Operating Instructions Diesel engine V 4000 M70 V 4000 M71 Application group 1B M015412/03E
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Table of Contents 1 Safety 1.1 1.2 1.3 1.4 1.5 General conditions Personnel and organizational requirements Transport Safety regulations for startup and operation Explosion hazard when removing inspection port cover on engine 1.6 Safety regulations for maintenance and repair work 1.7 Auxiliary materials, fire prevention and environmental protection 1.8 Conventions for safety instructions in the text 6 7 8 9 10 11 14 17 2 General Information 2.1 2.2 2.3 2.
100 101 102 103 104 105 106 5 Maintenance 5.1 Maintenance task reference table [QL1] 107 108 111 7 Task Description 7.1 Engine 112 7.2 Cylinder Liner 114 7.1.1 Engine – Barring manually 7.1.2 Engine – Barring with starting system 7.2.1 Cylinder liner – Endoscopic examination 7.2.2 Cylinder liner – Instructions and comments on endoscopic and visual examination 7.3 Crankcase Breather 7.3.1 Crankcase breather – Oil separator check 7.3.
7.20 Drive Systems, Driving End and Free End (Coupling) 177 7.21 Auxiliary PTO 178 7.22 Fuel Supply System 179 7.20.1 Coupling – Condition check 7.21.1 Bilge pump – Relief bore check 7.22.1 Water drain valve – Check 7.22.2 Differential pressure gauge – Check 7.22.3 Water level probe (3-in-1 rod electrode) – Check 7.22.4 Pump capacity – Check 7.22.5 Coalescer filter element – Replacement 7.23 Wiring (General) for Engine/Gearbox/Unit 7.23.1 Engine wiring – Check 7.
1 Safety 1.1 General conditions General In addition to the instructions in this publication, the applicable country-specific legislation and other com‐ pulsory regulations regarding accident prevention and environmental protection must be observed. This state-of-the-art engine has been designed to meet all applicable laws and regulations.
1.2 Personnel and organizational requirements Personnel requirements Work on the engine must only be carried out by appropriately qualified and instructed personnel. Observe the minimum legal age. Responsibilities of the operating, maintenance and repair personnel must be specified by the operating company. Organizational measures This publication must be issued to all personnel involved in operation, maintenance, repair or transporta‐ tion.
1.3 Transport Transport Use only the lifting eyes provided to lift the engine. Only use transport and lifting devices approved by MTU. Take the engine's center of gravity into account. Transport the engine in the installation position only, max. permissible diagonal pull 10°. In the case of special packaging with aluminum foil, suspend the engine by the lifting eyes of the trans‐ port pallet or transport with equipment suitable for heavy loads (forklift truck).
1.4 Safety regulations for startup and operation Safety requirements for initial operation Prior to initial operation of the unit, install the assembly or unit according to the specifications and check the installation according to the MTU specifications. Before putting the device or plant into operation, always ensure: • that all maintenance and repair work is completed, • that all loose parts have been removed from rotating machine components, • that nobody is in the danger area of moving machine parts.
1.5 Explosion hazard when removing inspection port cover on engine DANGER Explosion hazard due to oil vapors. Risk of serious injury – danger to life! • Allow the engine to cool down before opening the crankcase! • Avoid open flames, electrical sparks and ignition sources. Safety instructions Before starting maintenance work, allow the engine to cool down for at least 10 min. (danger of explosion due to oil vapors).
1.6 Safety regulations for maintenance and repair work Safety regulations for maintenance and repair work Have maintenance and repair work carried out by qualified and authorized personnel only. Allow the engine to cool down before starting maintenance work (risk of explosion of oil vapors). Before starting work, relieve pressure in systems and compressed-air lines which are to be opened. Take special care when removing ventilation or plug screws from the engine.
Welding work Never carry out welding work on the assembly, system, or engine-mounted units. Cover the engine when welding in its vicinity. Do not use the assembly or system as ground terminal. Do not route the welding lead over or near the wiring harnesses of MTU systems. The welding current may otherwise induce an interference voltage in the wiring harnesses which could conceivably damage the electrical system. Remove parts (e.g. exhaust pipes) which are to be welded from the engine beforehand.
TIM-ID: 0000000879 - 023 For conducting light-beam procedures and measurement work, only the following laser devices must be used: • Laser devices of classes 1, 2 or 3A. • Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700 nm), a maximum output of 5 mW, and in which the beam axis and surface are designed to prevent any risk to the eyes.
1.7 Auxiliary materials, fire prevention and environmental protection Fire prevention Rectify any fuel or oil leaks immediately; even splashes of oil or fuel on hot components can cause fires therefore always keep the engine in a clean condition. Do not leave cloths soaked with fluids and lubri‐ cants lying around on the engine. Do not store combustible fluids near the engine. Do not weld pipes and components carrying oil or fuel. Before welding, clean with a non-combustible fluid.
Lead • When working with lead or lead-containing pastes, avoid direct contact with the skin and do not inhale lead vapors. • Adopt suitable measures to avoid the formation of lead dust! • Switch on fume extraction system. • After coming into contact with lead or lead-containing materials, wash hands! Acids and alkaline solutions • When working with acids and alkalis, wear protective goggles or face mask, gloves and protective clothing.
Used oil Used oil may contain health-threatening combustion residues. TIM-ID: 0000002828 - 004 Rub barrier cream into hands! Wash hands after contact with used oil.
1.8 Conventions for safety instructions in the text DANGER WARNING CAUTION NOTICE Note: In the event of immediate danger. Consequences: Death or serious injury • Remedial action In the event of potentially dangerous situations. Consequences: Death or serious injury • Remedial action In the event of dangerous situations. Consequences: Minor injury or material damage • Remedial action In the event of a situation involving potentially adverse effects on the product. Consequences: Material damage.
2 General Information 2.1 Engine side and cylinder designations Engine sides are always designated as viewed from the driving end (KS). The cylinders of the left engine side are designated "A" and those of the right side "B" (as per DIN ISO 1204). The cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end of the engine. Other components are numbered in the same way, i.e. starting with No. 1 on driving end.
2.2 Product description Description of the engine Engine The engine is a liquid-cooled four-stroke diesel engine, rotating counterclockwise (seen from driving end), with direct injection, sequential turbocharging and charge air cooling. The engine is monitored by an engine control and monitoring system (MDEC). Monitoring in the engine room is carried out by the local operating panel (LOP).
Electronic engine control unit (ECU) Functions: • Engine speed control with fuel and speed limitation dependent on engine status and operating condi‐ tions; • Control of sequential turbocharging; • Data processing logistics for analog and binary signals; • Interface for data transfer to CAN field bus for remote control and ship-side monitoring; • RS 232 interface for connection of MTU dialog unit.
SOLAS – Fire protection specifications Fuel system, fuel lines with fuel pressure >1.8 bar 1 Return line 2 Fuel line on fuel delivery pump 3 Check valve 4 Sealing cone 5 Fuel line on HP fuel pump 6 Fuel line on vent line TIM-ID: 0000002179 - 002 All lines with SOLAS-compliant covers for pipe connections, according to MTU standard MTN5233, are shown.
Lube oil system, oil lines with oil pressure >1.8 bar 6 Oil line on distributor 7 Connection, oil line on control block 8 Oil line on control block 9 Oil lines on T-piece 10 Oil line, valve housing 11 Oil line, actuating cylinder to control block 12 Oil line, actuating cylinder to control block 13 Connection, oil line to ac‐ tuating cylinder All lines with SOLAS-compliant covers for pipe connections, according to MTU standard MTN5233, are shown.
Special connections In case of leakage, the following connection types are spray-protected even without a cover and have been confirmed compliant with SOLAS by GL and DNV. Plug-in pipe connection The sleeve (4) covers the joint to prevent lateral spray. TIM-ID: 0000002179 - 002 Only leak-off along the line is possible, the pressure is decreased significantly if an O-ring (3) defect oc‐ curs. The connection is confirmed as compliant with SOLAS by DNV and GL.
HP connections 1 2 3 4 5 6 7 Jacket pipe HP line O-ring Union nut Recess for O-ring Thrust ring Leakage overflow bore 8 9 10 11 12 13 14 Thrust ring Union nut Union nut Connecting piece Snap ring Thrust ring Compensating washers 15 16 17 18 19 20 Union nut Thrust ring External pipe of HP line Internal pipe of HP line Ball-type seal area Leak fuel connection The HP fuel line is sealed by the thrust ring (8).
Shielding of fuel filter and lube oil filter Shielding with a plastic ring The plastic ring (1) precludes lateral spray. The fluid is diverted to the catch basin whereby the pressure is significantly reduced. TIM-ID: 0000002179 - 002 Shielding by overhang design The overhang (1) prevents lateral spray. The fluid is diverted to the catch basin whereby the pressure is significantly reduced.
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Key to the engine model designation 16V 4000 Mxyz y Design index (0, 1) z R (reduced power / speed) TIM-ID: 0000036245 - 001 L (enhanced power / speed) 28 | General Information | M015412/03E 2012-02
3 Technical Data 3.1 8V 4000 M70 engine data: IMO, separate heat exchanger, copper-based alloy intercooler Explanation: DL BL A G R L N X Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated without changes (e.g.
Number of cylinders 8 Number of inlet valves per cylinder 2 Number of exhaust valves per cylinder 2 LUBE OIL SYSTEM Number of cylinders 8 Lube-oil operating temperature before engine, from R °C 85 Lube oil temperature before engine, to R °C 90 Lube oil operating pressure before engine, from R bar 5.5 Lube oil operating pressure before engine, to R bar 6.0 Lube oil operating pressure (low idle) (meas. point: before engine) R bar 2.
CAPACITIES Number of cylinders 8 Engine oil at initial filling (standard oil system) (Option: max. operating incli‐ R nations) liter 145 Oil change quantity, max. (standard oil system) (Option: max. operating in‐ clinations) R liter 120 Oil pan capacity, dipstick mark min. (standard oil system) (Option: max. op‐ L erating inclinations) liter 110 Oil pan capacity, dipstick mark max. (standard oil system) (Option: max.
3.2 8V 4000 M70 engine data: engine-mounted heat exchanger, IMO Explanation: DL BL A G R L N X Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated without changes (e.g.
RAW-WATER CIRCUIT (open circuit) Number of cylinders 8 Raw water pump: Inlet pressure, min. L bar -0.2 Raw water pump: Inlet pressure , max. L bar 0.5 Pressure loss in the external raw-water system, max. L bar 2.2 LUBE OIL SYSTEM Number of cylinders 8 Lube-oil operating temperature before engine, from R °C 85 Lube oil temperature before engine, to R °C 90 Lube oil operating pressure before engine, from R bar 5.5 Lube oil operating pressure before engine, to R bar 6.
INCLINATIONS, STANDARD OIL SYSTEM (reference: waterline) Number of cylinders Longitudinal inclination, continuous max. driving end down (Option: max. operating inclinations) 8 L degree 15 Longitudinal inclination, temporary max. driving end down (Option: max. op‐ L erating inclinations) degree 22.5 Longitudinal inclination, continuous max. driving end up (Option: max. oper‐ L ating inclinations) degree 10 Transverse inclination, continuous max. (Option: max.
3.3 12V 4000 M70 engine data: IMO -20%, separate heat exchanger, copper-based alloy intercooler Explanation: DL BL A G R L N X Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated without changes (e.g.
LUBE OIL SYSTEM Number of cylinders 12 Lube-oil operating temperature before engine, from R °C 85 Lube oil temperature before engine, to R °C 90 Lube oil operating pressure before engine, from R bar 5.5 Lube oil operating pressure before engine, to R bar 6.0 Lube oil operating pressure (low idle) (meas. point: before engine) R bar 2.0 FUEL SYSTEM Number of cylinders 12 Fuel pressure at engine supply connection, min. (when engine is starting) L bar -0.
CAPACITIES Number of cylinders 12 Engine oil at initial filling (standard oil system) (Option: max. operating incli‐ R nations) liter 265 Oil change quantity, max. (standard oil system) (Option: max. operating in‐ clinations) R liter 215 Oil pan capacity, dipstick mark min. (standard oil system) (Option: max. op‐ L erating inclinations) liter 160 Oil pan capacity, dipstick mark max. (standard oil system) (Option: max.
3.4 12V 4000 M70 engine data: IMO -20%, engine-mounted heat exchanger, copper-based alloy intercooler Explanation: DL BL A G R L N X Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated without changes (e.g.
RAW-WATER CIRCUIT (open circuit) Number of cylinders 12 Raw water pump: Inlet pressure, min. L bar -0.2 Raw water pump: Inlet pressure , max. L bar +0.5 Pressure loss in the external raw-water system, max. L bar 1.5 LUBE OIL SYSTEM Number of cylinders 12 Lube-oil operating temperature before engine, from R °C 85 Lube oil temperature before engine, to R °C 90 Lube oil operating pressure before engine, from R bar 5.5 Lube oil operating pressure before engine, to R bar 6.
INCLINATIONS, STANDARD OIL SYSTEM (reference: waterline) Number of cylinders Longitudinal inclination, continuous max. driving end down (Option: max. operating inclinations) 12 L degree 15 Longitudinal inclination, temporary max. driving end down (Option: max. op‐ L erating inclinations) degree 22.5 Longitudinal inclination, continuous max. driving end up (Option: max. oper‐ L ating inclinations) degree 10 Transverse inclination, continuous max. (Option: max. operating inclina‐ tions) degree 22.
3.5 12V 4000 M70 engine data: engine-mounted heat exchanger, EPA stage 2 Explanation: DL BL A G R L N X Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated without changes (e.g.
RAW-WATER CIRCUIT (open circuit) Number of cylinders 12 Raw water pump: Inlet pressure, min. L bar -0.2 Raw water pump: Inlet pressure , max. L bar 0.5 Pressure loss in the external raw-water system, max. L bar 1.5 LUBE OIL SYSTEM Number of cylinders 12 Lube-oil operating temperature before engine, from R °C 85 Lube oil temperature before engine, to R °C 90 Lube oil operating pressure before engine, from R bar 5.5 Lube oil operating pressure before engine, to R bar 6.
INCLINATIONS, STANDARD OIL SYSTEM (reference: waterline) Number of cylinders 12 Longitudinal inclination, continuous max. driving end down (Option: max. operating inclinations) L degree 15 Longitudinal inclination, temporary max. driving end down (Option: max. op‐ L erating inclinations) degree 22.5 Longitudinal inclination, continuous max. driving end up (Option: max. oper‐ L ating inclinations) degree 10 Transverse inclination, continuous max. (Option: max.
3.6 12V 4000 M70 engine data: separate heat exchanger, EPA stage 2 Explanation: DL BL A G R L N X Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated without changes (e.g.
LUBE OIL SYSTEM Number of cylinders 12 Lube-oil operating temperature before engine, from R °C 85 Lube oil temperature before engine, to R °C 90 Lube oil operating pressure before engine, from R bar 5.5 Lube oil operating pressure before engine, to R bar 6.0 Lube oil operating pressure (low idle) (meas. point: before engine) R bar 2.0 FUEL SYSTEM Number of cylinders 12 Fuel pressure at engine supply connection, min. (when engine is starting) L bar -0.
CAPACITIES Number of cylinders 12 Engine oil at initial filling (standard oil system) (Option: max. operating incli‐ R nations) liter 265 Oil change quantity, max. (standard oil system) (Option: max. operating in‐ clinations) R liter 215 Oil pan capacity, dipstick mark min. (standard oil system) (Option: max. op‐ L erating inclinations) liter 160 Oil pan capacity, dipstick mark max. (standard oil system) (Option: max.
3.7 16V 4000 M70 engine data: IMO, separate heat exchanger, copper-based alloy intercooler Explanation: DL BL A G R L N X Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated without changes (e.g.
LUBE OIL SYSTEM Number of cylinders 16 Lube-oil operating temperature before engine, from R °C 85 Lube oil temperature before engine, to R °C 90 Lube oil operating pressure before engine, from R bar 5.5 Lube oil operating pressure before engine, to R bar 6.0 Lube oil operating pressure (low idle) (meas. point: before engine) R bar 2.0 FUEL SYSTEM Number of cylinders 16 Fuel pressure at engine supply connection, min. (when engine is starting) L bar -0.
CAPACITIES Number of cylinders 16 Engine oil at initial filling (standard oil system) (Option: max. operating incli‐ R nations) liter 320 Oil change quantity, max. (standard oil system) (Option: max. operating in‐ clinations) R liter 250 Oil pan capacity, dipstick mark min. (standard oil system) (Option: max. op‐ L erating inclinations) liter 190 Oil pan capacity, dipstick mark max. (standard oil system) (Option: max.
3.8 16V 4000 M70 engine data: IMO, engine-mounted heat exchanger, copper-based alloy intercooler Explanation: DL BL A G R L N X Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated without changes (e.g.
RAW-WATER CIRCUIT (open circuit) Number of cylinders 16 Raw water pump: Inlet pressure, min. L bar -0.2 Raw water pump: Inlet pressure , max. L bar 0.5 Pressure loss in the external raw-water system, max. L bar 1.7 LUBE OIL SYSTEM Number of cylinders 16 Lube-oil operating temperature before engine, from R °C 85 Lube oil temperature before engine, to R °C 90 Lube oil operating pressure before engine, from R bar 5.5 Lube oil operating pressure before engine, to R bar 6.
INCLINATIONS, STANDARD OIL SYSTEM (reference: waterline) Number of cylinders Longitudinal inclination, continuous max. driving end down (Option: max. operating inclinations) 16 L degree 15 Longitudinal inclination, temporary max. driving end down (Option: max. op‐ L erating inclinations) degree 22.5 Longitudinal inclination, continuous max. driving end up (Option: max. oper‐ L ating inclinations) degree 10 Transverse inclination, continuous max. (Option: max. operating inclina‐ tions) degree 22.
3.9 16V 4000 M70 engine data: IMO -20%, separate heat exchanger, copper-based alloy intercooler Explanation: DL BL A G R L N X Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated without changes (e.g.
LUBE OIL SYSTEM Number of cylinders 16 Lube-oil operating temperature before engine, from R °C 85 Lube oil temperature before engine, to R °C 90 Lube oil operating pressure before engine, from R bar 5.5 Lube oil operating pressure before engine, to R bar 6.0 Lube oil operating pressure (low idle) (meas. point: before engine) R bar 2.0 FUEL SYSTEM Number of cylinders 16 Fuel pressure at engine supply connection, min. (when engine is starting) L bar -0.
CAPACITIES Number of cylinders 16 Engine oil at initial filling (standard oil system) (Option: max. operating incli‐ R nations) liter 320 Oil change quantity, max. (standard oil system) (Option: max. operating in‐ clinations) R liter 250 Oil pan capacity, dipstick mark min. (standard oil system) (Option: max. op‐ L erating inclinations) liter 190 Oil pan capacity, dipstick mark max. (standard oil system) (Option: max.
3.10 16V 4000 M70 engine data: IMO -20%, engine-mounted heat exchanger, copper-based alloy intercooler Explanation: DL BL A G R L N X Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated without changes (e.g.
RAW-WATER CIRCUIT (open circuit) Number of cylinders 16 Raw water pump: Inlet pressure, min. L bar -0.2 Raw water pump: Inlet pressure , max. L bar +0.5 Pressure loss in the external raw-water system, max. L bar 1.7 LUBE OIL SYSTEM Number of cylinders 16 Lube-oil operating temperature before engine, from R °C 85 Lube oil temperature before engine, to R °C 90 Lube oil operating pressure before engine, from R bar 5.5 Lube oil operating pressure before engine, to R bar 6.
INCLINATIONS, STANDARD OIL SYSTEM (reference: waterline) Number of cylinders Longitudinal inclination, continuous max. driving end down (Option: max. operating inclinations) 16 L degree 15 Longitudinal inclination, temporary max. driving end down (Option: max. op‐ L erating inclinations) degree 22.5 Longitudinal inclination, continuous max. driving end up (Option: max. oper‐ L ating inclinations) degree 10 Transverse inclination, continuous max. (Option: max. operating inclina‐ tions) degree 22.
3.11 16V 4000 M70 engine data: engine-mounted heat exchanger, EPA stage 2 Explanation: DL BL A G R L N X Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated without changes (e.g.
RAW-WATER CIRCUIT (open circuit) Number of cylinders 16 Raw water pump: Inlet pressure, min. L bar -0.2 Raw water pump: Inlet pressure , max. L bar 0.5 Pressure loss in the external raw-water system, max. L bar 1.7 LUBE OIL SYSTEM Number of cylinders 16 Lube-oil operating temperature before engine, from R °C 85 Lube oil temperature before engine, to R °C 90 Lube oil operating pressure before engine, from R bar 5.5 Lube oil operating pressure before engine, to R bar 6.
INCLINATIONS, STANDARD OIL SYSTEM (reference: waterline) Number of cylinders 16 Longitudinal inclination, continuous max. driving end down (Option: max. operating inclinations) L degree 15 Longitudinal inclination, temporary max. driving end down (Option: max. op‐ L erating inclinations) degree 22.5 Longitudinal inclination, continuous max. driving end up (Option: max. oper‐ L ating inclinations) degree 10 Transverse inclination, continuous max. (Option: max.
3.12 16V 4000 M70 engine data: separate heat exchanger, EPA stage 2 Explanation: DL BL A G R L N X Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated without changes (e.g.
LUBE OIL SYSTEM Number of cylinders 16 Lube-oil operating temperature before engine, from R °C 85 Lube oil temperature before engine, to R °C 90 Lube oil operating pressure before engine, from R bar 5.5 Lube oil operating pressure before engine, to R bar 6.0 Lube oil operating pressure (low idle) (meas. point: before engine) R bar 2.0 FUEL SYSTEM Number of cylinders 16 Fuel pressure at engine supply connection, min. (when engine is starting) L bar -0.
CAPACITIES Number of cylinders 16 Engine oil at initial filling (standard oil system) (Option: max. operating incli‐ R nations) liter 320 Oil change quantity, max. (standard oil system) (Option: max. operating in‐ clinations) R liter 250 Oil pan capacity, dipstick mark min. (standard oil system) (Option: max. op‐ L erating inclinations) liter 190 Oil pan capacity, dipstick mark max. (standard oil system) (Option: max.
3.13 12V 4000 M71 engine data: IMO, separate heat exchanger, copper-based alloy intercooler Explanation: DL BL A G R L N X Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated without changes (e.g.
RAW-WATER CIRCUIT (open circuit) Number of cylinders 12 Raw water pump: Inlet pressure, min. L bar -0.2 Raw water pump: Inlet pressure , max. L bar 0.5 Pressure loss in the external raw-water system, max. L bar 1.5 LUBE OIL SYSTEM Number of cylinders 12 Lube-oil operating temperature before engine, from R °C 85 Lube oil temperature before engine, to R °C 90 Lube oil operating pressure before engine, from R bar 5.5 Lube oil operating pressure before engine, to R bar 6.
INCLINATIONS, STANDARD OIL SYSTEM (reference: waterline) Number of cylinders 12 Longitudinal inclination, continuous max. driving end down (Option: max. operating inclinations) L degree 15 Longitudinal inclination, temporary max. driving end down (Option: max. op‐ L erating inclinations) degree 22.5 Longitudinal inclination, continuous max. driving end up (Option: max. oper‐ L ating inclinations) degree 10 Transverse inclination, continuous max. (Option: max.
3.14 12V 4000 M71 engine data: IMO, engine-mounted heat exchanger, copper-based alloy intercooler Explanation: DL BL A G R L N X Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated without changes (e.g.
LUBE OIL SYSTEM Number of cylinders 12 Lube-oil operating temperature before engine, from R °C 85 Lube oil temperature before engine, to R °C 90 Lube oil operating pressure before engine, from R bar 5.5 Lube oil operating pressure before engine, to R bar 6.0 Lube oil operating pressure (low idle) (meas. point: before engine) R bar 2.0 FUEL SYSTEM Number of cylinders 12 Fuel pressure at engine supply connection, min. (when engine is starting) L bar -0.
CAPACITIES Number of cylinders 12 Engine oil at initial filling (standard oil system) (Option: max. operating incli‐ R nations) liter 265 Oil change quantity, max. (standard oil system) (Option: max. operating in‐ clinations) R liter 215 Oil pan capacity, dipstick mark min. (standard oil system) (Option: max. op‐ L erating inclinations) liter 160 Oil pan capacity, dipstick mark max. (standard oil system) (Option: max.
3.15 12V 4000 M71 engine data: IMO, separate heat exchanger, copper-based alloy intercooler, intake air temperature 45° Explanation: DL BL A G R L N X Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated without changes (e.g.
LUBE OIL SYSTEM Number of cylinders 12 Lube-oil operating temperature before engine, from R °C 85 Lube oil temperature before engine, to R °C 90 Lube oil operating pressure before engine, from R bar 5.5 Lube oil operating pressure before engine, to R bar 6.0 Lube oil operating pressure (low idle) (meas. point: before engine) R bar 2.0 FUEL SYSTEM Number of cylinders 12 Fuel pressure at engine supply connection, min. (when engine is starting) L bar -0.
CAPACITIES Number of cylinders 12 Engine oil at initial filling (standard oil system) (Option: max. operating incli‐ R nations) liter 265 Oil change quantity, max. (standard oil system) (Option: max. operating in‐ clinations) R liter 215 Oil pan capacity, dipstick mark min. (standard oil system) (Option: max. op‐ L erating inclinations) liter 160 Oil pan capacity, dipstick mark max. (standard oil system) (Option: max.
3.16 16V 4000 M71 engine data: IMO, separate heat exchanger, copper-based alloy intercooler Explanation: DL BL A G R L N X Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated without changes (e.g.
LUBE OIL SYSTEM Number of cylinders 16 Lube-oil operating temperature before engine, from R °C 85 Lube oil temperature before engine, to R °C 90 Lube oil operating pressure before engine, from R bar 5.5 Lube oil operating pressure before engine, to R bar 6.0 Lube oil operating pressure (low idle) (meas. point: before engine) R bar 2.0 FUEL SYSTEM Number of cylinders 16 Fuel pressure at engine supply connection, min. (when engine is starting) L bar -0.
CAPACITIES Number of cylinders 16 Engine oil at initial filling (standard oil system) (Option: max. operating incli‐ R nations) liter 320 Oil change quantity, max. (standard oil system) (Option: max. operating in‐ clinations) R liter 250 Oil pan capacity, dipstick mark min. (standard oil system) (Option: max. op‐ L erating inclinations) liter 190 Oil pan capacity, dipstick mark max. (standard oil system) (Option: max.
3.17 16V 4000 M71 engine data: IMO, engine-mounted heat exchanger, copper-based alloy intercooler Explanation: DL BL A G R L N X Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated without changes (e.g.
RAW-WATER CIRCUIT (open circuit) Number of cylinders 16 Raw water pump: Inlet pressure, min. L bar -0.2 Raw water pump: Inlet pressure , max. L bar 0.5 Pressure loss in the external raw-water system, max. L bar 1.7 LUBE OIL SYSTEM Number of cylinders 16 Lube-oil operating temperature before engine, from R °C 85 Lube oil temperature before engine, to R °C 90 Lube oil operating pressure before engine, from R bar 5.5 Lube oil operating pressure before engine, to R bar 6.
INCLINATIONS, STANDARD OIL SYSTEM (reference: waterline) Number of cylinders 16 Longitudinal inclination, continuous max. driving end down (Option: max. operating inclinations) L degree 15 Longitudinal inclination, temporary max. driving end down (Option: max. op‐ L erating inclinations) degree 22.5 Longitudinal inclination, continuous max. driving end up (Option: max. oper‐ L ating inclinations) degree 10 Transverse inclination, continuous max. (Option: max.
3.18 16V 4000 M71 engine data: IMO, separate heat exchanger, copper-based alloy intercooler, intake air temperature 45° Explanation: DL BL A G R L N X Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated without changes (e.g.
LUBE OIL SYSTEM Number of cylinders 16 Lube-oil operating temperature before engine, from R °C 85 Lube oil temperature before engine, to R °C 90 Lube oil operating pressure before engine, from R bar 5.5 Lube oil operating pressure before engine, to R bar 6.0 Lube oil operating pressure (low idle) (meas. point: before engine) R bar 2.0 FUEL SYSTEM Number of cylinders 16 Fuel pressure at engine supply connection, min. (when engine is starting) L bar -0.
CAPACITIES Number of cylinders 16 Engine oil at initial filling (standard oil system) (Option: max. operating incli‐ R nations) liter 320 Oil change quantity, max. (standard oil system) (Option: max. operating in‐ clinations) R liter 250 Oil pan capacity, dipstick mark min. (standard oil system) (Option: max. op‐ L erating inclinations) liter 190 Oil pan capacity, dipstick mark max. (standard oil system) (Option: max.
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3.20 Engine – Main dimensions Engine – Main dimensions Length (A) Width (B) Height (C) 8V 4000 M70 approx. 2340 mm approx. 1380 mm approx. 1750 mm 12V 4000 M70 approx. 3220 mm approx. 1520 mm approx. 1835 mm 12V 4000 M71 approx. 3220 mm approx. 1520 mm approx. 1835 mm 16V 4000 M70 approx. 3690 mm approx. 1520 mm approx. 1835 mm 16V 4000 M71 approx. 3690 mm approx. 1520 mm approx.
4 Operation 4.1 LOP – Controls TIM-ID: 0000008861 - 002 LOP – Controls Item Color Inscription Meaning / Function 1 White F1 2 White F2 3 White F3 Function keys to control the man-machine inter‐ face. Functions vary and are displayed on the LCD screen. 4 White F4 5 White F5 6 White ALARM ACKNOWL Pressing the button the first time stops alarm sig‐ nalization. Pressing the button a second time acknowledges an active alarm. LED (spot) lights up when an alarm is active.
Item Color Inscription Meaning / Function 8 White DIM ↓ Holding down the button decreases LCD back‐ ground illumination. 9 White LAMP TEST Pressing the button initiates lamp test. 10 Red TEST OVERSPEED Pressing the button initiates overspeed test. LED (spot) lights up as long as the overspeed test is running. 11 Green (depending on type of gearbox and propulsion) FPP: Pressing the button engages gear ahead. CPP, WJ, VS: Pressing the button engages clutch.
4.2 Engine – Preparations for putting into operation after extended out-of-service periods (>3 months) Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Putting into operation after extended out-of-service periods (>3 months) Item Measure Engine Depreserve (→ MTU Fluids and Lubricants Specifications A001061/..). Lube oil system Check engine oil level (→ Page 155); preheat engine oil, if required.
4.3 Putting the engine into operation after scheduled out-ofservice-period Preconditions ☑ Engine is stopped and starting disabled. Putting into operation Item Action Lube oil system Check engine oil level (→ Page 155); , preheat engine oil, if required. Coolant circuit Check coolant level (→ Page 164). Coolant circuit Heat engine coolant with coolant preheating unit.
4.4 Tasks after extended out-of-service periods (>3 weeks) Tasks after extended out-of-service periods (>3 weeks) Operate fuel treatment system for at least 5 minutes. Start up fuel treatment system (→ Page 91). Shut down fuel treatment system (→ Page 105). TIM-ID: 0000007730 - 005 Note: 1. 2.
4.5 Checks prior to start-up Checks prior to start-up 1. 2. 3. 4. 5. 6. Result: TIM-ID: 0000007736 - 005 7. Result: Check tank and the entire pipework for cleanness. If microorganisms are detected: a) Clean affected components. b) Disinfect affected components with biocides (→ MTU Fluids and Lubricants Specifications A001061/..). Close drain valves on housing. Open all supply and discharge valves. Switch on fuel treatment system (→ Page 95). Check direction of rotation of pump.
4.6 Fuel treatment system – Putting into operation Fuel treatment system – Overview 1. 2. Result: Switch on fuel treatment system (→ Page 95). Check the differential pressure at differential pressure gauge (8). Differential pressure in a new system: 0.1 bar to 0.3 bar. If no differential pressure is measured, the coalescer filter element is probably being bypassed. 1. Remove coalescer filter element (→ Page 183). 2. Check sealing faces on coalescer filter element and in the pressure tank.
Simulation of filter replacement with the engine running: HAT 1. 2. 3. 4. Result: 5. Result: 6. Note: 7. Result: Switch on fuel treatment system (→ Page 95). Start engine (→ Page 93). Run engine at idling speed. Close ball cock (5) at the inlet to the fuel treatment system. 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). Open ball cock (19). Fuel emerges.
4.7 Starting the engine from LOP Preconditions ☑ Gearbox is in neutral position. ☑ External start interlock is not activated. ☑ Emergency air shutoff flaps (if fitted) are open. DANGER WARNING Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Before barring or starting the engine, make sure that nobody is in the danger zone. Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors.
4.8 Starting the engine at the BlueLine automation system (control stand) DANGER WARNING Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Before barring or starting the engine, make sure that nobody is in the danger zone. Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors. Barring engine (with out-of-service-period > 1 month) Item Action Engine Bar with starting system (→ Page 113).
4.9 Fuel treatment system – Switching on Preconditions ☑ The on-board power supply is switched on. CAUTION Damage to engine/plant. Major material damage! • Before switching on, ensure that the engine/plant 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. Switching on fuel treatment system Carry out checks prior to start-up (→ Page 90). Switch on master switch on switch cabinet.
4.10 Operational checks DANGER WARNING Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors.
4.11 Clutch – Engaging from LOP Preconditions ☑ LOCAL OPERATION button is illuminated brightly (local operating mode is active). ☑ Engine speed is within range for clutch engagement. ☑ No external clutch engagement interlock is activated. DANGER Vessel is sailing blind. In Local Operation mode, the propulsion plant is controlled from the engine room. Risk of accidents! • Only execute vessel movements on the instructions of a person who has visual contact with the area outside the vessel.
4.12 Clutch – Disengaging from LOP Preconditions ☑ LOCAL OPERATION button is illuminated brightly (local operating mode is active). ☑ Engine speed in disengagement window. Disengaging clutch without reversing gearbox (CPP, WJ, VS) Item Action LOP Press CLUTCH OUT button (→ Page 85). • CLUTCH OUT button flashes. • Clutch is disengaged. • After receiving the feedback signal from clutch, the CLUTCH OUT but‐ ton is illuminated brightly.
4.13 Waterjet – Flushing from LOP (optional) Preconditions ☑ LOCAL OPERATION button is illuminated brightly (local operating mode is active). ☑ Vessel at a standstill and Waterjet bucket below the waterline. ☑ Engine speed is within range for clutch engagement. ☑ No external clutch engagement interlock is activated. CAUTION Waterjet flushing puts excessive strain on the bearings. Bearing damage! • Do not flush waterjet for too long. • Follow instructions of the waterjet manufacturer.
4.14 Stopping the engine from LOP Preconditions ☑ Engine is running in local mode. CAUTION Stopping the engine when it is running at full load causes extreme stress to the engine. Risk of overheating, damage to components! • Before shutting down, disengage gear and run the engine at idle speed for at least 10 mins. until engine temperatures have dropped and constant values are displayed. Stopping the engine from LOP Item Action LOP Disengage gearbox (→ Page 85).
4.15 Stopping the engine at the BlueLine automation system (control stand) CAUTION Stopping the engine when it is running at full load causes extreme stress to the engine. Risk of overheating, damage to components! • Before shutting down, disengage gear and run the engine at idle speed for at least 10 mins. until engine temperatures have dropped and constant values are displayed.
4.16 Emergency stop from LOP CAUTION An emergency stop causes extreme stress to the engine. Risk of overheating, damage to components! • Initiate emergency stop only in emergency situations. Emergency stop from LOP Item Action LOP Open cap of EMERGENCY STOP button (→ Page 85). LOP Press EMERGENCY STOP button. • Engine is stopped by disconnecting the power supply to the ECU; • On engines with emergency air-shutoff flaps: flaps close; • EMERGENCY STOP button flashes, Horn, flashing lamp etc.
4.17 Engine emergency stop at BlueLine automation system (control stand) CAUTION An emergency stop causes extreme stress to the engine. Risk of overheating, damage to components! • Initiate emergency stop only in emergency situations. Engine emergency stop at BlueLine automation system Action Engine Emergency stop at BlueLine automation system (→ BlueLine Operating In‐ structions).
4.18 After stopping the engine Preconditions ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.
4.19 Fuel treatment system – Shutdown Shutting down fuel treatment system 1. TIM-ID: 0000007732 - 005 2. 3. 4. 5. Press the illuminated pushbutton "Water drain" on the switch cabinet until water discharge from the outlet stops. Switch off fuel treatment system. Close ball valve at the inlet to the fuel treatment system. Close ball valve at the outlet of the fuel treatment system. Open drain valve until pressure has escaped from fuel treatment system.
4.20 Plant – Cleaning Preconditions ☑ Engine is stopped and starting disabled. ☑ Operating voltage is not applied. Special tools, Material, Spare parts Designation / Use Part No. Qty. Steam jet cleaner - 1 30390 1 Cleaner (Hakupur 312) WARNING WARNING CAUTION Note: Compressed air Risk of injury! • Do not direct compressed-air jet at persons. • Wear protective goggles / safety mask and ear protectors. Water jet. Risk of injury and scalding! • Do not direct water jet at persons.
5 Maintenance 5.1 Maintenance task reference table [QL1] The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Maintenance Schedule is a stand-alone publication. TIM-ID: 0000034059 - 002 The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance Schedule.
6 Troubleshooting 6.1 Troubleshooting Engine does not turn when starter is actuated Component Cause Measure Battery Discharged or faulty Charge or replace (see manufacturer's documentation). Cable connections faulty Check if cable connections are proper‐ ly secured (see manufacturer's docu‐ mentation). Starter Engine cabling or starter faulty Check if cable connections are proper‐ ly secured, contact Service. Engine wiring Faulty Check (→ Page 185).
Component Cause Measure Fuel injection equip‐ ment Injector faulty Replace (→ Page 129). Engine wiring Faulty Check (→ Page 185). Engine Overloaded Contact Service. Engine speed not steady Component Cause Measure Fuel injection equip‐ ment Injector faulty Replace (→ Page 129). Speed sensor Faulty Contact Service. Fuel system Air in fuel system Vent fuel system (→ Page 135). ECU Faulty Contact Service.
Blue exhaust gas Component Cause Measure Engine oil Too much oil in engine Drain engine oil (→ Page 156). Oil separator or oil preseparator of crankcase breather clogged Replace. Exhaust turbocharg‐ Faulty er, cylinder head, pis‐ ton rings, cylinder lin‐ er Contact Service. White exhaust gas Component Cause Measure Engine Not at operating temperature Run engine to reach operating temper‐ ature. Fuel system Water in fuel Check fuel system at fuel prefilter Drain fuel prefilter (→ Page 139).
6.2 LOP fault messages TIM-ID: 0000008902 - 003 Fault messages and measuring points (status reports) are displayed as text messages on the LOP dis‐ play (DIS). Explanation of the displayed texts can be gathered by pressing the help button on the touch screen. Fault messages can also be caused by faulty sensors/actuators. Contact Service to have sen‐ sors/actuators checked and replaced as necessary if the troubleshooting measures listed in the table be‐ low prove unsuccessful.
7 Task Description 7.1 Engine 7.1.1 Engine – Barring manually Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use DANGER Part No. Qty. Barring device F6555766 1 Ratchet head with extension F30006212 1 Unguarded rotating and moving engine components. Risk of serious injury – Danger to life! • Before barring the engine, ensure that nobody is in the danger zone. Engine – Barring manually 1. Result: 2. 3. 4. TIM-ID: 0000010503 - 003 5.
7.1.
7.2 Cylinder Liner 7.2.1 Cylinder liner – Endoscopic examination Preconditions ☑ Engine is stopped and starting disabled Special tools, Material, Spare parts Designation / Use Part No. Qty. Rigid endoscope Y20097353 1 Preparatory steps 1. 2. Remove cylinder head cover (→ Page 127). Remove injector (→ Page 130). Positioning crankshaft at BDC 1. 2. Using barring gear, turn crankshaft until crankshaft journal of the cylinder to be inspected has reached BDC.
Final steps Install injector (→ Page 130). Install cylinder head cover (→ Page 127). TIM-ID: 0000000015 - 013 1. 2.
7.2.2 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 exami‐ nation report. Findings Measure Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing prod‐ ucts, particles, broken-off burrs). Removed cylinders clearly show such scoring on the running surface under endoscope magnification.
Findings Measure Burn mark This is caused by a malfunction in the liner / ring tribosystem. 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 pro‐ nounced from TDC-ring 1. The honing pattern is usually no longer visible and displays a clearly defined (straight) edge to the undisturbed surface. The dam‐ aged surface is usually discolored. The circumferential length varies.
7.3 Crankcase Breather 7.3.1 Crankcase breather – Oil separator check Preconditions ☑ Engine is running. Checking oil separator Note: 1. TIM-ID: 0000003511 - 005 2. A thin oil film is admissible. Check oil separator for damage and exces‐ sive oil discharge (arrow). Replace oil separator if it is defective (→ Page 119).
7.3.2 Crankcase breather – Oil separator replacement, diaphragm check and replacement Preconditions ☑ Engine shut down and starting disabled. Special tools, Material, Spare parts Designation / Use WARNING Part No. Qty. Torque wrench, 6-50 Nm F30027336 1 Ratchet adapter F30027340 1 Engine oil Filter element (→ Spare Parts Catalog) Diaphragm (→ Spare Parts Catalog) Gasket (→ Spare Parts Catalog) Hot oil. Oil can contain combustion residues which are harmful to health.
Crankcase breather – replacing filter element (variant B) 1. 2. 3. 4. Remove cover (2) with O-ring (3). Remove filter element (1) from housing (4). Insert new filter element in housing (4). Install cover (2) with new O-ring. 5. Use torque wrench to tighten the screws of cover (2) to the specified torque. Name Size Screw 6. Type Lubricant Value/Standard Tightening torque (Engine oil) 6 Nm +2 Nm Replace further oil separator elements in the same way. Checking diaphragm (variant B) 3. 4. 5. 6.
7.4 Valve Drive 7.4.1 Valve gear - Lubrication Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil Lubricating valve gear (valve bridge with guide) 1. 2. 3. 4. Remove cylinder head covers (→ Page 127). Fill oil chambers of valve bridges with oil. Fill oil chambers of rocker arms and adjust‐ ing screws with oil. Install cylinder head covers (→ Page 127). Lubricating valve gear (flying valve bridge) 1. 2.
7.4.2 Valve clearance – Check and adjustment Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine coolant temperature is max. 40 °C. ☑ Valves are closed. Special tools, Material, Spare parts Designation / Use Part No. Qty. Feeler gauge Y20010128 1 Torque wrench 10-60 Nm F30510423 1 Torque wrench 60-320 Nm F30047446 1 Ring socket wrench F30039518 1 Preparatory steps Remove cylinder head cover (→ Page 127). Install barring device (→ Page 112). 3.
Checking valve bridge balance Note: 1. Component X Valve bridge with guide Y Flying valve bridge Not applicable for engines with flying valve bridge. Prior to adjusting valve clearance, check valve bridge balance on all valve bridges. Use feeler gauge to determine distance be‐ tween valve bridge and rocker arm. TIM-ID: 0000004352 - 004 2. Fig.
3. 4. Insert feeler gauge with determined value between valve bridge and valve-stem end (A). At the opposite valve-stem end (B), a feeler gauge thicker by 0.05 mm should not fit, otherwise adjust valve bridge balance. Adjusting valve bridge balance 1. 2. 3. 4. 5. 6. Not applicable for engines with flying valve bridge. Hold valve bridge (1) firmly in position with open-end wrench and release locknut (2). Use feeler gauge to determine distance be‐ tween valve bridge and rocker arm.
7. 8. Tighten locknut (2) to 35 Nm +5 Nm, hold‐ ing valve bridge (1) in position with openend wrench. Recheck valve bridge balance.
1. 2. 3. 4. 5. Check TDC position of piston in cylinder A1: • If the rocker arms are unloaded on cylinder A1, the piston is in firing TDC. • If the rocker arms are under load on cylinder A1, the piston is in overlap TDC. Check valve clearance with cold engine: • Inlet valves (long rocker arm) = 0.2 mm • Exhaust valves (short rocker arm) = 0.5 mm Check all valve clearances in two crankshaft positions (firing TDC and overlap TDC of cylinder A1) as per diagram.
7.4.3 Cylinder head cover – Removal and installation Preconditions ☑ Engine shut down and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Gasket Qty. (→ Spare Parts Catalog) Removing cylinder head cover 1. 2. 3. Clean cylinder head covers prior to removal if they are heavily soiled. Remove screws. Remove cylinder head cover with gasket from cylinder head. Installing cylinder head cover Clean mating face. Check condition of gasket, replace if necessary.
7.5 Injection Pump / HP Pump 7.5.1 DANGER WARNING HP pump – Relief bore check Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors. HP pump – Relief bore check 1. 2. TIM-ID: 0000000924 - 005 3. Check relief bore for oil and fuel discharge by visual inspection.
7.6 Injection Valve / Injector 7.6.1 Injector – Replacement Special tools, Material, Spare parts Designation / Use Injector Part No. Qty. (→ Spare Parts Catalog) Replacing injector Remove injector and install new injector (→ Page 130).
7.6.2 Injector – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Installation and removal device for injector F6790161 1 Milling cutter F30452739 1 Slotted nut screwdriver F30452578 1 Torque wrench, 0.
Removing injector Note: 1. 2. 3. 4. 5. Remove screw (2) and take off hold-down clamp (1). Remove high-pressure fuel line (5). Install installation/removal device on cylin‐ der head. Remove injector with installation/removal device. Remove installation/removal device. TIM-ID: 0000000952 - 006 6. Always replace the first and last injectors of one engine side first. Replace the inner in‐ jectors only after the installation of the outer injectors on this engine side is completed.
7. 8. 9. Remove sealing ring (1) from injector or use a self-made wire hook to remove it from the cylinder head. Remove O-rings (2) from injector. Cover all connections and bores, or seal with suitable plugs. Installing injector 1. 2. 3. 4. 5. 6. 7. Clean sealing surface on cylinder head and protective sleeve with milling cutter. Insert injector into cylinder head ensuring that the HP line connection is aligned cor‐ rectly. Press in injector with installation/removal device.
9. 10. Use slotted screwdriver to check thrust ring at both line ends for secure seating. Tighten loose thrust ring to the specified tightening torque. Name Size TIM-ID: 0000000952 - 006 Thrust ring Type Lubricant Tightening torque Value/Standard 5 Nm to 10 Nm 11. Coat screw head mating face (2) and thread with engine oil. 12. Place hold-down clamp (1) in correct installation position. Tighten screw (2) with torque wrench to the specified initial tightening torque.
16. Tighten union nut of connecting piece (limiting valve) to specified torque using a torque wrench. Name Size Union nut 17. Type Lubricant Tightening torque Value/Standard 140 Nm + 10 Nm Tighten union nut of connecting piece (injector) to specified torque using a torque wrench. Name Size Union nut Type Lubricant Tightening torque Value/Standard 120 Nm +10 Nm 18. Twist cable several times. 19.
7.7 Fuel System 7.7.1 Fuel system – Venting and filling Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Filling device Part No. Qty. B80144852 1 Diesel fuel WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Venting and filling LP fuel system 1. 2. 3. TIM-ID: 0000004713 - 002 4. 5. Connect filling device to connection (2).
Venting and filling HP fuel system 1. 2. 3. 4. 5. Note: 6. 7. 8. During filling, the opening of the valves in the HP pump must be audible (whistling noise). To open the valves, minimum pressure of 9 bar must be provided. Fill fuel system with hand pump, providing 9 bar minimum pressure. If no whistling sound is audible, pump must be operated faster. Filling is completed if: • Whistling noise is no more audible during pumping; • Bubble-free fuel emerges from the return hose of the filling device.
7.8 Fuel Filter 7.8.1 Fuel filter – Replacement Preconditions ☑ Engine shut down and starting disabled. Special tools, Material, Spare parts Designation / Use Oil filter wrench DANGER WARNING WARNING Qty. F30379104 1 Diesel fuel Easy-change filter (→ Spare Parts Catalog) Plastic ring (→ Spare Parts Catalog) Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. Fuels are combustible.
Replacing fuel filter with the engine stopped 1. 2. 3. 4. 5. 6. 7. 8. 9. Cut out the filter to be replaced. A Both filters cut in (operating position) B Left filter cut out C Right filter cut out Unscrew cut-out easy-change filter with oil filter wrench. Clean sealing face on filter head. Check sealing ring on new easy-change fil‐ ter and moisten with fuel. Fit SOLAS shield (→ Page 19). Screw on easy-change filter and tighten by hand.
7.8.2 Fuel prefilter – Draining Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Diesel fuel Gasket WARNING Qty. (→ Spare Parts Catalog) Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Fuel prefilter – Draining 1. Cut out filter to be drained. I Left filter cut in II Right filter cut in 2. Open threaded vent plug (5) of filter to be drained.
7.8.3 Fuel prefilter ‒ Flushing Special tools, Material, Spare parts Designation / Use Diesel fuel Gasket DANGER WARNING WARNING Part No. Qty. (→ Spare Parts Catalog) Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Engine noise above 85 dB (A).
2. 3. Result: 4. Open threaded vent plug (5) of filter to be flushed. Unlock drain valve (6) by pressing toggle, open it and drain fuel. Fuel flows from filtered side back to the un‐ filtered side, flushing the filter deposits downwards out of the filter. Close threaded vent plug (5) and drain valve (6). Fuel prefilter, topping up with fuel Stop engine (→ Page 100) and disable engine start. Remove screws for cover and take off cover (2). Fill filter housing with clean fuel. Place new gasket in cover (2).
7.8.4 DANGER WARNING Fuel prefilter – Differential pressure gauge check and adjustment Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors. Adjusting differential pressure gauge 1. 2. When installing the new filter element: align adjustable pointer (2) with pressure-indicat‐ ing pointer (3) of pressure gauge (1).
7.8.5 Fuel prefilter – Filter element replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use WARNING Part No. Diesel fuel Filter element (→ Spare Parts Catalog) Gasket (→ Spare Parts Catalog) Qty. Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Replacing filter element Cut out filter to be drained.
2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. TIM-ID: 0000004944 - 003 14. Open threaded vent plug (5) of contaminat‐ ed filter. Unlock drain valve (6) by pressing toggle and open it. Drain water and dirt from filter. Close drain valve (6). Remove screws securing the cover and take off cover (2). Remove spring housing (4) and filter ele‐ ment (3). Insert new filter element (3) and spring housing (4). Fill filter housing with clean fuel. Place new gasket in cover (2).
7.9 Exhaust Turbocharger 7.9.1 Compressor wheel – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Cold cleaner WARNING WARNING CAUTION CAUTION Part No. Qty. X00056750 1 Compressed air Risk of injury! • Do not direct compressed-air jet at persons. • Wear protective goggles / safety mask and ear protectors. Chemical substances.
Final steps Install air intake. Install exhaust flap with actuators. Install exhaust system after exhaust turbocharger. Install air filter.(→ Page 149) Fill with engine coolant.(→ Page 167) TIM-ID: 0000034852 - 001 1. 2. 3. 4. 5.
7.10 Charge-Air Cooling 7.10.1 DANGER WARNING WARNING Intercooler – Checking condensate drain line for coolant discharge and obstruction Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors. Compressed air Risk of injury! • Do not direct compressed-air jet at persons. • Wear protective goggles / safety mask and ear protectors.
7.11 Air Filter 7.11.1 Air filter – Replacement Special tools, Material, Spare parts Designation / Use Air filter Part No. Qty. (→ Spare Parts Catalog) Replacing the air filter Remove old air filter and install new air filter (→ Page 149). Reset signal ring of contamination indicator (→ Page 152). TIM-ID: 0000005447 - 009 1. 2.
7.11.2 Air filter – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Air filter – Removal and installation 1. 2. 3. 4. TIM-ID: 0000000904 - 009 5. Release clamp (2). Remove air filter (3) and clamp (2) from flange of intake housing (1). Verify that there are no objects in the flange of the intake housing (1) and clean it. Place new air filter (3) with clamp (2) onto intake housing (1). Tighten clamp (2).
7.12 Starting Equipment 7.12.1 Starter – Condition check Preconditions ☑ Engine is stopped and starting disabled. Starter – Condition check Check securing screws and pressure hose of starter for secure seating and tighten if required. Check wiring (→ Page 185). TIM-ID: 0000019523 - 002 1. 2.
7.12.2 DANGER WARNING Air starter – Manual operation Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Before barring or starting the engine, make sure that nobody is in the danger zone. Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors. Air starter – Manual operation 1. 2. TIM-ID: 0000006076 - 003 3. Press pushbutton for manual start and hold it. Allow compressed air to enter the air start‐ er, until the engine fires evenly.
7.13 Air Intake 7.13.1 Contamination indicator – Signal ring position check Preconditions ☑ Engine is stopped and starting disabled. Checking signal ring position 1. 2. TIM-ID: 0000005484 - 006 Result: If the signal ring is completely visible in the control window (2), replace air filter (→ Page 148). After installation of new filter, press reset button (1). Engaged piston with signal ring moves back to initial position.
7.13.2 Air flap – Check for ease of movement Preconditions ☑ Engine is stopped and starting disabled. Checking air flap for easy movement 1. TIM-ID: 0000005490 - 003 Result: 2. Actuate lever several times to check ease of movement. The spring must push back the air flap. If spring does not return air flap to initial po‐ sition, contact Service.
7.13.3 Air pipework from air filter to ETC – Check Special tools, Material, Spare parts Designation / Use Air hose Part No. Qty. 0229979482 2 Checking air pipework from air filter to ETC Item Findings Measure Visually check outer layer of air hose. • • • • • • Replace Check clamp.
7.14 Lube Oil System, Lube Oil Circuit 7.14.1 Engine oil level – Check Preconditions ☑ Engine shut down and starting disabled. Checking oil level prior to engine start 1. 2. Note: 3. 4. 5. Withdraw oil dipstick from guide tube and wipe it. Insert oil dipstick into guide tube up to stop, withdraw after approx. 10 seconds and check oil level. After extended standstill, the oil level may exceed the mark (1) by up to 2 cm. This can be caused by oil flowing from e.g.
7.14.2 Engine oil – Change Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine is at operating temperature. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 40-200 Nm F30027337 1 Ratchet adapter F30027341 1 Engine oil Sealing ring WARNING (→ Spare Parts Catalog) Hot oil. Oil can contain combustion residues which are harmful to health.
6. Tighten drain plugs (2) and (3) with torque wrench to the specified torque. Name Size Type Screw M26 x 1.5 Tightening torque Lubricant Value/Standard (Engine oil) 100 Nm +10 Nm Filling with new engine oil 1. 2. TIM-ID: 0000034455 - 001 3. 4. 5. Open cap on filler neck. Pour in engine oil at filler neck up to “max.” mark on oil dipstick. Close cap on filler neck. Check engine oil level (→ Page 155). After oil change and oil filter replacement, bar engine with starting system (→ Page 113).
7.14.3 Engine oil – Sample extraction and analysis Preconditions ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use MTU test kit DANGER WARNING WARNING Part No. Qty. 5605892099/00 1 Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. Hot oil. Oil can contain combustion residues which are harmful to health.
7.15 Oil Filtration / Cooling 7.15.1 Engine oil filter – Replacement Special tools, Material, Spare parts Designation / Use Oil filter wrench Engine oil Oil filter DANGER WARNING WARNING CAUTION Part No. Qty. F30379104 1 (→ Spare Parts Catalog) Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors. Hot oil.
Oil filter replacement with the engine running 1. To cut out the filter to be replaced, set the three-way cock to the corresponding posi‐ tion. • Position A: Lower filters cut out • Position B: Both filters cut in (normal po‐ sition) • Position C: Upper filters cut out. 2. 3. 4. Unscrew oil filter with oil filter wrench. Clean sealing face on connecting piece. Check condition of the new sealing ring and coat it with oil. Fit SOLAS shield (→ Page 19). Screw on and tighten new engine oil filter by hand.
7.15.2 Centrifugal oil filter – Cleaning and filter sleeve replacement Preconditions ☑ Engine shut down and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 1 Torque wrench, 6-50 Nm F30027336 1 Ratchet adapter F30027339 1 50602 1 X00029933 1 Cold cleaner (Hakutex 60) Grease (Kluthe Hakuform 30-10/emulsifier) WARNING (→ Spare Parts Catalog) Sealing ring (→ Spare Parts Catalog) Sealing ring (→ Spare Parts Catalog) Hot oil.
1. 2. 3. 4. 19. 20. Undo screw (1) and remove. Remove clamp (3) and take off hood (2). Carefully remove rotor (5) from housing. Hold rotor assembly (5) firmly in position with filter wrench and undo knurled nut (7). Take off rotor cap (8). Remove filter sleeve (9), stiffener plate (10) and sealing ring (11). Measure thickness of oil residues on filter sleeve. If maximum layer thickness of oil residues exceeds 30 mm, shorten maintenance in‐ terval. Remove standpipe (12) from lower rotor section (13).
7.16 Coolant Circuit, General, High-Temperature Circuit 7.16.
7.16.2 Engine coolant – Level check Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down. • Wear protective clothing, gloves, and goggles / safety mask. Checking engine coolant level at filler neck: 1. 2. 3. Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to escape.
7.16.3 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine coolant Changing engine coolant Drain engine coolant (→ Page 166). Fill with engine coolant (→ Page 167). TIM-ID: 0000000036 - 028 1. 2.
7.16.4 Engine coolant – Draining Preconditions ☑ Engine is stopped and starting disabled. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down. • Wear protective clothing, gloves, and goggles / safety mask. Preparatory steps 1. 2. Provide an appropriate container to drain the coolant into. Switch off preheating unit. Engine coolant – Draining 1. 2. 3. 4. 5.
7.16.5 Engine coolant – Filling Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine coolant WARNING CAUTION Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down. • Wear protective clothing, gloves, and goggles / safety mask. Cold coolant in hot engine can cause thermal stress.
1. Connect appropriate pump with hose to fill‐ ing connection (arrow) on A side or B side. Alternatively: 2. Connect a suitable pump with a hose to drain valve (arrowed). Pump coolant into engine at 0.5 bar mini‐ mum until coolant emerges from the loos‐ ened unions at the coolant distributor. Tighten the union for coolant line at the coolant distributor (→ Page 163). Fill expansion tank until overflow edge is reached. Check proper condition of breather valve and clean sealing faces if required.
Filling with coolant through filler neck 1. TIM-ID: 0000006727 - 004 2. 3. 4. 5. 6. 7. 8. 9. 10. Alternatively: Fill coolant through filler neck on expansion tank until coolant emerges from the loosened unions at the coolant distribution. Tighten the union for coolant line at the coolant distributor (→ Page 163). Continue to fill until coolant level remains constant at top edge of filler neck. Tighten the coolant line union on both turbochargers (→ Page 163).
7.16.6 DANGER WARNING Engine coolant pump – Relief bore check Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors. Engine coolant pump – Relief bore check 1. 2. 3. TIM-ID: 0000000961 - 008 4. Check relief bore for oil and coolant dis‐ charge.
7.16.7 Engine coolant – Sample extraction and analysis Preconditions ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use MTU test kit DANGER WARNING WARNING Part No. Qty. 5605892099/00 1 Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down.
7.17 Raw Water Pump with Connections 7.17.1 DANGER WARNING Raw water pump – Relief bore check Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors. Checking relief bore on raw water pump 1. 2. 3. TIM-ID: 0000007282 - 004 4. Check relief bore for oil and raw water dis‐ charge.
7.18 Battery-Charging Generator 7.18.1 Battery-charging generator drive – Coupling condition check Preconditions ☑ Engine shut down and starting disabled. Checking condition of batterycharging generator drive coupling 1. 2. 3. TIM-ID: 0000007390 - 006 4. Remove protective cover. Check resilient coupling for cracks and de‐ formation (arrow). Contact Service in case of severe deforma‐ tion or cracking. Install protective cover.
7.19 Engine Mounting / Support 7.19.1 Engine mounts – Checking securing screws for firm seating Preconditions ☑ Engine is stopped and starting disabled. Engine mounts – Checking securing screws for firm seating Check securing screws for firm seating. Tighten loose threaded connections. TIM-ID: 0000007548 - 007 1. 2.
7.19.2 Engine mounts – Resilient element check Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine is filled with coolant and engine oil. Special tools, Material, Spare parts Designation / Use Part No. Qty. Feeler gauge Y20010128 1 Calipers Y20001743 1 Box wrench F30379609 1 Engine oil Engine mounts – Checking the condition of resilient elements 1. 2. 3. Wipe rubber surface with dry cloth, do not use organic detergents.
Engine mounts – Checking buffer clearance 1. 2. 3. 4. Take off protective cap (2). Check marking (1): • With marking 30: a = 3 mm +0,3 mm. • With marking 40: a = 4 mm +0,3 mm. Check dimension (a) with feeler gauge on measuring groove (4). If dimension (a) deviates from the above specifications, adjust buffer clearance. Engine mounts – Buffer clearance adjustment 1. 2. 3. Undo nut (3). Adjust buffer clearance by turning the central buffer (1).
7.20 Drive Systems, Driving End and Free End (Coupling) 7.20.1 Coupling – Condition check Preconditions ☑ Engine is stopped and starting disabled. Coupling – Condition check 1. 2. 3. TIM-ID: 0000007655 - 002 4. 5. Remove perforated plate(s). Wipe rubber element with dry cloth, do not use organic detergents. Check condition of coupling through assembly hole(s), using a torch. Hair cracks in the rubber elements are permissible.
7.21 Auxiliary PTO 7.21.1 DANGER WARNING Bilge pump – Relief bore check Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors. Bilge pump – Relief bore check 1. 2. 3. TIM-ID: 0000007771 - 003 4. Check relief bores for oil and water dis‐ charge. Stop engine (→ Page 100) and disable en‐ gine start.
7.22 Fuel Supply System 7.22.1 Water drain valve – Check Checking water drain valve Open water drain valve. Check water outlet for obstructions. Close water drain valve. TIM-ID: 0000007733 - 006 1. 2. 3.
7.22.2 WARNING Differential pressure gauge – Check Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Checking differential pressure gauge Switch on fuel treatment system (→ Page 95). Set the alarm points at the differential pressure gauge to zero. Alarm is initiated with preset delay. Reset the alarm points at the differential pressure gauge to the specified values. TIM-ID: 0000007737 - 005 1. 2. Result: 3.
7.22.3 Water level probe (3-in-1 rod electrode) – Check Preconditions ☑ System is put out of service and emptied. WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Water level probe (3-in-1 rod electrode) – Check Disconnect plug from water level probe. Unscrew water level probe. Disconnect plug from water level probe. Immerse water level probe into a tank filled with water until water level reaches the thread.
7.22.4 WARNING Pump capacity – Check Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Checking pump capacity 1. 2. Note: 3. 4. Install suitable pressure gauge at the neck of the intake side of the pump. Check pump pressure. a) Switch on fuel treatment system (→ Page 95). The pressure limiting valve at the pump might respond and open. Audible noise is caused by overflowing fuel and can be disregarded.
7.22.5 Coalescer filter element – Replacement Preconditions ☑ System is switched off and starting disabled. Special tools, Material, Spare parts Designation / Use WARNING CAUTION CAUTION Part No. Qty. Torque wrench, 6-50 Nm F30027336 1 Ratchet adapter F30027339 1 Diesel fuel Engine oil Coalescer filter element (→ Spare Parts Catalog) Gasket (→ Spare Parts Catalog) Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke.
16. Name Size Type Lubricant Value/Standard Nut M16 Tightening torque (Engine oil) 30 Nm +3 Nm Fit gasket (10). Install cover. Install screw (1), washer (2) and nut (9). Tighten nut (9). Open ball valve at the inlet and outlet of the fuel treatment system. The fuel treatment system is ready for operation. TIM-ID: 0000007735 - 006 17. 18. 19. 20. 21. Result: Tighten nut (3) to specified tightening torque using a torque wrench.
7.23 Wiring (General) for Engine/Gearbox/Unit 7.23.1 Engine wiring – Check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Isopropyl alcohol X00058037 1 Engine wiring – Check 1. 2. 3. 4. 5. 6. Close male connectors that are not plugged in with the protective cap supplied. Clean dirty connector housings, sockets and contacts with isopropyl alcohol. Ensure that all sensor connectors are securely engaged.
7.24 Accessories for (Electronic) Engine Governor / Control System 7.24.1 Engine governor and connectors – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Connector pliers 0135315483 1 Isopropyl alcohol X00058037 1 Cleaning engine governor and connectors 1. 2. 3. Remove heavy soiling from housing surface with isopropyl alcohol.
7.24.2 Engine monitoring unit and connectors – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Connector pliers 0135315483 1 Isopropyl alcohol X00058037 1 Engine monitoring unit and connectors – Cleaning 1. 2. 3. Remove coarse dirt from housing surface with isopropyl alcohol. Remove dirt from surface of connectors (1), connector sockets and shrink sleeves (2) using a cloth moistened with isopropyl alco‐ hol.
7.24.3 Limit switch for start interlock ‒ Check Preconditions ☑ Engine is stopped and starting disabled. Note: 1. 2. 3. Checking limit switch for start interlock Check whether switches (3) and guard plate (1) with engine support (4) are instal‐ led on both sides of flywheel housing (2). Check whether both switches (3) are actu‐ ated. If switches (3) and/or guard plate (1) with engine support (4) is/are not installed: • Screw on guard plate (1) with engine support (4).
7.24.4 Checking engine control unit plug connections Preconditions ☑ Engine shut down and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Connector pliers 0135315483 1 Checking engine control unit plug connections 1. 2. 3. TIM-ID: 0000000949 - 003 4. Use connector pliers (3) to make certain that all plug-in connections on engine con‐ trol unit are securely seated.
7.24.5 Engine monitoring unit – Plug connection check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Connector pliers 0135315483 1 Checking engine monitoring unit plug connections 1. 2. 3. TIM-ID: 0000008394 - 003 4. Use connector pliers (3) to make certain that all engine monitoring unit plug connec‐ tions are securely seated.
7.24.6 Engine control unit – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Connector pliers 0135315483 1 Covering caps for Cannon sockets Removing control unit from engine 1. 2. TIM-ID: 0000008487 - 004 3. 4. Note or mark assignment of cables to con‐ nector sockets. Use connector pliers (2) to disengage the bayonet union nuts (4) of the connectors (3) by turning them counterclockwise.
5. 6. 7. Disconnect ground strap from engine con‐ trol unit grounding stud (7). If the screws (4) are easily accessible: 1. Remove screws (4). 2. Remove engine control unit housing (3) from mounting plates (2). 3. Unscrew mounting plates (2), cable shock absorbers (5) and further fasten‐ ing parts (6) as one unit from engine. If the screws (4) are not easily accessible: 1. Unscrew screws (1). 2. Remove engine control unit housing (3) together with mounting plates (2). 3.
7.24.7 LOP – Visual inspection Preconditions ☑ Engine is stopped and starting disabled. Preparatory steps 1. Result: 2. 3. If READY FOR OPERATION button is illuminated brightly, press switch briefly. READY FOR OPERATION button returns to basic brightness. Switch master power switch to OFF. Disconnect battery in accordance with battery manufacturer's instructions. Checking housing and internal assemblies for secure seating 1. 2. 3. 4. Open LOP front door.
Checking unassigned connector sockets 1. 2. 3. Ensure that non-assigned connector sock‐ ets are protected with covering caps. Make certain that the two securing ele‐ ments (1) are engaged in the lugs (2) so that the covering cap (3) is held firmly in place in the socket. If this is not the case, press the securing el‐ ements (1) concerned in the direction of the arrow until they engage noticeably. Checking buttons and display 1. 2. 3.
8 Appendix A Abbreviations Abbrevia‐ tion Meaning Explanation ADEC Advanced Diesel Engine Control Engine governor AL Alarm Alarm (general) ANSI American National Standards Institute Governing body for US American standards ATL Abgasturbolader Exhaust turbocharger BR Baureihe Series BV Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU Publica‐ tion No. A01061/..
Abbrevia‐ tion Meaning Explanation LCD Liquid Crystal Display, Liquid Crystal Device LCU Local Control Unit LED Light Emitting Diode LMU Local Monitoring Unit LOP subassembly LO Low Alarm: Measured value lower than 1st minimum limit LOLO Low Low Alarm: Measured value lower than 2nd minimum limit LOP Local Operating Panel LOS Local Operating Station MCS Monitoring and Control System MG Message MPU Microprocessor Unit, Microprocessing Unit OT Oberer Totpunkt Top dead center P-xy
Local support Experienced and qualified specialists place their knowledge and expertise at your disposal. For locally available support, go to the MTU internet site: http://www.mtu-online.com 24h hotline With our 24h hotline and the outstanding flexibility of our service staff, we are always ready to assist you - either during operation, for preventive maintenance, corrective work in case of malfunction or changed operating conditions, or for spare parts supply.
9 Appendix B 9.1 Special Tools Barring device Part No.: F6555766 Qty.: Used in: 1 7.1.1 Engine – Barring manually (→ Page 112) Box wrench Part No.: F30379609 Qty.: Used in: 1 7.19.2 Engine mounts – Resilient element check (→ Page 175) Calipers Part No.: Y20001743 Qty.: Used in: 1 7.19.2 Engine mounts – Resilient element check (→ Page 175) Connector pliers Part No.: 0135315483 Qty.: Used in: 1 7.24.1 Engine governor and connectors – Cleaning (→ Page 186) Qty.: Used in: 1 7.24.
Filter wrench Part No.: F30379104 Qty.: Used in: 1 7.15.2 Centrifugal oil filter – Cleaning and filter sleeve replacement (→ Page 161) Installation and removal device for injector Part No.: F6790161 Qty.: Used in: 1 7.6.2 Injector – Removal and installation (→ Page 130) Milling cutter Part No.: F30452739 Qty.: Used in: 1 7.6.2 Injector – Removal and installation (→ Page 130) MTU test kit Part No.: 5605892099/00 Qty.: Used in: 1 7.14.
Ratchet head with extension Part No.: F30006212 Qty.: Used in: 1 7.1.1 Engine – Barring manually (→ Page 112) Rigid endoscope Part No.: Y20097353 Qty.: Used in: 1 7.2.1 Cylinder liner – Endoscopic examination (→ Page 114) Ring socket wrench Part No.: F30039518 Qty.: Used in: 1 7.4.2 Valve clearance – Check and adjustment (→ Page 122) Slotted nut screwdriver Part No.: F30452578 Qty.: Used in: 1 7.6.2 Injector – Removal and installation (→ Page 130) Steam jet cleaner Part No.: - Qty.
Torque wrench, 40-200 Nm Part No.: F30027337 Qty.: Used in: 1 7.14.2 Engine oil – Change (→ Page 156) Torque wrench, 6-50 Nm Part No.: F30027336 Qty.: Used in: 1 7.22.5 Coalescer filter element – Replacement (→ Page 183) Torque wrench, 6-50 Nm Part No.: F30027336 Qty.: Used in: 1 7.3.2 Crankcase breather – Oil separator replacement, diaphragm check and replace‐ ment (→ Page 119) Qty.: Used in: 1 7.15.
9.
Engine coolant pump – Relief bore check 170 Engine coolant – Draining 166 Engine emergency stop at BlueLine automation system (control stand) 103 Engine governor – Cleaning 186 Engine monitoring unit – Cleaning 187 – Plug connection check 190 Engine mounts – Resilient element check 175 Engine mounts – Checking securing screws for firm seating 174 Engine oil – Change 156 – Sample extraction and analysis 158 Engine oil filter – Replacement 159 Engine oil level – Check 155 Engine side – Designations 18 Engine
Stopping the engine from LOP 100 T Tasks – After extended out-of-service periods 89 Tasks after extended out-of-service periods (>3 weeks) 89 Transport 8 Troubleshooting 108 V Valve clearance – Adjustment 122 – Check 122 Valve gear – Lubrication 121 Venting points 163 W DCL-ID: 0000016671 - 001 Water drain valve – Check 179 Water level probe (3-in-1 rod electrode) – Check 181 Waterjet – Flushing from LOP (optional) 99 Wiring - engine – Check 185 204 | Appendix B | M015412/03E 2012-02
