MS150048 04e 20V4000M93
MS150048 04e 20V4000M93
Diesel Engine
20 V 4000 M93 x
MS150048/04E
Engine model kW/cyl. Application group
20V4000M93 195 kW/cyl. 1 DS, continuous operation, variable, low load
factors
20V4000M93L 215 kW/cyl. 1 DS, continuous operation, variable, low load
factors
Table 1: Applicability
Printed in Germany
© 2013 Copyright MTU Friedrichshafen GmbH
This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior
written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, mi-
crofilming and storage or processing on electronic systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage
during operation.
Subject to alterations and amendments.
Table of Contents
1 Safety 4.9 Fuel treatment system – Switching on 65
4.10 Engine emergency stop at BlueLine
1.1 Important provisions for all products 5 automation system (control stand) 66
1.2 Personnel and organizational requirements 6 4.11 Coupling – Engaging from LOP 67
1.3 Safety regulations for startup and operation 7 4.12 Coupling – Disengaging from LOP 68
1.4 Safety regulations for maintenance and 4.13 Waterjet – Flushing from LOP (optional) 69
repair work 8 4.14 Stopping the engine from LOP 70
1.5 Fire prevention and environmental 4.15 Stopping the engine at the BlueLine
protection, fluids and lubricants, auxiliary automation system (control stand) 71
materials 11 4.16 Emergency stop from LOP 72
1.6 Standards for safety notices in the text 13 4.17 After stopping the engine 73
1.7 Transport 14 4.18 Fuel treatment system – Shutdown 74
1.8 Crankshaft transport locking device 15 4.19 Plant – Cleaning 75
4.3 Putting the engine into operation after 7.4 Injection Pump / HP Pump 121
scheduled out-of-service-period 57 7.4.1 HP pump – Filling with engine oil 121
7.4.2 HP pump – Relief bore check 122
4.4 Starting the engine 58
4.5 Operational checks 59 7.5 Injection Valve / Injector 123
4.6 Tasks after extended out-of-service periods 7.5.1 Injector – Replacement 123
(>3 weeks) 60 7.5.2 Injector – Removal and installation 124
4.7 Checks prior to start-up 61 7.6 Fuel Filter 129
4.8 Fuel treatment system – Putting into 7.6.1 Fuel filter – Replacement 129
operation 62
General information
This product may pose a risk of injury or damage in the following cases:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Modifications or conversions
• Noncompliance with the safety instructions and warning notices
Correct use
The product is intended exclusively for the application specified in the contract or defined at the time of
delivery.
This means that the equipment must be operated:
• Within the permissible operating parameters in accordance with the (→ product data)
• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubri-
cants Specifications of the manufacturer)
• With spare parts approved by the manufacturer in accordance with the (→ applicable Spare Parts
Catalog)
• In the original as-delivered configuration or in a configuration approved by the manufacturer in writ-
ing (including engine control/parameters)
• In compliance with all safety instructions and in adherence to all warning notices in this manual
• In accordance with the maintenance requirements over the entire service life of the product (→ Main-
tenance Schedule)
• In compliance with the maintenance and repair instructions contained in this manual, in particular
with regard to the specified tightening torques
• With the exclusive use of technical personnel trained in commissioning, operation, maintenance and
repair
• By contracting only workshops authorized by the manufacturer to carry out repair and overhaul
Any other use is considered improper use and increases the risk of personnel injury or material damage
in product operation.The manufacturer will accept no liability for such damage.
Modifications or conversions
Unauthorized modifications to the product compromise safety.
TIM-ID: 0000040530 - 001
The manufacturer will accept no liability or warranty claims for any damage caused by unauthorized
modifications or conversions.
Spare parts
Only genuine spare parts must be used to replace components or assemblies.
The manufacturer will accept no liability or warranty claims for any damage caused by the use of other
spare parts.
Personnel requirements
All work on the product shall be carried out by trained and qualified personnel only.
• Training at the Training Center of the manufacturer
• Qualified personnel specialized in mechanical and plant engineering
The operator must define the responsibilities of the personnel involved in operation, maintenance, re-
pair and transport.
Operation
The following conditions must be fulfilled before starting the product:
• Wear ear protection.
• Ensure that the engine room is well ventilated.
• Do not inhale the exhaust gases of the product.
• Ensure that the exhaust system is free of leaks and that the gases are discharged to atmosphere.
• Mop up any leaked or spilt fluids and lubricants immediately or soak up with a suitable binding agent.
• Protect battery terminals, generator terminals or cables against accidental contact.
Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent
contact with other components. Do not place fuel or oil lines near hot components.
Do not touch elastomeric seals if they have carbonized or resinous appearance unless hands are prop-
erly protected.
Note cooling time for components which are heated for installation or removal (risk of burning).
When working high on the equipment, always use suitable ladders and work platforms. Make sure com-
ponents or assemblies are placed on stable surfaces.
Welding work
Welding operations on the product or mounted units are not permitted. Cover the product when weld-
ing in its vicinity.
Before starting welding work:
• Switch off the power supply master switch.
• Disconnect the battery.
• Separate the electrical ground of electronic equipment from the ground of the unit.
No other maintenance or repair work must be carried out in the vicinity of the product while welding is
going on. Risk of explosion or fire due to oil vapors and highly flammable fluids and lubricants.
Do not use product as ground terminal.
Never position the welding power supply cable adjacent to, or crossing wiring harnesses of the product.
The welding current may otherwise induce an interference voltage in the wiring harnesses which could
conceivably damage the electrical system.
Remove parts (e.g. exhaust pipes) which are to be welded from the product beforehand.
Observe the safety instructions of the battery manufacturer when working with batteries.
Gases emanating from the battery are explosive. Avoid sparks and naked flames.
Do not allow electrolyte to come in contact with skin or clothing.
Wear protective clothing and protective gloves.
Never place tools on the battery.
Before connecting the cable to the battery, check the battery polarity.Battery pole reversal may lead to
injury through the sudden discharge of acid or bursting of the battery body.
Noise
Noise can lead to an increased risk of accidents if it makes it more difficult to hear audible signals,
warning calls or noises indicating danger.
Wear ear defenders in work areas with a sound pressure level in excess of 85dB (A).
Used oil
Used oil contains combustion residues that are harmful to health.
Rub barrier cream into hands.
Wash hands after contact with used oil.
Compressed air
Observe special safety precautions when working with compressed air:
• Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII and B) out of
containers, risks causing an explosion.
• Wear goggles when blowing dirt off components or blowing away swarf.
• 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 to be connected must either be designed for that pressure, or, if the permis-
sible pressure is lower than the system pressure, a pressure reducing valve and safety valve (set to
the permissible pressure) must be connected between the assemblies/products and the system.
• Hose couplings and connections must be securely attached.
• Provide the snout of the air nozzle with a protective disk (e.g. rubber disk).
• First shut off compressed air lines before compressed air device is disconnected from the supply
line, or before device or tool is to be replaced.
• Carry out leak test in accordance with the specifications.
Liquid nitrogen
• Observe the relevant safety data sheet for all materials.
• Store liquid nitrogen only in small quantities and always in regulation containers (without gas-tight
caps).
• Avoid body contact (eyes, hands).
• Wear protective clothing, protective gloves, closed shoes and safety goggles.
• Make sure that working area is well ventilated.
• Avoid knocking or jolting the containers, fixtures or workpieces in any way.
• When working with acids and alkaline solutions, wear goggles or face mask, gloves and protective
clothing.
• Do not inhale vapors.
• If urea solution is swallowed, rinse out mouth and drink plenty of water.
• If spilled onto clothing, remove the affected clothing immediately.
• After contact with skin, rinse affected parts of the body with plenty of water.
• Rinse eyes immediately with eyedrops or clean tap water. Seek medical attention as soon as possi-
ble.
WARNING
In the event of a situation involving potential danger.
Consequences: Death, serious or permanent injury!
• Remedial action.
CAUTION
In the event of a situation involving potential danger.
Consequences: Minor or moderate injuries!
• Remedial action.
NOTICE
In the event of a situation involving potentially adverse effects on the product.
Consequences: Material damage.
• Remedial action
• Additional product information
Safety notices
u This manual with all safety instructions and safety notices must be issued to all personnel involved in
operation, maintenance, repair or transportation.
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For installation and removal of the transport locking device, follow the in-
structions below:
1. The transport locking device must remain installed as long as possible during engine installation in or-
der to avoid damage.
2. Prior to every engine transport, the transport locking device must be reinstalled on both 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
must also be installed.
4. Always use the screws supplied with or installed in the transport locking device to secure it on the en-
gine.
5. Starting or barring the engine is allowed only with the transport locking device removed. If the genera-
tor is already mounted on the engine, ensure that the transport locking device of the generator is also
removed.
Note: Attach plate (6) only to the upper part of the openings.
1. Secure the plates (6) with screws (4) and washers (5) at the bores 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 screw (1) up to the end of the thread.
3. The long end of the holder (3) must face downwards. Insert holder (3) through the openings in the
plate (6).
Note: The holder (3) must lock the flywheel only, not the ring gear.
4. Turn screw (1) in bores of holder (3) until holder (3) is secured.
Note: The screw (1) must be tightened alternately on both sides of the flywheel housing.
5. Tighten screw (1) to specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw M10 Tightening torque (Engine oil) 30 Nm +3 Nm
6. Place locknut (2) of screw (1) in position on plate (6) and lock it.
Fuel system
Electronically controlled common-rail-injection system with HP pump, pressure accumulator (rail) and
single injectors with integrated individual store.
The electronic control unit controls
• Injection start
• Injection quantity
• Injection pressure
Exhaust system
The exhaust system is equipped with triple-walled, water-cooled exhaust lines.
The triple-walled design permits
• low surface temperature,
• reduced amount of heat to be dissipated by the coolant,
• absolute gas-tightness.
Turbocharging
Sequential turbocharging with internal, engine-coolant-controlled charge air cooling. The right-hand ex-
haust turbocharger is cut-in and cut-out on 12V and 16V engines with electronically-controlled, hydraul-
ically-actuated flaps. ETC B1 A2 and B2 on 20V engines.
Cooling system
Engine 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 block
The service components are mounted at the auxiliary PTO end.
The layout permits easy access for maintenance.
Service components:
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Electronic system
Electronic control and monitoring system with integrated security and test system with interfaces to
remote control system (RCS) and to monitoring system (MCS).
Lube oil system, oil lines with oil pressure >1.8 bar
Special connections
In case of leakage, the following connection types are spray-protected even without a cover and have
been confirmed compliant with SOLAS by GL and DNV.
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L (enhanced power/speed)
1 B7 (lube oil temperature) 8 B10 (charge-air pressure) 15 B57.7 (main bearing tem-
2 B50 (crankcase pressure) 9 B57.1 (main bearing tem- perature)
3 B44.3 (turbocharger C perature) 16 B57.8 (main bearing tem-
speed) 10 B57.2 (main bearing tem- perature)
4 B4.23 (temperature, turbo- perature) 17 B57.9 (main bearing tem-
charger C) 11 B57.3 (main bearing tem- perature)
5 B4.21 (temperature, turbo- perature) 18 B57.10 (main bearing tem-
charger A) 12 B57.4 (main bearing tem- perature)
6 B3 (intake air temperature) perature) 19 B57.11 (main bearing tem-
7 B44.1 (turbocharger A 13 B57.5 (main bearing tem- perature)
speed) perature) 20 B5.1 (lube-oil pressure af-
14 B57.6 (main bearing tem- ter filter)
perature)
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1 F46 (leak-fuel level) 4 B54 (oil refill pump pres- 7 Connector XD1 – Dialog
2 B33 (fuel temperature) sure) unit
3 B1 (camshaft speed) 5 B6.2 (coolant tempera-
ture)
6 B6 (coolant temperature)
1 B44.2 (turbocharger B 7 B21 (raw water pressure) 13 B77.B5 (spray oil temp.
speed) 8 B77.B10 (spray oil temp. conrod bearing)
2 B4.22 (temperature, turbo- conrod bearing) 14 B77.B4 (spray oil temp.
charger B) 9 B77.B9 (spray oil temp. conrod bearing)
3 B49 (charge-air tempera- conrod bearing) 15 B77.B3 (spray oil temp.
ture, recirculation valve) 10 B77.B8 (spray oil temp. conrod bearing)
4 B4.24 (temperature, turbo- conrod bearing) 16 B77.B2 (spray oil temp.
charger D) 11 B77.B7 (spray oil temp. conrod bearing)
5 B44.4 (turbocharger D conrod bearing) 17 B77.B1 (spray oil temp.
speed) 12 B77.B6 (spray oil temp. conrod bearing)
6 B16 (coolant pressure) conrod bearing)
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REFERENCE CONDITIONS
Engine model 20V 4000
M93
Application 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 20
Rated engine speed A rpm 2100
Fuel stop power, ISO 3046 A kW 3900
FUEL SYSTEM
Number of cylinders 20
Fuel 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
STARTING (electric)
Number of cylinders 20
Rated starter voltage (standard design) R V= 24
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CAPACITIES
Number of cylinders 20
Engine coolant, engine side (with cooling system) R Liters 440
Engine oil on initial filling (standard oil system) (Option: max. operating inclina- R Liters 365
tions)
Oil change quantity, max. (standard oil system) (Option: max. operating incli- R Liters 320
nations)
Oil pan capacity at dipstick mark “min.” (standard oil system) (Option: max. L Liters 255
operating inclinations)
Oil pan capacity at dipstick mark “max.” (standard oil system) (Option: max. L Liters 300
operating inclinations)
NOISE
Number of cylinders 20
Exhaust noise, unsilenced - BL (free-field sound-pressure level Lp, 1m dis- R dB(A) 117
tance, ISO 6798, +3dB(A) tolerance)
Engine surface noise with attenuated intake noise (filter) - BL (free-field sound- R dB(A) 106
pressure level Lp, 1m distance, ISO 6798+2dB(A) tolerance)
TIM-ID: 0000010820 - 002
REFERENCE CONDITIONS
Engine model 20V 4000
M93
Application 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 20
Rated engine speed A rpm 2100
Fuel stop power, ISO 3046 A kW 3900
Number of cylinders 20
Cylinder arrangement: V angle Degrees 90
Bore mm 170
Stroke mm 190
Cylinder displacement Liters 4.31
Total displacement Liters 86.2
Number of inlet valves per cylinder 2
Number of exhaust valves per cylinder 2
FUEL SYSTEM
Number of cylinders 20
Fuel 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
STARTING (electric)
Number of cylinders 20
Rated starter voltage (standard design) R V= 24
CAPACITIES
Number of cylinders 20
Engine coolant, engine side (with cooling system) R Liters 440
Engine oil on initial filling (standard oil system) (Option: max. operating inclina- R Liters 365
tions)
Oil change quantity, max. (standard oil system) (Option: max. operating incli- R Liters 320
nations)
Oil pan capacity at dipstick mark “min.” (standard oil system) (Option: max. L Liters 255
operating inclinations)
Oil pan capacity at dipstick mark “max.” (standard oil system) (Option: max. L Liters 300
operating inclinations)
NOISE
Number of cylinders 20
Exhaust noise, unsilenced - BL (free-field sound-pressure level Lp, 1m dis- R dB(A) 117
tance, ISO 6798, +3dB(A) tolerance)
Engine surface noise with attenuated intake noise (filter) - BL (free-field sound- R dB(A) 106
pressure level Lp, 1m distance, ISO 6798+2dB(A) tolerance)
REFERENCE CONDITIONS
Engine model 20V 4000
M93L
Application 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 20
Rated engine speed A rpm 2100
Fuel stop power, ISO 3046 A kW 4300
Number of cylinders 20
Cylinder arrangement: V angle Degrees 90
Bore mm 170
Stroke mm 190
Cylinder displacement Liters 4.31
Total displacement Liters 86.2
Number of inlet valves per cylinder 2
Number of exhaust valves per cylinder 2
FUEL SYSTEM
Number of cylinders 20
Fuel 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
STARTING (electric)
Number of cylinders 20
Rated starter voltage (standard design) R V= 24
CAPACITIES
Number of cylinders 20
Engine coolant, engine side (with cooling system) R Liters 440
Engine oil on initial filling (standard oil system) (Option: max. operating inclina- R Liters 365
tions)
Oil change quantity, max. (standard oil system) (Option: max. operating incli- R Liters 320
nations)
Oil pan capacity at dipstick mark “min.” (standard oil system) (Option: max. L Liters 255
operating inclinations)
Oil pan capacity at dipstick mark “max.” (standard oil system) (Option: max. L Liters 300
operating inclinations)
NOISE
Number of cylinders 20
Exhaust noise, unsilenced - BL (free-field sound-pressure level Lp, 1m dis- R dB(A) 118
tance, ISO 6798, +3dB(A) tolerance)
Engine surface noise with attenuated intake noise (filter) - BL (free-field sound- R dB(A) 107
pressure level Lp, 1m distance, ISO 6798+2dB(A) tolerance)
TIM-ID: 0000010893 - 002
REFERENCE CONDITIONS
Engine model 20V 4000
M93L
Application 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 20
Rated engine speed A rpm 2100
Fuel stop power, ISO 3046 A kW 4300
Number of cylinders 20
Cylinder arrangement: V angle Degrees 90
Bore mm 170
Stroke mm 190
Cylinder displacement Liters 4.31
Total displacement Liters 86.2
Number of inlet valves per cylinder 2
Number of exhaust valves per cylinder 2
FUEL SYSTEM
Number of cylinders 20
Fuel 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
STARTING (electric)
Number of cylinders 20
Rated starter voltage (standard design) R V= 24
CAPACITIES
Number of cylinders 20
Engine coolant, engine side (with cooling system) R Liters 440
Engine oil on initial filling (standard oil system) (Option: max. operating inclina- R Liters 365
tions)
Oil change quantity, max. (standard oil system) (Option: max. operating incli- R Liters 320
nations)
Oil pan capacity at dipstick mark “min.” (standard oil system) (Option: max. L Liters 255
operating inclinations)
Oil pan capacity at dipstick mark “max.” (standard oil system) (Option: max. L Liters 300
operating inclinations)
NOISE
Number of cylinders 20
Exhaust noise, unsilenced - BL (free-field sound-pressure level Lp, 1m dis- R dB(A) 118
tance, ISO 6798, +3dB(A) tolerance)
Engine surface noise with attenuated intake noise (filter) - BL (free-field sound- R dB(A) 107
pressure level Lp, 1m distance, ISO 6798+2dB(A) tolerance)
DANGER
Rotating 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 en-
gine's danger zone.
WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.
WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.
Operational checks
Item Action
Engine oil Check engine oil level (→ Page 144).
Engine under load, Visually inspect engine for leaks and general condition;
engine at nominal speed Check speed, pressures and temperatures;
Check engine and external lines for leaks;
Check for abnormal running noises and vibration;
Check exhaust color (→ Page 79).
Air filter Check signal ring position of service indicator (→ Page 142);
Replace air filter (→ Page 140) if the signal ring is completely visible in the
service indicator observation window.
Intercooler Check condensate drain(s) for water discharge and obstruction
(→ Page 139).
Exhaust gas system Check condensate drain for obstructions.
Fuel prefilter(s) Drain water and contamination from fuel prefilter (if fitted) (→ Page 132).
Check pointer position of differential pressure gage at fuel prefilter (if appli-
cable).
HT coolant pump Check relief bore for oil and coolant discharge and contamination
(→ Page 163).
Raw water pump Check relief bore for oil and water discharge and contamination
(→ Page 165).
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NOTICE
Risk of damage to engine/system.
Risk of severe damage to property!
• Before switching on, ensure that the engine/system is ready for operation.
• Before switching on, ensure that all housings are closed.
• Before switching on, ensure that no work is in progress anywhere on the entire system.
DANGER
Vessel is sailing blind.
In Local Operation mode, the propulsion plant is controlled from the engine room.
Risk of accidents!
• Only execute vessel movements on the instructions of a person who has visual contact with the
area outside the vessel.
NOTICE
Waterjet flushing puts excessive strain on the bearings.
Bearing damage!
• Do not flush waterjet for too long.
• Follow instructions of the waterjet manufacturer.
NOTICE
Stopping the engine when it is running at full load causes extreme stress to the engine.
Risk of overheating, damage to components!
• Before shutting down, disengage gear and run the engine at idle speed for at least 10 minutes
until engine temperatures have dropped and constant values are displayed.
WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.
WARNING
Steam jet cleaner ejects jet of pressurized water.
Risk of injury to eyes and scalding!
• Never direct water jet at people.
• Wear protective clothing, protective gloves and safety goggles/face mask.
NOTICE
Cleaning agents should not be left to take effect for too long.
Damage to components is possible!
• Observe manufacturer's instructions.
NOTICE
Blowing down product with compressed air.
Entry of dirt and damage to components is possible!
• Do not aim compressed air gun directly at seals or electronic components such as connectors
or ECUs.
Plant – Cleaning
1. Carry out plant cleaning only in areas where an appropriate oil separator is provided (environmental
protection).
2. Prior to putting the cleaning unit into operation, read the Operating Instructions of the water/steam jet
unit carefully and observe the safety precautions.
3. For external cleaning of the plant with water or steam-jet cleaners:
• 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.
TIM-ID: 0000010171 - 027
81 – AL Rail Leakage
ZKP-Number: 18.004.046
201 – SD T-Coolant
ZKP-Number: 18.004.570
202 – SD T-Fuel
ZKP-Number: 18.004.572
break
206 – SD T-Exhaust A
ZKP-Number: 18.004.576
207 – SD T-Exhaust B
ZKP-Number: 18.004.577
212 – SD P-Coolant
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ZKP-Number: 18.004.564
214 – SD P-CrankCase
ZKP-Number: 18.004.568
215 – SD P-HD
ZKP-Number: 18.004.567
ZKP-Number: 18.004.562
240 – SD P-Fuel
ZKP-Number: 18.004.565
Time-of-flight measuring fault of u If alarm occurs frequently, replace solenoid valve of injector
injector in cylinder A7: Time-of
flight measured value extremely
low or extremely high.
Time-of-flight measuring fault of u If alarm occurs frequently, replace solenoid valve of injector
injector B2: Time-of flight
measured value extremely low
or extremely high.
Time-of-flight measuring fault of u If alarm occurs frequently, replace solenoid valve of injector
injector B7: Time-of flight
measured value extremely low
or extremely high.
371 – AL Wiring TO 1
ZKP-Number: 18.004.634
372 – AL Wiring TO 2
ZKP-Number: 18.004.635
373 – AL Wiring TO 3
ZKP-Number: 18.004.636
374 – AL Wiring TO 4
ZKP-Number: 18.004.637
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444 – SD U-PDU
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ZKP-Number: 18.004.578
464 – SD P-AUX 1
ZKP-Number: 18.004.589
468 – SD T-AUX 1
ZKP-Number: 18.004.579
469 – SD AUX 1
ZKP-Number: 18.004.590
470 – SD T-ECU
ZKP-Number: 18.004.587
ZKP-Number: 18.004.592
482 – SD T-Exhaust C
ZKP-Number: 18.004.596
483 – SD T-Exhaust D
ZKP-Number: 18.004.597
ZKP-Number: 18.004.202
wire break
was output.
601 – SD ETC1+ETC2
ZKP-Number: 13.011.227
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Before cranking 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 removed from the engine.
Preparatory steps
1. Remove cylinder head cover (→ Page 120).
2. Remove injector (→ Page 124).
Preparatory steps
1. Remove cylinder head cover (→ Page 120).
2. Install barring device (→ Page 109).
3. The OT (TDC) marking (1) (if fitted) on the
flywheel must not be used for reference.
per diagram.
1 Cylinder A1 is in firing TDC
2 Cylinder A1 is in overlap TDC
I Inlet valve
X Exhaust valve
4. Use feeler gauge to determine the distance between valve bridge and rocker arm.
5. If the deviation from the set value exceeds 0.1 mm, adjust valve clearance.
5. Tighten locknut (1) with torque wrench to the specified tightening torque, holding the adjusting
screw (2) to prevent it from turning.
Name Size Type Lubricant Value/Standard
Locknut M16 x 1.5 Tightening torque (Engine oil) 90 Nm +9 Nm
6. Replace or rectify adjusting screws and/or locknuts which do not move freely.
7. Check valve clearance.
Final steps
1. Remove barring device (→ Page 109).
2. Install cylinder head cover (→ Page 120).
TIM-ID: 0000000922 - 010
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
WARNING
Oils/oil vapors are combustible/explosive.
Risk of fire and explosion!
• Avoid open flames, electric sparks and ignition sources.
• Do not smoke.
NOTICE
HP fuel pump not filled with engine oil.
Damage to components, major material damage!
• Ensure that th HP fuel pump is filled with engine oil before it is installed or put into operation.
Filling HP pump
1. Remove plug screw (1).
2. Use pump oiler to fill HP pump with engine
oil until engine oil emerges.
3. Install plug screw (1).
TIM-ID: 0000001640 - 012
WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.
Replacing injector
u Remove injector and install new injector (→ Page 124).
TIM-ID: 0000000022 - 013
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
Preparatory steps
1. Shut off fuel supply to engine.
2. Remove cylinder head cover (→ Page 120).
Removing injector
1. Disconnect connectors on injector.
TIM-ID: 0000000925 - 009
10. Fit hold-down clamp (1) in the correct position and use torque wrench to tighten screw (2) to the speci-
fied initial tightening torque.
Name Size Type Lubricant Value/Standard
Screw M12 Preload torque (Engine oil) 5 Nm to 10 Nm
Note: Ensure special cleanness.
11. Coat thread and sealing cone of adapter (3) with engine oil.
12. Install adapter (3) and use torque wrench to tighten to the specified initial tightening torque.
Name Size Type Lubricant Value/Standard
Adapter Preload torque (Engine oil) 5 Nm to 10 Nm
13. Tighten screw (2) with torque wrench to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw M12 Tightening torque 100 Nm + 10 Nm
14. Tighten adapter (3) with torque wrench to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Adapter Tightening torque 100 Nm + 10 Nm
15. Install return line (7).
Note: Ensure special cleanness.
16. Coat thread and sealing cone of HP line (5) with engine oil.
Note: Two HP line versions (single- and double-walled) with different torques as described below.
17. Mount single-walled HP line (5) and use torque wrench to tighten to the specified torque. Tightening
TIM-ID: 0000000925 - 009
sequence:
1 Rail (6)
2 Adapter (4)
Name Size Type Lubricant Value/Standard
Union nut / thrust Tightening torque 30 Nm + 5 Nm
screw
Final steps
1. Install cylinder head cover (→ Page 120).
2. Open fuel supply to engine.
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.
NOTICE
Damage to component!
Severe material damage!
• For filter replacement with the engine running, operate the engine at low engine load.
• The filter which is to be replaced must be cut out for a brief period only.
TIM-ID: 0000012705 - 003
WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.
WARNING
Chemical substances.
Risk of irritation and chemical burns!
• Observe the instructions of the cleaning agent manufacturer.
NOTICE
Incorrect installation of electric lines .
Damage to component!
• Note down line assignment to connections before removal.
NOTICE
Inappropriate cleaning tool.
Risk of damage to component!
• Observe manufacturer's instructions.
• Use appropriate cleaning tool.
Preparatory steps
1. Drain engine coolant (→ Page 158).
2. Remove air filter (→ Page 141).
3. Remove exhaust system after exhaust turbocharger.
4. Remove exhaust flap with actuators.
5. Remove air intake.
Note: Do not use wire brush, scraper or similar tools for cleaning!
1. Clean compressor housing with paint brush or smooth brush.
2. Clean compressor wheel and bearing housing with cold cleaner.
3. Thoroughly blow out all parts with compressed air to remove cold cleaner.
WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.
WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.
5. Tighten screw on clamp (2) with torque wrench to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw - Tightening torque 5 Nm
TIM-ID: 0000005457 - 009
WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Wear protective clothing, gloves, and goggles / safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.
Oil change without semirotary hand pump: Draining oil via drain plug(s) on oil
pan
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.
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.
WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Wear protective clothing, gloves, and goggles / safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.
WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.
WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Wear protective clothing, gloves, and goggles / safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.
NOTICE
Contamination of components.
Damage to component!
• Observe manufacturer's instructions.
• Check components for special cleanliness.
WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Wear protective clothing, gloves, and goggles / safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.
WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.
NOTICE
Inappropriate cleaning tool.
Risk of damage to component!
• Observe manufacturer's instructions.
• Use appropriate cleaning tool.
Removing strainer
1. Clean oil indicator filter before disassem-
bling it.
2. Remove screws (1).
3. Take off cover (2) with O-ring (3).
4. Take strainer (5) from filter housing.
TIM-ID: 0000006402 - 005
Cleaning strainer
1. Wash strainer (5) with cleaner.
2. Remove stubborn deposits with soft brush.
3. Blow out strainer (5) with compressed air from inside.
Installing strainer
1. Coat square-section ring (4) on strainer (5) with engine oil and install strainer (5).
2. Coat O-ring (3) with engine oil and fit in filter housing.
3. Fit cover (2) and secure with screws (1) and washers.
WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Wear protective clothing, gloves, and goggles / safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.
WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.
TIM-ID: 0000000934 - 012
23. Tighten cover screw (2) with torque wrench to the specified torque.
Name Size Type Lubricant Value/Standard
Screw Tightening torque 5 Nm to 7 Nm
WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.
WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.
Preparatory steps
1. Provide an appropriate container to drain the coolant into.
2. Switch off preheating unit.
Final steps
1. Seal all open drain points
2. Place breather valve onto filler neck and close it.
TIM-ID: 0000014595 - 001
WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.
NOTICE
Cold coolant in hot engine can cause thermal stress.
Possible formation of cracks in the engine!
• Fill / top up coolant only into cold engine.
Preparatory steps
1. Turn breather valve of coolant expansion
tank counterclockwise to first stop and al-
low pressure to escape.
2. Continue to turn breather valve counter-
clockwise and remove.
3. Release the coolant line union on both tur-
bochargers (→ Page 155).
4. Release the coolant line union at the cool-
ant distributor (→ Page 155).
5. Close breather valve on expansion tank.
TIM-ID: 0000006727 - 006
WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.
WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.
WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.
WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
NOTICE
Contamination of components.
Damage to component!
• Observe manufacturer's instructions.
• Check components for special cleanliness.
NOTICE
Incorrect 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.
plate (4).
9. Remove coalescer filter element (5).
10. Catch fuel as it runs out.
11. Clean housing with a non-linting cloth,
rinse with fuel if required.
12. Check housing for corrosion.
13. Clean housing sealing surfaces.
14. Install coalescer filter element (5).
15. Install end plate (4), washer (8) and nut (3).
Note: In the OFF position, the limit switch initiates a start interlock, i.e. the engine cannot be started.
Checking limit switch for start
interlock
1. Check whether switches (3) and guard
plate (1) with engine support (4) are instal-
led on both sides of flywheel housing (2).
2. Check whether both switches (3) are actu-
ated.
3. If switches (3) and/or guard plate (1) with
engine support (4) is/are not installed:
• Screw on guard plate (1) with engine
support (4).
• Then screw on switch (3), ensuring that
the switch (3) is actuated by the guard
plate (1).
4. If switch (3) and guard plate (1) are instal-
led, but switch (3) is in the OFF position:
• Make certain that the guard plate (1) at
the side of the switch (3) is not distort-
ed.
• Release guard plate (1) and screw on
such that the switch (3) is actuated.
TIM-ID: 0000016782 - 006
Note: Always use test connectors to enter the connectors. Never use test leads for this purpose.Otherwise
the contacts could be bent.
NOTICE
Insertion 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.
NOTICE
Wrong engine governor installed.
Engine damage!
• When reassembling an engine, make sure that the governor with the data record for the given
engine is installed.
NOTICE
Wrong engine governor installed.
Engine damage!
• When reassembling an engine, make sure that the governor with the data record for the given
engine is installed.
Removing EMU
1. Unscrew screws on base of EMU (4).
2. Remove EMU (4) from ECU (1).
Installing EMU
1. Place EMU (4) on ECU (1).
2. Screw in and tighten screws on base of EMU (4).
Downloading software
1. The new EIM 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 185)).
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.
This is also integrated in the housing of the Engine Interface Module. It indicates the status of the fuses.
An orange LED is provided to allow diagnosis of a “tripped fuse” fault directly at the unit as it is often
difficult to pinpoint a fault in the field without cabling diagrams.
This LED is activated by the controller.
Functions of fuse lamp SILA
SILA dark Norma operating state.
SILA flashes orange One or more fuses have tripped.
Information about the status of the current paths of the EIM is also provided in the CAN message "Sta-
tus internal power supply".
TIM-ID: 0000038009 - 002
Cleaning LOP
1. Wipe LCD display with dry cloth, without applying excessive pressure.
2. Remove dirt from keys using isopropyl alcohol.
3. Remove heavy soiling from housing surface with isopropyl alcohol.
Local support
Experienced and qualified specialists place their knowledge and expertise at your disposal.
For locally available support, go to the MTU Internet site: http://www.mtu-online.com
24h hotline
With our 24h hotline and the outstanding flexibility of our service staff, we are always ready to assist
you – either during operation, for preventive maintenance, corrective work in case of malfunction or
changed operating conditions, or for spare parts supply.
Your contact person in our Customer Assistance Center:
E-mail: info@mtu-online.com
Tel.: +49 7541 9077777
Fax: +49 7541 9077778
Asia/Pacific: +65 6100 2688
North and Latin America: +1 248 560 8000
Feeler gauge
Part No.: Y20098771
Qty.: 1
Used in: 7.3.2 Valve clearance – Check and adjustment
(→ Page 116) DCL-ID: 0000015617 - 002
Milling cutter
Part No.: F30452739
Qty.: 1
Used in: 7.5.2 Injector – Removal and installation (→ Page 124)
Ratchet
Part No.: F30027341
Qty.: 1
Used in: 7.5.2 Injector – Removal and installation (→ Page 124)
Qty.: 1
Used in: 7.12.2 Engine oil – Change (→ Page 145)
Ratchet
Part No.: F30027339
Qty.: 1
Used in: 7.18.5 Coalescer filter element – Replacement
(→ Page 172)
Torque wrench
Part No.: F30027337
Qty.: 1
Used in: 7.12.2 Engine oil – Change (→ Page 145)
H
Hotline 191
HP pump
– Filling with engine oil 121
– Relief bore check 122
T
Tasks
– After extended out-of-service periods 60
Tasks after extended out-of-service periods (>3 weeks) 60
transport 14
Transport locking device
– Crankshaft
– Removal/installation 15
Troubleshooting 79
– Fuel treatment system 78
V
Valve clearance
– Adjustment 116
– Check 116
Valve gear
– Lubrication 115
Ventilation points 155
W
Water drain valve
– Check 168
Water level probe (3-in-1 rod electrode)
– Check 170
Waterjet
DCL-ID: 0000015617 - 002
– Flushing
– From LOP (option) 69