hakuform 30-15).

19.

Thread in HP line (5), ensuring that the sealing areas are not damage.

Value/Standard

100 Nm+10 Nm

Value/Standard

100 Nm+10 Nm


20.

Use torque wrench to tighten jacketed HP line (5) according to tightening sequence to specified tightening torque. Tightening sequence:

1 Adapter (4)

2 Rail (6)

Name

Union nut / thrust screw

Size Type

Tightening torque

Lubricant

(Engine oil)

Value/Standard

40 Nm +5 Nm

Note: Do not hold in place by hand.

21.

Turn union nuts (4) and (6) back by approx. 45° angle of rotation and – without releasing the tool – tighten immediately again to the specified tightening torque, following the same sequence. Tightening sequence:

1 Adapter (4)

2 Rail (6)

Name

Union nut / thrust screw

Size Type

Tightening torque

Lubricant

(Engine oil)

Value/Standard

40 Nm +5 Nm

22.

Screw in plug screw (1) and use torque wrench to tighten to specified tightening torque.

Name

Plug screw

Size

M10

Type

Tightening torque

Lubricant

(Engine oil)

Value/Standard

15 Nm +3 Nm


23.

Fit cable connector on injector.

For new assembly: CDC parameters – Reset

Note: Failure to reset drift compensation (CDC) will void the emissions certification of the engine.

u Reset drift compensation (CDC) with DiaSys® (→ Dialog system DiaSys® E531920/..). If DiaSys® is not available, contact Service.

Final steps

1.


2.

Open fuel supply to engine.


8.8 Fuel Filter

8.8.1 Additional fuel filter – Overview

1 Storage tank

2 Day tank

3 Passive fuel prefilter with water separator

4 LP pump

5 Additional fuel filter, switchable

6 Main engine filter, switchable

166 | Fuel Filter | MS15034/00E 2018-08

8.8.2 Additional fuel filter – Replacement

Preconditions



Designation / Use

Filter wrench

Diesel fuel

Easy-change filter

Synthetic ring

DANGER

Part No.

F30379104






Qty.

1

WARNING

WARNING




• Do not smoke.





NOTICE

Damage to component!

Severe material damage!

• For filter replacement with the engine running, operate the engine at low engine load.

• The filter which is to be replaced must be cut out for a brief period only.

Additional fuel filter – Replacement

1.

Replace additional fuel filter with the engine at standstill (→ Page 168).

2.

Replace additional fuel filter with the engine running (→ Page 168).

MS15034/00E 2018-08 | Fuel Filter | 167

8.8.3 Fuel filter – Replacement

Preconditions



Designation / Use

Filter wrench

Diesel fuel

Easy-change filter

Synthetic ring

DANGER

Part No.

F30379104






Qty.

1

WARNING

WARNING




• Do not smoke.





NOTICE





Replacing fuel filter with the engine stopped

A Both filters cut in

B Left filter cut out

C Right filter cut out

1 Fuel filter

168 | Fuel Filter | MS15034/00E 2018-08

1.

Cut out the filter to be replaced.

2.

Unscrew cut-out easy-change filter with oil filter wrench.

3.

Clean sealing surface on filter head.

4.

Check sealing ring of the new easy-change filter and moisten it with fuel.

5.

Fit SOLAS shield (REFDM TARGET NOT FOUND) .

6.

Screw on easy-change filter and tighten by hand.

7.

Set three-way cock to operating position (both filters cut in).

8.

Replace other fuel filters in the same way.

9.

Vent fuel system.

Replacing fuel filter with the engine running

1.

Cut out the filter to be replaced.

B Left-hand filter cut out

C Right-hand filter cut out

2.

Unscrew cut-out easy-change filter with oil filter wrench.

3.

Clean sealing surface on filter head.

4.

Check sealing ring of the new easy-change filter and moisten it with fuel.

5.

Fit SOLAS shield


6.

Screw on easy-change filter (1) and tighten by hand.

7.

Set three-way cock to operating position

(both filters cut in).

8.

Replace other fuel filters in the same way.

MS15034/00E 2018-08 | Fuel Filter | 169

8.8.4 Fuel prefilter – Differential pressure gage check and adjustment

DANGER




WARNING




Adjusting differential pressure gage

1.

When putting the new filter element into operation: Align adjustable pointer (2) with pressure-indicating pointer (3) of pressure gage (1).

2.

Verify that differential pressure is within the limit.

Fuel prefilter – Differential pressure check

1.

With the engine running at full load or rated power, read off pressure at gage (1).

2.

If differential pressure as indicated between position of adjustable pointer (2) and pressure-indicating point-

er (3) of pressure gage is ≥ 0.3 bar, flush filter element of the cut-in filter (→ Page 173).

170 | Fuel Filter | MS15034/00E 2018-08

8.8.5 Fuel prefilter – Draining

DANGER




WARNING

WARNING

WARNING











• Do not smoke.





Draining fuel prefilter

1.

Cut out the filter to be drained (A or B):

1 Filter A cut out

2 Filter B cut out

MS15034/00E 2018-08 | Fuel Filter | 171

2.

Open vent valves (1) of filter to be drained.

3.

Open drain valve (2).

4.

Drain water and contamination from filter until clean fuel emerges.

5.

Close drain valve (2).

6.

Open rotary slide valve (2) a little (turning to approx. 30°) to introduce fuel into the filter housing with the new filter element.

7.

Close vent valve (1) as soon as fuel emerges from vent pipe (4).

8.

Turn the rotary slide valve to the upright position (3) until it engages.

Result: Both filters are cut in.

9.

Set differential pressure gage (→ Page 170).

172 | Fuel Filter | MS15034/00E 2018-08

8.8.6 Fuel prefilter – Flushing

Preconditions

☑ Positive pressure at the prefilter inlet.

DANGER




WARNING

WARNING

WARNING











• Do not smoke.





Fuel prefilter – Flushing

1.

Cut out contaminated filter (A or B).

1 Filter A cut out

2 Filter B cut out

MS15034/00E 2018-08 | Fuel Filter | 173

2.

Open threaded vent plug (1) of the filter to be flushed.

3.

Remove drain valve (2) and drain fuel.

Result: Fuel flows from filtered side back to the unfiltered side, flushing the filter deposits downwards out of the filter.

4.

Close threaded vent plug (1) and drain valve (2).

5.


6.

Close vent valves (1) as soon as fuel emerges from vent pipe (4).

7.



8.

Set differential pressure gauge (→ Page 170).

174 | Fuel Filter | MS15034/00E 2018-08

8.8.7 Fuel prefilter with water separator – Filter element replacement

Preconditions

☑ Positive pressure at the prefilter inlet


Designation / Use


Ratchet adapter

Filter element

O-ring

Part No.

F30452769

F30027340



DANGER




Qty.

1

1

WARNING

WARNING

WARNING

WARNING

NOTICE

Tank is pressurized.

Risk of eye injuries resulting from fluid escaping under high pressure!

• Open tank slowly.

• Wear goggles or safety mask.











• Do not smoke.


Hot components/surfaces.

Risk of burns!

• Allow the engine to cool down to below 50 °C before beginning work.

• Wear suitable protective equipment/thermal gloves.

• Avoid unprotected contact with hot surfaces.





MS15034/00E 2018-08 | Fuel Filter | 175

Fuel prefilter with water separator – Filter element replacement

1.

Cut out the filter to be replaced (A or B):

1 Filter A cut out

2 Filter B cut out

2.

Open vent valve (3) of the filter to be replaced.

3.

Unlock drain valve (4) by pressing toggle and open it.

4.

Drain water and contaminants from filter.

5.

Close drain valve.

6.

Loosen screws (1) and (2).

7.

Turn filter housing aside around screw (2) until filter element is accessible.

8.

Remove filter element (5) with spring (6).

9.

Insert a new filter element in the filter housing.

10.

Insert new O-ring and turn filter housing back into position.

11.

Tighten screws (1) and (2) finger-tight.

12.

Tighten screws evenly to specified torque using a torque wrench (max. half a turn per screw).

Name

Screw

Size Type

Tightening torque

Lubricant Value/Standard

40 Nm

176 | Fuel Filter | MS15034/00E 2018-08

13.


14.

Close vent valve (1) as soon as fuel emerges from vent pipe (4).

15.



16.

Set differential pressure gage (→ Page 170).

MS15034/00E 2018-08 | Fuel Filter | 177

8.8.8 Fuel prefilter with water separator – O-ring replacement in rotary slide valve

Preconditions


☑ System is at atmospheric pressure.


Designation / Use

O-ring

Part No.


Qty.

WARNING

Tank is pressurized.

Risk of eye injuries resulting from fluid escaping under high pressure!

• Open tank slowly.

• Wear goggles or safety mask.

WARNING








WARNING




• Do not smoke.


Fuel prefilter with water separator – O-ring replacement in rotary slide valve

1.

Open vent valves (1) carefully to make sure that the system is not pressurized.

2.

Open drain valves (6) and drain fuel.

3.

Remove rotary slide valve retainer (4) with handle (5).

4.

Remove rotary slide valve (3) with O-rings (2).

5.

Replace O-rings (2).

6.

For assembly, follow the reverse sequence of working steps as described for disassembly.

178 | Fuel Filter | MS15034/00E 2018-08

8.9 Exhaust Turbocharger

8.9.1 Compressor wheel – Cleaning

Preconditions

☑ Engine is stopped and starting disabled


Designation / Use

Torque wrench, 4-20 Nm

Cleaning agent

Engine oil

Engine coolant

Sealing rings

Sealing rings

WARNING

Chemical substances.

Risk of irritation or burning of eyes, skin and airways!

• Observe information provided in the relevant safety data sheet.

• Wear protective gear as specified in the relevant safety data sheet.

Part No.

F30044239

40377



NOTICE

Inappropriate cleaning tool.



• Use appropriate cleaning tool.

NOTICE

Incorrect installation of components and lines.


• Ensure that components/lines are installed so that they are never under tension or strain.

• Ensure correct installation position of components.


1.

Drain engine coolant (→ Page 207).

2.

Remove air filter (→ Page 186).

3.

Seal openings with suitable covers.

Qty.

1

1

5

7

MS15034/00E 2018-08 | Exhaust Turbocharger | 179

4.

Remove air pipework (1) from exhaust turbocharger to charge-air cooler.

5.

Disconnect oil lines (2) from air flap actuator cylinder.

6.

Undo screws (3) and clamp (2).

7.

Remove intake housing (1) with actuating cylinder.

8.

Remove coolant lines (1) on compressor casing.

180 | Exhaust Turbocharger | MS15034/00E 2018-08

9.

Undo clamp (2).

10.

Remove compressor casing (1).

Cleaning compressor wheel

Note: Do not use wire brushes, scrapers or similar implements for cleaning!

1.

Clean compressor casing with a soft brush.

2.

Clean compressor wheel (2) and bearing housing (1).

3.

Thoroughly remove cleaning agent from all parts.

4.

Replace sealing rings between bearing housing/compressor casing and plug-in sleeves as necessary.

Final steps

1.

Reinstall compressor casing (1).


2.

Align clamp (2) and tighten to specified torque using a torque wrench.

Name

Clamp

Size Type

Tightening torque

Lubricant

(Engine oil)

3.

Install coolant lines (1) on compressor casing.

Value/Standard

5 Nm +1 Nm

4.

Install intake housing (1) with actuating cylinder.

5.

Align clamp (2) and tighten to specified torque using a torque wrench.

Name

Clamp

Size Type

Tightening torque

Lubricant

6.

Tighten screws (3) on holder.

Value/Standard

15 Nm +2 Nm

182 | Exhaust Turbocharger | MS15034/00E 2018-08

7.

Install oil lines (2).

8.

Install air pipework (1) from exhaust turbocharger to charge-air cooler.

9.

Install air filter (→ Page 186).

10.

Fill with engine coolant (→ Page 208).


8.10 Charge-Air Cooling

8.10.1 Intercooler – Check water drain for coolant leakage and obstruction

DANGER




WARNING




WARNING





Checking intercooler water drain for coolant leakage and obstruction

1.

With the engine running check the drain bore(s) on the right and left of the engine for emerging air (at driving end). If no air escapes:

2.

Clean drain bore(s) and blow out with compressed air.

3.

More significant coolant leakage indicates a leaking intercooler. Contact the Service.

Emergency measures prior to engine start with a leaking intercooler

1.

Remove injectors (→ Page 159).

2.

Bar engine manually (→ Page 141).

3.

Crank engine on starting system to blow out cylinder chambers (→ Page 141).

4.

Install injectors (→ Page 159).

184 | Charge-Air Cooling | MS15034/00E 2018-08

8.11 Air Filter

8.11.1 Air filter – Replacement


Designation / Use

Air filter

Replacing air filter

1.

Remove old air filter and install new air filter (→ Page 186).

2.

Reset signal ring of contamination indicator (→ Page 187).

Part No.


Qty.

MS15034/00E 2018-08 | Air Filter | 185

8.11.2 Air filter – Removal and installation

Preconditions


Air filter – Removal and installation

1 Intake housing

2 Clamp

3 Air filter

1.

Loosen clamp (2).

2.

Remove air filter (3) and clamp (2) from flange of intake housing (1).

3.

Verify that there are no objects in the flange of the intake housing (1) and clean it.

4.

Place new air filter (3) with clamp (2) onto intake housing (1).

5.

Tighten clamp (2).

186 | Air Filter | MS15034/00E 2018-08

8.12 Air Intake

8.12.1 Contamination indicator – Signal ring position check

Preconditions


WARNING

The engine draws in large volumes of ambient air for combustion. This air intake results in a strong vacuum.

Risk of injury if body parts are drawn in! There is also a danger if opening of the entrance door can be prevented!

• Only operate the engine with installed air filters.

• Never open air-carrying components during operation.

• Ensure that the engine room is well-ventilated.

Checking signal ring position

1.

If the signal ring is completely visible in the viewing window (2), replace air filter

(→ Page 185).

2.

After installation of new filter, press reset button (1).

Result: Engaged plunger with signal ring returns to initial position.

MS15034/00E 2018-08 | Air Intake | 187

8.13 Starting Equipment

8.13.1 Starter – Condition check

Preconditions


Starter – Condition check

1.

Check securing screws of starter and nut on cable connection for secure seating and tighten if required.

2.

Check cabling (→ Page 234).

188 | Starting Equipment | MS15034/00E 2018-08

8.14 Lube Oil System, Lube Oil Circuit

8.14.1 Engine oil level – Check

Preconditions


WARNING

Oil is hot.







Checking engine oil level after extended standstill

1.

Pull out dipstick from guide tube and wipe it.

2.

Insert oil dipstick into guide tube up to the stop, pull it out after approx. 10 seconds and check oil level.

Note: After extended standstill, the oil level may be up to 2 cm above mark (1). This may be caused e.g. by oil from oil filters and heat exchangers flowing back into the oil pan. After extended standstill, the oil level "2 cm above mark (2)" is the minimum oil level.

3.

Oil level must be at least 2 cm above mark (2).

4.

If necessary, top up with oil, maximum to

mark (1) (→ Page 190).

5.

Insert oil dipstick into guide tube up to the stop.

Checking oil level immediately after engine stop

1.

5 minutes after stopping the engine, pull out oil dipstick from guide tube and wipe it.

2.

Insert oil dipstick into guide tube up to the stop, pull it out after approx. 10 seconds and check oil level.

3.

Oil level must be between marks (1) and (2).

4.

If necessary, top up with oil, maximum to mark (1) (→ Page 190).

5.

Insert oil dipstick into guide tube up to the stop.

MS15034/00E 2018-08 | Lube Oil System, Lube Oil Circuit | 189

8.14.2 Engine oil – Change

Preconditions


☑ Engine is at operating temperature.

☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.


Designation / Use


Ratchet bit

Engine oil

Sealing ring

Part No.

F30027337

F30027341


WARNING

Oil is hot.







Qty.

1

1

Oil change without semirotary hand pump: Draining oil at drain plug(s) on oil pan

1.

Provide a suitable vessel in which to collect the engine oil.

2.

Remove drain plug(s) and drain engine oil.

3.

Install drain plug(s) with new sealing ring.

Oil change with semirotary hand pump: Engine oil extraction

1.


2.

Extract all oil from oil pan using the semirotary hand pump.

Draining residual oil at gearcase

1.


2.

Remove drain plugs (1) and (2) and drain engine oil:

• Approx. 12 liters at (1)

• Approx. 5 liters at (2)

3.

Install drain plug(s) with new sealing ring.

190 | Lube Oil System, Lube Oil Circuit | MS15034/00E 2018-08

4.

Tighten drain plugs (1) and (2) to specified torque using a torque wrench:

Name

Screw

Size

M26x1.5

Type

Tightening torque

Lubricant

(Engine oil)

Filling with new engine oil

1.

Open cap (1) on filler neck.

2.

Pour oil in at filler neck up to “max.” mark on oil dipstick.

3.

Close cap on filler neck.

4.

Check engine oil level (→ Page 189).

5.

Bar engine with starting system after engine

oil change (→ Page 143).

Value/Standard

100 Nm+10 Nm



Preconditions



Designation / Use

MTU test kit

Part No.

5605892099/00

DANGER




WARNING

WARNING

Oil is hot.










Engine oil sample extraction and analysis (engine with standard oil filter)

Note: Only take the engine oil sample by opening an oil drain screw with the engine stationary.

1.

With the engine shut down, open the screw, e.g. at the oil filter.

2.

Drain approx. 1 liter engine oil into a clean container.

3.

Seal oil drain screw again with a new sealing ring.

4.

Using the equipment and chemicals in the

MTU test kit, analyze the engine oil for:

• Dispersion capability (spot test)

• Proportion of water

• Fuel dilution

Qty.

1

192 | Lube Oil System, Lube Oil Circuit | MS15034/00E 2018-08

Engine oil, sample extraction and analysis

1.

With the engine running at operating temperature, open screw on centrifugal oil filter carrier by 1 to 2 rotations.

2.

Drain approx. 2 liters engine oil to flush out the oil sludge.

3.


4.

Close screw.

5.





• Fuel dilution

Engine oil, sample extraction and analysis (engine with switchable oil filter)

1.

With the engine running at operating temperature, open screw on flange of centrifugal oil filter by 1 to 2 rotations.

2.

Drain approx. 2 liters engine oil to flush out the oil sludge.

3.


4.

Close screw.

5.





• Fuel dilution


8.15 Oil Filtration / Cooling

8.15.1 Engine oil filter – Replacement


Designation / Use

Filter wrench

Engine oil

Oil filter

DANGER

Part No.

F30379104





Qty.

WARNING




WARNING

Oil is hot.







NOTICE





Engine oil filter – Replacement

1.

Stop engine (→ Page 92) and disable engine

start.

2.

Unscrew engine oil filter using filter wrench.

3.

Clean sealing surface on connecting piece.

4.

Check condition of the new engine oil filter sealing ring and coat it with engine oil.

5.

Fit SOLAS shield


6.

Screw on engine oil filter and tighten by hand.

7.

Replace other engine oil filters in the same way.

8.

Crank engine on starting system after every engine oil change and filter replacement

(→ Page 143).

9.


194 | Oil Filtration / Cooling | MS15034/00E 2018-08

Engine oil filter with diverter

(option) – Oil filter replacement with engine at standstill

1.


start.

2.


3.


4.


5.

Fit SOLAS shield


6.


7.


8.

Crank engine on starting system after every engine oil change and filter replacement

(→ Page 143).

9.


Engine oil filter with diverter

(option) – Oil filter replacement with engine running

1.

To cut out the filter to be replaced, set the three-way cock to the corresponding position.

• Position A: Lower filters cut out

• Position B: Both filters cut in (normal operating position)

• Position C: Upper filters cut out

2.


3.


4.


5.

Fit SOLAS shield


6.


7.


8.


MS15034/00E 2018-08 | Oil Filtration / Cooling | 195

8.15.2 Oil indicator filter – Cleaning and check

Preconditions



Designation / Use

Cleaner (Snow-White 11-0)

Cleaner (Hakupur 50/136)

Engine oil

Strainer

Square-section ring

O-ring

WARNING

Part No.

X00054118

X00056700




Oil is hot.







WARNING





NOTICE

Inappropriate cleaning tool.



• Use appropriate cleaning tool.

Removing basket strainer – variant A

1.

Clean oil indicator filter before disassembling it.

2.

Remove screws (1).

3.

Take off cover (2) and O-ring (3).

4.

Remove spring (4) and strainer (6) from filter housing and allow oil to drip into container.

Qty.

1

1


Cleaning strainer

1.

Shake coarse contamination out of strainer (6).

2.

Clean all metallic parts with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 50/136).

Note: Do not damage the fabric of the strainer.

3.

Use a soft brush to remove stubborn deposits from strainer as necessary.

4.

Blow out strainer (6) with compressed air from outside to inside.

Checking strainer

Item

Strainer

Findings

Metallic residues

Strainer

Square-section ring

O-ring

Damaged

Damaged

Damaged

Task

• Clean

• Monitor engine operation

• Check strainer daily

• Contact Service.

Replace

Replace

Replace

Installing strainer

1.

Coat square-section ring (5) on strainer (6) with engine oil and install strainer (6).

2.

Coat O-ring (3) with engine oil and install in filter housing.

3.

Install spring (4).

4.

Fill housing with new engine oil.

5.

Install cover (2) and secure with screws (1) and washers.

Removing basket strainer – variant B

Note: Cover (2) is under tension due to spring (4).

1.

Remove screws (1).

2.

Take off cover (2) and O-ring (3).

3.

Remove spring (4).

4.

Take strainer (5) out of filter housing.

Cleaning strainer

1.

Shake coarse contamination out of strainer (5).

2.

Clean all metallic parts with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 50/136).

Note: Do not damage the fabric of the strainer.

3.

Use a soft brush to remove stubborn deposits from strainer as necessary.

4.

Blow out strainer (5) with compressed air from outside to inside.


Checking strainer

Item

Strainer

Strainer

Square section ring

Spring

O-ring

Findings

Metallic residues

Damaged

Damaged

Damaged

Damaged

Task

• Clean

• Monitor engine operation

• Check strainer daily

• Contact Service.

Replace

Replace

Replace

Replace

Installing strainer

1.

Coat square section ring on basket strainer (5) with engine oil and install basket strainer (5).

2.

Coat O-ring (3) with engine and install in filter housing.

3.

Move spring (4) into fitting position.

4.

Install cover (2) and secure with screws (1).


8.15.3 Centrifugal oil filter – Cleaning and filter sleeve replacement

Preconditions



Designation / Use



Ratchet bit

Cold cleaner (Hakutex 60)


Engine oil

Filter sleeve

Sealing ring

Sealing ring

Sealing ring

Part No.

F30044239

F30026582

F30027340

X00056750

X00067260





WARNING

Oil is hot.







WARNING





Qty.

1

1

1

1


Centrifugal oil filter – Cleaning and filter sleeve replacement

1.

Remove clamp (14).

2.

Loosen Tommy nut (2) and take off hood (1).

3.

Carefully lift rotor (11), allow oil to drain and remove from housing.

4.

Holding the rotor (11) firmly, loosen rotor cover nut (3).

5.

Take off rotor cover (4).

6.

Remove filter sleeve (6).

7.

Measure layer thickness of oil residues on filter sleeve (6).

Result: If the oil residues exceed the maximum layer thickness of 45 mm, shorten the maintenance interval.

8.

Disassemble rotor tube (7), conical disk (8) and rotor base (10).

9.

Wash rotor cover (4), rotor tube (7), conical disk (8) and rotor base (10) with cold cleaner.

10.

Blow out with compressed air.

11.

Check sealing ring (9), fit new one as necessary.

12.

Assemble rotor tube (7), conical disk (8) and rotor base (10) with sealing ring (9).

13.

Insert new filter sleeve (6) in rotor tube (7) with the smooth paper surface facing the outer wall.

14.


15.

Mount rotor cover (4) with sealing ring (5).

16.

Tighten rotor cover nut (3) to specified torque using a torque wrench.

Name

Nut

Size Type

Tightening torque

Lubricant

17.

Place rotor (11) in housing (12) and check for ease of movement.

18.


19.

Fit sealing ring (13) on housing (12).

20.

Fit hood (1).

21.

Tighten Tommy nut (2) by hand.

22.

Install clamp (14) and tighten to specified torque using a torque wrench.

Name

Clamp

Size Type

Tightening torque

Lubricant

23.

Tighten cover nut (2) to specified torque using a torque wrench.

Name

Screw

Size Type

Tightening torque

Lubricant

Value/Standard

80 Nm ± 12 Nm

Value/Standard

20 Nm ± 3 Nm

Value/Standard

7 Nm ± 1 Nm


Cleaning centrifugal oil filter and replacing filter sleeve (oil filters with diverter)

1.

Undo screw (1) and remove.

2.

Remove clamp (3) and take off hood (2).

3.

Carefully remove rotor assembly (5) from housing.

4.

Hold rotor assembly (5) firmly in position with filter wrench and undo knurled nut (7).

5.

Take off rotor cap (8).

6.

Take off filter sleeve (9), stiffener plate (10 ) and sealing ring (11).

7.

Measure thickness of oil residue on filter sleeve.

8.

If maximum layer thickness of oil residues exceeds 30 mm, shorten maintenance interval.

9.

Remove standpipe (12) from lower rotor section (13).

10.

Wash out hood (2), rotor cap (8), stiffener plate (10), stand pipe (12), base (13) and nozzles (14) with cleaner and blow out with compressed air. Do not use sharp-edged objects for cleaning.

11.

Check nozzles (14) for obstructions.

12.

Press standpipe (12) onto rotor lower section (13).

13.

Insert new filter sleeve (9) with stiffener plate (10) into rotor cap (8), ensuring that smooth surface of filter sleeve (9) faces rotor cap (8).

14.

Check sealing ring (11), replace as necessary. Coat sealing ring with grease and insert in groove of rotor cap (8).

15.

Place rotor cap (8) onto standpipe (12).

16.

Hold rotor assembly (5) firmly in position with filter wrench and tighten knurled nut (7).

17.

Lubricate bearings of rotor assembly (5), insert into housing (6) and check for ease of movement.

18.

Check sealing ring (4), replace as necessary.

Fit sealing ring on housing (6).

19.

Fit hood (2).

20.

Tighten screw (1) by hand.

21.

Install clamp (3) and tighten to specified torque using a torque wrench:

Name

Clamp

Size Type

Tightening torque

Lubricant

22.

Tighten screw (1) to specified torque using a torque wrench:

Name

Screw

Size Type

Tightening torque

Lubricant

Value/Standard

6 Nm + 1 Nm

Value/Standard

6 Nm + 1 Nm


8.16 Coolant Circuit, General, High-Temperature Circuit

8.16.1 Drain and vent points

Coolant line to carrier housing

1 Venting point

Coolant line to intercooler

Arrows Vent points

202 | Coolant Circuit, General, High-Temperature Circuit | MS15034/00E 2018-08

Coolant line to crankcase breather

1 Venting point

Coolant line to raw water cooler

1 Distribution cross

2 Venting point

MS15034/00E 2018-08 | Coolant Circuit, General, High-Temperature Circuit | 203

Coolant drain point, driving end

1 Drain points

Coolant drain point, free end

1 Drain point


8.16.2 Engine coolant level – Check

Preconditions



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.

Checking engine coolant level at filler neck:

1.

Turn breather valve on coolant expansion tank (for engines with remote heat exchanger: the expansion tank is part of the remote cooling system) counterclockwise up to the first stop and allow pressure to escape.

2.

Continue to turn breather valve counterclockwise and remove.

3.

Check coolant level (coolant must be visible at the bottom edge of the cast-in eye in the filler neck).

Checking engine coolant level at external cooler:

1.

Check coolant level (coolant must be visible at marker plate).

2.

Top up with treated coolant as necessary

(→ Page 208).

3.

Check and clean breather valve.

4.

Set breather valve onto filler neck and close it.

Checking engine coolant level by means of level sensor:

1.

Switch on engine control system and check readings on the display.

2.

Top up with treated coolant as necessary (→ Page 208).


8.16.3 Engine coolant – Change


Designation / Use

Coolant

Engine coolant change

1.

Drain engine coolant (→ Page 207).

2.

Fill with engine coolant (→ Page 208).

Part No.

Qty.


8.16.4 Engine coolant – Draining

Preconditions


WARNING






1.

Provide an appropriate container to drain the coolant into.

2.

Switch off preheating unit.

Engine coolant – Draining

1.

Turn breather valve on expansion tank (for engines with remote heat exchanger: the expansion tank is part of the remote cooling system) counterclockwise up to the first stop and allow pressure to escape.

2.

Continue to turn breather valve counterclockwise and remove.

3.

Draw off precipitated corrosion inhibitor oil from the expansion tank through filler neck.

4.

Open vent valves at the following points:

• On carrier housing and near the crankcase breather (1)

• On seawater cooler (2) (with remote heat exchanger, the seawater cooler is not engine-mounted)

5.

Open drain screws and drain engine coolant at the following drain points:

• Elbow of HT coolant pump (3)

• Crankcase, left and right side (4)

Final steps

1.

Close all open drain and vent points.

2.

Set breather valve onto filler neck and close it.


8.16.5 Engine coolant, filling

Preconditions




Designation / Use

Engine coolant

WARNING





NOTICE

Cold coolant in hot engine can cause thermal stress.

Possible formation of cracks in the engine!

• Fill / top up coolant only into cold engine.


1.

Turn valve cover (1) on expansion tank (for engines with remote heat exchanger: the expansion tank is part of the remote cooling system) counterclockwise up to the first stop and allow pressure to escape.

2.

Continue to turn valve cover counterclockwise and remove.

Part No.

Qty.


Filling with coolant through filler neck

1.

Open vent points on exhaust turbocharger, charge-air cooler, at the crankcase ventilation and on plate-core heat exchanger (arrows).

2.

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.

3.

When coolant emerges from the vent points, close vent points one by one, proceeding from the lowest point upwards.

4.

Check proper condition of valve cover and clean sealing faces if required.

5.

Set valve cover onto filler neck and turn until the first stop.

6.


7.

After 10 seconds of running the engine with-

out load, shut down the engine (→ Page 92).

8.

Turn valve cover counterclockwise and remove.

9.

Check coolant level (→ Page 205) and top up

coolant as required: a) Repeat the steps from "Start engine"

(→ Step 6) until coolant is no longer

needed to be topped up.

b) Check proper condition of valve cover and clean sealing faces if required.

c) Place valve cover on filler neck and close.

Final steps

1.

Start the engine and run it without load for some minutes.

2.

Check coolant level (→ Page 205) and top up coolant as required.


8.16.6 HT coolant pump – Relief bore check

DANGER




WARNING




HT coolant pump – Relief bore check

1.

Check relief bore for oil and coolant discharge.

2.

Stop engine (→ Operating Instructions for

Electronic System) and disable engine start.

3.

Clean relief bore with a wire if dirty.

• Admissible engine coolant discharge: up to

10 drops per hour;

• Admissible oil discharge: up to 5 drops per hour.

4.

Contact Service if discharge exceeds the specified limits.



Preconditions



Designation / Use

MTU test kit

DANGER

Part No.

F6798833




WARNING

WARNING








Engine coolant – Sample extraction and analysis

1.

Open drain valve on engine coolant pump elbow with the engine running.

2.

Drain off approx. 1 liter engine coolant.

Result: Sampling point is clean.

3.


Qty.

1

4.

Tighten shut-off cock (arrow) with torque wrench to the specified tightening torque.

Name

Spindle

Size

11a/f

Type

Tightening torque

Lubricant

5.

Using the equipment and chemicals of the MTU test kit, examine engine coolant for:

• antifreeze concentration

• concentration of corrosion protection oil

• pH value

6.

For engine coolant change intervals, see (→ MTU Fluids and Lubricants Specifications).

Value/Standard

12 Nm


8.16.8 Engine coolant filter – Replacement

Preconditions



Designation / Use

Filter wrench

Engine oil

Engine coolant filter

WARNING





Engine coolant filter – Replacement

1.

Remove locking device (1).

2.

Close shut-off cock (3).

3.

Remove engine coolant filter (2) with filter wrench.

4.


5.

Coat seal on new engine coolant filter (2) with engine oil.

6.

Screw on engine coolant filter (2) and tighten hand-tight.

7.

Open shut-off cock (3).

8.

Install locking device (1).

Part No.

F30379104


Qty.

1


8.16.9 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.


Checking operation

Note: The coolant temperature must correlate to the control range of the thermostat when the preheater is ready for operation.

1.

Check coolant preheating temperature.

2.

Set the thermostat accordingly if the temperatures are not in the control range.

Checking for leaks

1.

Check leak-tightness at coolant inlet and outlet.

2.

Tighten any leaking unions.


8.16.10 Preheating unit

HotstartPreheating unit

1 Plastic cap (drain)

2 On/Off switch

3 Plastic cap (inlet)

4 Shut-off valve

5 Continuous flow heater

6 Vent valve

Rated voltage / frequency

7 Thermostat

8 Circulating pump

Heating output kW Number of cylinders

8 V 230 V / 50 Hz

400 V / 50 Hz

230 V / 60 Hz

440 V / 60 Hz

9

9

9

9

Function

The preheating unit heats up the engine coolant. The circulating pump (8) ensures the circulation of the preheated coolant through the engine.

The flow heater (5) incorporates a heating element. When the coolant temperature has reached the value of the thermostat setting (7), the thermostat switches off the preheating unit via contactors.

In the event of excessive coolant temperature, the temperature limiter of the thermostat (7) opens the control loop. The preheating unit is switched off.

The system is reset manually after the fault has been eliminated.


HilzingerPreheating unit

Number of

8 V

1 On/Off switch

Rated voltage / frequency cylinders

230 V / 50 Hz

400 V / 50 Hz

230 V / 60 Hz

440 V / 60 Hz

Heating output kW

4.5

4.5

4.5

4.5


1 Flange (supply and return)

2 Junction box

3 Non-return flap

4 Continuous flow heater

5 Thermostat

6 Circulating pump

Function

The preheating unit heats up the engine coolant. The circulating pump (6) ensures the circulation of the preheated coolant through the engine.

The flow heater (4) incorporates a heating element. A non-return flap (3) prevents coolant from flowing through the preheating unit when the engine is running.

When the coolant temperature has reached the value of the thermostat setting, the thermostat (5) switches off the preheating unit via contactors.

In the event of excessive coolant temperature, the temperature limiter in the thermostat (5) opens the control loop. The preheating unit is switched off.

The system is reset manually after the fault has been eliminated.


8.16.11 Preheater – Overhaul

Preconditions


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





Overhauling preheater

1.

Disconnect power supply to heating element.

2.

Close shut-off valve in coolant line before and after preheater.

3.

Drain coolant at drain valve into a clean container.

4.

Clean and flush coolant circuit.

5.

Check hoses for cracks and other damage. Replace as necessary.

6.

Check wiring for damage and overheating.

7.

Remove heating element.

8.

Clean heating element and tank.

9.

Remove pump from volute (if applicable) and check for residues in impeller and lines.

10.

Install heating element.

11.

Connect heating element to power supply.

12.

Connect hoses and open shut-off valves.

13.

Check preheater for leakage and correct operation (→ Page 213).

14.



8.17 Raw Water Pump with Connections

8.17.1 Raw water pump – Relief bore check

DANGER




WARNING




Raw water pump – Relief bore check

1.

Check relief bore for oil and coolant discharge.

2.


start.

3.

Clean the relief bore with a wire if it is contaminated.

• Admissible engine coolant discharge: up to

10 drops per hour

• Admissible oil discharge: up to 5 drops per hour

4.

If discharge exceeds the specified limits, contact Service.

218 | Raw Water Pump with Connections | MS15034/00E 2018-08

8.18 Battery-Charging Generator

8.18.1 Battery-charging generator drive – Coupling condition check

Preconditions



Designation / Use

Endoscope

Part No.

Y20097353

Battery-charging generator drive, coupling condition check

1.

Install barring tool (→ Page 141).

2.

Guide endoscope optics between guard plate (1) and battery-charging generator carrier (2) (arrow).

Note: Seek the assistance of a second person

3.

Bar engine slowly by hand.

4.

Examine the resilient coupling over the entire circumference for plastic deformation and cracks.

5.

If there is serious deformation or crack formation, contact Service.

6.

Remove barring gear (→ Page 141).

Qty.

1

MS15034/00E 2018-08 | Battery-Charging Generator | 219

8.19 Engine Mounting / Support

8.19.1 Engine mounting – Checking resilient element

NOTICE

Contamination of engine mounts made of natural rubber with fuel or oil.

Engine mounts swell. Risk of shorter service life or destruction of the mounts!

• Cover engine mounts when working with fuel or oil.

• Remove contaminations on the rubber mounts immediately with a dry cloth and degrease them.

Engine mounting – Check

Item Findings

Visually inspect resilient elements. • Damage

• Brittleness

• Deformation

• Crack formation

• Swelling

Action

Replace (contact Service).

220 | Engine Mounting / Support | MS15034/00E 2018-08

8.20 Auxiliary PTO

8.20.1 Bilge pump – Relief bore check

DANGER




WARNING




Bilge pump – Relief bore check

1.

Check relief bores for oil and water discharge.

2.


start.

3.

Clean relief bores with a wire if dirty.

• Permissible water discharge: up to 10 drops per hour;

• Permissible oil discharge: up to 5 drops per hour

4.

If discharge exceeds the specified limits:

Contact Service.

MS15034/00E 2018-08 | Auxiliary PTO | 221

8.21 Fuel Supply System

8.21.1 Water drain valve – Check

Water drain valve – Check

1.

Open water drain valve.

2.

Check water outlet for obstructions.

3.

Close water drain valve.

222 | Fuel Supply System | MS15034/00E 2018-08

8.21.2 Differential pressure gage – Alarm function check

WARNING




• Do not smoke.


Checking differential pressure gage alarm function

1.


2.

Set the alarm points at the differential pressure gage to zero.

Result: Alarm is issued after preset time.

3.

Reset alarm points at differential pressure gage.

MS15034/00E 2018-08 | Fuel Supply System | 223

8.21.3 Water level probe (3-in-1 rod electrode) – Check

Preconditions

☑ System is put out of service and emptied.

WARNING




• Do not smoke.


Checking water level probe (3-in-1 rod electrode)

1.

Disconnect plug from water level probe.

2.

Unscrew water level probe.

3.


4.

Immerse water level probe into a tank filled with water until water level reaches the thread.

5.

Switch on plant.

Result: Water drain valve opens.

6.

Leave water level probe in tank.

Result: Alarm must be issued after the preset time.

7.

Switch off the system.

8.


9.

Remove water level probe from tank.

10.

Screw in water level probe.

11.

Connect plug for water level probe.

12.

Fill system, vent and put into operation.


8.21.4 Pump capacity – Check

WARNING




• Do not smoke.


Checking pump capacity

1.

Install suitable pressure gauge in the intake connection of the pump.

2.

Check pump pressure.

a) Switch on fuel treatment system (→ Page 90).

Note: The pressure limiting valve at the pump might respond and open. Audible noise is caused by overflowing fuel and can be disregarded.

b) Close ball valve at the outlet of the fuel treatment system.

c) Check pressure at the pressure gauge in the inlet to the fuel treatment system and note down.

3.

Checking pump pressure with reduced suction.

a) Reduce suction pressure of pump to -0.8 bar with the shut-off valve at the pump intake side.

b) Check pressure at the pressure gauge in the inlet to the fuel treatment system and note down.

c) Open ball valve at inlet and outlet of fuel treatment system.

4.

Calculate wear limit.

Example:

Measured value (normal condition).

Measured value (reduced suction condition).

3 bar

2.6 bar

The wear limit has been reached when the measured value (reduced suction) is 10% lower than the measured pressure (normal). Repair pump (Contact Service).



Preconditions

☑ System is stopped and starting disabled.


Designation / Use


Ratchet adapter

Fuel

Engine oil

Coalescer filter element

Gasket

WARNING

Part No.

F30043446

F30027340






• Do not smoke.


NOTICE

Contamination of components.



• Check components for special cleanliness.

NOTICE

Incorrect installation of components and lines.


• Ensure that components/lines are installed so that they are never under tension or strain.

• Ensure correct installation position of components.

Replacing coalescer filter element

1.

Close ball valve at the inlet and outlet of the fuel treatment system.

2.

Open drain ball valve.

3.

Drain fuel.

4.

Close drain ball valve.

5.

Remove nuts (9) with washers (2).

6.

Remove screws (1).

7.

Remove cover with seal (10).

8.

Remove nut (3), washer (8) and end plate (4).

9.

Remove coalescer filter element (5).

10.

Catch fuel as it runs out.

11.

Clean housing with a lint-free cloth. Rinse with fuel as necessary.

12.

Check housing for corrosion.

13.

Clean housing sealing faces.

14.

Install coalescer filter element (5).

15.

Install end plate (4), washer (8) and nut (3).

Qty.

1

1


16.

Tighten nut (3) to specified torque using a torque wrench.

Name

Nut

Size

M16

Type

Tightening torque

Lubricant

(Engine oil)

17.

Fit seal (10).

18.

Install cover.

19.

Install screws (1), washers (2) and nuts (9).

20.

Tighten nuts (9).

21.

Open ball valve at the inlet and outlet of the fuel treatment system.

Result: The fuel treatment system is ready for operation.

Value/Standard

30 Nm +3 Nm


8.22 Wiring (General) for Engine/Gearbox/Unit

8.22.1 Engine wiring harness and mounts – Overview

Designation

Sensors

Level monitor

Pump

Limit switch

B44.2

B48

B49

B50

B54

F33

XF33

XXF33

F46

M8

S37.1

S37.2

B6

B7

B9

B10

B13

B16

B33

B34.1

B34.2

B34.3

B44.1

Terminal assignment

B1

B3

B4.21

B4.22

B5.1

B5.3

B5.8

Camshaft speed


Exhaust gas temperature, A-side

Exhaust temperature, B-side

Lube oil pressure after filter

Lube oil pressure before filter

Lube oil pressure before ETC, A-side (optional)

Coolant temperature

Lube oil temperature

Charge-air temperature

Charge-air pressure

Crankshaft speed

Coolant pressure

Fuel temperature

Fuel pressure after filter

Fuel pressure before filter

Fuel pressure before external filter

Exhaust turbocharger A speed

Exhaust turbocharger B speed

HP fuel

Charge air before recirculation

Crankcase pressure

Replenishment pump pressure

Coolant level

Coolant level adaption

Coolant level, hull-mounted cooling system

Leak fuel level

Fuel pump

Start interlock A

Start interlock B

228 | Wiring (General) for Engine/Gearbox/Unit | MS15034/00E 2018-08

Designation

Adaption

Valves

Injectors

Terminal assignment

X1

X2

X3

X4

X37

X52

XB19

XD1

XG03

XY1

Y26

Y27

Y39A1 to Y39AX

Y39B1 to Y39BX

ECU

Governor ECU-7

ECU Power

Governor ECU-7

Start interlock turning

EIM engine box

Starting air pressure

Dialog

Battery-charging generator

Starting system

Charge-air recirculation

Exhaust turbocharger

Engine side A

Engine side B

MS15034/00E 2018-08 | Wiring (General) for Engine/Gearbox/Unit | 229

Engine wiring harness for sensors

X2 Engine governor

B1 Camshaft speed

B3 Intake air temperature

B4.21 Exhaust gas temperature, Aside

B4.22 Exhaust temperature, B-side

B5.1 Lube oil pressure after filter

B5.3 Lube oil pressure before filter

B6 Coolant temperature

B7 Lube oil temperature

B9 Charge-air temperature

B10 Charge-air pressure

B13 Crankshaft speed

B16 Coolant pressure

B33 Fuel temperature

B34.1 Fuel pressure after filter

B34.2 Fuel pressure before filter

B34.3 Fuel pressure before external filter

B44.1 Exhaust turbocharger A speed

B44.2 Exhaust turbocharger B speed

B48 HP fuel

B49 Charge air before recirculation

B50 Crankcase pressure

B54 Refill pump pressure

F33 Coolant level

M8 Fuel pump

F46 Leak fuel level

S37.1 Start interlock limit switch A

S37.2 Start interlock limit switch B

X37 Start interlock turning

Y26 Charge-air recirculation

Y27 Turbocharger valve

XG03 Battery-charging generator

XF33 Coolant level

XXF33 Coolant level


Engine wiring harness for injectors

80 Injector wiring harness


Engine wiring harness for EIM

1 XD1

2 X1

3 X3

4 X52

5 XY1

6 X11

7 XB19

8 X37


Engine wiring harness for electric starter

1 EIM terminals 2 Fuse FM1 3 Starter connecting terminals


8.22.2 Engine cabling – Check

Preconditions



Designation / Use

Solvent (isopropyl alcohol)

Part No.

X00058037

Engine cabling – Check

1.

Check securing screws of cable clamps on engine and tighten loose screw connections.

2.

Ensure that cables are securely seated in clamps and cannot move freely.

3.

Check if all cable clips are closed and intact.

4.

Replace faulty cable clips.

5.

Check cable clamps for secure fit, tighten loose clamps.

6.

Replace faulty cable clamps.

7.

Visually inspect the following electrical components for damage:

• Connector housings

• Contacts

• Plug connectors

• Cables and terminals

• Plug-in contacts

Result: If cable conductors are damaged, contact Service.

Note: Close connectors that are not plugged in with the protective cap supplied.

8.

Use isopropyl alcohol to clean dirty connector housings, plug connectors and contacts.

9.

Ensure that all connecting plugs of the sensors are correctly engaged.

Qty.

1


8.23 Accessories for (Electronic) Engine Governor / Control System

8.23.1 Limit switch for start interlock – Check

Preconditions


Note: In the OFF position, the limit switch activates a start interlock, i.e. the engine cannot be started.

Limit switch for start interlock –

Check

1.

Check whether switches (3) and guard plate (2) with engine support (1) are installed on both sides of flywheel housing (4).

2.

Check whether both switches (3) are actuated.

3.

If switches (3) and/or guard plate (2) with engine support (1) is/are not installed:

• Screw on guard plate (2) with engine support (1).

• Then screw on switch (3), ensuring that the switch (3) is actuated by the guard plate (2).

4.

If switch (3) and guard plate (2) are installed, but switch (3) is in the OFF position:

• Make certain that the guard plate (2) at the side of the switch (3) is not distorted.

• Loosen guard plate (2) and screw on such that the switch (3) is actuated.

MS15034/00E 2018-08 | Accessories for (Electronic) Engine Governor / Control System | 235

8.23.2 Engine Control Unit ECU 7 – Checking plug connections

Preconditions


Check plug connections on ECU

7

1.

Check all connectors on ECU for firm seating.

Ensure that the clips (1) are engaged.

2.

Check screws (2) of cable clamps on ECU for firm seating. Ensure that cable clamps are not faulty.

236 | Accessories for (Electronic) Engine Governor / Control System | MS15034/00E 2018-08

8.23.3 Engine Monitoring Unit EMU 7 – Plug connection check

Preconditions


Checking EMU plug connections

1.

Check both connectors on EMU (2) for firm seating. Make sure that frames (3) are engaged.

2.

Check screws (1) of cable clamps on EMU (2) for firm seating. Make sure that cable clamps are not defective.


8.23.4 Interface module EIM plug connections – Check

Preconditions


Checking EIM plug connections

1.

Check both Tyco plugs (62-pole) (2) on EIM for firm seating. Ensure that clips (3) are engaged.

2.

Check screws (1) of cable clamps on EIM for firm seating. Ensure that cable clamps are not faulty.


8.23.5 Engine governor ECU 7 – Removal and installation

Preconditions


☑ Engine electronics is powered off.

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 engine governor from engine

1.

Note or mark assignment of cables and plugs.

2.

Remove all screws (3).

3.

Undo clips (2) on connectors.

4.

Remove all male connectors.

5.

Remove screws (1).

6.

Take off engine governor.

Installing engine governor on engine

1.

Install in reverse order. Ensure correct assignment of plugs and sockets.

2.

Check resilient mount before installing.

Result: If resilient mount is porous or defective then replace it.


8.23.6 Engine Interface Module EIM 2 – Removal and installation

Preconditions


Removing Engine Interface Module from engine

1.

Note or mark assignment of cables and connectors.

2.

Unscrew all screws (1).

3.


4.

Disconnect all connectors.

5.

Unscrew power and starter cable.

6.

Remove screws (3).

7.

EIM 2.

Installing Engine Interface Module on engine

1.

Install in reverse order. When doing so, observe correct assignment between cables and connectors.

2.

Check seal before installing.

Result: Replace seal if porous or defective.

Downloading software

1.

The new EIM 2 still does not have appropriate FSW and parameter/descriptor module (the diagnostic lamp

(DILA) indicates flashing code 4 when the power supply is connected, (→ Page 241)).

2.

The FSW and the parameter/descriptor module must first be downloaded from the central database (CDB) based on the relevant engine number using the DiaSys ® software tool, and then loaded in the EIM 2.


8.23.7 Engine Interface Module EIM 2 – Diagnostic features

Diagnostic lamp (DILA)

A diagnostic lamp (LED, blue) is integrated in the housing of the Engine Interface Module (EIM 2).

It indicates the operating status of the EIM 2.

Functions of diagnostic lamp DILA

DILA glows Engine Interface Module (EIM 2) is OK.

DILA dark

DILA flashes

EIM 2 supply voltage missing or diagnostic lamp activation is faulty.

Hardware or software fault in the Engine Interface Module

The diagnostic lamp (DILA) signals the following states:

1 Time in seconds

2 Timing: 1/8 s

3 Ready for operation

4 Application loader active

5 External RAM defective

6 External FLASH defective

7 No firmware

8 Application crashed

Fuse lamp (SILA)

A second indicator is the fuse lamp.

This is also integrated in the housing of the Engine Interface Module. It indicates the status of the fuses.

An orange LED is provided to allow diagnosis of a “tripped fuse” fault directly at the unit as it is often difficult to pinpoint a fault in the field without cabling diagrams.

This LED is activated by the controller.

Functions of fuse lamp SILA

SILA dark Normal operating state

SILA flashes orange One or more fuses have tripped.

The fuse lamp (SILA) signals the following states:


1 Preamble

2 Engine Control Unit current path failed (S1)

3 MCS current path failed

(S2)

4 EMU current path failed

(S3)

5 Starter voltage: Terminal

30, 31 not connected and

PR 10.0600.001 has value

1 or 2 (S4)

6 VSP current path failed (S5)

7 SLD current path failed (S6)

8 DDV current path failed (S7)

9 Gear monitoring current path failed (S8)

10 Emergency stop current path failed – 24 V internal

(S9)

11 ES pushbutton current path failed – 24 V external (S10)

12 Key switch current path failed (S11)

13 SDAF 1 and 2 current path failed (S12)

14 PIM current path failed

(S13)

15 Spare current path failed

(S14) (for EIM 2 with ECU 9 only)

The failed current paths are signaled consecutively following the preamble (1) (LED on for 4 seconds). There is a pause lasting 4 seconds in between.


Sample flashing sequences

A Fuse S5 failure (1/2 second steps)

B Fuse S1 and fuse S4 failure

(1/2 second steps)

Note:

These bit patterns are continuously transmitted.

The CAN message “Status of internal power supply” also contains information on the current path states of the EIM 2.


8.23.8 EMU 7 – Removal and installation

Preconditions


☑ Engine electronics is powered off.

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

1.

Note or mark assignment of cables and plugs.

2.

Remove all screws (2).

3.


4.

Remove all male connectors.

5.

Remove screws (1).

6.

Remove ECU (5) with EMU (4).

Removing EMU

1.

Unscrew screws on base of EMU (4).

2.

Remove EMU (4) from ECU (5).

Installing EMU

1.

Place EMU (4) on ECU (5).

2.

Screw in and tighten screws on base of EMU (4).

Installing ECU with EMU on engine

1.

Install in reverse order. Ensure correct assignment of plugs and sockets.

2.

Check resilient mount before installing.

Result: If resilient mount is porous or defective then replace it.


8.23.9 CDC parameters – Reset

Preconditions


Note: Failure to reset drift compensation (CDC parameters) will void the emissions certification.

Resetting CDC parameters with DiaSys®

u (→ Dialog system DiaSys® E531920/..).

Resetting CDC parameters without DiaSys®

u If no DiaSys® is available, contact Service.


9 Appendix A

9.1 List of abbreviations

DIS

DL

ECS

ECU

EDM

EIM

EIL

EMU

EPA

ETK

FPP

GCU

GMU

HAT

HI

HIHI

HT

ICFN

Abbreviation

ADEC

AL

ANSI

ATL

BR

BV

CAN

CDC

CPP

DILA

DIN

IDM

Meaning

Advanced Diesel Engine Control

Alarm

American National Standards Institute

Explanation

Engine Control Unit

Alarm (general)

Association of American standardization organizations

Abgasturbulader

Baureihe

Betriebsstoffvorschrift

Controller Area Network

Calibration Drift Compensation

Exhaust turbocharger

Series

Fluids and Lubricants Specifications, MTU Publication

No. A01061/..

Data bus system, bus standard

Setting for drift correction with DiaSys in Engine Control Unit

Controllable Pitch Propeller

Diagnostic lamp On EIM

Deutsches Institut für Normung e. V.

German National Standards Institute, at the same time identifier of German standards (DIN = “Deutsche

Industrie-Norm”)

Display Unit

Default Lost

Engine Control System

Engine Control Unit

Engine Data Module

Engine Interface Module

Engine Ident Label

Engine Monitoring Unit

Environmental Protection Agency

Spare parts catalog

Fixed Pitch Propeller

Gear Control Unit

Gear Monitoring Unit

Harbor Acceptance Test

High

High High

High Temperature

ISO – Continuous rating – Fuel stop power – Net

Interface Data Module

Display panel

Alarm: Default CAN bus failure

Engine management system

Engine governor

Memory module for engine data

Interface to engine monitoring system

Electronic nameplate which identifies the engine

US regulatory body which implements federal laws on environmental protection and develops standards to ensure compliance with these laws

Range violation alarm (1st upper limit)

Range violation alarm (2nd upper limit)

Power specification in accordance with DIN-ISO

3046-7

Memory module for interface data

246 | Appendix A | MS15034/00E 2018-08

LCU

LED

LMU

LO

LOLO

LOP

LOS

MCS

MG

MPU

SS

SSK

T-xyz

TD

UT

VS

WJ

WZK

ZKP

PIM

RCS

RL

SAE

SAT

SD

OT

P-xyz

PAN

PCU

SDAF

SILA

SOLAS

Abbreviation

IIG

Meaning

IMO

ISO

KGS

KS

LCD

Explanation

Initial Injector Equalization Entering of injector code with DiaSys in engine governor

International Maritime Organization

International Organization for Standardization

Kraftgegenseite

Kraftseite

Liquid Crystal Display, Liquid Crystal

Device

Local Control Unit

Light Emitting Diode

Local Monitoring Unit

Low

Low Low

Local Operating Panel

Local Operating Station

Monitoring and Control System

Message

Microprocessor Unit, Microprocessing

Unit

Oberer Totpunkt

Pressure-xyz

Panel

Propeller Control Unit

Peripheral Interface Module

Remote Control System

Redundancy Lost

Society of Automotive Engineers

Sea Acceptance Test

Sensor Defect

Shut Down Air Flap(s)

Fuse lamp

International Convention for the Safety of Life at Sea

Safety System

Schnellschlussklappe(n)

Temperature-xyz

Transmitter Deviation

Unterer Totpunkt

Voith Schneider

Water jet

Werkzeugkatalog

Zugehörigkeit-Kategorie-Parameter

International umbrella organization for all national standardization institutes

Engine free end in accordance with DIN ISO 1204

Engine driving end in accordance with DIN ISO 1204

LOP subassembly

LOP subassembly

Range violation alarm (1st lower limit value)

Range violation alarm (2nd lower limit value)

Control console, control panel

Top Dead Center

Pressure measuring point xyz

Control panel

Propeller controller

Alarm: Redundant CAN bus failure

U.S. standardization organization

Alarm: Sensor failure

Emergency air-shutoff flap(s) on EIM

Safety system alarm

Emergency air-shutoff flap(s)

Temperature measuring point xyz

Alarm: Deviation in transmitter values

Bottom Dead Center

Voith-Schneider drive

Water jet drive

Tool catalog

Assignment category parameter; number scheme for signals from the ADEC engine governor

MS15034/00E 2018-08 | Appendix A | 247

9.2 MTU Contact/Service Partners

The worldwide network of the sales organization with subsidiaries, sales offices, representatives and customer service centers ensure fast and direct support on site and ensure the high availability of our products.

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 high flexibility, we're your contact around the clock: during each operating phase, preventive maintenance and corrective operations in case of a malfunction, for information on changes in conditions of use and for supplying spare parts.

Your contact person in our Customer Assistance Center:

E-mail: [email protected]

Tel.: +49 7541 9077777

Fax.: +49 7541 9077778

Asia/Pacific: +65 6100 2688

North and Latin America: +1 248 560 8000

Spare Parts Service

Fast, simple and correct identification of spare parts for your drive system or vehicle fleet. The right spare part at the right time at the right place.

With this aim in mind, we can call on a globally networked spares logistics system, a central warehouse at headquarters and on-site stores at our subsidiary companies, agencies and service workshops.

Your contact at Headquarters:

E-mail: [email protected]

Tel.: +49 7541 9077777

Fax.: +49 7541 9077778

248 | Appendix A | MS15034/00E 2018-08

10 Appendix B

10.1 Special Tools

Barring tool

Part No.:

Qty.:

Used in:

Qty.:

Used in:

F6555766

1

8.2.1 Engine – Barring manually (→ Page 141)

1


(→ Page 144)

Endoscope

Part No.:

Qty.:

Used in:

Qty.:

Used in:

Y20097353

1


(→ Page 144)

1

8.18.1 Battery-charging generator drive – Coupling condition check (→ Page 219)

Feeler gauge

Part No.:

Qty.:

Used in:

Y20098771

1


(→ Page 150)

MS15034/00E 2018-08 | Appendix B | 249

Filter wrench

Fuel suction device

Part No.:

Qty.:

Used in:

Qty.:

Used in:

Qty.:

Used in:

Qty.:

Used in:

F30379104

1

8.8.2 Additional fuel filter – Replacement (→ Page 167)

1

8.8.3 Fuel filter – Replacement (→ Page 168)

8.15.1 Engine oil filter – Replacement (→ Page 194)

1

8.16.8 Engine coolant filter – Replacement (→ Page 212)

Part No.:

Qty.:

Used in:

F30378207

1

8.6.1 HP fuel pump – Filling with engine oil (→ Page 155)

High-pressure cleaner

Part No.:

Qty.:

Used in:

Installation/removal jig

Part No.:

Qty.:

Used in:

1

5.15 Plant – Cleaning (→ Page 95)

F6789889

1

8.7.2 Injector – Removal and installation (jacketed fuel system) (→ Page 159)

250 | Special Tools | MS15034/00E 2018-08

Milling cutter

Part No.:

Qty.:

Used in:

F30452739

1


MTU test kit

Part No.:

Qty.:

Used in:

5605892099/00

1


(→ Page 192)

MTU test kit

Part No.:

Qty.:

Used in:

F6798833

1


(→ Page 211)

Ratchet adapter

Part No.:

Qty.:

Used in:

Qty.:

Used in:

F30027340

1

8.8.7 Fuel prefilter with water separator – Filter element replacement (→ Page 175)

1


(→ Page 226)

MS15034/00E 2018-08 | Special Tools | 251

Ratchet bit

Part No.:

Qty.:

Used in:

Qty.:

Used in:

F30027341


(→ Page 154)

1

8.14.2 Engine oil – Change (→ Page 190)

Ratchet bit

Ratchet bit

Part No.:

Qty.:

Used in:

Qty.:

Used in:

F30027340

1


1

8.15.3 Centrifugal oil filter – Cleaning and filter sleeve replacement (→ Page 199)

Part No.:

Qty.:

Used in:

F30027342

1



Part No.:

Qty.:

Used in:

Qty.:

Used in:

F30006212

1

8.2.1 Engine – Barring manually (→ Page 141)

1


(→ Page 144)


Socket wrench, 24 mm

Part No.:

Qty.:

Used in:

F30039526

1


(→ Page 150)


Part No.:

Qty.:

Used in:

F30510423


(→ Page 154)


Part No.:

Qty.:

Used in:

Qty.:

Used in:

Qty.:

Used in:

F30452769

1

8.6.1 HP fuel pump – Filling with engine oil (→ Page 155)

1


1

8.8.7 Fuel prefilter with water separator – Filter element replacement (→ Page 175)


Part No.:

Qty.:

Used in:

F30026582

1



Torque wrench, 4-20 Nm

Part No.:

Qty.:

Used in:

F30044239

1

8.9.1 Compressor wheel – Cleaning (→ Page 179)


Part No.:

Qty.:

Used in:

F30027337

1

8.14.2 Engine oil – Change (→ Page 190)


Part No.:

Qty.:

Used in:

F30044239

1



Part No.:

Qty.:

Used in:

Qty.:

Used in:

F30452768

1


(→ Page 150)

1




Part No.:

Qty.:

Used in:

F30043446

1


(→ Page 226)


10.2 Index

A

Additional fuel filter

– Overview

166

– Replacement 167

ADEC (ECU 7)

– Fault messages

104

Adhesive tape for SOLAS shielding

– Application

140

After shutdown

94

Air filter

– Replacement 185

Air filter – Removal and installation

186

B

Battery-charging generator drive

– Check

219

Bilge pump

– Relief bore check

221

C

Cabling

– Check

– On engine

234

CDC parameters

– Reset

245

Centrifugal oil filter

– Cleaning 199

Checks

– Prior to start-up

86

Coalescer filter element

– Replacement 226

Compressor wheel

– Cleaning 179

Contact persons 248

Contamination indicator

– Signal ring position check

187

Controls

79

Coolant

– Change

206

Coupling

– Check

219

Crankcase breather

– Oil mist fine separator

– Replacement

148

Cylinder

– Designation 52

Cylinder head cover

– Installation

153, 154

– Removal 153, 154

Cylinder liner

– Endoscopic examination 144

– Endoscopic inspection

– Instructions and comments on endoscopic and visual examination

146

256 | Index | MS15034/00E 2018-08

D

Diagnostic lamp (DILA)

– EIM 2

241

Diagnostics

– EIM 2

241

Differential pressure gage

– Adjustment

– Fuel prefilter

170

– Alarm function check

223

– Check

– Fuel prefilter

170

Drain and vent points

202

Drift compensation

– Reset

245

E

ECU 7

– Installation 239

– Removal

239

EMU 7


– Removal

244

Endoscopic inspection

– Cylinder liner

– Instructions and comments

146

Engine

– Barring

– Manually

141

– With starting system

143

– Emergency stop

93

– Start

83

– Stopping 92

Engine cabling

– Check

234

Engine Control Unit ECU 7

– Checking plug connections 236

Engine coolant

– Change 206

– filling 208

– Filter replacement 212

– Sample analysis

211

– Sample extraction

211

Engine coolant level

– Check

205

Engine coolant – Draining

207

Engine data

– 8V4000M53, EPA Tier 2, EU Stage IIIA, IMO Tier II

67

– 8V4000M63, EPA Tier 2, EU Stage IIIA, IMO Tier II

72

ENGINE DATA 8V4000M53R (provisional) 63

Engine driving end

– Definition 52

Engine free end

– Definition 52

Engine governor ADEC (ECU 7)

– Fault messages 104

Engine governor ECU 7

– Installation

239

– Removal

239

Engine Monitoring Unit EMU 7

– Plug connection check 237

Engine mounting

– Check 220

Engine oil

– Change 190

– Sample extraction and analysis

192

Engine oil filter

– Replacement 194

Engine oil level

– Check 189

Engine overview 21

Engine sides

– Designation

52

Engine wiring harness

– Overview 228

F

Fault messages

– Engine governor ADEC (ECU 7)

104

Filter

– Engine coolant

– Replacement 212

Filter sleeve

– Replacement 199

Firing order

77

Fuel

– Treatment system

– Switching on 90

– Troubleshooting 103

– treatment system

– Shutdown

91

Fuel filter

– Replacement 168

Fuel prefilter

– Adjustment

– Differential pressure gage 170

– Check

– Differential pressure gage 170

Fuel prefilter with water separator

– Draining 171

– Filter element

– Flushing

173

– Replacement 175

– Replacement

– O-ring in rotary slide valve

178

Fuel treatment system

– Initial start-up 87

– Shutdown

91

– Switching on 90

Fuse lamp (SILA)

– EIM 2 241

H

Hotline

248

HP pump

– Filling with engine oil 155

– Relief bore check 157

HT coolant pump

– Check

– Relief bore 210

I

Injector

– Installation

159

– Removal 159

– Replacement

158

Intercooler

– Check water drain for coolant leakage and obstruction

184

Interface module EIM

– Check 238

Interface module EIM 2

– Removal and installation

240

L

Lifting requirements 19

Limit switch for start interlock

– Check 235

List of abbreviations

246

M

Main engine dimensions

– With engine-mounted heat exchanger

78

– With separate heat exchanger 78

Maintenance Schedule

– Maintenance task reference table [QL1] 96, 98

MTU contact persons

248

O

Oil indicator filter

– Check 196

– Cleaning

196

Operational checks

84

P

Plant

– Cleaning

95

Plug connections

– Check 238

Preheater

– Overhaul 217

– Function and leak-tightness

– check 213

Preheating unit

214

Product description 25

Pump capacity

– Check 225

Putting the engine into operation after extended out-ofservice periods (>3 months)

80

Putting the engine into operation after scheduled out-ofservice-period

81

MS15034/00E 2018-08 | Index | 257

R

Raw water pump

– Relief bore check

218

S

Safety regulations

– Assembly work

11

– Auxiliary materials 15

– Environmental protection

15

– Fire prevention

15

– Fluids and lubricants 15

– Important provisions 5, 7

– Initial start-up

9

– Maintenance work

11

– Operation

9

– Organizational requirements 8

– Personnel requirements

8

– Repair work 11

Safety requirements

– Warning notices, standards

17

Sensors and actuators – Overview

53

Service partners 248

SOLAS shielding

– Adhesive tape application 140


– As per MTN 5233 131

– Installation locations

133

Spare parts service

248

Starter

– Condition check 188

T

Tasks after extended out-of-service periods (>3 weeks) 85

Tightening specifications

– Nuts

39

– Screws and bolts

39

– Screws, nuts and bolts

39

transport 18

Transportation

– Lifting requirements 19

Troubleshooting

100

– Fuel treatment system

103

V

Valve clearance

– Adjustment

150

– Check

150

Valve gear

– Lubrication 149

W

Warning notices, standards

17

Water drain valve

– Check

222

Water level probe (3-in-1 rod electrode)

– Check

224

258 | Index | MS15034/00E 2018-08

No results