Diesel Engine 20V4000M93x - mtu-online.com · installation 254 7.21.11 Engine Interface Module EIM...

Operating InstructionsDiesel Engine20V4000M93x

MS150048/05E

Engine model kW/cyl. Application group20V4000M93 195 kW/cyl. 1 DS, continuous operation, variable, low load

factors20V4000M93L 215 kW/cyl. 1 DS, continuous operation, variable, low load

factors

Table 1: Applicability

© 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 writ-ten consent of MTU Friedrichshafen GmbH. This particularly applies to its reproduction, distribution, editing, translation, micro-filming 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 GmbHreserves the right to change, delete or supplement the information provided as and when required.

Table of Contents1 Safety

1.1 Important provisions for all products 61.2 Correct use of all products 81.3 Personnel and organizational requirements 91.4 Initial start-up and operation – Safety

regulations 101.5 Assembly, maintenance, and repair work –

Safety regulations 121.6 Fire and environmental protection, fluids

and lubricants 161.7 Standards for warning notices in the text

and highlighted information 181.8 Transport 191.9 Crankshaft transport locking device 20

2 General Information

2.1 Tightening specifications for screws, nutsand bolts 23

2.2 Engine side and cylinder designations 362.3 Product description 372.4 Engine – Overview 462.5 Sensors and actuators – Overview 472.6 Engine wiring harness – Overview 52

3 Technical Data

3.1 20V4000M93 engine data: IMO, engine-mounted heat exchanger, intercooler madeof copper-based alloy 58

3.2 20V4000M93 engine data: EPA 2, engine-mounted heat exchanger 61

3.3 20V4000M93L engine data: IMO, engine-mounted heat exchanger, intercooler madeof copper-based alloy 64

3.4 20V4000M93L engine data: EPA 2, engine-mounted heat exchanger 67

3.5 Engine – Main dimensions 703.6 Firing order 71

4 Operation

4.1 Controls 724.2 Putting the engine into operation after

extended out-of-service periods (>3 months) 734.3 Putting the engine into operation after

scheduled out-of-service-period 744.4 Re-starting the engine following an

automatic safety shutdown 754.5 Starting the engine 76

4.6 Operational checks 774.7 Tasks after extended out-of-service periods

(>3 weeks) 784.8 Checks prior to start-up 794.9 Fuel treatment system – Initial start-up 80

4.10 Fuel treatment system – Switching on 834.11 Emergency engine stop at BlueLine

automation system (control stand) 844.12 Clutch – Engagement at LOP 854.13 Coupling – Disengaging from LOP 864.14 Waterjet – Flushing from LOP (optional) 874.15 Stopping the engine from LOP 884.16 Stopping the engine at the BlueLine

automation system (control stand) 894.17 After shutting down the engine 904.18 Emergency stop from LOP 914.19 Fuel treatment system – Shutdown 924.20 Plant – Cleaning 93

5 Maintenance

5.1 Maintenance schedule task reference table[QL1] 94

6 Troubleshooting

6.1 Control cabinet of fuel treatment system –Troubleshooting 96

6.2 Troubleshooting 976.3 Engine governor ADEC (ECU 7) fault

messages for Series 4000 engines, marineapplication 100

6.4 ADEC engine governor – Fault codes 101

7 Task Description

7.1 SOLAS 1277.1.1 SOLAS shielding as per MTN 5233 –

Installation 1277.1.2 Installation locations for SOLAS shields 1287.1.3 Adhesive tape for SOLAS shielding –

Application 137

7.2 Engine 1387.2.1 Engine – Barring manually 1387.2.2 Barring engine with starting system 139

7.3 Cylinder Liner 1407.3.1 Cylinder liner – Endoscopic examination 1407.3.2 Cylinder liner – Instructions and comments on

endoscopic and visual examination 142

7.4 Crankcase Breather 144

MS150048/05E 2018-03 | Table of Contents | 3

DCL-

ID: 0

0000

1561

7 - 0

03

7.4.1 Crankcase breather – Oil separator elementreplacement 144

7.5 Valve Drive 1467.5.1 Valve gear – Lubrication 1467.5.2 Valve clearance – Check and adjustment 1477.5.3 Cylinder head cover – Removal and

installation 151

7.6 Injection Pump / HP Pump 1527.6.1 HP fuel pump – Filling with engine oil 1527.6.2 HP fuel pump – Relief bore check 154

7.7 Injection Valve / Injector 1557.7.1 Injector – Replacement 1557.7.2 Injector – Removal and installation (jacketed

fuel system) 156

7.8 Fuel Filter 1637.8.1 Fuel filter – Replacement 1637.8.2 Fuel prefilter – Differential pressure gage

check and adjustment 1657.8.3 Fuel prefilter – Draining 1667.8.4 Fuel prefilter – Flushing 1687.8.5 Fuel prefilter with water separator – Filter

element replacement 170

7.9 Exhaust Turbocharger 1737.9.1 Compressor wheel – Cleaning 173

7.10 Charge-Air Cooling 1777.10.1 Intercooler – Checking condensate drain for

coolant leakage and obstruction 177

7.11 Air Filter 1797.11.1 Air filter – Replacement 1797.11.2 Air filter – Removal and installation 180

7.12 Air Intake 1817.12.1 Contamination indicator – Signal ring position

check 181

7.13 Lube Oil System, Lube Oil Circuit 1827.13.1 Engine oil level – Check 1827.13.2 Engine oil ‒ Change 1837.13.3 Engine oil – Sample extraction and analysis 185

7.14 Oil Filtration / Cooling 1867.14.1 Automatic oil filter – Overview 1867.14.2 Automatic oil filter – Preparatory steps 1897.14.3 Automatic oil filter – Removal 1907.14.4 Automatic oil filter – Disassembly 1927.14.5 Automatic oil filter – Cleaning 1937.14.6 Automatic oil filter – Check 1947.14.7 Automatic oil filter – Assembly 1957.14.8 Automatic oil filter – Installation 1967.14.9 Automatic oil filter – Final steps 198

7.14.10 Automatic oil filter – Checking flushing armrotation 199

7.14.11 Oil filter element – Overview 2007.14.12 Oil filter element – Removal 2037.14.13 Oil filter element – Disassembly 204

7.14.14 Oil filter element – Cleaning 2067.14.15 Oil filter element – Check 2077.14.16 Oil filter element – Assembly 2087.14.17 Oil filter element – Installation 2127.14.18 Oil indicator filter – Cleaning and check 2157.14.19 Centrifugal oil filter – Overview 2177.14.20 Centrifugal oil filter – Preparatory steps 2187.14.21 Centrifugal oil filter – Removal 2197.14.22 Centrifugal oil filter - Cleaning 2207.14.23 Centrifugal oil filter – Cleaning and filter-

sleeve replacement 2217.14.24 Centrifugal oil filter – Installation 223

7.15 Coolant Circuit, General, High-TemperatureCircuit 2247.15.1 Vent points 2247.15.2 Engine coolant – Level check 2257.15.3 Engine coolant – Change 2277.15.4 Engine coolant draining 2287.15.5 Engine coolant – Filling 2297.15.6 Engine coolant pump – Relief bore check 2337.15.7 Engine coolant – Sample extraction and

analysis 234

7.16 Raw Water Pump with Connections 2357.16.1 Raw water pump – Relief bore check 235

7.17 Battery-Charging Generator 2367.17.1 Battery-charging generator drive – Coupling

condition check 236

7.18 Engine Mounting / Support 2377.18.1 Engine mounting – Checking resilient element 237

7.19 Fuel Supply System 2387.19.1 Water drain valve – Check 2387.19.2 Differential pressure gage – Alarm function

check 2397.19.3 Water level probe (3-in-1 rod electrode) –

Check 2407.19.4 Pump capacity – Check 2417.19.5 Coalescer filter element ‒ Replacement 242

7.20 Wiring (General) for Engine/Gearbox/Unit 2447.20.1 Engine cabling – Check 244

7.21 Accessories for (Electronic) EngineGovernor / Control System 2457.21.1 CDC parameters – Reset with DiaSys® 2457.21.2 EMU and connectors – Cleaning 2467.21.3 Limit switch for start interlock – Check 2477.21.4 Engine governor and connector – Cleaning 2487.21.5 Engine Monitoring Unit EMU 8 – Plug

connections check 2497.21.6 Interface module EIM plug connections –

Check 2507.21.7 Engine governor plug connections – Check 2517.21.8 Engine governor ECU 7 – Removal and

installation 252

4 | Table of Contents | MS150048/05E 2018-03

DCL-

ID: 0

0000

1561

7 - 0

03

7.21.9 Engine Monitoring Unit EMU 8 – Removal andinstallation 253

7.21.10 Engine Interface Module EIM 2 – Removal andinstallation 254

7.21.11 Engine Interface Module EIM 2 – Diagnosticfeatures 255

7.22 Emergency Instrumentation (LocalOperating Panel) 2587.22.1 LOP and connectors – Cleaning 258

8 Appendix A

8.1 List of abbreviations 2598.2 MTU Contact/Service Partners 261

9 Appendix B

9.1 Special Tools 2629.2 Index 270

MS150048/05E 2018-03 | Table of Contents | 5

DCL-

ID: 0

0000

1561

7 - 0

03

1 Safety

1.1 Important provisions for all products

GeneralThis 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

NameplatesThe product is identified by nameplate, model designation or serial number. This data must match the speci-fications 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 deliv-ered "loosely" with the engine. If the nameplate secured to the engine after installation in the vehicle/systemis not visible without the removal of components, the system integrator must install the second nameplate ina clearly visible area on the vehicle/system.

Emission specifications and emission label

Responsibility for compliance with emission regulationsModification or removal of any mechanical/electronic components or the installation of additional compo-nents including the execution of calibration processes that might affect the emission characteristics of theproduct are prohibited by emission regulations. Emission-related components must only be serviced, ex-changed 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 bythe emissions regulation authorities. The manufacturer does not accept any liability for violations of theemission regulations.

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

Emission certification applicable to engines with EPA Nonroad Tier 4 emissioncertification in accordance with 40 CFR 1039Extract from the standard:

Failing to follow these instructions when installing a certified engine in a piece of nonroad equipment violatesfederal 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 readduring normal engine maintenance, you must place a duplicate label on the equipment, as described in 40CFR 1068.105.

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

6 | Safety | MS150048/05E 2018-03

TIM

-ID: 0

0000

4053

0 - 0

13

Replacing components with emission labelsOn all MTU engines fitted with emission labels, these labels must remain on the engine throughout its opera-tional life.

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

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.

MS150048/05E 2018-03 | Safety | 7

TIM

-ID: 0

0000

4053

0 - 0

13

1.2 Correct use of all products

Correct useThe product is intended for use in accordance with its contractually-defined purpose as described in the rele-vant 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 Represerva-

tion Specifications of the manufacturer)• With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU con-

tact/Service partner)• In the original as-delivered configuration or in a configuration approved by the manufacturer in writing (al-

so 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 re-

pair

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

Any other use, particularly misuse, is considered as being contrary to the intended purpose. Such improperuse increases the risk of injury and damage when working with the product. The manufacturer shall not beheld 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 conversionsUnauthorized 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 author-ized by the manufacturer. The manufacturer shall not be held liable for any damage resulting from unauthor-ized changes or modifications.

8 | Safety | MS150048/05E 2018-03

TIM

-ID: 0

0000

6567

1 - 0

05

1.3 Personnel and organizational requirements

Organizational measures of the user/manufacturerThis manual must be issued to all personnel involved in operation, maintenance, repair, assembly, installa-tion, 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, per-sonnel 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 requirementsAll 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, as-sembly, installation, and transport in writing.

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

Clothing and personal protective equipmentAlways 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 descrip-tions of the individual activities.

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

MS150048/05E 2018-03 | Safety | 9

TIM

-ID: 0

0000

4053

1 - 0

12

1.4 Initial start-up and operation – Safety regulations

Safety regulations for initial start-upInstall the product correctly and carry out acceptance in accordance with the manufacturer's specificationsbefore putting the product into service. All necessary approvals must be granted by the relevant authoritiesand 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 switchedon.

• 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 neces-

sary.• 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 duringthis 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 aswell as the monitoring, signaling and alarm systems work properly.

Smoking is prohibited in the area of the product.

Safety regulations during operationThe 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 topresent operating status, violation of limit values and warning or alarm messages.

Malfunctions and emergency stopPractice 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 eliminat-ed.

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

OperationDo not remain in the operating room when the product is running unless absolutely necessary. Keep yourstay as short as possible.

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

10 | Safety | MS150048/05E 2018-03

TIM

-ID: 0

0000

4053

3 - 0

20

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 equipmentWhen 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 alltimes.

MS150048/05E 2018-03 | Safety | 11

TIM

-ID: 0

0000

4053

3 - 0

20

1.5 Assembly, maintenance, and repair work – Safety regulations

Safety regulations for work prior to assembly, maintenance, and repairHave 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 suita-ble containers of adequate capacity to catch fluids and lubricants.

Release residual pressure before removing or replacing a component in the supply line. To depressurize pres-surized 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 arefitted.

Before working on the exhaust gas aftertreatment system, close the shutoff valve on the reducing agenttank. 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 equipmentUse only proper and calibrated tools. Observe the specified tightening torques during assembly or disassem-bly.

Setting down, lifting and climbingCarry 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 thecenter 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 preventcomponents/tools from falling down.

Assume a safe standing position when performing assembly work.

Never use the product as a climbing aid.

12 | Safety | MS150048/05E 2018-03

TIM

-ID: 0

0000

4053

5 - 0

21

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

Removing, installing and cleanlinessPay 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 asuitable corrosion inhibitor as necessary.

LinesEnsure 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 contactwith other components. Do not place fuel or oil lines near hot components.

MiscellaneousSufficient ventilation must be guaranteed during the work.

Wear a breathing mask offering protection against soot, dust, and mineral fibers (filter class P3) when work-ing on exhaust components. Clean the work area with a dust extraction machine of class H. Wear protectivegloves 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 orresinous 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 workBefore 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 (especial-ly 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.

MS150048/05E 2018-03 | Safety | 13

TIM

-ID: 0

0000

4053

5 - 0

21

Welding workWelding operations on the product or mounted units are not permitted. Cover the product when welding inits 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 weld-ing is in progress. There is a risk of explosion or fire due to oil vapors or highly flammable fluids and lubri-cants.

Do not use product as ground terminal.

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

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

Hydraulic installation and removalCheck the function and safe operating condition of tools and fixtures to be used. Use only the specified devi-ces 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 enduntil correct sealing is established.

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

Working with batteriesObserve 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 sprayacid if the battery terminals are connected incorrectly.

Working on electrical and electronic assembliesAlways obtain the permission of the person in charge before commencing assembly, maintenance, and repairwork 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 dischargemust always be carried out with appropriate equipment. Appropriate equipment is e.g. electrically conductivework surfaces or antistatic wristbands.

14 | Safety | MS150048/05E 2018-03

TIM

-ID: 0

0000

4053

5 - 0

21

Do not damage wiring during removal work. When reconnecting, ensure that cabling cannot be damaged dur-ing 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 emergen-cy stop function must be tested in particular. The functional check of the emergency stop, during which thevoltage 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. Packagefaulty electronic components or assemblies properly before dispatching for repair:• Moisture-proof• Shock-proof• Wrapped in antistatic foil (as necessary)

Working with laser equipmentWork with laser devices shall be carried out by trained and qualified personnel only. Follow the safety in-structions 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 typeand application.

Measuring component dimensionsWorkpieces, components and measuring equipment lie in the specified tolerance range at a reference tem-perature of 20 °C.

MS150048/05E 2018-03 | Safety | 15

TIM

-ID: 0

0000

4053

5 - 0

21

1.6 Fire and environmental protection, fluids and lubricants

Fire prevention and fireFire, 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 andobserve any relevant safety regulations or recommendations. Products that comply with the SOLAS Conven-tion 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 causefires, so keep the product clean at all times. Do not leave rags saturated with fluids and lubricants on theproduct. 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 onpipes and components carrying oil or fuel.

When starting the engine with an external power source, connect the ground lead last and remove it first. Toavoid sparks in the vicinity of the battery, connect the ground cable from the external power source to theground 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 familiarwith their correct handling.

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

NoiseWear 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 dan-ger are compromised.

Environmental protection and disposalDispose 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 recy-cled.

Fluids and lubricants/auxiliary materials (process materials)Process materials can also be or contain hazardous or toxic substances. When using process materials andother chemical substances, observe the associated safety data sheet. The safety data sheet may be obtainedfrom the relevant manufacturer or from MTU.

Only process materials approved by the manufacturer in accordance with the Fluids and Lubricants Specifi-cations 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 sep-arate containers and their own drip trays. Even extremely small amounts of reducing agent contaminationcan 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.

16 | Safety | MS150048/05E 2018-03

TIM

-ID: 0

0000

4053

6 - 0

18

Registration, evaluation, approval and restriction of chemicals (REACHordinance)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 con-

tainers, 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• Observe the relevant safety data sheet for all materials.• 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)• Observe the relevant safety data sheet for all materials.• When working with acids and alkaline solutions, wear goggles or face mask, gloves and protective cloth-

ing.• 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 contain-ers and use separate drip trays. Even extremely slight contamination can lead to malfunctions in the ex-haust aftertreatment system.Mistakenly filling the tank of the reducing agent system with fuel can cause leakage at the seals and inthe hoses.

MS150048/05E 2018-03 | Safety | 17

TIM

-ID: 0

0000

4053

6 - 0

18

1.7 Standards for warning notices in the text and highlightedinformation

DANGERIn the event of immediate danger.Consequences: Death, serious or permanent injury!• Remedial action.

WARNINGIn the event of a situation involving potential danger.Consequences: Death, serious or permanent injury!• Remedial action.

CAUTIONIn the event of a situation involving potential danger.Consequences: Minor or moderate injuries!• Remedial action.

NOTICEIn the event of a situation involving potentially adverse effects on the product.Consequences: Material damage!• Remedial action.• Additional product information.

Warning notices1. This manual with all safety instructions and warning notices must be issued to all personnel involved in oper-

ation, 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 per-

sonal injury shall be considered to include a warning of potential damage.

Highlighted informationImportantThis 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.

18 | Safety | MS150048/05E 2018-03

TIM

-ID: 0

0000

4057

8 - 0

06

1.8 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 andgearbox).

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 transportpallet or transport with equipment for heavy loads (forklift truck).

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

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

Setting the engine down after transportPlace 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 doso.

MS150048/05E 2018-03 | Safety | 19

TIM

-ID: 0

0000

0262

1 - 0

04

1.9 Crankshaft transport locking device

Special tools, Material, Spare partsDesignation / Use Part No. Qty.

Torque wrench, 10–60 Nm F30452769 1Torque wrench, 60–320 Nm F30452768 1Engine oil

Transport locking devices

Note: The transport locking device on both sides protects the crankshaft bearings from shocks and vibration dam-age during engine transport.

For installation and removal of the transport locking device, follow the in-structions below:

1. The transport locking device must remain installed on both engine sides as long as possible during engineinstallation in order to avoid damage.

2. Prior to every engine transport, the transport locking device must be reinstalled on both engine sides accord-ing to the instructions.

3. If the engine is to be moved together with the generator, the transport locking device for the generator mustalso be installed.

4. Always use the screws supplied with or installed in the transport locking device to secure it on the engine.5. Starting or barring the engine is allowed only with the transport locking device removed. If the generator is

already mounted on the engine, ensure that the transport locking device of the generator is also removed.

Removing guard plates and en-gine mounting brackets (if appli-cable) on driving end (KS)

1. Remove screws (4) on both sides and take offwith washers (3), guard plates (1) and enginesupports (2).

2. Store the removed parts of the transportlocking device carefully for possible reuse.

20 | Safety | MS150048/05E 2018-03

TIM

-ID: 0

0000

0401

0 - 0

16

Installing the transport lockingdevice on driving end (KS)

Note: Install plate (6) on the upper part of the openings only.1. Secure the plates (6) with screws (4) and washers (5) at the lateral openings on both sides of the flywheel

housing and tighten to the specified tightening torque.

Name Size Type Lubricant Value/Standard

Screw M16 Tightening torque (Engine oil) 250 nm +25 nm

2. Screw locknut (2) onto screws (1) up to the end of the thread.3. The long side of holder (3) must point downwards. Insert holder (3) through the openings of plate (6).

Note: Holder (3) must lock only the flywheel, not the ring gear.4. Screw in screw (1) in bores of holder (3) until holder (3) is locked in position.

Note: Screw (1) must be tightened stepwise and alternately on both sides of the flywheel housing.5. Tighten screw (1) to specified tightening torque.


Screw M10 Tightening torque (Engine oil) 30 Nm +3 Nm

6. Install locknut (2) of screw (1) on plate (6) and tighten.

Removing the transport lockingdevice from driving end (KS)

1. Release the locknuts (2) on both sides of theflywheel housing, remove screw (1) and takeoff holder (3).

2. Remove screws (4) and take off with wash-ers (5) and plates (6).

3. Store the removed parts of the transportlocking device carefully together with thisdocumentation for possible reuse.

MS150048/05E 2018-03 | Safety | 21

TIM

-ID: 0

0000

0401

0 - 0

16

Installing guard plates and en-gine mounting brackets (if appli-cable) on driving end (KS)

Note: Always use the screws supplied with the equipment or removed from the guard plates and engine supportsto secure them on the engine.

u Install engine supports (2) on both sides with guard plates (1) washers (3) and screws (4) and tighten tospecified tightening torque tightening.


Screw M16 Tightening torque (Engine oil) 250 Nm +25 Nm

22 | Safety | MS150048/05E 2018-03

TIM

-ID: 0

0000

0401

0 - 0

16

2 General Information

2.1 Tightening specifications for screws, nuts and bolts

Tightening torques for setscrew and connections as per MTN 5008 standardThis 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 MA are specified for screws of strength class 8.8 (surface condition bare, phosphatized orgalvanized) 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 permit-ted.

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

Tightening torques for setscrews

ThreadHand-tightening Machine-tightening

8.8 MA (Nm) 10.9 M A (Nm) 8.8 MA (Nm) 10.9 M A (Nm)

M6 9 12 8 11M8 21 31 20 28M8 x 1 23 32 21 30M10 42 60 40 57M10 x 1.25 45 63 42 60M12 74 100 70 92M12 x 1.25 80 110 75 105M12 x 1.5 76 105 72 100M14 115 160 110 150M14 x 1.5 125 180 120 170M16 180 250 170 235M16 x 1.5 190 270 180 255

MS150048/05E 2018-03 | General Information | 23

TIM

-ID: 0

0000

0233

3 - 0

18

ThreadHand-tightening Machine-tightening

8.8 MA (Nm) 10.9 M A (Nm) 8.8 MA (Nm) 10.9 M A (Nm)

M18 250 350 240 330M18 x 1.5 280 400 270 380M20 350 500 330 475M20 x 1.5 390 550 350 520M22 480 680 450 650M22 x 1.5 520 730 490 700M24 600 850 570 810M24 x 1.5 680 950 640 900M24 x 2 660 900 620 850M27 900 1250 850 1175M27 x 2 960 1350 900 1275M30 1200 1700 1100 1600M30 x 2 1350 1900 1250 1800MA = tightening torques

Tightening torques for studs

Threadscrewed into

Steel M A

(Nm)Gray cast iron MA

(Nm)AI alloy MA

(Nm)M6 9 6 6M8 11 9 10M10 17 13 13M12 27 23 18M14 37 33 33M16 55 45 –MA = tightening torques

Tightening torques for setscrews and nuts made of stainless steelThe values in the table are based on a friction coefficient µtot = 0.12, lubricated with Molykote on the threadand under the screw head.

Basic size

Strength class

Material70 80

M A

(Nm)MA

(Nm)M5 3.7 4.9 A2 / A4M6 6.4 8.5 A2 / A4M8 15.3 20.4 A2 / A4M10 31 41 A2 / A4M12 52 70 A2 / A4M16 126 167 A2 / A4M20 254 326 A2 / A4MA = tightening torques

24 | General Information | MS150048/05E 2018-03

TIM

-ID: 0

0000

0233

3 - 0

18

Tightening torque for self-locking hex nuts

Thread MA (Nm) Lubricants

M6 7.5 +1 –M8 17 +2 –M10 35 +4 –M12 59 +6 –M14 100 +10 –M16 140 +14 –M20 290 +29 –MA = tightening torques

Tightening torque for stress bolt connections as per MTN 5007 standardThis standard applies to stress pin bolts and stress bolts which are subjected to static and dynamic load ofstrength 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 389standard (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 duringthe tightening process.

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

Thread Not torsion-protected MA(Nm) Torsion-protected MA (Nm)

M6 9 12M8 21 28M8 x 1 24 30M10 42 55M10 x 1.25 46 60M12 75 93M12 x 1.5 78 99M14 120 150M14 x 1.5 135 160M16 180 225M16 x 1.5 200 245M18 250 315M18 x 1.5 300 360M20 350 450M20 x 1.5 430 495M22 500 620M22 x 1.5 560 675M24 640 790M24 x 2 700 850M27 900 1170M27 x 2 1000 1230


TIM

-ID: 0

0000

0233

3 - 0

18

Thread Not torsion-protected MA(Nm) Torsion-protected MA (Nm)

M30 1250 1575*Protect screw shaft from torsion when tightening.MA= tightening torques.

Tightening torques for plug screws as per MTN 5183-1 standardThis standard applies to plug screws to DIN 908, DIN 910 and DIN 7604 with threaded end to DIN 3852Form A (sealed with sealing ring to DIN 7603-Cu).


TIM

-ID: 0

0000

0233

3 - 0

18

Tightening torques MA are given for screw plugs made of steel (St) with surface protected by a phosphatecoating 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).

Threadscrewed into

Steel/gray cast iron MA

(Nm)AI alloy MA

(Nm)M10 x 1 15 15M12 x 1.5 25 25M14 x 1.5 35 30M16 x 1.5 40 35M18 x 1.5 50 40M20 x 1.5 60 50M22 x 1.5 70 70M24 x 1.5 85 80M26 x 1.5 100 100M27 x 2 100 100M30 x 1.5 110 110M30 x 2 120 120M33 x 2 160 160M36 x 1.5 190 180M38 x 1.5 220 200M42 x 1.5 260 240M45 x 1.5 290 270M48 x 1.5 310 300M52 x 1.5 325 320M56 x 2 380 360


TIM

-ID: 0

0000

0233

3 - 0

18

Threadscrewed into


(Nm)AI alloy MA

(Nm)M64 x 2 400 400MA = tightening torques

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

Threadscrewed into

Steel/gray cast iron M A

(Nm)AI alloy MA

(Nm)M8 x 1 10 10M22 x 1.5 80 65M26 x 1.5 105 90M30 x 1.5 130 130M38 x 1.5 140 120M45 x 1.5 160 140MA = tightening torques

Tightening torque for banjo screws as per MTN 5183-2 standardThis standard applies to banjo screws to MMN 223 and N 15011 sealed with sealing ring to DIN 7603-Cu.


TIM

-ID: 0

0000

0233

3 - 0

18

The stated tightening torques MA apply to steel (St) banjo screws with a phosphatized surface and oiled orgalvanized and for copper-aluminum alloy.



Tightening torques for steel banjo screws

Threadinserted in steel/gray cast iron/aluminum alloy

MA

(Nm)M8 x 1 10M10 x 1 15M12 x 1.5 20M14 x 1.5 25M16 x 1.5 25M18 x 1.5 30M22 x 1.5 60M26 x 1.5 90M30 x 1.5 130M38 x 1.5 140M45 x 1.5 160MA = tightening torques

Tightening torques for copper-aluminum alloy banjo screws

Threadinserted in steel/gray cast iron/aluminum alloy

MA

(Nm)M10 x 1 15M16 x 1.5 30MA = tightening torques


TIM

-ID: 0

0000

0233

3 - 0

18

Tightening torques for male connectors as per MTN 5183-3 standardThis standard applies to male unions to DIN 2353 Series L with threaded end to DIN 3852 Form A (sealed bysealing ring to DIN 7603-Cu).

Tightening torques MA are given for male unions made of steel (St) with phosphatized surface coating andoiled, or galvanized.



Threadinserted in steel/gray cast iron MA

(Nm)M10 x 1 15M12 x 1.5 20M14 x 1.5 35M16 x 1.5 50M18 x 1.5 60M22 x 1.5 70M26 x 1.5 100M32 x 2 160M42 x 2 260M48 x 2 320MA = tightening torques


TIM

-ID: 0

0000

0233

3 - 0

18

Tightening torques for union nuts as per DIN 3859-2

1 Union nut2 Screw fixture3 O-ring4 Linear ball bearing

Union nut: On installing the ball-type union, after tightening the union nut firmly by hand (noticeable increasein 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

Thread Torque (Nm) +10%M8 x 1 10M10 x 1 20M12 x 1.5 35M14 x 1.5 45M16 x 1.5 55M18 x 1.5 70

M20 x 1.51) 80

M22 x 1.5 100


TIM

-ID: 0

0000

0233

3 - 0

18

Thread Torque (Nm) +10%M27 x 2 170M33 x 2 310M42 x 2 330M48 x 2 420M60 x 2 5001)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

Thread Torque (Nm) +10%M8 x 1 8M10 x 1 15M12 x 1.5 25M14 x 1.5 35M16 x 1.5 40M18 x 1.5 45M22 x 1.5 60M27 x 2 100M33 x 2 160M42 x 2 210M48 x 2 260M60 x 2 315


TIM

-ID: 0

0000

0233

3 - 0

18

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

Threadscrewed into


(Nm)AI alloy MA

(Nm)M10 x 1 20 10 +2M12 x 1.5 35 14 +2M14 x 1.5 45 15 +3M16 x 1.5 55 18 +3M18 x 1.5 70 23 +3M22 x 1.5 100 33 +4M27 x 2 170 57 +5M33 x 2 310 103 +10M42 x 2 330 110 +11M48 x 2 420 140 +14M60 x 2 – 200 +20MA = tightening torques

Assembly instructions and tightening torque for hose fittings with union nutsThese instructions do not apply to ORFS fittings. In contrast to the instructions for pipe unions, hose fittingswith 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 aturn 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 turnwith a wrench.

Hoses must be properly aligned before tightening the union nuts.

Sealing head/sealing cone with metric union nut

Metric thread Pipe outer dia. Torque (Nm)M12 x 1.5 6 20M14 x 1.5 8 38


TIM

-ID: 0

0000

0233

3 - 0

18

Sealing head/sealing cone with metric union nut

Metric thread Pipe outer dia. Torque (Nm)M16 x 1.5 8

1045

M18 x 1.5 1012

51

M20 x 1.5 12 58M22 x 1.5 14

1574

M24 x 1.5 16 74M26 x 1.5 18 105M30 x 2 20

22135

M36 x 2 2528

166

M42 x 2 30 240M45 x 2 35 290M52 x 2 38

42330

Sealing head with BSP union nut

BSPP thread Torque (Nm)G1/4 20G3/8 34G1/2 60G5/8 69G3/4 115G1 140G1.1/4 210G1.1/2 290G2 400

SAE sealing cone with union nut JIC 37°

UNF thread Size Torque (Nm)7/16–20 –4 151/2–20 –5 209/16–18 –6 303/4–16 –8 507/8–14 –10 691.1/16–12 –12 981.3/16–12 –14 1181.5/16–12 –16 1401.5/8–12 –20 2101.7/8–12 –24 2902.1/2–12 –32 450


TIM

-ID: 0

0000

0233

3 - 0

18

ORFS – flat sealing with union nut

UNF thread Size Torque (Nm)9/16–18 –4 14 +211/16–16 –6 24 +313/16–16 –8 43 +41–14 –10 60 +81.3/16–12 –12 90 +51.3/16–12 –14 90 +51.7/16–12 –16 125 +101.11/16–12 –20 170 +202–12 –24 200 +252–1/2–20 –32 460 +30


TIM

-ID: 0

0000

0233

3 - 0

18

2.2 Engine side and cylinder designations

1 Left engine side (A-side)2 Engine free end in accord-

ance with DIN ISO 1204(KGS = Kupplungsgegen-seite)

3 Right engine side (B-side)4 Engine driving end in ac-

cordance withDIN ISO 1204 (KS = Kup-plungsseite)

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 left-hand side of the engine (1) and letter "Bx" refers to the cylinders on the right-hand side (3). The cylinders ofeach 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).


TIM

-ID: 0

0000

0218

5 - 0

14

2.3 Product description

Description of the engine

EngineThe engine is a liquid-cooled four-stroke diesel engine, rotating counterclockwise (as viewed on driving end),with direct injection, sequential turbocharging and charge-air cooling.

The engine is monitored by an engine control and monitoring system (ADEC).

Monitoring in the engine room is carried out by the engine control and monitoring unit (LOP).

Fuel systemElectronically controlled common-rail-injection system with HP pump, pressure accumulator (rail) and injec-tors with integrated individual accumulators.

The electronic control unit controls• Injection start• Injection quantity• Injection pressure

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

The triple-walled design permits• Low surface temperature• Reduced coolant heat quantity,• absolute gas-tightness reached.

TurbochargingSequential turbocharging with internal, engine-coolant-controlled charge air cooling

The exhaust turbochargers B1, A2 and B2 are cut in and out via electronically-controlled, hydraulically-actu-ated flaps.

Cooling systemEngine cooling as split-circuit cooling system with plate-core 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.

Service blockThe service components are mounted on the auxiliary PTO end.

The layout permits easy access for maintenance.

Service components:• Raw water pump, coolant pump• Fuel duplex filter, switchable• Automatic oil filter• Centrifugal lube-oil filter

Electronic systemElectronic control and monitoring system with integrated security and test system with interfaces to remotecontrol system (RCS) and to monitoring system (MCS)


TIM

-ID: 0

0000

1005

7 - 0

05

Connection box EIM (Engine Interface Module)The Engine Interface Module (EIM) is the central connection box on the engine. It covers the entire minimumscope of a marine engine series. It has no controls or parts requiring maintenance.

Functions:• Start control (start repetition tooth-on-tooth, 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 is divided into two parts. The first part is integrated via a Tyco connector X52, 62-pin, inthe engine wiring harness. The second part comprises the signals at which a higher current flows. These sig-nals are guided out via M-threaded pins and are also integrated in the engine wiring harness.

Functions• ECU supply• EMU supply• Plant signals (ECU7 connector X1)• Bus interface (2x MCS5 CAN)• CAN dialog output (1xMCS5 CAN)• Emergency stop ECU and EMU• Electric starter• Terminal 45 starter A/B (engaged)• Pneumatic starter• Starting air pressure valve• Start-air pressure sensor• Barring device (barring gear 1 and 2)• Battery-charging generator (with excitation control)• Emergency-air shutoff flaps option• Control signals to SDAF 1+2• Feedback signals from SDAF 1+2

Electronic 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• RS 232 interface for connection of MTU dialog unit

Electronic Engine Monitoring Unit (EMU), optionalFunctions:• Data processing logistics for analog and binary signals• Interface for data transfer to CAN field bus for remote control and ship-side monitoring

Electronic Gear Control Unit (GCU), ship-side wall-mountingFunctions:• Date processing logistics for gear coupling control• Input/output signals as well as data transfer to CAN field bus for remote control and ship-side monitoring


TIM

-ID: 0

0000

1005

7 - 0

05

Monitoring in engine roomEngine control and monitoring unit (LOP)

Functions:• Alphanumeric, monochrome LCD display for monitoring of measured values as well as alarms when limits

are violated• Pushbuttons for menu control and dimming unit• Combined control and display elements for local engine/gear control;• Flashing light and horn for summary alarm in engine room• Interface to CAN field bus for connected, communicating monitoring system components

SOLAS – Fire safety requirementsThe following figures show all lines with SOLAS-compliant covers for pipe connections according to MTUstandard MTN 5233.

Fuel system, fuel lines with fuel pressure >1.8 bar

1 Fuel line to fuel filter head

1 Fuel line from fuel filter head


TIM

-ID: 0

0000

1005

7 - 0

05

1 Fuel line to HP pump

Lube oil system, oil lines with oil pressure >1.8 bar

1 Parting line ETC oil supply free end

1 Parting line ETC oil supply driving end


TIM

-ID: 0

0000

1005

7 - 0

05

1 Oil line on equipment carrier

1 Oil supply to HP pump

1 Oil supply to flap control free end


TIM

-ID: 0

0000

1005

7 - 0

05

1 ETC oil supply on main oil gallery

1 Switching cylinder air flap A2

1 Oil line connection2 Switching cylinder exhaust flap turbo-

charger A23 T piece flap control


TIM

-ID: 0

0000

1005

7 - 0

05

1 Connection oil line to turbocharger B12 Switching cylinder exhaust flap turbo-

charger B13 T piece flap control turbocharger B1

1 Switching cylinder air flap turbocharg-er B1

1 Connection oil line to turbocharger B22 Switching cylinder exhaust flap turbo-

charger B23 Switching cylinder air flap turbocharg-

er B24 T piece flap control turbocharger B2


TIM

-ID: 0

0000

1005

7 - 0

05

1 Flap control distributor

Special connectionsIn case of leakage, the following connection types are spray-protected even without a cover and have beenconfirmed compliant with SOLAS by GL and DNV.

Plugs and sensors, plug-in pipe connections

Plugs and sensors (a)Screwed-in seal plugs (4) are sealed toward the outside either with a copper sealing ring (1), according toDIN, or an O-ring (ISO).

In case of a loose thread or a faulty sealing ring (1), the liquid first has to pass the thread.


TIM

-ID: 0

0000

1005

7 - 0

05

The pressure is so greatly reduced by this and the faulty sealing ring (1) that any leakage is not under pres-sure.

Plug-in pipe connection (b)The sleeve (3) covers the joint to prevent lateral spray.

Only leak-off along the line is possible, the pressure is decreases significantly if an O-ring (2) defect occurs.

The connection is confirmed as compliant with SOLAS by DNV and GL.

High-pressure unions

1 Jacketed pipe2 HP line3 O-ring4 Union nut5 Recess for O-ring6 Thrust ring7 Leak overflow bore

8 Thrust ring9 Union nut

10 Union nut11 Connecting piece12 Snap ring13 Thrust ring14 Shims

15 Union nut16 Thrust ring17 External pipe of HP line18 Internal pipe of HP line19 Ball-type seal area20 Connection leak fuel

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

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 at atmospheric pressure via the overflow bore (7). The leakage chamber issealed by the O-rings (3).

This prevents leaking fuel from escaping.

The connection is confirmed as compliant with SOLAS by DNV and GL.


TIM

-ID: 0

0000

1005

7 - 0

05

2.4 Engine – Overview

1 Oil cooler2 Crankcase breather3 Air filter4 Exhaust turbocharger5 Intercooler

6 Cylinder head7 Charge-air pipework8 Oil filler neck9 Oil pan

10 Engine mounting

11 HP fuel pump12 Automatic oil filter13 Centrifugal oil filter(s)14 Fuel filter15 Engine governor

Engine model designationKey to engine model designation 20V4000Mxyz20 Number of cylindersV Cylinder configuration: V-engine4000 SeriesM Applicationx Application segmenty Design statusz L (enhanced power/speed)


TIM

-ID: 0

0000

0999

2 - 0

04

2.5 Sensors and actuators – Overview

Top view 20V4000M

1 B4.A1 (T-Exhaust cylinderA1)






7 B4.A7 (T exhaust cylinderA7)




11 B5.2 (P-Lube oil after filter)12 B34.2 (P-Fuel before filter)13 B34.1 (P-Fuel after filter)14 B5.3 (P-Lube-oil before fil-

ter)15 B48 (P-Fuel in common rail)16 B4.B10 (T exhaust cylinder

B10)17 B4.B9 (T exhaust cylinder

B9)18 B4.B8 (T exhaust cylinder

B8)

19 B4.B7 (T exhaust cylinderB7)

20 B4.B6 (T-Exhaust cylinderB6)







TIM

-ID: 0

0000

3473

3 - 0

06

20V4000M left side

1 B7 (T-Lube oil)2 B50 (P-Crankcase)3 B44.3 (N turbocharger C)4 B4.23 (T-Turbocharger C)5 B4.21 (T-Turbocharger A)6 B3 (T-Intake air)7 B44.1 (N-Turbocharger A)

8 B10 (P-Charge air)9 B57.1 (T-Main bearing)

10 B57.2 (T-Main bearing)11 B57.3 (T-Main bearing)12 B57.4 (T-Main bearing)13 B57.5 (T-Main bearing)14 B57.6 (T-Main bearing)

15 B57.7 (T-Main bearing)16 B57.8 (T-Main bearing)17 B57.9 (T-Main bearing)18 B57.10 (T-Main bearing)19 B57.11 (T-Main bearing)20 B5.1 (P-Lube oil after filter)


TIM

-ID: 0

0000

3473

3 - 0

06

20V4000M free end

1 F46 (H-Leak-fuel level)2 B33 (T-Fuel)3 B1 (N-Camshaft)

4 B54 (P-Oil level pump)5 B6.2 (T-Coolant)6 B6 (T-Coolant)

7 Connector XD1 – Dialogunit


TIM

-ID: 0

0000

3473

3 - 0

06

20V4000M right side

1 B44.2 (N-Turbocharger B)2 B4.22 (T-Turbocharger B)3 B49 (T-Charge air, recircula-

tion valve)4 B4.24 (T-Turbocharger D)5 B44.4 (N-Turbocharger D)6 B16 (P-Coolant)

7 B21 (P-Raw water)8 B77.B10 (T-Spray oil, con-

rod bearing)9 B77.B9 (T-Spray oil, conrod

bearing)10 B77.B8 (T-Spray oil, conrod



bearing)

13 B77.B5 (T-Spray oil, conrodbearing)





18 B9 (T-Charge air)


TIM

-ID: 0

0000

3473

3 - 0

06

20V4000M driving end

1 B13.2 (N-Crankshaft)2 B13 (N-Crankshaft)

3 S37.2 (S-Safety switch)4 S37.1 (S-Safety switch)


TIM

-ID: 0

0000

3473

3 - 0

06

2.6 Engine wiring harness – OverviewPin assignment DesignationX2 Governor ECU-7

B1 Camshaft speed

B3 Intake air temperature

B4.A1 to AX Cylinder exhaust temperature on A side (option)

B4.B1 to BX Cylinder exhaust temperature on B side (option)

B4.21 Exhaust gas temperature, A side

B4.22 Exhaust gas temperature, A side

B5.1 Lube oil pressure after filter

B5.2 Lube oil pressure after filter (option)

B5.3 Lube oil pressure before filter

B6 Coolant temperature

B7 Lube oil temperature

B9 Charge-air coolant temperature

B10 Charge-air pressure

B13 Crankshaft speed

B16 Coolant pressure

B21 Raw water pressure

B33 Fuel temperature

B34.1 Fuel pressure after filter

B34.2 Fuel pressure before filter

B44.1 Exhaust turbocharger speed A

B44.2 Exhaust turbocharger speed B

B44.3 Turbocharger C speed

B44.4 Turbocharger D speed

B48 High-pressure fuel

B49 Charge air before air recirculation valve

B50 Crankcase pressure

B54 Oil-level regulating pump (option)

B57.1 to 57.X Main bearing temperature (option)

B77.B1 to BX Splash-oil temperature for conrod bearings (option)

F33 Coolant level

M8 Fuel pump

F46 Leak fuel level

S37.1 Limit switch for start interlock A

S37.2 Limit switch for start interlock B

X37 Start interlock turning

Y26 Charge air circulation


TIM

-ID: 0

0000

3473

2 - 0

03

Pin assignment DesignationY27 Turbocharger valve

XG03 Battery-charging generator

Table 2: Engine wiring harness for sensors

Pin assignment DesignationX4 Governor ECU-7

E4.X KF thermostat heating

Y39A1 to Y39AX Injectors, engine side A

Y39B1 to Y39BX Injectors, engine side B

Table 3: Engine wiring harness for injectors

Pin assignment DesignationX1 Engine Control Unit ECU

X3 Engine Control Unit ECU Power

X11 EMU Power

X37 Start interlock

X52 EIM engine box

XB19 Starting-air pressure

XD1 Dialog unit

XY1 Starter

Table 4: Adaption


TIM

-ID: 0

0000

3473

2 - 0

03

Engine wiring harness for sensors 20V

1 B44.32 B503 B34 B44.15 S37.16 B5.17 B78 B109 B34.2

10 XY2711 B34.112 B48

13 B4.2314 F4615 B3316 B117 B4.2118 XG0319 B5.320 M821 X222 X3723 XF3324 B6

25 B44.426 B1627 B4.2428 B4.2229 B4930 Y2631 B44.232 B933 B1334 S37.2


TIM

-ID: 0

0000

3473

2 - 0

03

Engine wiring harness for injectors 20V

1 Y39A12 Y39A23 Y39A34 Y39A45 Y39A56 Y39A67 Y39A78 Y39A89 Y39A9

10 Y39A1011 X412 E4.113 E4.214 E4.315 E4.416 E4.517 Y39B918 Y39B10

19 Y39B820 Y39B721 Y39B622 Y39B523 Y39B424 Y39B325 Y39B226 Y39B1


TIM

-ID: 0

0000

3473

2 - 0

03

Engine wiring harness for EIM

1 XD12 X13 X3

4 X525 XY16 X11

7 XB198 X37


TIM

-ID: 0

0000

3473

2 - 0

03

Engine wiring harness for electric starter

1 EIM terminals 2 Fuse F1 3 Starter connecting termi-nals


TIM

-ID: 0

0000

3473

2 - 0

03

3 Technical Data

3.1 20V4000M93 engine data: IMO, engine-mounted heatexchanger, intercooler made of copper-based alloyEXPLANATIONAbbr. MeaningDL Reference value: Continuous power (CP)BL Reference value: Fuel stop power (FSP)A Design valueG Guaranteed valueR BenchmarkL Limit value up to which the engine can be operated without change, e.g. of power setting.N Not yet defined value- Not applicableX Applicable

REFERENCE CONDITIONSEngine model 20V4000

M93Application group 1DS

Intake air temperature °C 25

Raw water inlet temperature °C 25

Barometric pressure mbar 1000

Site altitude above sea level m 100

POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)Number of cylinders 20Rated engine speed A rpm 2100

Fuel stop power, ISO 3046 A kW 3900

GENERAL CONDITIONS (for maximum power)Number of cylinders 20Intake depression (new filter) A mbar 15

Intake depression, max. L mbar 30

MODEL-RELATED DATA (basic design)Number of cylinders 20Cylinder arrangement: V angle Degrees 90

Bore mm 170

Stroke mm 190

Cylinder displacement Liters 4.31

58 | Technical Data | MS150048/05E 2018-03

TIM

-ID: 0

0000

1082

0 - 0

03

Number of cylinders 20Total displacement Liters 86.2

Number of inlet valves per cylinder 2

Number of exhaust valves per cylinder 2

RAW WATER CIRCUIT (open circuit)Number of cylinders 20Raw water pump: Inlet pressure, min. L bar -0.2

Raw water pump: Inlet pressure, max. L bar 0.5

Pressure loss in off-engine raw water system, max. L bar 0.7

LUBE OIL SYSTEMNumber of cylinders 20Lube oil operating temperature before engine, from R °C 72*

Lube oil operating temperature before engine, to R °C 80*

Lube oil operating pressure before engine, from R bar 6

Lube oil operating pressure before engine, to R bar 8

Lube oil operating pressure (low idle) (measuring point: before engine) R bar 2.0

FUEL SYSTEMNumber of cylinders 20Fuel pressure at engine inlet connection, min. (during engine start) L bar -0.1

Fuel pressure at engine inlet connection, min. (during engine operation) L bar -0.3

Fuel pressure at engine inlet connection, max. (during engine start) L bar 1.5

Fuel supply rate, max. R liters/min 30

GENERAL OPERATING DATANumber of cylinders 20Firing speed, from R rpm 80

Firing speed, to R rpm 120

STARTING (electric)Number of cylinders 20Rated starter voltage (standard design) R V= 24

STARTING (with pneumatic/hydraulic starter)Number of cylinders 20Starting-air pressure before starter motor, min. R bar 8

Starting-air pressure before starter motor, max. R bar 10

MS150048/05E 2018-03 | Technical Data | 59

TIM

-ID: 0

0000

1082

0 - 0

03

INCLINATIONS, STANDARD OIL SYSTEM (Reference: Waterline)Number of cylinders 20Longitudinal inclination, continuous max., driving end down (Option: max. op-erating inclinations)

L Degrees 15

Longitudinal inclination, temporary max., driving end down (Option: max. oper-ating inclinations)

L Degrees 22.5

Longitudinal inclination, continuous max., driving end up (Option: max. operat-ing inclinations)

L Degrees 10

Longitudinal inclination, temporary max., driving end up (Option: max. operat-ing inclinations)

L Degrees NN

Transverse inclination, continuous max. (Option: max. operating inclinations) L Degrees 22.5

Transverse inclination, temporary max. (Option: max. operating inclinations) L Degrees --

CAPACITIESNumber of cylinders 20Engine coolant, engine side (with cooling system) R Liters 440

Engine oil on initial filling (standard oil system) (Option: max. operating inclina-tions)

R Liters 365

Oil change quantity, max. (standard oil system) (Option: max. operating incli-nations)

R Liters 320

Oil pan capacity at dipstick mark “min.” (standard oil system) (Option: max.operating inclinations)

L Liters 255

Oil pan capacity at dipstick mark “max.” (standard oil system) (Option: max.operating inclinations)

L Liters 300

WEIGHTS / MAIN DIMENSIONSNumber of cylinders 20Dry engine weight (with standard accessories, without coupling) R kg 12080

NOISENumber of cylinders 20Exhaust noise, unsilenced - BL (free-field sound-pressure level Lp, 1m dis-tance, ISO 6798, +3dB(A) tolerance)

R dB(A) 117

Engine surface noise with attenuated intake noise (filter) - BL (free-field sound-pressure level Lp, 1m distance, ISO 6798+2dB(A) tolerance)

R dB(A) 106


TIM

-ID: 0

0000

1082

0 - 0

03

3.2 20V4000M93 engine data: EPA 2, engine-mounted heatexchangerEXPLANATIONAbbr. MeaningDL Reference value: Continuous power (CP)BL Reference value: Fuel stop power (FSP)A Design valueG Guaranteed valueR BenchmarkL Limit value up to which the engine can be operated without change, e.g. of power setting.N Not yet defined value- Not applicableX Applicable


M93Application group 1DS










Bore mm 170

Stroke mm 190


Total displacement Liters 86.2




TIM

-ID: 0

0000

1085

7 - 0

03



















L Degrees 15


L Degrees 22.5


L Degrees 10


TIM

-ID: 0

0000

1085

7 - 0

03

Number of cylinders 20Longitudinal inclination, temporary max., driving end up (Option: max. operat-ing inclinations)

L Degrees NN


Transverse inclination, temporary max. (Option: max. operating inclinations) L Degrees --



R Liters 365


R Liters 320


L Liters 255


L Liters 300



R dB(A) 117


R dB(A) 106


TIM

-ID: 0

0000

1085

7 - 0

03

3.3 20V4000M93L engine data: IMO, engine-mounted heatexchanger, intercooler made of copper-based alloyEXPLANATIONAbbr. MeaningDL Reference value: Continuous power (CP)BL Reference value: Fuel stop power (FSP)A Design valueG Guaranteed valueR BenchmarkL Limit value up to which the engine can be operated without change, e.g. of power setting.N Not yet defined value- Not applicableX Applicable


M93LApplication group 1DS










Bore mm 170

Stroke mm 190






TIM

-ID: 0

0000

1089

3 - 0

03



















L Degrees 15


L Degrees 22.5


L Degrees 10


TIM

-ID: 0

0000

1089

3 - 0

03


L Degrees NN




R Liters 365


R Liters 320


L Liters 255


L Liters 300



R dB(A) 118


R dB(A) 107


TIM

-ID: 0

0000

1089

3 - 0

03

3.4 20V4000M93L engine data: EPA 2, engine-mounted heatexchangerEXPLANATIONAbbr. MeaningDL Reference value: Continuous power (CP)BL Reference value: Fuel stop power (FSP)A Design valueG Guaranteed valueR BenchmarkL Limit value up to which the engine can be operated without change, e.g. of power setting.N Not yet defined value- Not applicableX Applicable


M93LApplication group 1DS










Bore mm 170

Stroke mm 190






TIM

-ID: 0

0000

1062

9 - 0

03




LUBE OIL SYSTEMNumber of cylinders 20Lube oil operating temperature before engine, from R °C 75**

Lube oil operating temperature before engine, to R °C 80**














L Degrees 15


L Degrees 22.5


L Degrees 10


TIM

-ID: 0

0000

1062

9 - 0

03


L Degrees NN




R Liters 365


R Liters 320


L Liters 255


L Liters 300



R dB(A) 118


R dB(A) 107


TIM

-ID: 0

0000

1062

9 - 0

03

3.5 Engine – Main dimensions

Engine – Main dimensions

Engine model Length (A) Width (B) Height (C)12V4000M73/93 (L) approx. 2991 mm approx. 1463 mm approx. 2368 mm16V4000M73/93 (L) approx. 3583 mm approx. 1463 mm approx. 2368 mm20V4000M73/93 (L) approx. 4192 mm approx. 1484 mm approx. 2368 mm


TIM

-ID: 0

0000

1004

4 - 0

04

3.6 Firing orderNumber ofcylinders

Firing order

20V A1-B5-A8-B7-A5-B2-A7-B10-A2-B3-A10-B6-A3-B4-A6-B9-A4-B1-A9-B8


TIM

-ID: 0

0000

3506

8 - 0

03

4 Operation

4.1 Controls

Automation system controlsRefer to automation system operating instructions

72 | Operation | MS150048/05E 2018-03

TIM

-ID: 0

0000

1695

9 - 0

03

4.2 Putting the engine into operation after extended out-of-serviceperiods (>3 months)

Preconditions☑Engine is stopped and starting disabled.

☑Preservation and Represervation Specifications A001070/.. are available.

Putting into operation after extended out-of-service periods (>3 months)Item ActionEngine Depreserve (→ MTU Preservation and Represervation Specifications

A001070/..).Lube oil system Check engine oil level (→ Page 182);

Preheat engine oil as necessary.Lubricate valve gear (→ Page 146).

Raw water pump (if locatedabove waterline)

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

Coolant circuit If engine is out of service for more than one year, change coolant(→ Page 227).

Coolant circuit Check coolant level (→ Page 225).Coolant circuit Heat engine coolant with coolant preheater.HP fuel pump Only for engines without oil priming pump

Fill HP fuel pump with fresh engine oil (→ Page 152).Engine Control System Switch master switch to ON;

Press illuminated pushbutton READY FOR OPERATION (→ Page 72).Engine Control Unit ECU Check plug connections (→ Page 251).EIM Check plug connections (→ Page 250).EMU 8 Check plug connections (→ Page 249).LOP Press illuminated pushbutton LAMP TEST (→ Page 72).

MS150048/05E 2018-03 | Operation | 73

TIM

-ID: 0

0000

1009

3 - 0

07

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


Putting into operationItem ActionLube oil system Check engine oil level (→ Page 182);

Preheat engine oil if required.Coolant circuit Check coolant level (→ Page 225).Coolant circuit Heat coolant with coolant preheating unit.Engine control system Switch master switch to ON;

Press illuminated pushbutton READY FOR OPERATION (→ Page 72).LOP Press illuminated pushbutton LAMP TEST (→ Page 72).ECU Check plug connections (→ Page 251).EIM Check plug connections (→ Page 250).EMU 8 Check plug connections (→ Page 249).

74 | Operation | MS150048/05E 2018-03

TIM

-ID: 0

0000

1065

6 - 0

04

4.4 Re-starting the engine following an automatic safetyshutdown

NOTICERe-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 faulthas been identified and eliminated.

Procedure following an automatic safety shutdown1. Eliminate fault.2. If the root cause cannot be identified or eliminated, contact Service.

ImportantThe function "Overdrive safety system" (if fitted), which is only used in emergency situations, is not affect-ed.

MS150048/05E 2018-03 | Operation | 75

TIM

-ID: 0

0000

8138

3 - 0

01

4.5 Starting the engine

Preconditions☑External start interlock is not activated.

☑Emergency air-shutoff flaps (if applicable) open.

DANGERRotating and moving engine parts.Risk of crushing, danger of parts of the body being caught or pulled in!• Before cranking the engine with starter system, make sure that there are no persons in the engine's

danger zone.

WARNINGHigh level of engine noise when the engine is running.Risk of damage to hearing!• Wear ear protectors.

NOTICERe-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.

The engine can be started from the following pointsItem ActionControl stand (→ Operating instructions for electronic system)Local Operating Panel LOP (→ Operating instructions for electronic system)Local Operating Station LOS (→ Operating instructions for electronic system)CCU (→ Operating instructions for electronic system)

76 | Operation | MS150048/05E 2018-03

TIM

-ID: 0

0000

0224

0 - 0

05

4.6 Operational checksDANGER

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.


Operational checksItem ActionEngine oil Check engine oil level (→ Page 182).Engine under load,engine at nominal speed

Visually inspect engine for leaks and general condition;Check speed, pressures and temperatures;Check engine and external lines for leaks;Check for abnormal running noises and vibration;Check exhaust color (→ Page 97).

Air filter Check signal ring position of service indicator (→ Page 181);Replace air filter (→ Page 179) if the signal ring is completely visible in theservice indicator observation window.

Fuel prefilter Drain water and contaminants from fuel prefilter (→ Page 166).Check pointer position of differential pressure gage at fuel prefilter(→ Page 165).

HT coolant pump Check relief bore for oil and coolant discharge and contamination(→ Page 233).

Raw water pump Check relief bore for oil and water discharge and contamination(→ Page 235).

MS150048/05E 2018-03 | Operation | 77

TIM

-ID: 0

0000

1013

1 - 0

08

4.7 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 (→ ).2. Shut down fuel treatment system (→ Page 92).

78 | Operation | MS150048/05E 2018-03

TIM

-ID: 0

0000

0773

0 - 0

06

4.8 Checks prior to start-up

Checks prior to start-up1. 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 83).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.

Result: Bypass line is vented via the overflow tank.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.

MS150048/05E 2018-03 | Operation | 79

TIM

-ID: 0

0000

0773

6 - 0

05

4.9 Fuel treatment system – Initial start-up

Overview of fuel treatment system

1 Pressure-free overflow2 Bypass 13 Bypass 24 Safety valve, 3 bar5 Ball valve, inlet6 Pressure gage7 Ventilation, sample extrac-

tion8 Differential pressure gage

9 Ball valve, outlet10 Check valve 700 mbar11 Check valve 5 mbar12 Return to overflow tank13 Engine14 Overflow tank15 Filter water separator16 Drain ball valve

17 Automatic water drain18 Water level electrode19 Ball valve, sample extrac-

tion, inlet20 Switchgear cabinet21 Pump22 Coarse filter23 Fuel supply from tank24 Tank

Switching on fuel treatment system1. Switch on fuel treatment system (→ Page 83).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 242).2. Check sealing surfaces on coalescer filter element and in the pressure tank.

80 | Operation | MS150048/05E 2018-03

TIM

-ID: 0

0000

1577

3 - 0

07

Initial start-up: HAT1. Replace fuel filter on engine (→ Page 163).

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 (→ ).

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

4. Start engine (→ Page 76).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 replace-ment simulation with the engine running as part of the Harbor Acceptance Tests.

Simulating filter replacement with the engine running: HAT1. Switch on fuel treatment system (→ Page 83).2. Start engine (→ Page 76).3. Run engine at idling speed.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 unitopens 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.

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.

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

Simulating power failure (emergency): HAT1. Switch on fuel treatment system (→ Page 83).2. Start engine (→ Page 76).3. Run engine at idling speed.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. Check suction pressure at the engine-mounted fuel delivery pump.

Note: If the suction pressure is within the admissible limits and engine operation is satisfactory.6. Increase engine speed to 1000 rpm and monitor suction pressure.

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

MS150048/05E 2018-03 | Operation | 81

TIM

-ID: 0

0000

1577

3 - 0

07

Simulating power failure (emergency): SAT1. Switch on fuel treatment system (→ Page 83).2. Start engine (→ Page 76).3. Run engine at idling speed.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. Check suction pressure at the engine-mounted fuel delivery pump.

Note: If the suction pressure is within the admissible limits and engine operation is satisfactory.6. Operate engine at full load and monitor suction pressure.

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

82 | Operation | MS150048/05E 2018-03

TIM

-ID: 0

0000

1577

3 - 0

07

4.10 Fuel treatment system – Switching on

Preconditions☑The on-board power supply is switched on.

NOTICERisk 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 on1. Carry out checks prior to start-up (→ Page 79).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.

MS150048/05E 2018-03 | Operation | 83

TIM

-ID: 0

0000

0773

1 - 0

06

4.11 Emergency engine stop at BlueLine automation system(control stand)

NOTICEAn 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 engine stop at BlueLine automation systemItem MeasureEngine Emergency stop at BlueLine automation system (→ Operating Instructions for

BlueLine).

84 | Operation | MS150048/05E 2018-03

TIM

-ID: 0

0000

0270

4 - 0

06

4.12 Clutch – Engagement at LOP

Preconditions☑ Illuminated pushbutton LOCAL OPERATION brightly lit (local control mode is active).

☑Engine speed is within range for clutch engagement.

☑No external engagement interlock active.

DANGERIn Local mode, the propulsion plant is controlled from the engine room. The person controlling the ves-sel has no visual contact with the surrounding area.Risk of collision and serious injury!• Only operate the vessel using the LOP when a second person is keeping lookout and is ready to alert

the person at the LOP to any potential hazards. These two persons must remain in direct voice con-tact at all times, e.g. by radio.

Engaging clutch without reversing gearbox (CPP, WJ, VS)Item ActionLOP Press illuminated pushbutton CLUTCH IN (→ Page 72).

• Illuminated pushbutton CLUTCH IN flashes.• Clutch is engaged.• After receiving the feedback signal from the clutch, illuminated pushbut-

ton CLUTCH IN lights up brightly.

Engaging clutch in ahead direction with reversing gearbox (FPP, WJ)Item ActionLOP Press illuminated pushbutton CLUTCH AHEAD (→ Page 72).

• Illuminated pushbutton CLUTCH AHEAD flashes.• Gearbox is engaged in AHEAD direction.• After receiving the feedback signal from the clutch, illuminated pushbut-

ton CLUTCH AHEAD lights up brightly.

Engaging clutch in astern direction with reversing gearbox (FPP)Item ActionLOP Press illuminated pushbutton CLUTCH ASTERN (→ Page 72).

• Illuminated pushbutton CLUTCH ASTERN flashes.• Gearbox is engaged astern.• After receiving the feedback signal from the clutch, illuminated pushbut-

ton CLUTCH ASTERN lights up brightly.

MS150048/05E 2018-03 | Operation | 85

TIM

-ID: 0

0000

0270

0 - 0

05

4.13 Coupling – Disengaging from LOP

Preconditions☑LOCAL OPERATION illuminated pushbutton lights up brightly (local operating mode is active).

☑Engine speed in disengagement window.

Disengaging coupling without reversing gearbox (CPP, WJ, VS)Item MeasureLOP Press COUPLING OUT illuminated pushbutton (→ Page 72).

• COUPLING OUT button flashes.• Coupling is disengaged.• After receiving the feedback signal from coupling, the COUPLING OUT but-

ton is illuminated brightly.

Disengaging coupling with reversing gearbox (FPP, WJ)Item MeasureLOP Press COUPLING NEUTRAL illuminated pushbutton (→ Page 72).

• COUPLING NEUTRAL button flashes.• Gearbox is disengaged (neutral position).• After receiving the feedback signal from coupling, the COUPLING NEU-

TRAL button is illuminated brightly.

86 | Operation | MS150048/05E 2018-03

TIM

-ID: 0

0000

0281

0 - 0

04

4.14 Waterjet – Flushing from LOP (optional)

Preconditions☑LOCAL OPERATION illuminated switch is lit brightly (local operating mode is active).

☑Waterjet-BucketVessel at standstill and waterjet bucket is below the waterline.

☑Engine speed is in engagement window.

☑No external engagement interlock is active.

NOTICEWaterjet flushing puts excessive strain on the bearings.Bearing damage!• Do not flush waterjet for too long.• Follow instructions of the waterjet manufacturer.

Flushing with reversing gearbox and flushing modeItem MeasureLOP Press and hold down FLUSH illuminated pushbutton (→ Page 72).

• FLUSH illuminated pushbutton flashes.• Gearbox is engaged ASTERN.• FLUSH illuminated pushbutton is brightly lit after receiving feedback sig-

nal from clutch.LOP Release FLUSH illuminated pushbutton.

• FLUSH illuminated pushbutton flashes.• Gearbox is disengaged (neutral position).• FLUSH illuminated pushbutton goes out after receiving feedback signal

from clutch.

MS150048/05E 2018-03 | Operation | 87

TIM

-ID: 0

0000

0233

0 - 0

08

4.15 Stopping the engine from LOP

Preconditions☑Engine is running in local mode.

NOTICEStopping 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 minutes until

engine temperatures have dropped and constant values are displayed.

Stopping the engine from LOPItem MeasureLOP Disengage gearbox (→ Page 72).LOP Operate engine at idle speed (→ Page 72).Temperature indications Wait until engine temperatures do not fall any further.LOP Press STOP illuminated pushbutton (→ Page 72).

• STOP button is illuminated.• Engine at a standstill.

88 | Operation | MS150048/05E 2018-03

TIM

-ID: 0

0000

0230

0 - 0

05

4.16 Stopping the engine at the BlueLine automation system(control stand)

NOTICEStopping 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 minutes until

engine temperatures have dropped and constant values are displayed.

Stopping the engine at the BlueLine automation system (control stand)Item MeasureEngine Stop the engine at the BlueLine automation system (control stand) (→ Blue-

Line Operating Instructions).

MS150048/05E 2018-03 | Operation | 89

TIM

-ID: 0

0000

0270

2 - 0

05

4.17 After shutting down the engine

Preconditions☑MTU Fluids and Lubricants Specifications (A001061/..) are available.

NOTICEEngine coolant with inadequate freeze protection. Water remaining in the pressure sensors freezes attemperatures below 0 °C.Risk of sensor damage!• Remove pressure sensors and shake off residual water.

After shutting down the engineItem MeasureCoolant circuit Drain coolant (→ Page 228) if:

• freezing temperatures are to be expected and the engine is to remain outof service for an extended period and if no antifreeze has been added tothe coolant;

• the engine room is not heated;• the coolant is not kept at a suitable temperature;• the antifreeze concentration is insufficient for the engine-room tempera-

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

-40 °C.Raw water Drain

• if freezing temperatures are expected and the engine is to remain out ofservice for a longer period.

Engine control system Switch off.Air intake and exhaust sys-tem

Out-of-service-period > 1 week:• Seal engine's air and exhaust sides.

Engine Out-of-service-period > 1 month:• Carry out engine preservation (→ MTU Preservation and Represervation

Specifications A001070/..)

90 | Operation | MS150048/05E 2018-03

TIM

-ID: 0

0000

0232

4 - 0

10

4.18 Emergency stop from LOPNOTICE

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 from LOPItem ActionLOP Open cap of illuminated EMERGENCY STOP pushbutton (→ Page 72).LOP Press illuminated pushbutton EMERGENCY STOP.

• Engine is stopped by disconnecting the power supply to the ECU;• On engines with emergency-air shutoff flaps: the flaps close;• Illuminated pushbutton EMERGENCY STOP flashes. Horn, flashing lamp

etc. are tripped.

After an emergency stop at LOPItem ActionLOP Press ALARM ACKNOWLEDGE illuminated pushbutton (→ Page 72).

• Audible and visual alarm output stops.LOP Press illuminated pushbutton ALARM ACKNOWLEDGE again.

• Power is supplied to ECU again;• Alarm has been acknowledged.

Engine On engines with emergency-air shutoff flaps: open flaps.• Engine is ready for starting.

MS150048/05E 2018-03 | Operation | 91

TIM

-ID: 0

0000

0231

4 - 0

05

4.19 Fuel treatment system – Shutdown

Shutting down fuel treatment system1. 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.

92 | Operation | MS150048/05E 2018-03

TIM

-ID: 0

0000

0773

2 - 0

05

4.20 Plant – Cleaning


☑No operating voltage applied.


High-pressure cleaner (→ Tools Catalog) 1Cleaner (Hakupur 50/136) X00056700 1

WARNINGCompressed 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.

WARNINGWater 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.

NOTICECleaning agents should not be left to take effect for too long.Damage to components is possible!• Observe manufacturer's instructions.

NOTICEBlowing 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 plant1. Carry out plant cleaning only in areas where an appropriate oil separator is provided (environmental protec-

tion).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.

MS150048/05E 2018-03 | Operation | 93

TIM

-ID: 0

0000

1017

1 - 0

34

5 Maintenance

5.1 Maintenance schedule task reference table [QL1]The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Mainte-nance Schedule is a stand-alone publication.

The task numbers in this table provide reference to the maintenance tasks specified in the MaintenanceSchedule.

Task Option Maintenance tasksW0500 Check engine oil level. (→ Page 182)

W0501 Visually inspect engine for leaks and generalcondition.

(→ Page 77)

W0502 X Check intercooler condensate drain. (→ Page 177)

W0503 Check service indicator of air filter. (→ Page 181)

W0504 Check relief bores of HP fuel pump. (→ Page 154)

W0505 Check relief bores of water pump(s). (→ Page 233)

W0506 Check engine for abnormal running noises,exhaust color and vibrations.

(→ Page 77)

W0507 X Drain water and contaminants from fuel pre-filter.

(→ Page 77)

W0508 X Check reading on differential pressure gaugeof fuel prefilter.

(→ Page 165)

W1001 Replace fuel filter or fuel filter element (→ Page 163)

W1005 Replace air filter. (→ Page 179)

W1006 Replace fuel injection valves/injectors. (→ Page 155)

W1008 Replace engine oil filter when changing en-gine oil, or when the interval (years) isreached, at the latest.

(→ Page 186)

W1009 X Check layer thickness of oil residues, cleanand replace filter sleeve at each oil change,at the latest.

(→ Page 221)

W1011 Perform endoscopic examination. (→ Page 140)

W1016 Generator: Check condition of coupling. (→ Page 236)

W1036 X Replace coolant filter. No longer installed.

W1047 Check and clean oil indicator filter. (→ Page 215)

W1076 Exhaust turbocharger: Clean compressorwheel (MTU-ZR turbocharger).

(→ Page 173)

W1207 Check and adjust valve clearance. ATTEN-TION! First adjustment after 1,000 operatinghours.

(→ Page 147)

W1244 X Check function of rod electrode. (→ Page 240)

W1245 X Check alarm function of differential pressuregauge.

(→ Page 239)

W1246 X Check pump capacity. (→ Page 241)

94 | Maintenance | MS150048/05E 2018-03

TIM

-ID: 0

0000

3526

0 - 0

03

Task Option Maintenance tasksW1463 Check general condition of engine mounting

(visual inspection).(→ Page 237)

W1713 Injector: Reset drift correction (CDC) param-eters.

(→ Page 245)

Table 5: Maintenance schedule task reference table [QL1]

MS150048/05E 2018-03 | Maintenance | 95

TIM

-ID: 0

0000

3526

0 - 0

03

6 Troubleshooting

6.1 Control cabinet of fuel treatment system – Troubleshooting

Water alarmCause Corrective action

When the maximum water level isreached, the water level electrodeopens the water drain valve andwater is discharged. If the openingperiod of the valve exceeds apreset limit (4 minutes), the pumpwill switch off and an alarm isinitiated.

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 faultCause Corrective action

The drive motor is equipped withan overload protection. If themaximum permissible currentconsumption is exceeded, e.g. incase of a blockage or dry-running,the motor protection relaytriggers and the pump is switchedoff.

u Reset motor protection relay.

Pre-alarmCause Corrective action

The differential pressureexceeded 1.3 bar.

u Replace coalescer filter element (→ Page 242).

Replace filter elementCause Corrective action

The max. permissible differentialpressure exceeded 1.5 bar. If thecoalescer filter element is notreplaced, pressure will increasefurther and the safety valve willopen. Fuel will be led via thebypass directly into the overflowtank.

1. Replace coalescer filter element (→ Page 242).2. Press illuminated pushbutton 'Water alarm' for acknowledgment.

96 | Troubleshooting | MS150048/05E 2018-03

TIM

-ID: 0

0000

0773

4 - 0

09

6.2 Troubleshooting

Engine does not rotate when starter is actuated.Cause Corrective action

Battery discharged or faulty. u Charge or replace (see special documentation).Battery: Cable connections faulty. u Check if cable connections for secure seating (see special

documentation).Starter: Incorrect design of powersupply (battery/cable)

u Check starter power supply and correct the design if necessary(battery/cable resistance).

Engine cabling faulty. u Check (→ Page 244).Assemblies or connectors on LOPloose.

u Inspect visually.

Plug connections on EngineControl Unit loose.

u Check plug connections (→ Page 251).

Plug connections on EngineInterface Module (EIM) loose.

u Check plug connections (→ Page 250).

Fuse F1 (→ Page 52) in enginewiring harness faulty (fuse lampon EIM flashes with relevantflashing code).

u Check fuse, replace as necessary, and re-start system by actuatingkey switch.

Engine blocked (crankshaftcannot be rotated by hand).

1. Check start interlock (→ Page 247).2. Contact Service.

Engine rotates when started but does not fire.Cause Corrective action

Poor turning on starter: Batterydischarged or faulty.

u Charge or replace battery (see special documentation).

Engine cabling faulty. u Check (→ Page 244).Engine Control Unit faulty. 1. Replace (→ Page 252).

2. Contact Service.Starter: Incorrect design of powersupply (battery/cable)

u Check starter power supply and correct the design if necessary(battery/cable resistance).

Engine fires unevenly.Cause Corrective action

Engine cabling faulty. u Check (→ Page 244).Injector defective. u Replace (→ Page 155).Engine Control Unit faulty. 1. Replace (→ Page 252).

2. Contact Service.

MS150048/05E 2018-03 | Troubleshooting | 97

TIM

-ID: 0

0000

4407

3 - 0

04

Engine does not reach rated speed.Cause Corrective action

Engine: Overload. u Reduce load.Air filter clogged. 1. Check signal ring position of service indicator (→ Page 181).

2. Replace air filter (→ Page 179).Fuel prefilter clogged. 1. Drain water and contaminants from fuel prefilter (→ Page 166).

2. Replace filter element (→ Page 170).Easy-change fuel filter clogged. u Replace (→ Page 163).Engine cabling faulty. u Check (→ Page 244).Injector defective. u Replace (→ Page 155).

Engine speed not stable.Cause Corrective action

Injector defective. u Replace (→ Page 155).Speed sensor faulty. u Check and replace as necessary (→ Instructions for Exchange of

Sub-assemblies).Engine Control Unit faulty. 1. Check plug connections (→ Page 251).

2. Replace Engine Control Unit (→ Page 252).3. Contact Service.

Charge-air temperature too high.Cause Corrective action

Engine: Overload. u Reduce load.Air inlet temperature too high. u Check fans and air supply/ventilation ducts for engine room.Incorrect engine coolantconcentration.

1. Check engine coolant level (→ Page 225).2. Check engine coolant (MTU test kit) (→ Page 234).

Intercooler clogged. u Replace (→ Instructions for Exchange of Sub-assemblies).

Charge-air pressure too low.Cause Corrective action

Air filter clogged. 1. Check signal ring position of service indicator (→ Page 181).2. Replace air filter (→ Page 179).

Intercooler clogged. u Replace (→ Instructions for Exchange of Sub-assemblies).Exhaust turbocharger defective. 1. Clean compressor wheel (→ Page 173).

2. Replace exhaust turbocharger (→ Instructions for Exchange of Sub-assemblies).

Engine coolant escapes at intercooler.Cause Corrective action

Intercooler leaky, major coolantdischarge.

u Replace intercooler (→ Instructions for Exchange of Sub-assemblies).


TIM

-ID: 0

0000

4407

3 - 0

04

Black exhaust gas.Cause Corrective action

Overload. u Reduce load.Air filter clogged. 1. Check signal ring position of service indicator (→ Page 181).

2. Replace air filter (→ Page 179).Injector defective. u Replace (→ Page 155).

Blue exhaust gasCause Corrective action

Too much engine oil in the engine. u Drain engine oil (→ Page 183).Oil separator of crankcasebreather contaminated.

u Replace oil separator (→ Page 144).

Exhaust turbocharger defective. u Replace (→ Instructions for Exchange of Sub-assemblies).Cylinder head defective. 1. Check cylinder compression.

2. Replace cylinder head (→ Instructions for Exchange of Sub-assemblies).

Piston rings or cylinder linerdefective.

1. Check cylinder compression.2. Carry out endoscopic examination of cylinder liner (→ Page 140).3. Replace piston rings (→ Instructions for Exchange of Sub-

assemblies).4. Replace cylinder liner (→ Instructions for Exchange of Sub-

assemblies).5. Contact Service.

White exhaust gasCause Corrective action

Engine is not at operatingtemperature.

u Run engine to reach operating temperature.

Intercooler leaky. 1. Check condensate drain for coolant discharge and obstruction(→ Page 177).

2. Replace intercooler (→ Instructions for Exchange of Sub-assemblies).


TIM

-ID: 0

0000

4407

3 - 0

04

6.3 Engine governor ADEC (ECU 7) fault messages for Series 4000engines, marine applicationThe 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/actuatorstested and replaced as necessary if troubleshooting as described in the table (→ Page 101) proves unsuc-cessful.

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

Fault code list (→ Page 101).


TIM

-ID: 0

0000

1686

7 - 0

06

6.4 ADEC engine governor – Fault codes

29 – HI ETC Idle Speed too HighZKP-Number: 1.8004.206

Cause Corrective action

Idle speed of one of thesecondary turbochargers is toohigh.

u Contact Service.

38 – AL ETC Speed DeviationZKP-Number: 1.8004.205


Speeds of one of the secondaryturbochargers deviates fromprimary turbocharger speed.

1. Reduce power.2. Contact Service.

39 – AL ETC2 CutIn FailureZKP-Number: 1.8004.204


ETC2 could not be cut in. 1. Reduce power.2. Contact Service.

81 – AL Rail LeakageZKP-Number: 1.8004.046


Pressure gradient in rail is too lowduring starting or too high duringstopping (HP system leaky or airin the system)

u Contact Service.

102 – AL Cons. Counter DefectZKP-Number: 1.8004.624


Consumption meter faulty. u Contact Service.

104 – AL Eng Hours Counter DefectZKP-Number: 1.8004.623


Hourmeter faulty. u Contact Service.


TIM

-ID: 0

0000

1838

9 - 0

04

141 – AL Power too highZKP-Number: 1.1088.007


This alarm occurs if the averagevalue of power over the last 24hours exceeded the maximumvalue specified in PR1.1088.001.

u Reduce power.

142 – AL MCR exceeded 1 hourZKP-Number: 1.1088.006


This alarm occurs if the MCR wasexceeded for more than 1 hourwithin the last 12 hours.

u Reduce power.

201 – SD T-CoolantZKP-Number: 1.8004.570


Coolant temperature sensorfaulty; Short circuit or wire break

1. Check sensor and cabling (B6), replace as necessary.2. Error cleared after restarting the engine.

202 – SD T-FuelZKP-Number: 1.8004.572


Coolant temperature sensorfaulty; Short circuit or wire break


203 – SD T-Charge AirZKP-Number: 1.8004.571


Charge-air temperature sensorfaulty; Short circuit or wire break


204 – SD Level Lube OilZKP-Number: 1.8004.602


lube oil level sensor faulty; Shortcircuit or wire break

u Check sensor and cabling, replace as necessary.


TIM

-ID: 0

0000

1838

9 - 0

04

205 – SD T-Coolant IntercoolerZKP-Number: 1.8004.574


Charge-air cooler coolanttemperature sensor faulty; Shortcircuit or wire break

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

206 – SD T-Exhaust AZKP-Number: 1.8004.576


Exhaust temperature sensor on A-side faulty; Short circuit or wirebreak

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

207 – SD T-Exhaust BZKP-Number: 1.8004.577


Exhaust temperature sensor on B-side faulty; Short circuit or wirebreak


208 – SD P-Charge AirZKP-Number: 1.8004.566


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


211 – SD P-Lube OilZKP-Number: 1.8004.563


Lube oil pressure sensor faulty;Short circuit or wire break


212 – SD P-CoolantZKP-Number: 1.8004.564


Coolant pressure sensor faulty;Short circuit or wire break



TIM

-ID: 0

0000

1838

9 - 0

04

213 – SD P-Coolant charge-air coolerZKP-Number: 1.8004.569


Charge-air cooler coolantpressure sensor faulty; Shortcircuit or wire break


214 – SD P-CrankCaseZKP-Number: 1.8004.568


Crankcase pressure sensor faulty;Short circuit or wire break


215 – SD P-HDZKP-Number: 1.8004.567


Rail pressure sensor faulty; high-pressure regulator emergencymode; Short circuit or wire break


216 – SD T-Lube OilZKP-Number: 1.8004.575


Lube oil temperature sensorfaulty; Short circuit or wire break


219 – SD T-Intake AirZKP-Number: 1.8004.573


Intake air temperature sensorfaulty; Short circuit or wire break


220 – SD Level Coolant WaterZKP-Number: 1.8004.584


Coolant level sensor faulty; Shortcircuit or wire break

1. Check sensor and cabling (F33), replace as necessary.2. Error cleared after restarting the engine.


TIM

-ID: 0

0000

1838

9 - 0

04

221 – SD P-Diff-Lube OilZKP-Number: 1.8004.585


Lube oil differential pressuresensor faulty; Short circuit or wirebreak


222 – SD Level Leakage FuelZKP-Number: 1.8004.582


Leak-off fuel level sensor faulty;Short circuit or wire break


223 – SD Level Coolant IntercoolerZKP-Number: 1.8004.583


Coolant level sensor of charge-aircooler faulty; Short circuit or wirebreak


227 – SD P-Lube Oil before FilterZKP-Number: 1.8004.620


Sensor for lube oil pressurebefore filter faulty; Short circuit orwire break

1. Check sensor and cabling (B5.3), replace as necessary.2. Error cleared after restarting the engine.

228 – SD P-Fuel before FilterZKP-Number: 1.8004.595


Fuel pressure sensor faulty; Shortcircuit or wire break


229 – AL Stop Camshaft Sensor DefectZKP-Number: 1.8004.562


Engine shutdown due to camshaftsensor fault (and a priorcrankshaft sensor fault in thesame operating cycle).

1. Check connector and cabling to sensor B1, replace as necessary.2. Error cleared after restarting the engine.


TIM

-ID: 0

0000

1838

9 - 0

04

230 – SD Crankshaft SpeedZKP-Number: 1.8004.498


Crankshaft sensor faulty; Shortcircuit or wire break


231 – SD Camshaft SpeedZKP-Number: 1.8004.499


Camshaft sensor faulty; Shortcircuit or wire break


232 – SD Charger 1 SpeedZKP-Number: 1.3011.128


Speed sensor of primaryturbocharger faulty; Short circuitor wire break


233 – SD Charger 2 SpeedZKP-Number: 1.3011.129


Speed sensor of secondaryturbocharger faulty; Short circuitor wire break


239 – SD P-Diff FuelZKP-Number: 1.8004.598


Fuel differential pressure sensorfaulty; occurs only in combinationwith alarm "SD P-Fuel beforeFilter" or "SD P-Fuel after Filter".

u Note further fault messages. Pressure sensor before or after filteris faulty.

240 – SD P-FuelZKP-Number: 1.8004.565


Fuel pressure sensor faulty; Shortcircuit or wire break



TIM

-ID: 0

0000

1838

9 - 0

04

241 – SD T-Circulating airZKP-Number: 1.8004.581


Recirculation temperature sensorfaulty; Short circuit or wire break


242 – SD T-Coolant (R)ZKP-Number: 1.8004.622


Redundant coolant temperaturesensor faulty; Short circuit or wirebreak

1. Check sensor and cabling, replace as necessary.2. Error cleared after restarting the engine.

244 – SD P-Lube Oil (R)ZKP-Number: 1.8004.621


Redundant lube oil pressuresensor faulty; Short circuit or wirebreak

1. Check sensor and cabling, replace as necessary.2. Error cleared after restarting the engine.

301 – AL Timing Cylinder A1ZKP-Number: 1.8004.500


Time-of-flight measuring fault ofinjector in cylinder A1: Time-offlight measured value extremelylow or extremely high.

u If alarm occurs frequently, replace solenoid valve of injector










TIM

-ID: 0

0000

1838

9 - 0

04






















TIM

-ID: 0

0000

1838

9 - 0

04









311 – AL Timing Cylinder B1ZKP-Number: 1.8004.510


Time-of-flight measuring fault ofinjector B1: Time-of flightmeasured value extremely low orextremely high.








Time-of-flight measuring fault ofinjector B3: Time-of-flightmeasurement value is extremelysmall or extremely large.



TIM

-ID: 0

0000

1838

9 - 0

04






















TIM

-ID: 0

0000

1838

9 - 0

04









321 – AL Wiring Cylinder A1ZKP-Number: 1.8004.520


Short-circuit in injector cabling tocylinder A1. Result: Misfiring

1. Rectify injector solenoid valve short circuit (positive to negative)(e.g.by exchanging injectors).

2. Error cleared after restarting the engine.




1. Rectify injector solenoid valve short circuit (positive to negative)(e.g. by exchanging injectors).













TIM

-ID: 0

0000

1838

9 - 0

04
































TIM

-ID: 0

0000

1838

9 - 0

04

331 – AL Wiring Cylinder B1ZKP-Number: 1.8004.530


Cabling fault in injector cabling tocylinder B1. Result: Misfiring





























TIM

-ID: 0

0000

1838

9 - 0

04





















341 – AL Open Load Cylinder A1ZKP-Number: 1.8004.540


Disruption fault in injector cablingto cylinder A1. Result: Misfiring

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

2. Error clearance: After each working cycle.







TIM

-ID: 0

0000

1838

9 - 0

04
























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








TIM

-ID: 0

0000

1838

9 - 0

04











351 – AL Open Load Cylinder B1ZKP-Number: 1.8004.550


Disruption fault in injector cablingto cylinder B1. Result: Misfiring



















TIM

-ID: 0

0000

1838

9 - 0

04
































TIM

-ID: 0

0000

1838

9 - 0

04

361 – AL Power Stage LowZKP-Number: 1.8004.496


Internal electronic fault(electronics possibly faulty). If bit"1.1020.021" (Power StageFailure: Stop Engine) is set,engine will be shut down asadditional measure.

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

362 – AL Power Stage HighZKP-Number: 1.8004.497




363 – AL Stop Power StageZKP-Number: 1.8004.560




365 – AL Stop MV-Wiring GroundZKP-Number: 1.8004.561


Injector cabling fault. If bit"1.1020.021" (Power StageFailure: Stop Engine) is set,engine will be shut down asadditional measure. Possiblecauses:

1. Short circuit of positiveconnection of one or moreinjectors to ground

2. Short circuit of negativeconnection of one or moreinjectors to ground.

u Check wiring, replace wiring harness as necessary.


TIM

-ID: 0

0000

1838

9 - 0

04

371 – AL Wiring TO 1ZKP-Number: 1.8004.634


Short circuit or wire break ontransistor output 1 (TO 1).

1. Check charger valve/cabling, repair as necessary.2. Replace engine governor




1. Check air recirculation valve/cabling, repair as necessary.2. Replace engine governor




u Check wiring of charger valve 2 (marine engine)




u Check wiring of charger valve 3 (marine engine)

390 – AL MCR exceededZKP-Number: 1.1085.009


DBR/MCR feature: MCR(maximum continuous rating) wasexceeded.

1. If the alarm occurs temporarily, no action required.2. If the alarm is permanently active, contact Service.

396 – TD T-CoolantZKP-Number: 1.8004.626


Maximum deviation of coolanttemperature values from sensors

1. Check sensor and cabling, replace as necessary.2. Contact Service.


TIM

-ID: 0

0000

1838

9 - 0

04

397 – TD P-Lube OilZKP-Number: 1.8004.625


Maximum deviation of lube oilpressure values from sensors


417 – SD Level Water Fuel PrefilterZKP-Number: 1.8004.594


Water level sensor in fuel prefilterfaulty; Short circuit or wire break


419 – SD T-Coolant b.EngineZKP-Number: 1.8004.604


Coolant inlet temperature sensorfaulty; Short circuit or wire break

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

444 – SD U-PDUZKP-Number: 1.8004.578


Injector power stage sensordefect; Internal fault in ECU7

u Replace ECU7.

445 – SD P-Ambient AirZKP-Number: 1.8004.580


Ambient air pressure sensorfaulty.

1. Check pressure sensor and cabling, replace as necessary.2. Replace engine governor.

464 – SD P-AUX 1ZKP-Number: 1.8004.589


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

u Check pressure sensor and cabling, replace as necessary.


TIM

-ID: 0

0000

1838

9 - 0

04

468 – SD T-AUX 1ZKP-Number: 1.8004.579


Analog input signal for Aux 1temperature faulty;.

1. Check signal transmitter and cabling, replace as necessary.2. Replace engine governor.

469 – SD AUX 1ZKP-Number: 1.8004.590


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

u Check signal transmitter and cabling, replace as necessary.

470 – SD T-ECUZKP-Number: 1.8004.587


Temperature sensor for ECUfaulty; Short circuit or wire break


471 – SD Coil CurrentZKP-Number: 1.8004.592


Control of HP fuel control blockfaulty; Short circuit or wire break


473 – AL Wiring PWM_CM2ZKP-Number: 1.8004.593


Cable break or short circuit onchannel PWM_CM2.

1. Check cabling.2. Contact Service.

475 – AL CR Trigger Engine StopZKP-Number: 1.8010.009


Activated if the crash recorderwas triggered due to an enginestop.

1. Determine cause of trigger/engine stop and rectify.2. Contact Service.


TIM

-ID: 0

0000

1838

9 - 0

04

476 – AL Crash Rec. Init. ErrorZKP-Number: 1.8010.007


Crash recorder initialization error. 1. Check setting with DiaSys.2. Contact Service.

482 – SD T-Exhaust CZKP-Number: 1.8004.596




483 – SD T-Exhaust DZKP-Number: 1.8004.597






ETC4 could not be cut in. u Check control valve on ETC 4.



ETC3 could not be cut in. u Check control valve on ETC 3.

500 – AL Wiring POM Starter 1ZKP-Number: 1.4500.900


A wiring fault was detected in theconnection between starter 1 andPOM. This may be a missingconsumer, a wire break, or a shortcircuit.

u Check connection between POM and starter.


TIM

-ID: 0

0000

1838

9 - 0

04

501 – AL Wiring POM Starter 2ZKP-Number: 1.4500.901


A wiring fault was detected in theconnection between starter 2 andPOM. This may be a missingconsumer, a wire break, or a shortcircuit.


502 – AL Open Load POM AlternatorZKP-Number: 1.4500.902


Open load was detected at theconnection of the battery-charging generator on the POM.


503 – AL Battery not ChargingZKP-Number: 1.4500.903


The battery-charging generatordoes not charge the battery.

u Check battery-charging generator and cabling.

504 – AL CAN POM node LostZKP-Number: 1.4500.904


POM missing on CAN bus. u Check connection and POM. If alarm occurs in combination withalarm 508, the resistor in the POM cabling is missing.

506 – AL Low Starter VoltageZKP-Number: 1.4500.906


battery voltage is too low toaccomplish a starting procedure.

u Check battery-charging generator and cabling.

507 – AL POM ErrorZKP-Number: 1.4500.907


A general POM error occurred. u Replace POM.


TIM

-ID: 0

0000

1838

9 - 0

04

508 – AL Wrong POM-IDZKP-Number: 1.4500.908


POM transmits an unexpected IDnumber. If alarm occurs incombination with alarm 504, theresistor in the POM cabling ismissing.

u Check POM wiring harness.

519 – Oillevel Calibration ErrorZKP-Number: 1.0158.921


Error when writing the calibrationvalue into the Flash or SD memoryof the level sensor; associated PV:AL Group 6 Mot Bit 11


525 – SD P-Lube Oil (R2)ZKP-Number: 1.8004.638


Redundant lube oil pressuresensor faulty; Short circuit or wirebreak


526 – SD T-Coolant (R2)ZKP-Number: 1.8004.639


Redundant coolant temperaturesensor faulty; Short circuit or wirebreak


527 – TD EngineSpd. Sensor DeviationZKP-Number: 1.0480.093


Maximum deviation of speedsensors

1. Check cabling of speed sensors. Observe additional messages.2. Contact Service.

528 – SD Engine Speed 3rd SensorZKP-Number: 1.2500.102


Redundant crankshaft sensorfaulty; Short circuit or wire break



TIM

-ID: 0

0000

1838

9 - 0

04

576 – AL ESCM OverrideZKP-Number: 1.1075.083


Violation of corrected MCR orDBR/MCR curve. Engine overload!

u Reduce power.

577 – SD T-Lube Oil PanZKP-Number: 1.0137.900


Temperature sensor in oil pandefective; Short circuit or wirebreak


582 – AL Emergency Stop FailedZKP-Number: 1.1005.006


This alarm occurs if the enginefails to come to a standstill withina specified (by parametrization)period of time after theemergency stop signal wasoutput.

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

588 – SD P-Oil Refill PumpZKP-Number: 1.0159.910


Pressure sensor faulty; Shortcircuit or wire break


596 – AL Develop PR SetZKP-Number: 1.8004.645


The parameter set used is a testparameter set.

u The alarm remains active until a series-production parameter setwas installed.

600 – SD T-Exhaust A+BZKP-Number: 1.8004.646


SD T-Exhaust A and T-Exhaust B u Check sensor and cabling, replace as necessary.


TIM

-ID: 0

0000

1838

9 - 0

04

601 – SD ETC1+ETC2ZKP-Number: 1.3011.227


SD ETC1 and ETC2 u Check sensor and cabling, replace as necessary.

625 – SD P-Fuel before PrefilterZKP-Number: 1.8004.600


Analog input signal for pressurebefore prefilter faulty; Shortcircuit or wire break

1. Check pressure sensor and cabling, replace as necessary.2. Error cleared after restarting the engine.


TIM

-ID: 0

0000

1838

9 - 0

04

7 Task Description

7.1 SOLAS

7.1.1 SOLAS shielding as per MTN 5233 – Installation



Shield A4 735233000100 3Shield A5 735233000101 43Shield A6 735233000102 5Shield A7 735233000103 4Shield A8 735233000104 6Shield B2 735233000200 2Shield B4 735233000202 1Shield E5 735233000500 1

Installing SOLAS shielding1. Pinpoint installation location (→ Page 128).2. Install suitable shielding.3. Press shielding until locked.

MS150048/05E 2018-03 | Task Description | 127

TIM

-ID: 0

0000

7660

8 - 0

01

7.1.2 Installation locations for SOLAS shields

General informationFit SOLAS shields as per MTN 5233 by way of preference (→ Page 127).

Shield unions with adhesive tape if SOLAS shield as per MTN 5233 is not possible (→ Page 137).

When affixing adhesive connections ensure that escaping fluid can flow out without pressure (→ Page 137).

Fuel system, fuel lines with fuel pressure >1.8 bar

Item Type of shield Installation location1 2 x shield A5 Fuel line to fuel filter head

Item Type of shield Installation location1 2 x shield A8 Fuel line from/to fuel filter head

128 | SOLAS | MS150048/05E 2018-03

TIM

-ID: 0

0000

7660

9 - 0

01

Item Type of shield Installation location1 Shield A8 Fuel line to HP pump2 Shield E5 Fuel line to HP pump

Lube oil system, oil lines with oil pressure >1.8 bar

Item Type of shield Installation location1 1 x shield A5

1 x shield A4Oil line connection

2 2 x shield A5 Actuating cylinder for exhaust flap of ETC B23 2 x shield A5 Actuating cylinder for air flap of ETC B24 3 x shield A5 T piece of flap control

MS150048/05E 2018-03 | SOLAS | 129

TIM

-ID: 0

0000

7660

9 - 0

01



2 2 x shield A5 Actuating cylinder for exhaust flap of ETC B13 3 x shield A5 T piece of flap control

Item Type of shield Installation location1 2 x shield A5 Actuating cylinder for air flap of

ETC B1

130 | SOLAS | MS150048/05E 2018-03

TIM

-ID: 0

0000

7660

9 - 0

01

Item Type of shield Installation location1 2 x shield A5 Actuating cylinder for air flap of ETC A2



2 2 x shield A5 Actuating cylinder for exhaust flap of ETC A23 3 x shield A5 T piece flap control

MS150048/05E 2018-03 | SOLAS | 131

TIM

-ID: 0

0000

7660

9 - 0

01

Item Type of shield Installation location1 2 x shield A5 Air recirculation valve

Item Type of shield Installation location1 Shield A6 Oil supply line to HP pump: To HP pump

132 | SOLAS | MS150048/05E 2018-03

TIM

-ID: 0

0000

7660

9 - 0

01

Item Type of shield Installation location1 * Shield B4 Oil supply line to HP pump: On equipment carrier* This shield must be installed on the assembly line. Assembly in this position is no longer possible afterpainting.

Item Type of shield Installation location1 5 x shield A5 Flap control distributor

MS150048/05E 2018-03 | SOLAS | 133

TIM

-ID: 0

0000

7660

9 - 0

01

Item Type of shield Installation location1 6 x shield A5 Distributor2 * 2 x shield A8 Distributor* This shield must be installed on the assembly line. Assembly in this position is no longer possible afterpainting.

Item Type of shield Installation location1* 1 x shield A8 Flap control to main oil gallery, free end* This shield must be installed on the assembly line. Assembly in this position is no longer possible afterpainting.

134 | SOLAS | MS150048/05E 2018-03

TIM

-ID: 0

0000

7660

9 - 0

01

Item Type of shield Installation location1* 4 x shield A7 ETC oil supply connection to main oil gallery* This shield must be installed on the assembly line. Assembly in this position is no longer possible afterpainting.

Item Type of shield Installation location1 2 x shield A5 Connection of ETC oil supply, free end2 2 x shield A6 Connection of ETC oil supply, free end

MS150048/05E 2018-03 | SOLAS | 135

TIM

-ID: 0

0000

7660

9 - 0

01

Item Type of shield Installation location1 2 x shield A5 Connection of ETC oil supply, driving end2 2 x shield A6 Connection of ETC oil supply, driving end

136 | SOLAS | MS150048/05E 2018-03

TIM

-ID: 0

0000

7660

9 - 0

01

7.1.3 Adhesive tape for SOLAS shielding – Application



Adhesive tape

Applying adhesive tape – gener-al information

Note: Use the cable clamp to make a drainagechannel. This allows fluid to flow out withoutpressure 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 adhe-

sive tape.

Sealing cone unionsNote: For installation positions of sealing cone un-

ions, see (→ Page 128).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 adhe-sive tape overlaps at least half its own width.

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

Plug-in connectionsNote: For installation positions of plug-in connections, see (→ Page 128).

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.

MS150048/05E 2018-03 | SOLAS | 137

TIM

-ID: 0

0000

3833

0 - 0

02

7.2 Engine

7.2.1 Engine – Barring manually



Barring tool F6555766 1Ratchet with extension F30006212 1

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

Engine – Barring manually1. Remove guard plate.

Result: Safety switch preventing engine starting isactivated.

2. Engage barring device (2) in ring gear (3) andinstall on flywheel housing.

3. Apply ratchet (1) to barring device (2).4. Rotate crankshaft in engine direction of rota-

tion. Apart from the normal compression re-sistance, there should be no resistance.

5. For barring device removal, follow reverse se-quence of working steps.

138 | Engine | MS150048/05E 2018-03

TIM

-ID: 0

0000

1050

3 - 0

06

7.2.2 Barring engine with starting system

Barring using the automation systemRefer to automation system operating instructions

MS150048/05E 2018-03 | Engine | 139

TIM

-ID: 0

0000

1753

2 - 0

04

7.3 Cylinder Liner

7.3.1 Cylinder liner – Endoscopic examination



Rigid endoscope Y20097353 1

Preparatory steps1. Remove cylinder head cover (→ Page 151).2. Remove injector (→ Page 156).

Positioning crankshaft at BDC1. Using barring gear, turn crankshaft until crankshaft journal of the cylinder to be inspected has reached BDC.2. Insert endoscope through the mount of the injector into the cylinder liner.

Cylinder liner – Endoscopic examinationFindings Measure• Thin carbon coating around carbon scraper ring• Minor localized additive deposits at top edge• Localized smooth areas at bottom edge• Carbon deposits on entire circumference in clearance area 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• Flawless, even honing pattern• First signs of marks left by lower cooling bores• Running pattern seems darker

No action required

• 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 circum-

ference can not be faulted• Piston rings can not be faulted

Further endoscopic examina-tion required as part of mainte-nance work

• On the entire circumference, apart from light areas of discoloration (donot impair operation) clearly darker stripes that start at the top pistonring

• Heat discoloration in the direction of stroke and honing pattern dam-age

• Heat discoloration of piston rings

Cylinder liner must be replaced,contact Service.

1. Compile endoscopic report using the table.2. Use technical terms for description of the liner surface (→ ).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.

140 | Cylinder Liner | MS150048/05E 2018-03

TIM

-ID: 0

0000

0001

5 - 0

17

Final steps1. Install injector (→ Page 156).2. Install cylinder head cover (→ Page 151).

MS150048/05E 2018-03 | Cylinder Liner | 141

TIM

-ID: 0

0000

0001

5 - 0

17

7.3.2 Cylinder liner – Instructions and comments on endoscopic and visualexamination

Terms used for endoscopic examinationUse the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic examina-tion report.

Findings Explanations/ActionMinor dirt scores 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 therunning surface under endoscope magnification. Cannot be felt with the fingernail.Findings not critical

Single scores Clearly visible scores caused by hard particles. They usually start in the TDC areaand cross through the honing pattern in the direction of stroke.Findings not critical

Scored area These areas consist of scores of different length and depth next to one another. Inmost cases, they are found at the 6-o'clock and 12-o'clock positions (inlet/exhaust) along the transverse engine axis.Findings not critical

Polished area Polished areas are on the running surface but almost the whole honing pattern isstill visible. Polished areas appear brighter and more shiny than the surroundingrunning surface.Findings not critical

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

Discoloration This is caused by oxidation (surface discoloration through oil or fuel) and tempera-ture differences around the liner. It appears rather darker within the honed struc-ture in contrast to the bright metallic running surface. The honing pattern is undis-turbed. Discolorations extend in stroke direction and may be interrupted.Findings not critical

Corrosion fields /spots

Corrosion fields / spots result from moisture (condensate) with the valves in theoverlap (open) position. They are clearly visible due to the dark color of the honinggroove bottom.This corrosion is not critical unless there is corrosion pitting.

Black lines Black lines are a preliminary stage of burn marks. They are visible as a clear discol-oration from TDC to BDC in the running surface and the start of localized damageto the honing pattern.Cylinder liners with a large number of black lines around the running surface havelimited service life and should be replaced.

Burn mark These are caused by a disturbance in the liner / ring tribo system. Usually they runover the whole ring-travel area (TDC/BDC), starting at the first TDC-ring and be-coming more visible from the second TDC-ring 2 onwards and less pronouncedfrom TDC-ring 1. The honing pattern is usually no longer visible and displays aclearly defined (straight) edge to the undisturbed surface. The damaged surface isusually discolored. The circumferential length varies.Liners with burn marks starting in TDC ring 1 have to be replaced.

Seizure marks, scuff-ing

Irregular circumference lengths and depths. Can be caused either by the pistonskirt or the piston crown. Material deposits on the liner (smear), heavy discolora-tion. Severe, visible scoring.Replace liner.

Table 6: Endoscopic examination – Terms used

142 | Cylinder Liner | MS150048/05E 2018-03

TIM

-ID: 0

0000

0001

4 - 0

17

Evaluation of findings and further measuresThe findings in the start phase of oxidation discoloration and burn marks are similar. A thorough investigationand compliance with the above evaluation criteria allow an unambiguous evaluation. To avoid unnecessarydisassembly work, it is recommended that another inspection be carried out after further operation of theengine.

MS150048/05E 2018-03 | Cylinder Liner | 143

TIM

-ID: 0

0000

0001

4 - 0

17

7.4 Crankcase Breather

7.4.1 Crankcase breather – Oil separator element replacement



Torque wrench, 4–20 Nm F30044239 1Ratchet adapter F30027340 1Engine oilFilter element (→ Spare Parts Catalog)O-ring (→ Spare Parts Catalog)

WARNINGOil 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.

Oil separator element – Replace-ment

1. Remove cover (2) with O-ring (3).2. Remove filter element (1) from oil separator

housing (4).3. Insert new filter element (1) in correct posi-

tion in oil separator housing (4).4. Install cover (2) with new O-ring.

144 | Crankcase Breather | MS150048/05E 2018-03

TIM

-ID: 0

0000

4861

3 - 0

05

5. Use torque wrench to tighten screws (2) of cover (1) to the specified tightening torque.


Screw Tightening torque (Engine oil) 10 Nm −2 Nm

6. Replace further filter elements in the same way.7. Check oil separator for leaks.

MS150048/05E 2018-03 | Crankcase Breather | 145

TIM

-ID: 0

0000

4861

3 - 0

05

7.5 Valve Drive

7.5.1 Valve gear – Lubrication



Engine oil

Valve gear – Lubrication1. Remove cylinder head covers (→ Page 151).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 151).

146 | Valve Drive | MS150048/05E 2018-03

TIM

-ID: 0

0000

0092

1 - 0

10

7.5.2 Valve clearance – Check and adjustment


☑Engine coolant temperature is max. 40 °C.

☑Valves are closed.


Feeler gauge Y20098771 1Valve setting gauge Y4349603 1Angular screw driver F30002815 1Torque wrench, 60–320 Nm F30452768 1Socket wrench, 24 mm F30039526 1Engine oil

Preparatory steps1. Remove cylinder head covers (→ Page 151).2. Install barring tool (→ Page 138).

Note: Pointer (1) is located in the lower opening ofthe flywheel housing (arrow).

3. Use barring tool to turn crankshaft in direc-tion of rotation until marking OT/A1 on therear side of the flywheel housing and point-er (1) are aligned.

MS150048/05E 2018-03 | Valve Drive | 147

TIM

-ID: 0

0000

0092

2 - 0

16

Note: Danger of confusion: There might be an addi-tional OT/A1 mark (1) on the outer perimeterof the flywheel.

4. The additional OT/A1 mark (1) (if applicable)on the outer perimeter of the flywheel mustnot be used for reference.

Diagram for 8V engines – Twocrankshaft positions


148 | Valve Drive | MS150048/05E 2018-03

TIM

-ID: 0

0000

0092

2 - 0

16



Checking valve clearance at two crankshaft positions1. 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.

2. Check valve clearance adjustment with cold engine:• Inlet valves (long rocker arm) = 0.2 mm ±0.05 mm• Exhaust valves (short rocker arm) = 0.5 mm ±0.05 mm

3. Check all valve clearances in two crankshaft positions (firing TDC and overlap TDC of cylinder A1) as perdiagram:

1 Cylinder A1 is in firing TDC2 Cylinder A1 is in overlap TDCI Inlet valve

X Exhaust valve4. Use valve setting gauge or feeler gauge to determine the distance between valve bridge and rocker arm.5. If the deviation from the set value exceeds 0.1 mm, adjust valve clearance.

MS150048/05E 2018-03 | Valve Drive | 149

TIM

-ID: 0

0000

0092

2 - 0

16

Adjusting valve clearance1. Release locknut (1).2. Insert valve setting gauge (3) between valve

bridge and rocker arm.

Note: Replace or rectify adjusting screws and/orlocknuts which do not move freely.

3. Using angular screw driver, set adjustingscrew (2) so that the specified valve clear-ance is provided.

Note: Valve setting gauge must just pass throughthe gap.

4. Pass valve setting gauge (3) between valvebridge and rocker arm.

5. Tighten locknut (1) to specified torque using a torque wrench, holding the adjusting screw (2) in place toprevent it from turning.


Locknut M16x1.5 Tightening torque (Engine oil) 90 Nm +9 Nm

6. Check valve clearance, adjust as necessary.

Final steps1. Remove barring tool (→ Page 138).2. Install cylinder head covers (→ Page 151).

150 | Valve Drive | MS150048/05E 2018-03

TIM

-ID: 0

0000

0092

2 - 0

16

7.5.3 Cylinder head cover – Removal and installation



Torque wrench, 10–60 Nm F30510423Ratchet bit F30027341Assembly compound (Kluthe Hakuform 30-15) X00067260 1Engine oilO-ring (→ Spare Parts Catalog)

Removing cylinder head cover1. 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).

Installing cylinder head cover1. 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.


Screw M10 Tightening torque (Engine oil) 42 Nm

MS150048/05E 2018-03 | Valve Drive | 151

TIM

-ID: 0

0000

1230

9 - 0

17

7.6 Injection Pump / HP Pump

7.6.1 HP fuel pump – Filling with engine oil



Torque wrench, 10–60 Nm F30452769 1Fuel suction device F30378207 1Engine oil

WARNINGFuels 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.

WARNINGLiquid 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 eyesand 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.

WARNINGOils/oil vapors are combustible/explosive.Risk of fire and explosion!• Avoid open flames, electric sparks and ignition sources.• Do not smoke.

NOTICEHP 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.

NOTICEContaminated components.Risk of damage to component!• Check components for special cleanliness and clean if necessary.

152 | Injection Pump / HP Pump | MS150048/05E 2018-03

TIM

-ID: 0

0000

0164

0 - 0

16

Preparatory stepsu Loosen nut (2) and remove oil line (1) from

HP pump.

HP pump – Filling1. 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.


Neck M16x1.5 Tightening torque 40 Nm

Final stepsu Install oil line.

MS150048/05E 2018-03 | Injection Pump / HP Pump | 153

TIM

-ID: 0

0000

0164

0 - 0

16

7.6.2 HP fuel pump – Relief bore check

DANGERComponents 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.


HP fuel pump, checking reliefbore

1. Visually inspect relief bore (1) for fuel dis-charge.

2. If fuel discharge is found or indicated, con-tact Service.

154 | Injection Pump / HP Pump | MS150048/05E 2018-03

TIM

-ID: 0

0000

1237

5 - 0

09

7.7 Injection Valve / Injector

7.7.1 Injector – Replacement


Injector (→ Spare Parts Catalog)

Replacing injectoru Remove injector and install new injector (→ Page 156).

MS150048/05E 2018-03 | Injection Valve / Injector | 155

TIM

-ID: 0

0000

0002

2 - 0

17

7.7.2 Injector – Removal and installation (jacketed fuel system)



Installation/removal jig F6789889 1Milling cutter F30452739 1Torque wrench, 10–60 Nm F30452769 1Ratchet bit F30027340 1Torque wrench, 60–320 Nm F30452768 1Ratchet bit F30027342 1Assembly compound (Molykote P 37) 50564 1Assembly compound (Kluthe Hakuform 30-15) X00067260 1Multi-purpose grease 40320 1Engine oilDamping ring (→ Spare Parts Catalog) 1O-ring (→ Spare Parts Catalog) 2O-ring (→ Spare Parts Catalog) 1Sealing ring (→ Spare Parts Catalog) 1O-ring (→ Spare Parts Catalog) 1



WARNINGHot 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.

156 | Injection Valve / Injector | MS150048/05E 2018-03

TIM

-ID: 0

0000

0092

5 - 0

31

WARNINGInternal load and residual pressure in the HP fuel system. Parts may be expelled at high speed on re-lease.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.

NOTICEContamination of components.Damage to component!• Observe manufacturer's instructions.• Check components for special cleanliness.

Preparatory steps1. Allow HP system to cool down.2. Shut off fuel supply to engine.3. Remove cylinder head cover (→ Page 151).

Removing injector1. Disconnect cable connector on injector.

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

2. Place a suitable collecting vessel underneath.3. Remove plug screw (1).


TIM

-ID: 0

0000

0092

5 - 0

31

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 outwhen 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 cylinderhead.

10. Remove injector with installation/removal jigand take off hold-down clamp.

11. Remove installation/removal jig.

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

12. Remove sealing ring (4) from injector or use aself-made wire hook or magnet to take it outof 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.


TIM

-ID: 0

0000

0092

5 - 0

31

Installing injectorNote: • 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 posi-tion is correct.

Note: If the milling cutter is pressed with excessiveforce into the seat of the injector, this cancause damage to the cylinder head.

2. Remove oil carbon from sealing face on cylin-der head and protective sleeve by using themilling cutter with little force.

Note: Remove seal plugs on HP line only before in-stallation of the adapter.

3. Remove seal plug.

Note: The damper ring is already in place for newassembly. Coat damper ring with assemblycompound.

4. Fit damper ring (1) on injector and coat withassembly compound (Molykote P 37).

Note: The O-rings are already in place for new as-sembly. Coat O-rings with assembly com-pound.

5. Fit new O-rings (3) and (2) on injector andcoat with assembly compound (Kluthe Haku-form 30-15).

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

6. Ensure that the sealing ring (4) is correctlyseated.

7. Insert injector with hold-down clamp into cyl-inder head, ensuring that the HP line connec-tion is correctly aligned.


TIM

-ID: 0

0000

0092

5 - 0

31

8. Press in injector with installation/removal jig.9. Remove installation/removal jig.

10. Coat screw mating face (2) and thread withengine oil.

11. Fit hold-down clamp (1) in correct position, fitscrew (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.


Screw M12 Tightening torque (Engine oil) 100 Nm+10 Nm

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


Adapter Tightening torque (Engine oil) 100 Nm+10 Nm

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.


TIM

-ID: 0

0000

0092

5 - 0

31

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

1 Adapter (4)2 Rail (6)


Union nut / thrustscrew

Tightening torque (Engine oil) 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)


Union nut / thrustscrew

Tightening torque (Engine oil) 40 Nm +5 Nm

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


Plug screw M10 Tightening torque (Engine oil) 15 Nm +3 Nm


TIM

-ID: 0

0000

0092

5 - 0

31

23. Fit cable connector on injector.

For new assembly: CDC parameters – ResetNote: 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 steps1. Install cylinder head cover (→ Page 151).2. Open fuel supply to engine.


TIM

-ID: 0

0000

0092

5 - 0

31

7.8 Fuel Filter

7.8.1 Fuel filter – Replacement

Preconditions☑Engine is shut down and starting disabled, or engine is running in lower partial-load operational range.

☑Positive pressure at inlet to engine (for work on stationary engine).


Oil filter wrench F30379104 1FuelEasy-change filter (→ Spare Parts Catalog)





NOTICEDamage 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.

MS150048/05E 2018-03 | Fuel Filter | 163

TIM

-ID: 0

0000

1270

5 - 0

11

Replacing fuel filterNote: • The left fuel filter (5) is cut out when the

lever is in position (3)• The right fuel filter (4) is cut out when the

lever is in position (7)1. Cut out fuel filter to be replaced. Pull locking

pin (1) and turn lever (6) to the left or rightstop.

2. Unscrew cut-out fuel filter using an oil filterwrench.

3. Clean sealing surface on filter head.4. Check sealing ring of new fuel filter and coat

with fuel.5. Screw on fuel filter and tighten by hand.6. Return lever to normal position (6) and lock

with locking pin (1).7. Replace second fuel filter in the same way.

Note: If the engine is running, the filter does nothave to be vented.

8. Vent fuel system at fuel vent (2).

164 | Fuel Filter | MS150048/05E 2018-03

TIM

-ID: 0

0000

1270

5 - 0

11

7.8.2 Fuel prefilter – Differential pressure gage check and adjustment



Adjusting differential pressuregage

1. When putting the new filter element into op-eration: Align adjustable pointer (2) withpressure-indicating pointer (3) of pressuregage (1).

2. Verify that differential pressure is within thelimit.

Fuel prefilter – Differential pressure check1. 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 168).

MS150048/05E 2018-03 | Fuel Filter | 165

TIM

-ID: 0

0000

0492

5 - 0

11

7.8.3 Fuel prefilter – Draining

Preconditions☑Engine is stopped and starting disabled (only in the case of single fuel prefilter).


Diesel fuelGasket (→ Spare Parts Catalog)





166 | Fuel Filter | MS150048/05E 2018-03

TIM

-ID: 0

0000

0492

9 - 0

10

Fuel prefilter – DrainingNote: Only for dual fuel prefilter:

1. Cut out filter to be drained.1 Left filter cut in2 Right filter cut in

2. Open threaded vent plug (5) of filter to bedrained.

3. Unlock drain valve (6) by pressing toggle andopen it.

4. Drain water and contaminants from filter untilpure fuel emerges.

5. Close drain valve (6).6. Remove screws for cover and take off cov-

er (2).7. Fill filter housing with clean fuel.8. Place new gasket in cover (2).9. Fit cover with gasket and secure it with

screws.

Note: Only for dual fuel prefilter:10. Cut in the cut-out filter again.11. Close threaded vent plug (5) when fuel

emerges from system.

MS150048/05E 2018-03 | Fuel Filter | 167

TIM

-ID: 0

0000

0492

9 - 0

10

7.8.4 Fuel prefilter – Flushing

Preconditions☑Positive pressure at the prefilter inlet.





Fuel prefilter – Flushing1. Cut out contaminated filter (A or B).

1 Filter A cut out2 Filter B cut out

168 | Fuel Filter | MS150048/05E 2018-03

TIM

-ID: 0

0000

1272

8 - 0

12

2. Open threaded vent plug (1) of the filter to beflushed.

3. Remove drain valve (2) and drain fuel.Result: Fuel flows from filtered side back to the unfil-

tered side, flushing the filter deposits down-wards out of the filter.

4. Close threaded vent plug (1) and drainvalve (2).

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

6. Close vent valves (1) as soon as fuel emergesfrom vent pipe (4).

7. Turn the rotary slide valve to the upright posi-tion (3) until it engages.

Result: Both filters are cut in.8. Set differential pressure gauge (→ Page 165).

MS150048/05E 2018-03 | Fuel Filter | 169

TIM

-ID: 0

0000

1272

8 - 0

12

7.8.5 Fuel prefilter with water separator – Filter element replacement

Preconditions☑Positive pressure at the prefilter inlet


Torque wrench, 10–60 Nm F30452769 1Ratchet adapter F30027340 1Filter element (→ Spare Parts Catalog)O-ring (→ Spare Parts Catalog)


WARNINGTank is pressurized.Risk of eye injuries resulting from fluid escaping under high pressure!• Open tank slowly.• Wear goggles or safety mask.



WARNINGHot 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.

NOTICEDamage 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.

170 | Fuel Filter | MS150048/05E 2018-03

TIM

-ID: 0

0000

1275

0 - 0

15

Fuel prefilter with water separa-tor – Filter element replacement

1. Cut out the filter to be replaced (A or B):1 Filter A cut out2 Filter B cut out

2. Open vent valve (3) of the filter to be re-placed.

3. Unlock drain valve (4) by pressing toggle andopen 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) un-

til filter element is accessible.8. Remove filter element (5) with spring (6).9. Insert a new filter element in the filter hous-

ing.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).


Screw Tightening torque 40 Nm

MS150048/05E 2018-03 | Fuel Filter | 171

TIM

-ID: 0

0000

1275

0 - 0

15

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

14. Close vent valve (1) as soon as fuel emergesfrom vent pipe (4).

15. Turn the rotary slide valve to the upright posi-tion (3) until it engages.

Result: Both filters are cut in.16. Set differential pressure gage (→ Page 165).

172 | Fuel Filter | MS150048/05E 2018-03

TIM

-ID: 0

0000

1275

0 - 0

15

7.9 Exhaust Turbocharger

7.9.1 Compressor wheel – Cleaning



Torque wrench, 10–60 Nm F30452769 1Ratchet bit F30027340 1Cleaner 40377 1Engine oilSealing rings 007603030101 3Sealing rings 007603042101 4

WARNINGChemical 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.

NOTICEIncorrect installation of components and lines.Damage to component!• Ensure that components/lines are installed so that they are never under tension or strain.• Ensure correct installation position of components.

NOTICEInappropriate cleaning tool.Risk of damage to component!• Observe manufacturer's instructions.• Use appropriate cleaning tool.

Preparatory steps1. Drain engine coolant (→ Page 228).2. Remove air filter (→ Page 180).3. Seal openings with suitable covers.

MS150048/05E 2018-03 | Exhaust Turbocharger | 173

TIM

-ID: 0

0000

1866

9 - 0

10

4. Remove charge-air pipework (1) from exhaustturbocharger to intercooler.

5. Remove oil lines (2).

6. Loosen clamp (1).7. Remove intake housing (3) with actuating cyl-

inder (2).

8. Remove coolant lines (1) from compressorhousing (3).

9. Remove coolant vent line (2) from compres-sor housing (3).

174 | Exhaust Turbocharger | MS150048/05E 2018-03

TIM

-ID: 0

0000

1866

9 - 0

10

10. Loosen and remove screws (1).11. Remove compressor housing (2).

Compressor wheel – CleaningNote: Never use a wire brush, scraper or similar ob-

ject for cleaning!1. Clean compressor housing with a smooth

paint brush or brush.2. Clean compressor wheel (2) and bearing

housing (1).3. Thoroughly remove cleaner from all compo-

nents.4. Replace sealing rings between bearing hous-

ing/compressor housing and plug-in sleevesas necessary.

Final steps1. Place compressor housing (2) in position.

MS150048/05E 2018-03 | Exhaust Turbocharger | 175

TIM

-ID: 0

0000

1866

9 - 0

10

2. Screw in screws (1) and tighten to specified tightening torque using a torque wrench .


Screw M10x18 Tightening torque (Engine oil) 44 Nm ± 6.5 Nm

3. Install coolant vent line and coolant lines on compressor housing.

4. Install intake housing (3) with actuating cylin-der (2).

5. Align clamp (1) and tighten to specified torque using a torque wrench.


Clamp Tightening torque 15 Nm + 2 Nm

6. Install oil lines (2). Tighten screw-fitting union at actuating cylinder to specified torque using a torquewrench.


Screw-fitting union 10 G 1/4A

Tightening torque (Engine oil) 40 Nm + 4 Nm

7. Install charge-air pipework (1) between exhaust turbocharger and intercooler.8. Install air filter (→ Page 180).9. Fill with engine coolant (→ Page 229).

176 | Exhaust Turbocharger | MS150048/05E 2018-03

TIM

-ID: 0

0000

1866

9 - 0

10

7.10 Charge-Air Cooling

7.10.1 Intercooler – Checking condensate drain for coolant leakage and obstruction

DANGERMoving or rotating parts.Risk of crushing, danger of limbs being caught up or drawn in!• Operate engine in lower load range only. Keep away from the danger zone of the engine.



Checking condensate drain ofintercooler for coolant leakageand obstruction

u With the engine running, check outlet of the two condensate drain bores (arrows).

Item Findings ActionOily water (condensate) escapes Normal No action requiredAir escapes Condensate drain bore is

free of obstructions(Air escapes freely)

No action required

Condensate drain bore isclogged(Air cannot escape or es-cape with restrictions only)

Clean drain bores (arrowed)and blow out with com-pressed air.

Coolant escapes Intercooler leaky Contact Service.Carry out emergency meas-ures (→ Page 178) beforere-starting the engine.

MS150048/05E 2018-03 | Charge-Air Cooling | 177

TIM

-ID: 0

0000

1324

6 - 0

12

Emergency measures prior to engine start for continued operation with leak-ing intercooler

1. Remove injectors (→ Page 156).2. Bar engine manually (→ Page 138).3. Bar engine with starting system to blow out combustion chambers (→ Page 138).4. Install injectors (→ Page 156).

178 | Charge-Air Cooling | MS150048/05E 2018-03

TIM

-ID: 0

0000

1324

6 - 0

12

7.11 Air Filter

7.11.1 Air filter – Replacement


Air filter (→ Spare Parts Catalog)

Replacing air filter1. Remove old air filter and install new air filter (→ Page 180).2. Reset signal ring of contamination indicator (→ ).

MS150048/05E 2018-03 | Air Filter | 179

TIM

-ID: 0

0000

0544

7 - 0

10

7.11.2 Air filter – Removal and installation


DANGERFalling from great heights.Risk of serious injury – danger to life!• When working high on the equipment, always use suitable ladders or work platforms.• Use personal protective equipment.

WARNINGFor all described tasks at the genset:Risk of injury!• For all tasks, the respective required personal protective equipment (safety shoes, ear protection,

protective gloves, safety goggles, respiratory protection, etc.) is to be used.

NOTICEStepping or climbing on the genset to perform installation tasks is to be avoided.Otherwise, there is a risk of component damage or leakage!• Use suitable and approved climbing aids or work platforms.

Removing and installing air fil-ter

1. Release clamp (2).2. Remove air filter (1) and clamp (2) from con-

necting flange of intake housing (3).3. Verify that there are no objects in the con-

necting flange of the intake housing (3) andclean it.

4. Place new air filter (1) with clamp (2) onto in-take housing (3).

5. Tighten clamps (2).

180 | Air Filter | MS150048/05E 2018-03

TIM

-ID: 0

0000

0545

7 - 0

13

7.12 Air Intake

7.12.1 Contamination indicator – Signal ring position check


WARNINGThe engine draws in large volumes of ambient air for combustion. This air intake results in a strong vac-uum.Risk of injury if body parts are drawn in! There is also a danger if opening of the entrance doorcan 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 position1. If the signal ring is completely visible in the

viewing window (2), replace air filter(→ Page 179).

2. After installation of new filter, press resetbutton (1).

Result: Engaged plunger with signal ring returns toinitial position.

MS150048/05E 2018-03 | Air Intake | 181

TIM

-ID: 0

0000

0548

4 - 0

10

7.13 Lube Oil System, Lube Oil Circuit

7.13.1 Engine oil level – Check



Checking engine oil level afterextended 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 andcheck oil level.

Note: After extended standstill, the oil level may beup to 2 cm above mark (1). This may becaused e.g. by oil from oil filters and heat ex-changers flowing back into the oil pan. Afterextended standstill, the oil level "2 cm abovemark (2)" is the minimum oil level.

3. Oil level must be at least 2 cm abovemark (2).

4. If necessary, top up with oil, maximum tomark (1) (→ Page 183).

5. Insert oil dipstick into guide tube up to thestop.

Checking oil level immediately after engine stop1. 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 183).5. Insert oil dipstick into guide tube up to the stop.

182 | Lube Oil System, Lube Oil Circuit | MS150048/05E 2018-03

TIM

-ID: 0

0000

0093

1 - 0

17

7.13.2 Engine oil ‒ Change


☑Engine is at operating temperature.

☑MTU Fluids and Lubricants Specifications (A001061/..) are available.


Torque wrench, 60–320 Nm F30452768 1Ratchet adapter F30027341 1Engine oilSealing ring (→ Spare Parts Catalog)


Oil change without semirotary hand pump: Draining oil via drain plug(s) on oilpan

1. Provide a suitable container to collect the oil.2. Remove drain plug(s) and drain oil.3. Install drain plug(s) with new sealing ring.

Oil change using semirotary hand pump: Oil extraction1. Provide a suitable container to collect the oil.2. Extract all oil from oil pan using the semirotary hand pump.

Draining residual oil at equip-ment carrier

1. Provide a suitable container to collect the oil.2. Remove drain plugs (1) and (2) and drain oil:

• Approx. 12 liters at (1)• Approx. 5 liters at (2)

3. Check oil indicator filter (→ Page 215).4. Install drain plug(s) with new sealing ring.

MS150048/05E 2018-03 | Lube Oil System, Lube Oil Circuit | 183

TIM

-ID: 0

0000

1410

0 - 0

06

5. Tighten drain plugs (1) and (2) to specified torque using a torque wrench:


Screw M26x1.5 Tightening torque 100 Nm+10 Nm

Filling with new oil1. Open cover (1) on filler neck.2. Pour oil in at filler neck up to “max.” mark at

oil dipstick.3. Close cap (1) on filler neck.4. Check engine oil level (→ Page 182).5. After oil change, bar engine with starting sys-

tem (→ Page 139).

184 | Lube Oil System, Lube Oil Circuit | MS150048/05E 2018-03

TIM

-ID: 0

0000

1410

0 - 0

06

7.13.3 Engine oil – Sample extraction and analysis



MTU test kit 5605892099/00 1




Take engine oil sample and ana-lyze

1. With the engine running at operating temper-ature, loosen screw on automatic oil filter by1 to 2 turns.

2. Drain approx. 2 liters engine oil to flush outthe oil sludge.

3. Drain approx. 1 liter engine oil into a cleancontainer.

4. Close screw.5. Using the equipment and chemicals in the

MTU test kit, analyze the engine oil for:• Dispersing capacity (spot test);• Water content;• Dilution with fuel

MS150048/05E 2018-03 | Lube Oil System, Lube Oil Circuit | 185

TIM

-ID: 0

0000

1411

4 - 0

08

7.14 Oil Filtration / Cooling

7.14.1 Automatic oil filter – Overview

Automatic oil filter

1 Filter housing2 Oil filter element3 O-ring4 Cover5 Nut6 Gasket7 Screw-fitting union8 Gasket

9 Neck10 Screw11 Scavenge oil line12 Neck13 Gearbox flange14 O-ring15 Screw16 Cover

17 O-ring18 Compression spring19 O-ring20 Strainer21 O-ring22 Indicator housing23 Screw24 Opening for screw-fitting

union (scavenge oil line)

186 | Oil Filtration / Cooling | MS150048/05E 2018-03

TIM

-ID: 0

0000

7116

7 - 0

01

1 Sealing ring2 Plug screw3 Sealing ring4 Plug screw5 Sealing ring6 Plug screw7 O-ring

8 Plug screw9 O-ring

10 Plug screw11 Bypass valve12 Sealing ring13 O-ring14 Cover

15 Screw16 Sealing ring17 Screw18 O-ring19 Cover20 Screw

MS150048/05E 2018-03 | Oil Filtration / Cooling | 187

TIM

-ID: 0

0000

7116

7 - 0

01

1 Screw2 Securing bushing3 Compression spring4 Scavenge bushing5 Sight glass6 Flat gasket

7 O-ring8 O-ring9 Clamping ring

10 Spring washer11 Screw12 Worm gear

13 Grooved pin14 Impeller15 Washer16 Stud17 Nut


TIM

-ID: 0

0000

7116

7 - 0

01

7.14.2 Automatic oil filter – Preparatory steps


Automatic oil filter preparatory steps1. Observe safety instructions.2. Remove centrifugal oil filter (→ Page 217).


TIM

-ID: 0

0000

1423

3 - 0

05

7.14.3 Automatic oil filter – Removal

Preconditions☑Preparatory steps have been completed.

DANGERSuspended 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).

WARNINGHeavy part, risk of falling or overturning due to lack of stability.Risk of crushing body or limbs!• Use appropriate lifting gear and appliances.• Wear safety shoes.



NOTICEIngress of contamination from automatic oil filter in the engine oil system.Severe engine damage possible!• Remove the automatic oil filter before changing the oil filter candles.• Keep everything scrupulously clean when performing maintenance and repair work.• Cover all exposed openings when opening assemblies.



TIM

-ID: 0

0000

7116

8 - 0

04

Draining oilu Remove plug screw (2) with sealing ring (1)

and drain off oil into a suitable container.

Removing automatic oil filterNote: Clean interface between automatic oil filter

and coolant distribution housing.1. Attach automatic oil filter (1) to crane with a

lightly tensioned lifting strap.2. Remove screws (2).3. Remove automatic oil filter (1) from coolant

distribution housing (3).4. Collect any oil that runs out.5. Remove O-rings (4).6. Seal openings on coolant distribution housing

(3) with suitable covers.


TIM

-ID: 0

0000

7116

8 - 0

04

7.14.4 Automatic oil filter – Disassembly

Preconditions☑Automatic oil filter has been removed from engine.

Automatic oil filter – Disassembly1. Observe safety instructions.2. Disassemble automatic oil filter as per overview drawing (→ Page 186).


TIM

-ID: 0

0000

1423

2 - 0

04

7.14.5 Automatic oil filter – Cleaning


Cleaner (Snow-White 11-0) X00054118 1Cleaner (Hakupur 50/136) X00056700 1


WARNINGChemical substances in cleaners.Risk of irritation and chemical burns!• Always obey manufacturer's instructions for use.

WARNINGCleaner is extremely caustic.Risk of injury and suffocation!• Avoid contact with eyes and skin.• Do not inhale vapors and smoke.• Do not eat, drink, smoke when working with cleaner.• Wear protective clothing, gloves, and goggles / safety mask.• Take measures against electrostatic charging.


Automatic oil filter – Cleaning1. Carefully clean all components and connections.

• Clean all metallic parts with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 50/136).• Flush all oil ducts thoroughly with cleaner.• Blow out all components thoroughly with compressed air.

2. Wipe all sealing and mating faces dry with a clean, lint-free cloth.3. Inspect visually to ensure that all sealing and mating faces are clean. If not, repeat cleaning procedure.4. Remove corrosion inhibitor from new components with cleaner (Hakupur 50/136).


TIM

-ID: 0

0000

1422

8 - 0

07

7.14.6 Automatic oil filter – Check


Oilstone, flat F30454308/03 1

Automatic oil filter – CheckItem Findings ActionVisually inspect all components forwear, impact marks, and damage.

• Signs of wear• Impact marks• Damage visible

• Smooth with crocus cloth or oil-stone.

• ReplaceCheck gearwheel on worm gearfor indentations, signs of wear anddamage.

• Indentations• Wear traces• Damage visible

• Smooth minor wear traces anddamage with crocus cloth or oil-stone.

• ReplaceCheck flushing arms on oil filter el-ement for ease of movement(→ Page 212). Blow compressedair into the oil supply aperture tomake the impeller rotate.

• Flushing arms do not rotate. • Check worm gear and replaceas necessary (→ Page 186).

Check oil filter element (→ Page 207).


TIM

-ID: 0

0000

1423

0 - 0

08

7.14.7 Automatic oil filter – Assembly


Engine oilAssembly compound (Kluthe Hakuform 30-15) X00067260 1Seal kit (→ Spare Parts Catalog)




Assembling automatic oil filter1. The assembly procedure is identical with that described for disassembly, but in reverse sequence of work

steps.2. Additionally, the following instructions are to be observed:

a) Replace all sealing elements.b) Coat O-rings with assembly compound.c) Insert O-rings in grooves.


TIM

-ID: 0

0000

6953

7 - 0

01

7.14.8 Automatic oil filter – Installation



Assembly compound (Kluthe Hakuform 30-15) X00067260 1Engine oilO-ring (→ Spare Parts Catalog)

DANGERSuspended 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).







TIM

-ID: 0

0000

7116

9 - 0

02

Automatic oil filter – Installation1. Remove all covers.

Note: Replace all O-rings.2. Coat O-rings (4) with assembly compound.3. Insert O-rings in ring groove.4. Attach automatic oil filter (1) with lifting strap

to crane.5. Install automatic oil filter on coolant distribu-

tion housing (3).6. Coat screws (2) with engine oil.7. Insert and tighten screws.


TIM

-ID: 0

0000

7116

9 - 0

02

7.14.9 Automatic oil filter – Final steps

Final steps1. Install centrifugal oil filter (→ Page 217).2. Check engine oil level and fill up as necessary (→ Page 182).3. Enable engine start.


TIM

-ID: 0

0000

1423

7 - 0

06

7.14.10 Automatic oil filter – Checking flushing arm rotation

Preconditions☑Engine is running.

WARNINGRotating parts.Risk of injury!• Keep sufficiently clear off rotating parts.

Automatic oil filter – Checkingflushing arm rotation

1. Check at sight glass that plastic spinner (1)turns.

2. If the plastic spinner turns irregularly or if itdoes not turn at all, check the whole auto-matic oil filter (→ Page 186).


TIM

-ID: 0

0000

7122

2 - 0

01

7.14.11 Oil filter element – Overview

Oil filter candle element

1 Filter indicator2 Screw3 Sealing nut4 Spring washer

5 Washer6 O-ring7 Upper flushing arm8 Screw

9 O-ring10 Filter candles


TIM

-ID: 0

0000

7029

1 - 0

01

1 O-ring2 Top strainer plate3 Screw4 Grooved ball bearing

5 Grooved ball bearing6 Coiled spring pin7 Connecting pipe8 Overflow valve

9 Bottom strainer plate10 Protective screen


TIM

-ID: 0

0000

7029

1 - 0

01

1 O-ring2 Flushing arm shaft3 Lower flushing arm

4 Spacer ring5 Gear6 Screw

7 Screw


TIM

-ID: 0

0000

7029

1 - 0

01

7.14.12 Oil filter element – Removal

Preconditions☑Automatic oil filter is removed from engine.



Removing oil filter element1. Remove nuts (2) from oil filter cover (1).2. Remove oil filter cover.

3. Loop cable ties (2) around the flushing armand close loosely.

4. Take filter element (1) out of automatic oil fil-ter housing by pulling the cable ties.

5. Remove O-ring.


TIM

-ID: 0

0000

6954

1 - 0

04

7.14.13 Oil filter element – Disassembly

Disassembling oil filter element1. Remove screw (2).2. Pull out filter indicator (1) with spring.3. Lock flushing arm (6) in position and remove

sealing nut (3).4. Remove spring washer (4) and washer (5).5. Remove screw (8).6. Remove flushing arm from strainer plate (7).

7. Remove filter element (1) from flushing armshaft (2).

8. Turn filter element through 180° and pressfilter candles (1) out towards top strainerplate using removal tool (2).

9. Remove filter candles.


TIM

-ID: 0

0000

7029

4 - 0

01

10. Remove screws (1).11. Remove top strainer plate (2) with coiled

spring pin (6).12. Take off O-ring (3).13. Remove protective strainer (4) from connect-

ing pipe (5) with bottom strainer plate attach-ed.

14. Remove O-ring from bottom strainer plate.

Removing overflow valveu Unscrew overflow valves (1) and remove from

connecting pipe (2).


TIM

-ID: 0

0000

7029

4 - 0

01

7.14.14 Oil filter element – Cleaning




WARNINGChemical substances in cleaners.Risk of irritation and chemical burns!• Always obey manufacturer's instructions for use.



Oil filter element – CleaningNote: • The outer side and the inner side of the protective strainer are installed in the filtered-oil side.

• Do not place the oil filter element on the jacket surface.1. Carefully clean all components and connections.

• Clean all metallic parts with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 50/136).• Flush all oil ducts thoroughly with cleaner.• Blow out all components thoroughly with compressed air.

2. Wipe all sealing and mating faces dry with a clean, lint-free cloth.3. Inspect visually to ensure that all sealing and mating faces are clean. If not, repeat cleaning procedure.4. Remove corrosion inhibitor from new components with cleaner (Hakupur 50/136).


TIM

-ID: 0

0000

6954

4 - 0

03

7.14.15 Oil filter element – Check


Feeler gauge Y20098771 1Oil filter candles (→ Spare Parts Catalog)Sealing ring (→ Spare Parts Catalog)O-ring (→ Spare Parts Catalog)Grooved ball bearing (→ Spare Parts Catalog)Grooved ball bearing (→ Spare Parts Catalog)Gear (→ Spare Parts Catalog)

Oil filter element – CheckItem Findings ActionCheck grooved ball bearing onflushing arm shaft.

• Damage• Tight

Replace

Check flushing arm gap (betweenflushing arm and strainer plate).Gap: 0.05 to 0.3 mm

Gap incorrect Oil filter insert - Replacement

Check gear • Indentations• Wear traces• Damage visible

• Smooth minor wear traces anddamage with crocus cloth or oil-stone.

• Replace


TIM

-ID: 0

0000

6953

9 - 0

04

7.14.16 Oil filter element – Assembly


Torque wrench, 8–40 Nm F30043446 1Ratchet adapter F30027340 1Feeler gauge Y20098771 1Assembly compound (Kluthe Hakuform 30-15) X00067260 1Engine oilScrew locking compound (Loctite 243) 40573 1Gasket kit (→ Spare Parts Catalog) 1O-ring (→ Spare Parts Catalog) 2O-ring (→ Spare Parts Catalog) 96Oil filter candles (→ Spare Parts Catalog) 48Overflow valve (→ Spare Parts Catalog) 6



Installing overflow valve

Note: The overflow valves must be replaced in any case.u Screw overflow valves (1) in connecting pipe (2) and tighten to the specified tightening torque.


Overflow valve Tightening torque (Engine oil) 20 Nm


TIM

-ID: 0

0000

7029

6 - 0

03

Assembling oil filter element1. Coat O-ring with assembly compound and in-

sert in groove in bottom strainer plate.2. Install protective strainer (4) on connecting

pipe (5) with bottom strainer plate attached.3. Insert coiled spring pin (7) in top strainer

plate (2).4. Coat O-ring (3) with assembly compound and

insert in groove in top strainer plate.5. Align coiled spring pin (7) with groove (6) in

connecting pipe (5) and install top strainerplate.

6. Coat threads of screws (1) with screw lockingcompound.

7. Insert screws (1) and tighten.

8. Coat O-rings (1) with assembly compoundand insert in ring grooves on both ends of fil-ter candles.

9. Insert new filter candles (2) through topstrainer plate with chamfer facing down.

10. Insert flushing arm shaft (2) in filter ele-ment (1) through bottom strainer plate.


TIM

-ID: 0

0000

7029

6 - 0

03

11. Coat O-ring (2) with assembly compound andinsert in groove on upper flushing arm (7).

12. Fit top flushing arm on flushing arm shaft andtop strainer plate (6).

13. Install washer (3) and spring washer (4).

Note: Note position of screw in relation to elongat-ed hole on shaft.

14. Screw in screw (1) loosely.15. Screw on sealing nut (5).

16. Lock flushing arm (4) in position and tighten sealing nut (5) with torque wrench to the specified torque.


Sealing nut Tightening torque (Engine oil) 40 Nm

Note: Tolerances for gap on both sides: 0.05 to 0.3 mm.17. Check gap (1) between flushing arm (4) and strainer plate (2) with feeler gage . If the tolerances are not met,

replace oil filter element.18. Tighten screw (3).


TIM

-ID: 0

0000

7029

6 - 0

03

19. Insert screw (3) and tighten to specified torque using a torque wrench.


Screw Tightening torque (Engine oil) 9 Nm

20. Fit filter indicator (2) with spring on sealing nut (1).


TIM

-ID: 0

0000

7029

6 - 0

03

7.14.17 Oil filter element – Installation

Preconditions☑Automatic oil filter is removed from engine.


Torque wrench, 20–200 Nm F30026582 1Ratchet adapter F30027340 1Assembly compound (Kluthe Hakuform 30-15) X00067260 1Engine oilO-ring (→ Spare Parts Catalog)


NOTICEBlowing through lines (gas lines, supply lines, etc.) with compressed air will result in airborne particles.Risk of penetration of contaminants leading to component damage!• Disconnect the engine from the cooling water network by fitting blanking plates at the connecting

flanges.• Seal off connecting flanges, so that no dirt particles are blown into the engine.




TIM

-ID: 0

0000

7117

0 - 0

05

Oil filter element – Installation1. Coat new O-ring with assembly compound

and insert in groove of bottom strainer plate.2. Insert oil filter element (1) into housing.

3. Insert new gasket in oil filter cover (1).4. Install oil filter cover.

5. Screw on nuts (2) and use torque wrench to tighten to specified tightening torque.


Nut Tightening torque (Engine oil) 65 Nm


TIM

-ID: 0

0000

7117

0 - 0

05

Flushing arms on oil filter ele-ment – Check for ease of move-ment

Note: Opening (2) is located on the filtered-oil side.Ensure particular cleanness.

1. Cover opening (2).

Note: Constrict opening with a suitable cover.2. Blow compressed air into opening (1).3. Check that flushing arm turns at sight glass

(3).4. If flushing arm does not turn, remove oil filter

element, disassemble, check again(→ Page 207) and replace as necessary.


TIM

-ID: 0

0000

7117

0 - 0

05

7.14.18 Oil indicator filter – Cleaning and check



Cleaner (Snow-White 11-0) X00054118 1Cleaner (Hakupur 50/136) X00056700 1Engine oilStrainer (→ Spare Parts Catalog)Square-section ring (→ Spare Parts Catalog)Spring (→ Spare Parts Catalog)O-ring (→ Spare Parts Catalog)




NOTICEInappropriate cleaning tool.Risk of damage to component!• Observe manufacturer's instructions.• Use appropriate cleaning tool.


TIM

-ID: 0

0000

0640

2 - 0

09

Removing strainer1. Clean oil indicator filter before disassembling

it.2. Remove screws (1).3. Take off cover (2) with O-ring (3).4. Extract spring (4) and strainer (6) from filter

housing.

Checking strainerItem Findings MeasureStrainer Metallic residues • Clean

• Monitor engine operation• Check strainer daily• Contact Service

Strainer Damaged ReplaceSquare-section ring Damaged ReplaceO-ring Damaged Replace

Cleaning strainer1. Wash strainer (6) with cleaner.2. Remove stubborn deposits with soft brush.3. Blow out strainer (6) with compressed air from inside.

Installing strainer1. 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. Insert spring (4).4. Fit cover (2) and secure with screws (1) and washers.


TIM

-ID: 0

0000

0640

2 - 0

09

7.14.19 Centrifugal oil filter – Overview

Centrifugal oil filter

1 Centrifugal oil filter2 O-ring3 Flange4 Washer5 Screw6 O-ring

7 Socket pipe8 O-ring9 Threaded adapter

10 Sealing ring11 O-ring12 Stud

13 Flange14 Socket pipe15 Washer16 Nut


TIM

-ID: 0

0000

4437

7 - 0

03

7.14.20 Centrifugal oil filter – Preparatory steps

Preconditions☑Engine shut down and starting disabled.

Preparatory steps1. Observe safety regulations.2. Drain engine oil from centrifugal oil filter.


TIM

-ID: 0

0000

1426

9 - 0

03

7.14.21 Centrifugal oil filter – Removal

Preconditions☑Preparatory steps have been carried out.

Removing centrifugal oil filter1. Remove centrifugal oil filter as shown in overview drawing (→ Page 217).2. Seal all openings with suitable covers.


TIM

-ID: 0

0000

0643

3 - 0

03

7.14.22 Centrifugal oil filter - Cleaning






Cleaning rotor unit1. Clean all metallic parts with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 50/136).2. Blow out all parts with compressed air.


TIM

-ID: 0

0000

0641

7 - 0

09

7.14.23 Centrifugal oil filter – Cleaning and filter-sleeve replacement



Torque wrench, 4–20 Nm F30044239 1Torque wrench, 10–60 Nm F30452769 1Ratchet bit F30027340 1Cold cleaner (Hakutex 60) X00056750 1Filter sleeve (→ Spare Parts Catalog)Sealing ring (→ Spare Parts Catalog)




TIM

-ID: 0

0000

0093

4 - 0

21

Centrifugal oil filter – Cleaningand filter-sleeve replacement

1. Remove clamp (14).2. Loosen cover screw (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 thickness of oil residues on filter

sleeve (6).Result: Shorten maintenance interval if the oil resi-

dues exceed the maximum thickness of45 mm.

8. Disassemble rotor pipe (7), conical disk (8)and rotor base (10).

9. Wash rotor cover (4), rotor pipe (7), conicaldisk (8) and rotor base (10) with cold cleaner.

10. Blow out with compressed air.11. Check sealing ring (9), replace if necessary.12. Assemble rotor pipe (7), conical disk (8) and

rotor base (10) with sealing ring (9).13. Insert new filter sleeve (6) in rotor pipe (7)

with the smooth paper surface facing the out-er wall.

14. Check sealing ring (5), replace if necessary.15. Install rotor cover (4) with sealing ring (5).

16. Use torque wrench to tighten rotor cover nut (3) to specified tightening torque.


Nut Tightening torque 80 Nm ±12 Nm

17. Insert rotor (11) in housing (12) and check for ease of movement.18. Check sealing ring (13), replace if necessary.19. Place sealing ring (13) on housing (12).20. Fit hood (1).21. Tighten cover screw (2) by hand.

22. Install clamp (14) and use torque wrench to tighten to specified tightening torque.


Clamp Tightening torque 20 Nm ± 3 Nm

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


Screw Tightening torque 7 Nm ± 1 Nm


TIM

-ID: 0

0000

0093

4 - 0

21

7.14.24 Centrifugal oil filter – Installation


Assembly compound (Kluthe Hakuform 30-15) X00067260 1O-ring (→ Spare Parts Catalog)



Installing centrifugal oil filter1. Remove all covers.2. Coat O-ring with (Assembly compound (Kluthe Hakuform 30-15)) and install.3. Install centrifugal oil filter as shown in overview drawing (→ Page 217).


TIM

-ID: 0

0000

0644

6 - 0

07

7.15 Coolant Circuit, General, High-Temperature Circuit

7.15.1 Vent points

Coolant line to ETC

1 Vent point

224 | Coolant Circuit, General, High-Temperature Circuit | MS150048/05E 2018-03

TIM

-ID: 0

0000

1454

7 - 0

02

7.15.2 Engine coolant – Level check



WARNINGCoolant is hot and under pressure.Risk of injury and scalding!• Let the engine cool down.• Wear protective clothing, gloves, and goggles / safety mask.

Checking coolant level at filler neck:1. Turn cap on coolant expansion tank counterclockwise to the first stop and allow pressure to escape.2. Continue to turn cap counterclockwise and remove.3. Check engine coolant level (engine coolant must be visible at bottom edge of cast-in eye of filler neck).

Checking coolant level at exter-nal cooler:

Note: Engine coolant must be visible at markerplate.

1. Check engine coolant level.2. Top up engine coolant as necessary

(→ Page 229).3. Check and clean cap.4. Place cap on filler neck and close.

Checking coolant level with level sensor:Note: Engine coolant level is automatically monitored by the engine control system.

1. Switch on engine control system and check readings on the display.2. Top up engine coolant as necessary (→ Page 229).

MS150048/05E 2018-03 | Coolant Circuit, General, High-Temperature Circuit | 225

TIM

-ID: 0

0000

0093

7 - 0

15

Checking engine coolant level atsight glass

1. Check coolant level (coolant level must bebetween “min.” and “max.” mark).

2. Top up coolant if necessary (→ Page 229).


TIM

-ID: 0

0000

0093

7 - 0

15

7.15.3 Engine coolant – Change


Coolant

Engine coolant change1. Drain engine coolant (→ Page 228).2. Fill with engine coolant (→ ).


TIM

-ID: 0

0000

0003

6 - 0

31

7.15.4 Engine coolant draining



Preparatory steps1. Provide an appropriate container to drain the coolant into.2. Switch off preheating unit.

Engine coolant draining1. Turn breather valve of filler neck on expan-

sion tank counterclockwise to first stop andallow pressure to escape.

2. Continue to turn breather valve counterclock-wise and remove.

3. Draw off precipitated corrosion inhibitor oilfrom the expansion tank through filler neck.

4. Open drain valves and drain plugs and draincoolant at the following points:• Preheating unit• Elbow of HT coolant pump (2)• Crankcase, left and right side (3)• T piece (5) on engine driving end;• Intercooler• Carrier housing (1)

Final steps1. Seal all open drain points2. Place breather valve onto filler neck and close it.


TIM

-ID: 0

0000

1459

5 - 0

02

7.15.5 Engine coolant – Filling




Engine coolant


NOTICECold coolant in hot engine can cause thermal stress.Possible formation of cracks in the engine!• Fill / top up coolant only into cold engine.

Preparatory steps1. Turn breather valve (1) of coolant expansion

tank counterclockwise to first stop and allowpressure to escape.

2. Continue to turn breather valve (1) counter-clockwise and remove.

3. Release the coolant line union on both turbo-chargers (→ Page 224).

4. Release the coolant line union at the coolantdistributor (→ Page 224).

5. Close breather valve (1) on expansion tank.


TIM

-ID: 0

0000

0672

7 - 0

08

Filling with coolant using apump

1. Connect appropriate pump with hose to fillingconnection (arrowed) on A side or B side. Al-ternatively:


TIM

-ID: 0

0000

0672

7 - 0

08

2. Connect a suitable pump with a hose to drainvalve (arrowed).

3. Pump coolant into engine at 0.5 bar minimumuntil coolant emerges from the loosened un-ions at the coolant distributor.

4. Tighten the union for coolant line at the cool-ant distributor (→ Page 224).

5. Continue filling process until coolant emergesfrom the loosened unions at the turbocharg-ers.

6. Tighten the coolant line union at the turbo-chargers (→ Page 224).

7. Open breather valve of expansion tank andtop up with coolant until level reaches theoverflow edge.

8. Check condition of breather valve and cleansealing faces if required.

9. Start engine with open expansion tank(→ Page 76) and operate it at idle.

10. Open vent points successively, starting at thelowest point and proceeding upwards. Waituntil air no longer emerges from the ventpoints and close them.

11. When coolant temperature is 40 °C (T-Cool-ant), increase engine speed to 1,000 rpm forapprox. 2 minutes, then reduce engine speedto idle speed.

12. With the engine running idle, top up the ex-pansion tank with coolant until the level is atthe overflow edge.

13. Stop engine (→ Page 88) and remove handpump.

14. Start engine with open expansion tank andrun it up to nominal speed (full load).

15. Operate engine at idle for approx. 5 minutesuntil coolant temperature is steady. Checkcoolant level in expansion tank. If the level ishigher than 50%, close breather valve of ex-pansion tank. If the coolant level in expansiontank is less than 50%, stop engine(→ Page 88) and fill coolant into expansiontank until coolant level is at the overflowedge.

16. Close breather valve on expansion tank andbriefly run up engine to full load.

17. Stop engine (→ Page 88).18. Allow the engine to cool down, then top up

with coolant until coolant level is at the over-flow edge. Close breather valve on expansiontank.


TIM

-ID: 0

0000

0672

7 - 0

08

Filling with coolant through filler neck1. Fill coolant through filler neck on expansion tank until coolant emerges from the loosened unions at the cool-

ant distributor.2. Tighten the union for coolant line at the coolant distributor (→ Page 224).3. Continue to fill until coolant level remains constant at top edge of filler neck.4. Tighten the coolant line union on both turbochargers (→ Page 224).5. Check satisfactory condition of breather valve and clean sealing faces if required.6. Start engine with open expansion tank (→ Page 76) and operate it at idle.7. Open vent points successively, starting at the lowest point and proceeding upwards. Wait until air no longer

emerges from the vent points and close them.8. Top up coolant in expansion tank until coolant level is at the overflow edge.9. When coolant temperature is 40 °C (T-Coolant), increase engine speed to 1,000 rpm for approx. 2 minutes.

With the engine running idle, top up the expansion tank with coolant until coolant level is at the overflowedge.

10. Start engine with open expansion tank and run it up to nominal speed (full load).11. Operate engine at idle for approx. 5 minutes until coolant temperature is steady. Check coolant level in ex-

pansion tank. If coolant level is above 50%, close filler neck cover. If the coolant level in expansion tank isless than 50%, stop engine (→ Page 88) and fill coolant into expansion tank until coolant level is at the over-flow edge.

12. Close breather valve on expansion tank and briefly run up engine to full load.13. Stop engine (→ Page 88).14. Allow the engine to cool down, then top up with coolant until coolant level is at the overflow edge. Close

breather valve on expansion tank.


TIM

-ID: 0

0000

0672

7 - 0

08

7.15.6 Engine coolant pump – Relief bore check



Engine coolant pump, relief borecheck

1. Check relief bore for oil and coolant dis-charge.

2. Stop engine (→ Page 76) and disable enginestart, observe general safety instructions onmaintenance and repair.

3. Clean the relief bore with a wire if it is dirty.• Permissible coolant discharge: up to 10

drops per hour;• Permissible oil discharge: up to 5 drops

per hour4. If discharge exceeds the specified limits:

Contact Service.


TIM

-ID: 0

0000

1462

3 - 0

05

7.15.7 Engine coolant – Sample extraction and analysis



MTU test kit F6798833 1




Engine coolant – Sample extrac-tion and analysis

1. Open drain valve on engine coolant pump el-bow with the engine running.

2. Drain off approx. 1 liter engine coolant.Result: Sampling point is clean.

3. Drain approx. 1 liter engine oil into a cleancontainer.

4. Tighten shut-off cock (arrow) with torque wrench to the specified tightening torque.


Spindle 11a/f Tightening torque 12 Nm

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).


TIM

-ID: 0

0000

1460

8 - 0

10

7.16 Raw Water Pump with Connections

7.16.1 Raw water pump – Relief bore check



Raw water pump, relief borecheck

1. Check relief bore for oil and raw water dis-charge.

2. Stop engine (→ Page 76) and disable enginestart, observe general safety instructions“Maintenance and Repair”.

3. Clean the relief bore with a wire if it is dirty.• Permissible raw water discharge: up to 10

drops per hour;• Permissible oil discharge: up to 5 drops

per hour4. If discharge exceeds the specified limits:

Contact Service.

MS150048/05E 2018-03 | Raw Water Pump with Connections | 235

TIM

-ID: 0

0000

1517

4 - 0

07

7.17 Battery-Charging Generator

7.17.1 Battery-charging generator drive – Coupling condition check



Endoscope Y20097353 1

Battery-charging generator drive, coupling condition check1. Install barring tool (→ Page 138).

2. Guide endoscope optics between guardplate (1) and battery-charging generator car-rier (2) (arrow).

Note: Seek the assistance of a second person3. Bar engine slowly by hand.4. Examine the resilient coupling over the entire

circumference for plastic deformation andcracks.

5. If there is serious deformation or crack for-mation, contact Service.

6. Remove barring gear (→ Page 138).

236 | Battery-Charging Generator | MS150048/05E 2018-03

TIM

-ID: 0

0000

0739

0 - 0

10

7.18 Engine Mounting / Support

7.18.1 Engine mounting – Checking resilient element

NOTICEContamination 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 – CheckItem Findings ActionVisually inspect resilient elements. • Damage

• Brittleness• Deformation• Crack formation• Swelling

Replace (contact Service).

MS150048/05E 2018-03 | Engine Mounting / Support | 237

TIM

-ID: 0

0000

1537

0 - 0

07

7.19 Fuel Supply System

7.19.1 Water drain valve – Check

Water drain valve – Check1. Open water drain valve.2. Check water outlet for obstructions.3. Close water drain valve.

238 | Fuel Supply System | MS150048/05E 2018-03

TIM

-ID: 0

0000

0773

3 - 0

07

7.19.2 Differential pressure gage – Alarm function check


Checking differential pressure gage alarm function1. Switch on fuel treatment system (→ Page 83).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.

MS150048/05E 2018-03 | Fuel Supply System | 239

TIM

-ID: 0

0000

0773

7 - 0

07

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

Preconditions☑System is put out of service and emptied.


Checking water level probe (3-in-1 rod electrode)1. Disconnect plug from water level probe.2. Unscrew water level probe.3. Disconnect plug from water level probe.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. Disconnect plug from water level probe.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.


TIM

-ID: 0

0000

0773

9 - 0

09

7.19.4 Pump capacity – Check


Checking pump capacity1. Install suitable pressure gauge in the intake connection of the pump.2. Check pump pressure.

a) Switch on fuel treatment system (→ Page 83).

Note: The pressure limiting valve at the pump might respond and open. Audible noise is caused by overflowing fueland 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 suctiona) 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). 3 bar

Measured value (reduced suction condition). 2.6 bar

If the determined pressure (restricted) is undershot by the determined pressure (normal) by 10%, the wearlimit has been reached. Repair pump (contact Service).


TIM

-ID: 0

0000

2861

2 - 0

02

7.19.5 Coalescer filter element ‒ Replacement

Preconditions☑System is stopped and starting disabled.


Torque wrench, 8–40 Nm F30043446 1Ratchet adapter F30027340 1FuelEngine oilCoalescer filter element (→ Spare Parts Catalog)Gasket (→ Spare Parts Catalog)




Replacing coalescer filter ele-ment

1. Close ball valve at the inlet and outlet of thefuel 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).


TIM

-ID: 0

0000

0773

5 - 0

13

16. Tighten nut (3) to specified torque using a torque wrench.


Nut M16 Tightening torque (Engine oil) 30 Nm +3 Nm

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.


TIM

-ID: 0

0000

0773

5 - 0

13

7.20 Wiring (General) for Engine/Gearbox/Unit

7.20.1 Engine cabling – Check



Solvent (isopropyl alcohol) X00058037 1

Engine cabling – Check1. 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.

244 | Wiring (General) for Engine/Gearbox/Unit | MS150048/05E 2018-03

TIM

-ID: 0

0000

0002

9 - 0

25

7.21 Accessories for (Electronic) Engine Governor / Control System

7.21.1 CDC parameters – Reset with DiaSys®


Resetting CDC parameters (DiaSys® is available)Note: The CDC parameters must be reset, otherwise the emission certification of the engine is no longer applica-

ble.u Reset the CDC parameters with DiaSys® (→ Manufacturer's documentation).

Resetting CDC parameters (DiaSys® is not available)Note: The CDC parameters must be reset, otherwise the emission certification of the engine is no longer applica-

ble.u Contact Service.

MS150048/05E 2018-03 | Accessories for (Electronic) Engine Governor / Control System | 245

TIM

-ID: 0

0000

2973

1 - 0

02

7.21.2 EMU and connectors – Cleaning




NOTICEInsertion of unsuitable test probe, e.g. test prod.The contacts in the plug connection can be bent!• Carry out check of plug connection only with test connectors.

Cleaning EMU and connectors1. Remove coarse dirt from housing surface using a cloth moistened with isopropyl alcohol.2. Remove dirt from the connector and cable surfaces with isopropyl alcohol.3. Check legibility of cable labels. Clean or replace illegible labels.

Cleaning severely contaminated connectors on EMU1. Release the latch and pull off connector.2. Clean connector housings, connector socket housings and all contacts with isopropyl alcohol.3. When connectors, sockets and all contacts are dry: Fit and latch connectors.

246 | Accessories for (Electronic) Engine Governor / Control System | MS150048/05E 2018-03

TIM

-ID: 0

0000

0839

2 - 0

04

7.21.3 Limit switch for start interlock – Check


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 guardplate (2) with engine support (1) are installedon both sides of flywheel housing (4).

2. Check whether both switches (3) are actuat-ed.

3. If switches (3) and/or guard plate (2) with en-gine support (1) is/are not installed:• Screw on guard plate (2) with engine sup-

port (1).• Then screw on switch (3), ensuring that

the switch (3) is actuated by the guardplate (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.


TIM

-ID: 0

0000

1678

2 - 0

07

7.21.4 Engine governor and connector – Cleaning





Engine governor and connector – Cleaning1. Use isopropyl alcohol to remove coarse dirt from housing surface.2. Use isopropyl alcohol to remove dirt from the connector and cable surfaces.3. Check legibility of cable labels. Clean or replace illegible labels.

Heavily contaminated connectors on engine governor – CleaningNote: Close connectors that are not plugged in with the protective cap supplied.

1. Release latches of connectors and withdraw connectors.2. Clean connector housings, connector socket housings and all contacts with isopropyl alcohol.3. When connectors, sockets and all contacts are dry: Fit connectors and latch them.


TIM

-ID: 0

0000

0004

7 - 0

14

7.21.5 Engine Monitoring Unit EMU 8 – Plug connections check


Checking EMU plug connections1. Check both connectors on EMU (2) for firm

seating. Ensure that the clips (1) are engag-ed.

2. Check screws (3) of cable clamps on EMU (2)for firm seating. Ensure that cable clamps arenot faulty.


TIM

-ID: 0

0000

4401

6 - 0

02

7.21.6 Interface module EIM plug connections – Check


Checking EIM plug connections1. Check both Tyco plugs (62-pole) (2) on EIM

for firm seating. Ensure that clips (3) are en-gaged.

2. Check screws (1) of cable clamps on EIM forfirm seating. Ensure that cable clamps arenot faulty.


TIM

-ID: 0

0000

1703

4 - 0

04

7.21.7 Engine governor plug connections – Check

Preconditions☑Engine stopped and starting disabled.

☑Electronic engine management system is de-energized.


Checking plug connections at engine governor1. Check all plug connections for secure seating.2. Lock loose connectors.3. Check dust cap on ECU and EXU connectors for damage and correct seating.


TIM

-ID: 0

0000

0004

8 - 0

09

7.21.8 Engine governor ECU 7 – Removal and installation


☑Engine electronics is powered off.

NOTICEWrong 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 fromengine

1. Note or mark assignment of cables andplugs.

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 engine1. 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.


TIM

-ID: 0

0000

0004

9 - 0

09

7.21.9 Engine Monitoring Unit EMU 8 – Removal and installation


NOTICEWrong 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 Control Unitwith Engine Monitoring Unitfrom engine

1. Note or mark assignment of cables and con-nectors.

2. Remove all screws (2).3. Undo clips (3) on connectors.4. Disconnect all connectors.5. Remove screws (1).6. Remove Engine Control Unit (5) with Engine

Monitoring Unit (4).

Removing Engine Monitoring Unit1. Unscrew screws on base of EMU (4).2. Remove EMU 8 (4) from ECU (5).

Installing Engine Monitoring Unit1. Place EMU 8 (4) on ECU (5).2. Screw in and tighten screws on base of EMU (4).

Installing Engine Control Unit with Engine Monitoring Unit on engine1. Install in reverse order. Ensure correct assignment of connectors and sockets.2. Check resilient mount before installing.

Result: If resilient mount is porous or defective then replace it.


TIM

-ID: 0

0000

4401

7 - 0

03

7.21.10 Engine Interface Module EIM 2 – Removal and installation


Removing Engine Interface Mod-ule from engine

1. Note or mark assignment of cables and con-nectors.

2. Unscrew all screws (1).3. Undo clips (2) on connectors.4. Disconnect all connectors.5. Unscrew power and starter cable.6. Remove screws (3).7. EIM 2.

Installing Engine Interface Module on engine1. 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 software1. 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 255)).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.


TIM

-ID: 0

0000

1703

5 - 0

06

7.21.11 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 DILADILA glows Engine Interface Module (EIM 2) is OK.DILA dark EIM 2 supply voltage missing or diagnostic lamp activation is faulty.DILA flashes Hardware or software fault in the Engine Interface Module

The diagnostic lamp (DILA) signals the following states:

1 Time in seconds2 Timing: 1/8 s3 Ready for operation

4 Application loader active5 External RAM defective6 External FLASH defective

7 No firmware8 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 difficultto pinpoint a fault in the field without cabling diagrams.

This LED is activated by the controller.

Functions of fuse lamp SILASILA dark Normal operating stateSILA flashes orange One or more fuses have tripped.

The fuse lamp (SILA) signals the following states:


TIM

-ID: 0

0000

3800

9 - 0

05

1 Preamble2 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 andPR 10.0600.001 has value1 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 pathfailed – 24 V external (S10)

12 Key switch current pathfailed (S11)

13 SDAF 1 and 2 current pathfailed (S12)

14 PIM current path failed(S13)

15 Spare current path failed(S14) (for EIM 2 with ECU 9only)

The failed current paths are signaled consecutively following the preamble (1) (LED on for 4 seconds). Thereis a pause lasting 4 seconds in between.


TIM

-ID: 0

0000

3800

9 - 0

05

Sample flashing sequences

A Fuse S5 failure (1/2 secondsteps)

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 ofthe EIM 2.


TIM

-ID: 0

0000

3800

9 - 0

05

7.22 Emergency Instrumentation (Local Operating Panel)

7.22.1 LOP and connectors – Cleaning




Cleaning LOP1. Wipe LCD screen with dry cloth, without applying excessive pressure.2. Remove dirt from pushbuttons using solvent.3. Remove coarse dirt on housing surface using solvent.

Cleaning connectors on LOP1. Remove dirt from connector and socket surfaces using solvent.2. Check legibility of cable labels. Clean or replace illegible labels.

258 | Emergency Instrumentation (Local Operating Panel) | MS150048/05E 2018-03

TIM

-ID: 0

0000

0886

7 - 0

07

8 Appendix A

8.1 List of abbreviationsAbbrevia-tion

Meaning Explanation

ADEC Advanced Diesel Engine Control Engine Control UnitAL Alarm Alarm (general)ANSI American National Standards Institute Association of American standardization organiza-

tionsATL Abgasturbulader Exhaust turbochargerBR Baureihe SeriesBV Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU Publication

No. A01061/..CAN Controller Area Network Data bus system, bus standardCDC Calibration Drift Compensation Setting for drift correction with DiaSys in Engine Con-

trol UnitCPP Controllable Pitch PropellerDILA Diagnostic lamp On EIMDIN Deutsches Institut für Normung e. V. German National Standards Institute, at the same

time identifier of German standards (DIN = “DeutscheIndustrie-Norm”)

DIS Display Unit Display panelDL Default Lost Alarm: Default CAN bus failureECS Engine Control System Engine management systemECU Engine Control Unit Engine governorEDM Engine Data Module Memory module for engine dataEIM Engine Interface Module Interface to engine monitoring systemEIL Engine Ident Label Electronic nameplate which identifies the engineEMU Engine Monitoring UnitEPA Environmental Protection Agency US regulatory body which implements federal laws

on environmental protection and develops standardsto ensure compliance with these laws

ETK Spare parts catalogFPP Fixed Pitch PropellerGCU Gear Control UnitGMU Gear Monitoring UnitHAT Harbor Acceptance TestHI High Range violation alarm (1st upper limit)HIHI High High Range violation alarm (2nd upper limit)HT High TemperatureICFN ISO – Continuous rating – Fuel stop

power – NetPower specification in accordance with DIN-ISO3046-7

IDM Interface Data Module Memory module for interface data

MS150048/05E 2018-03 | Appendix A | 259

TIM

-ID: 0

0000

0205

0 - 0

07

Abbrevia-tion

Meaning Explanation

IIG Initial Injector Equalization Entering of injector code with DiaSys in engine gover-nor

IMO International Maritime OrganizationISO International Organization for Stand-

ardizationInternational umbrella organization for all nationalstandardization institutes

KGS Kraftgegenseite Engine free end in accordance with DIN ISO 1204KS Kraftseite Engine driving end in accordance with DIN ISO 1204LCD Liquid Crystal Display, Liquid Crystal

DeviceLCU Local Control Unit LOP subassemblyLED Light Emitting DiodeLMU Local Monitoring Unit LOP subassemblyLO Low Range violation alarm (1st lower limit value)LOLO Low Low Range violation alarm (2nd lower limit value)LOP Local Operating Panel Control console, control panelLOS Local Operating StationMCS Monitoring and Control SystemMG MessageMPU Microprocessor Unit, Microprocessing

UnitOT Oberer Totpunkt Top Dead CenterP-xyz Pressure-xyz Pressure measuring point xyzPAN Panel Control panelPCU Propeller Control Unit Propeller controllerPIM Peripheral Interface ModuleRCS Remote Control SystemRL Redundancy Lost Alarm: Redundant CAN bus failureSAE Society of Automotive Engineers U.S. standardization organizationSAT Sea Acceptance TestSD Sensor Defect Alarm: Sensor failureSDAF Shut Down Air Flap(s) Emergency air-shutoff flap(s)SILA Fuse lamp on EIMSOLAS International Convention for the Safety

of Life at SeaSS Safety System Safety system alarmSSK Schnellschlussklappe(n) Emergency air-shutoff flap(s)T-xyz Temperature-xyz Temperature measuring point xyzTD Transmitter Deviation Alarm: Deviation in transmitter valuesUT Unterer Totpunkt Bottom Dead CenterVS Voith Schneider Voith-Schneider driveWJ Water jet Water jet driveWZK Werkzeugkatalog Tool catalogZKP Zugehörigkeit-Kategorie-Parameter Assignment category parameter; number scheme for

signals from the ADEC engine governor

260 | Appendix A | MS150048/05E 2018-03

TIM

-ID: 0

0000

0205

0 - 0

07

8.2 MTU Contact/Service PartnersThe worldwide network of the sales organization with subsidiaries, sales offices, representatives and custom-er service centers ensure fast and direct support on site and ensure the high availability of our products.

Local SupportExperienced 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 HotlineWith 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 inconditions 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 ServiceFast, simple and correct identification of spare parts for your drive system or vehicle fleet. The right sparepart 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 atheadquarters 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

MS150048/05E 2018-03 | Appendix A | 261

TIM

-ID: 0

0000

0087

3 - 0

16

9 Appendix B

9.1 Special ToolsAngular screw driver

Part No.: F30002815Qty.:Used in:

1 7.5.2 Valve clearance – Check and adjustment(→ Page 147)

Barring tool


1 7.2.1 Engine – Barring manually (→ Page 138)

Endoscope

Part No.: Y20097353Qty.:Used in:

1 7.17.1 Battery-charging generator drive – Coupling condi-tion check (→ Page 236)

262 | Appendix B | MS150048/05E 2018-03

DCL-

ID: 0

0000

1561

7 - 0

03

Feeler gauge



Qty.:Used in:

1 7.14.15 Oil filter element – Check (→ Page 207)

Qty.:Used in:

1 7.14.16 Oil filter element – Assembly (→ Page 208)

Fuel suction device


1 7.6.1 HP fuel pump – Filling with engine oil (→ Page 152)

High-pressure cleaner

Part No.:Qty.:Used in:

1 4.20 Plant – Cleaning (→ Page 93)

Installation/removal jig


1 7.7.2 Injector – Removal and installation (jacketed fuelsystem) (→ Page 156)

MS150048/05E 2018-03 | Special Tools | 263

DCL-

ID: 0

0000

1561

7 - 0

03

Milling cutter



MTU test kit

Part No.: 5605892099/00Qty.:Used in:

1 7.13.3 Engine oil – Sample extraction and analysis(→ Page 185)

MTU test kit


1 7.15.7 Engine coolant – Sample extraction and analysis(→ Page 234)

Oil filter wrench


1 7.8.1 Fuel filter – Replacement (→ Page 163)

264 | Special Tools | MS150048/05E 2018-03

DCL-

ID: 0

0000

1561

7 - 0

03

Oilstone, flat

Part No.: F30454308/03Qty.:Used in:

1 7.14.6 Automatic oil filter – Check (→ Page 194)

Ratchet adapter


1 7.4.1 Crankcase breather – Oil separator element re-placement (→ Page 144)

Qty.:Used in:

1 7.8.5 Fuel prefilter with water separator – Filter elementreplacement (→ Page 170)

Qty.:Used in:


Qty.:Used in:

1 7.14.17 Oil filter element – Installation (→ Page 212)

Qty.:Used in:

1 7.19.5 Coalescer filter element ‒ Replacement(→ Page 242)

Ratchet adapter


1 7.13.2 Engine oil ‒ Change (→ Page 183)

Ratchet bit


7.5.3 Cylinder head cover – Removal and installation(→ Page 151)


DCL-

ID: 0

0000

1561

7 - 0

03

Ratchet bit



Qty.:Used in:

1 7.9.1 Compressor wheel – Cleaning (→ Page 173)

Qty.:Used in:

1 7.14.23 Centrifugal oil filter – Cleaning and filter-sleevereplacement (→ Page 221)

Ratchet bit



Ratchet with extension


1 7.2.1 Engine – Barring manually (→ Page 138)

Rigid endoscope


1 7.3.1 Cylinder liner – Endoscopic examination(→ Page 140)


DCL-

ID: 0

0000

1561

7 - 0

03

Socket wrench, 24 mm



Torque wrench, 10–60 Nm


1 1.9 Crankshaft transport locking device (→ Page 20)

Qty.:Used in:

1 7.6.1 HP fuel pump – Filling with engine oil (→ Page 152)

Qty.:Used in:


Qty.:Used in:

1 7.8.5 Fuel prefilter with water separator – Filter elementreplacement (→ Page 170)

Qty.:Used in:

1 7.9.1 Compressor wheel – Cleaning (→ Page 173)

Qty.:Used in:




7.5.3 Cylinder head cover – Removal and installation(→ Page 151)


DCL-

ID: 0

0000

1561

7 - 0

03



1 7.14.17 Oil filter element – Installation (→ Page 212)



1 7.4.1 Crankcase breather – Oil separator element re-placement (→ Page 144)

Qty.:Used in:




1 1.9 Crankshaft transport locking device (→ Page 20)

Qty.:Used in:


Qty.:Used in:


Qty.:Used in:

1 7.13.2 Engine oil ‒ Change (→ Page 183)




Qty.:Used in:

1 7.19.5 Coalescer filter element ‒ Replacement(→ Page 242)


DCL-

ID: 0

0000

1561

7 - 0

03

Valve setting gauge




DCL-

ID: 0

0000

1561

7 - 0

03

9.2 IndexNumerics

20V 4000 M93 engine data: EPA 2, engine-mounted heatexchanger 61

20V4000M93 engine data: IMO, engine-mounted heat ex-changer, intercooler made of copper-based alloy 58

20V4000M93L engine data: EPA 2, engine-mounted heatexchanger 67

20V4000M93L engine data: IMO, engine-mounted heat ex-changer, intercooler made of copper-based alloy 64

A

Actuators – Overview 47ADEC (ECU 7) – Fault messages 100Adhesive tape for SOLAS shielding – Application 137After stopping the engine 90Air filter – Installation 180– Removal 180– Replacement 179Automatic oil filter – Assembly 195– Check 194– Checking flushing arm rotation 199– Cleaning 193– Disassembly 192– Final steps 198– Installation 196– Overview 186– Preparatory steps 189– Removal 190

B

Battery-charging generator drive – Check 236

C

Cabling – Check

– On engine 244CDC parameters – Reset 245Centrifugal oil filter – Cleaning 220, 221– Installation 223– Overview 217– preparatory steps 218– Removal 219Checks – Prior to start-up 79Clutch engagement – At LOP 85

Coalescer filter element – Replacement 242Compressor wheel – Cleaning 173Connector – Cleaning 248Connectors – Cleaning 246Contact persons 261Contamination indicator – Signal ring position check 181Controls 72Coolant – Change 227– engine

– draining 228Coupling – Check 236Crankcase breather – Oil separator element

– Replacement 144Crankshaft – Transport locking device

– Installation/removal 20Cylinder – Designation 36Cylinder head cover – Installation 151– Removal 151Cylinder liner – Endoscopic examination 140– Endoscopic inspection

– Instructions and comments on endoscopic and visu-al examination 142

D

Diagnostic lamp (DILA) – EIM 2 255Diagnostics – EIM 2 255Differential pressure gage – Adjustment

– Fuel prefilter 165– Alarm function check 239– Check

– Fuel prefilter 165Disengaging – from LOP 86

E

ECU 7 – Installation 252– Removal 252Emergency engine stop – At BlueLine automation system (control stand) 84

270 | Index | MS150048/05E 2018-03

DCL-

ID: 0

0000

1561

7 - 0

03

Emergency stop – From LOP 91EMU – Cleaning 246EMU 8 – Installation 253– Removal 253Endoscopic inspection – Cylinder liner

– Instructions and comments 142Engine – Barring

– With starting system 139– Barring manually 138– Overview 46– Start 76– Stopping

– At the BlueLine automation system (control stand) 89

– From LOP 88Engine cabling – Check 244Engine coolant – Change 227– Check

– Level at external cooler 225– Level at filler neck 225– Level via level sensor 225

– draining 228– Filling 229– Sample analysis 234– Sample extraction 234Engine coolant pump – Relief bore

– Check 233Engine driving end – Definition 36Engine free end – Definition 36Engine governor – Cleaning 248– Plug connections

– Check 251Engine governor ADEC (ECU 7) – Fault messages 100Engine governor ECU 7 – Installation 252– Removal 252Engine Monitoring Unit EMU 8 – Plug connections check 249Engine mounting – Check 237

Engine oil – Centrifugal oil filter

– Cleaning 221– Change 183– Filter sleeve

– Replacement 221– Sample analysis 185– Sample extraction 185Engine oil level – Check 182Engine sides – Designation 36Engine wiring harness – Overview 52Engine – Main dimensions 70

F

Fault messages – Engine governor ADEC (ECU 7) 100Filter – Fuel

– Replacement 163Filter sleeve – Replacement 221Firing order 71Fuel – Treatment system

– Switching on 83– Troubleshooting 96

– treatment system – Shutdown 92

Fuel filter – Replacement 163Fuel prefilter – Adjustment

– Differential pressure gage 165– Check

– Differential pressure gage 165– Draining 166Fuel prefilter with water separator – Filter element

– Flushing 168– Replacement 170

Fuel treatment system – Initial start-up 80– Shutdown 92– Switching on 83Fuse lamp (SILA) – EIM 2 255

H

Hotline 261HP pump – Filling with engine oil 152– Relief bore check 154

MS150048/05E 2018-03 | Index | 271

DCL-

ID: 0

0000

1561

7 - 0

03

I

Injector – Installation 156– Removal 156– Replacement 155Intercooler – Checking condensate drain for coolant discharge and

obstruction 177Interface module EIM – Check 250Interface module EIM 2 – Removal and installation 254

L

Limit switch for start interlock – Check 247List of abbreviations 259LOP – Cleaning 258– Connector cleaning 258

M

Maintenance schedule – Maintenance schedule task reference table [QL1] 94MTU contact persons 261

O

Oil filter – Final steps 198– Preparatory steps 189Oil filter candles – Check 207– Cleaning 206Oil filter element – Assembly 208– Check 207– Check for ease of movement 212– Cleaning 206– Disassembly 204– Installation 212– Overview 200– Removal 203Oil indicator filter – Check 215– Cleaning 215Operational checks 77Overflow valve – Removal 204Overflow valves – Installation 208Overview – Engine 46

P

Plant – Cleaning 93Plug connections – Check 250Product description 37

Pump capacity – Check 241Putting the engine into operation after extended out-of-

service periods (>3 months) 73Putting the engine into operation after scheduled out-of-

service-period 74

R

Raw water pump – Relief bore

– Check 235

S

Safety regulations – Assembly work 12– Auxiliary materials 16– Environmental protection 16– Fire prevention 16– Fluids and lubricants 16– Important provisions 6, 8– Initial start-up 10– Maintenance work 12– Operation 10– Organizational requirements 9– Personnel requirements 9– Repair work 12Safety requirements – Warning notices, standards 18Sensors – Overview 47Service partners 261SOLAS shielding – Adhesive tape application 137SOLAS shields – Installation locations 128SOLAS shielding – Installation

– As per MTN 5233 127Spare parts service 261

T

Tasks after extended out-of-service periods (>3 weeks) 78Tightening specifications – Nuts 23– Screws and bolts 23– Screws, nuts and bolts 23transport 19Transport locking device – Crankshaft

– Installation/removal 20Troubleshooting 97– Fuel treatment system 96

V

Valve clearance – Adjustment 147– Check 147Valve gear – Lubrication 146

272 | Index | MS150048/05E 2018-03

DCL-

ID: 0

0000

1561

7 - 0

03

Vent points 224

W

Warning notices, standards 18Water drain valve – Check 238Water level probe (3-in-1 rod electrode) – Check 240Waterjet – Flushing

– From LOP (option) 87

MS150048/05E 2018-03 | Index | 273

DCL-

ID: 0

0000

1561

7 - 0

03

Diesel Engine 20V4000M93x - mtu-online.com · installation 254 7.21.11 Engine Interface Module EIM...

Documents

Transcript of Diesel Engine 20V4000M93x - mtu-online.com · installation 254 7.21.11 Engine Interface Module EIM...