Operating Instructions: Diesel Engine 12 V 4000 M63 16 V 4000 M63 16 V 4000 M63R
Operating Instructions: Diesel Engine 12 V 4000 M63 16 V 4000 M63 16 V 4000 M63R
Operating Instructions: Diesel Engine 12 V 4000 M63 16 V 4000 M63 16 V 4000 M63R
Diesel engine
12 V 4000 M63
16 V 4000 M63
16 V 4000 M63R
MS150066/02E
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 accident if acoustic signals, warning shouts or noises indicating
danger are drowned.
Wear ear protectors in work areas with a sound pressure level in excess of 85dB (A).
ble materials, avoid contact with ignition sources and do not smoke.
Used oil
Used oil contains harmful combustion residue.
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 (danger class AI, AII and B) out of
containers, results in a risk of explosion.
• Wear goggles when blowing off components or blowing away chips.
• Forcing compressed air into thin-walled containers (e.g. containers made of tin, plastic and glass) for
drying purposes or to check for leaks, results in a risk of bursting.
• Pay special attention to the pressure level in the compressed air network or pressure vessel.
• Assemblies or products to be connected must either be designed for this pressure, or, if the permit-
ted pressure for the connecting elements is lower than the pressure required, a pressure reducing
valve and safety valve (set to permitted pressure) must form an intermediate connection.
• 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 equipment is disconnected from the supply
line, or before the equipment 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 specified containers (without fixed cov-
ers).
• Avoid body contact (eyes, hands).
• Wear protective clothing, protective gloves, closed shoes and protective goggles.
• Make sure that working area is well ventilated.
• Avoid all knocks and jars to the containers, fixtures or workpieces.
• When working with acids and alkaline solutions, wear face mask, gloves and protective clothing.
• Do not inhale vapors.
• If urea solution was swallowed, rinse mouth and drink plenty of water.
• If the solutions was spilled onto clothing, remove the affected clothing immediately.
• In case of skin contact, rinse parts of the body thoroughly with clean 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 possible 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
Warning notices
u This manual with all safety instructions and waring notices must be issued to all personnel involved in
operation, maintenance, repair or transportation.
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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.
Cooling system
Split-circuit engine cooling system with remote or engine-mounted heat exchanger.
Heating of the charge air in idle and low-load operation prevents white smoke formation.
Seawater flows only through engine coolant cooler and fuel cooler as well as the raw water pump (if
fitted).
Service block
The service components are mounted on the auxiliary PTO end.
The layout permits easy access for maintenance.
Service-components:
• Raw water pump (if applicable), coolant pump
TIM-ID: 0000010054 - 008
Electronic system
Electronic control and monitoring system with integrated safety and test system, providing interfaces to
remote control system (RCS) and monitoring system (MCS).
Low-load operation
12/16V4000M53R/M53/M63R/M63/M63L engines
1 Oil return
1 Oil supply for actuating 2 Oil supply for T-piece of 3 Oil supply for actuating
cylinder of turbocharger flap control cylinder of turbocharger
B1 air flap B1 air flap
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1 Oil lines for B-side flap 2 Oil lines for B-side flap
control from main oil gal- control to main oil gallery
lery
1 B49/Y26 (charge-air tem- 4 B10 (charge-air pressure) 7 B34.1 (fuel pressure after
perature before recircula- 5 B34.3 (fuel pressure be- filter)
tion valve)/(recirculation fore filter) (only if supple- 8 F46 (leak fuel level)
valve A) mentary fuel filter is fitted)
2 B3 (intake air temperature) 6 B34.2 (fuel pressure be-
3 B44.1 (turbocharger A fore filter)
speed)
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1 B7 (lube oil temperature) 4 B33 (fuel temperature in 7 B54 (oil refill pump pres-
2 B5.3 (lube-oil pressure be- common rail) sure) (optional)
fore filter) 5 B48 (fuel pressure in com- 8 B6.2 (coolant tempera-
3 B5.1 (lube-oil pressure af- mon rail) ture) (optional)
ter filter) 6 B1 (camshaft speed) 9 B6 (coolant temperature)
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1 B49/Y26 (charge-air tem- 4 B10 (charge-air pressure) 7 B34.1 (fuel pressure after
perature before recircula- 5 B34.3 (fuel pressure be- filter)
tion valve)/(recirculation fore filter) (only if supple- 8 F46 (leak fuel level)
valve A) mentary fuel filter is fitted)
2 B3 (intake air temperature) 6 B34.2 (fuel pressure be-
3 B44.1 (turbocharger A fore filter)
speed)
TIM-ID: 0000012941 - 002
1 B7 (lube oil temperature) 4 B33 (fuel temperature in 7 B54 (oil refill pump pres-
2 B5.3 (lube-oil pressure be- common rail) sure) (optional)
fore filter) 5 B48 (fuel pressure in com- 8 B6.2 (coolant tempera-
3 B5.1 (lube-oil pressure af- mon rail) ture) (optional)
ter filter) 6 B1 (camshaft speed) 9 B6 (coolant temperature)
1 B50 (crankcase pressure) 4 B10 (charge-air pressure) 7 B34.1 (fuel pressure after
2 B3 (intake air temperature) 5 B34.3 (fuel pressure be- filter)
3 B44.1 (turbocharger A fore filter) (only if supple- 8 F46 (leak fuel level)
speed) mentary fuel filter is fitted)
6 B34.2 (fuel pressure be-
fore filter)
1 B7 (lube oil temperature) 4 B33 (fuel temperature in 7 B54 (oil refill pump pres-
2 B5.3 (lube oil pressure be- common rail) sure) (optional)
fore filter) 5 B48 (fuel pressure in com- 8 B6.2 (coolant tempera-
3 B5.1 (lube oil pressure af- mon rail) ture) (optional)
ter filter) 6 B1 (camshaft speed) 9 B6 (coolant temperature)
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1 B50 (crankcase pressure) 4 B3 (intake air temperature) 7 B34.2 (fuel pressure be-
2 B49/Y26 (charge-air tem- 5 B10 (charge-air pressure) fore filter)
perature before recircula- 6 B34.3 (fuel pressure be- 8 B34.1 (fuel pressure after
tion valve)/(recirculation fore filter) (only if supple- filter)
valve A) mentary fuel filter is fitted) 9 F46 (leak fuel level)
3 B44.1 (turbocharger A
speed)
TIM-ID: 0000018445 - 002
1 B7 (lube oil temperature) 4 B33 (fuel temperature in 7 B54 (oil refill pump pres-
2 B5.3 (lube oil pressure be- common rail) sure) (optional)
fore filter) 5 B48 (fuel pressure in com- 8 B6.2 (coolant tempera-
3 B5.1 (lube oil pressure af- mon rail) ture) (optional)
ter filter) 6 B1 (camshaft speed) 9 B6 (coolant temperature)
1 B7 (lube oil temperature) 4 B33 (fuel temperature in 7 B54 (oil refill pump pres-
2 B5.3 (lube-oil pressure be- common rail) sure) (optional)
fore filter) 5 B48 (fuel pressure in com- 8 B6.2 (coolant tempera-
3 B5.1 (lube-oil pressure af- mon rail) ture) (optional)
ter filter) 6 B1 (camshaft speed) 9 B6 (coolant temperature)
TIM-ID: 0000018445 - 002
1 B7 (lube oil temperature) 4 B33 (fuel temperature in 7 B54 (oil refill pump pres-
2 B5.3 (lube-oil pressure be- common rail) sure) (optional)
fore filter) 5 B48 (fuel pressure in com- 8 B6.2 (coolant tempera-
3 B5.1 (lube-oil pressure af- mon rail) ture) (optional)
ter filter) 6 B1 (camshaft speed) 9 B6 (coolant temperature)
POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)
Heat exchanger Heat exchanger
engine-mounted remote
Rated engine speed A rpm 1800 1800 1800 1800
Fuel stop power ISO 3046 A kW 1500 1500 1500 1500
FUEL SYSTEM
Heat exchanger Heat exchanger
engine-mounted remote
Fuel pressure at engine inlet connection, L bar -0.1 -0.1 -0.1 -0.1
min. (when engine is starting)
Fuel pressure at engine inlet connection, L bar -0.3 -0.3 -0.3 -0.3
min. (during engine operation)
Fuel pressure at engine inlet connection, L bar 1.5 1.5 1.5 1.5
max. (when engine is starting)
Fuel supply flow, max. A Liters/
min
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CAPACITIES
Heat exchanger Heat exchanger
engine-mounted remote
Engine coolant, engine side (with cooling R Liters 305 305 -- --
system)
Total engine oil capacity at initial filling R Liters 265 265 265 265
(standard oil system) (Option: max. oper-
ating inclinations)
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ACOUSTICS
Heat exchanger Heat exchanger
engine-mounted remote
Exhaust noise, unsilenced - BL (free-field R dB(A) 107 107 107 107
sound pressure level Lp, 1m distance, ISO
6798, +3dB(A) tolerance)
Engine surface noise with attenuated in- R dB(A) 105 105 105 105
take noise (filter) - BL (free-field sound
power level Lp, 1 m distance, ISO 6798,
+2dB(A) tolerance)
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POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)
Heat exchanger Heat exchanger
engine-mounted remote
Rated engine speed A rpm 1800 1800 1800 1800
Fuel stop power ISO 3046 A kW 2000 2000 2000 2000
FUEL SYSTEM
Heat exchanger Heat exchanger
engine-mounted remote
Fuel pressure at engine inlet connection, L bar -0.1 -0.1 -0.1 -0.1
min. (when engine is starting)
Fuel pressure at engine inlet connection, L bar -0.3 -0.3 -0.3 -0.3
min. (during engine operation)
Fuel pressure at engine inlet connection, L bar 1.5 1.5 1.5 1.5
max. (when engine is starting)
Fuel supply flow, max. A Liters/
min
STARTER (electric)
Heat exchanger Heat exchanger
engine-mounted remote
Rated starter voltage (standard design) R V= 24 24 24 24
CAPACITIES
Heat exchanger Heat exchanger
engine-mounted remote
Engine coolant, engine side (with cooling R Liters 350 350 -- --
system)
Total engine oil capacity at initial filling R Liters 280 280 280 280
(standard oil system) (Option: max. oper-
ating inclinations)
Oil change quantity, max. (standard oil R Liters
system) (Option: max. operating inclina-
tions)
Oil pan capacity at dipstick mark “min.” L Liters 211 210 211 210
(standard oil system) (Option: max. oper-
ating inclinations)
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Oil pan capacity at dipstick mark “max.” L Liters 250 250 250 250
(standard oil system) (Option: max. oper-
ating inclinations)
POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)
Heat exchanger Heat exchanger
engine-mounted remote
Rated engine speed A rpm 1600 1600 1600 1600
Fuel stop power ISO 3046 A kW 1920 1920 1920 1920
FUEL SYSTEM
Heat exchanger Heat exchanger
engine-mounted remote
Fuel pressure at engine inlet connection, L bar -0.1 -0.1 -0.1 -0.1
min. (when engine is starting)
Fuel pressure at engine inlet connection, L bar -0.3 -0.3 -0.3 -0.3
min. (during engine operation)
Fuel pressure at engine inlet connection, L bar 1.5 1.5 1.5 1.5
max. (when engine is starting)
Fuel supply flow, max. A Liters/
min
STARTER (electric)
Heat exchanger Heat exchanger
engine-mounted remote
Rated starter voltage (standard design) R V= 24 24 24 24
CAPACITIES
Heat exchanger Heat exchanger
engine-mounted remote
Engine coolant, engine side (with cooling R Liters 350 350 -- --
system)
Total engine oil capacity at initial filling R Liters 280 280 280 280
(standard oil system) (Option: max. oper-
ating inclinations)
Oil change quantity, max. (standard oil R Liters
system) (Option: max. operating inclina-
tions)
Oil pan capacity at dipstick mark “min.” L Liters 210 210 210 210
(standard oil system) (Option: max. oper-
ating inclinations)
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Oil pan capacity at dipstick mark “max.” L Liters 250 250 250 250
(standard oil system) (Option: max. oper-
ating inclinations)
WARNING
Engine noise above 85 dB (A).
Risk of damage to hearing!
• Wear ear protectors.
Operational checks
Item Task
Engine under load Check engine visually for leaks and general condition; Check air pipework be-
Engine at nominal speed tween air filter and exhaust turbocharger for leaks and damage.
Check for abnormal running noise, vibration, and exhaust color (→ Page 102).
Charge-air cooler Check condenstae drain (→ Page 173).
Air filter Check signal ring position of service indicator (→ Page 176).
Replace air filter (→ Page 174), if the signal ring is completely visible in the
service indicator control window.
HP fuel pump Check relief bores for fuel discharge (→ Page 145).
HT coolant pump Check relief bore for oil and coolant discharge and obstructions
(→ Page 201).
Fuel prefilter (optional) Check reading on differential pressure gauge (→ Page 176);
Drain water and contaminants (→ Page 159).
Raw-water pump (only on Check relief bore for oil and coolant discharge and obstructions
engines with engine-mount- (→ Page 207).
ed or optional remote heat
exchanger)
Bilge pump (optional) Check relief bore for oil and coolant discharge and obstructions
(→ Page 209).
TIM-ID: 0000018474 - 001
tank (14) back to tank (24). Water that collects in the tank is separated.
4. Start engine (→ Page 88).
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 permissible 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 re-
placement simulation with the engine running as part of the Harbor Acceptance Tests.
CAUTION
Damage to engine/plant.
Major material damage!
• Before switching on, ensure that the engine/plant is ready for operation.
• Before switching on, ensure that all housings are closed.
• Before switching on, ensure that no work is in progress anywhere on the entire system.
Emergency stop
1. Refer to automation system operating instructions.
2. Follow instructions.
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WARNING
Compressed air
Risk of injury!
• Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
WARNING
Water jet.
Risk of injury and scalding!
• Do not direct water jet at persons.
• Wear protective clothing, gloves, and goggles / safety mask.
CAUTION
Excessive reaction time of cleaning agents on components.
Damage to component!
• Observe manufacturer's instructions.
• Wear protective clothing, gloves, and goggles / safety mask.
NOTICE
Dry with compressed air.
Damage to component!
• Never aim compressed air directly at electronic components.
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. During external cleaning of the plant with water/steam-jet units, 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.
TIM-ID: 0000010171 - 024
4. For external cleaning with high-pressure jet, use a flat-mouth nozzle only.
5. Carry out external cleaning as follows:
a) Seal all openings in a suitable fashion.
b) Remove coarse dirt.
c) Spray on cleaner sparingly and leave it for 1 to 5 minutes.
d) Use the high-pressure jet to remove the loosened dirt.
Note: Never aim compressed air directly at electronic components.
e) Dry engine.
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
Short circuit or wire break on u Check wiring of charger valve 3 (marine engine)
transistor output 4 (TO 4).
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
was output.
601 – SD ETC1+ETC2
ZKP-Number: 13.011.227
DANGER
Unguarded rotating and moving engine components.
Risk of serious injury – Danger to life!
• Before barring the engine, ensure that nobody is in the danger zone.
Preparatory steps
1. Remove cylinder head cover (→ Page 143).
2. Remove injector (→ Page 147).
Preparatory steps
1. Remove cylinder head cover (→ Page 143).
2. Install barring gear (→ Page 133).
3. Do not use the OT mark (1) (if present) on
the flywheel.
5. Tighten locknut (1) to the specified tightening torque, holding adjusting screw (2) firmly.
Name Size Type Lubricant Value/Standard
Locknut 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 gear (→ Page 133).
2. Install cylinder head cover (→ Page 143).
TIM-ID: 0000012224 - 005
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.
CAUTION
Fuel system high-pressure pump not filled with engine oil.
Damage to components, major material damage!
• Make sure that the high-pressure fuel pump is filled with engine oil before installation or initial
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. Insert plug screw (1).
WARNING
Engine noise above 85 dB (A).
Risk of damage to hearing!
• Wear ear protectors.
Replacing injector
u Remove injector and install new injector (→ Page 147).
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 143).
Removing injector
1. Disconnect cable connector on injector.
TIM-ID: 0000000925 - 008
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 - 008
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 143).
2. Open fuel supply to engine.
TIM-ID: 0000000925 - 008
DANGER
Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
• Take special care when working on a running engine.
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
WARNING
Engine noise above 85 dB (A).
Risk of damage to hearing!
• Wear ear protectors.
CAUTION
Damage to component.
Serious damage to plant!
• For filter replacement with the engine running, operate the engine at low engine load.
• The filter which is to be exchanged must be cut out for a brief period only.
DANGER
Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
• Take special care when working on a running engine.
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
WARNING
Engine noise above 85 dB (A).
Risk of damage to hearing!
• Wear ear protectors.
CAUTION
Damage to component.
Serious damage to plant!
• For filter replacement with the engine running, operate the engine at low engine load.
• The filter which is to be exchanged must be cut out for a brief period only.
WARNING
Engine noise above 85 dB (A).
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
Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
• Take special care when working on a running engine.
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
WARNING
Engine noise above 85 dB (A).
Risk of damage to hearing!
• Wear ear protectors.
WARNING
Tank is pressurized.
Risk of injury!
• Allow pressure to escape slowly.
• Wear goggles or facial protection.
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
WARNING
Component is hot.
Risk of burning!
• Wear protective gloves.
9. Tighten screws (6 or 3) to specified torque (max. half a turn per screw) using a torque wrench.
Name Size Type Lubricant Value/Standard
Screw Tightening torque 40 Nm TIM-ID: 0000012750 - 003
WARNING
Tank is pressurized.
Risk of injury!
• Allow pressure to escape slowly.
• Wear goggles or facial protection.
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
WARNING
Chemical substances.
Risk of irritation and chemical burns!
• Always obey manufacturer's instructions for use!
CAUTION
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.
CAUTION
Unsuitable cleaning tool.
Damage to component!
• Observe manufacturer's instructions.
• Use appropriate cleaning tool.
5. Align clamp (1) and tighten to specified torque using a torque wrench.
Name Size Type Lubricant Value/Standard
Clamp Tightening torque 15 Nm + 2 Nm
6. Install oil lines (2). Tighten threaded adapter at actuating cylinder to specified torque using a torque
wrench.
Name Size Type Lubricant Value/Standard
Threaded adapter 10 G 1/4 Tightening torque (Engine oil) 40 Nm + 4 Nm
A
7. Install charge-air pipework (1) between exhaust turbocharger and intercooler.
8. Install air filter (→ Page 175).
9. Fill with engine coolant (→ Page 199).
5. Align clamp (1) and tighten to specified torque using a torque wrench.
Name Size Type Lubricant Value/Standard
Clamp Tightening torque 15 Nm + 2 Nm
TIM-ID: 0000018629 - 005
WARNING
Engine noise above 85 dB (A).
Risk of damage to hearing!
• Wear ear protectors.
WARNING
Compressed air
Risk of injury!
• Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Air filter
1. Release clamp (2).
2. Remove air filter (3) and clamp (2) from
flange of intake housing (1).
3. Verify that there are no objects in the
flange of the intake housing (1) and clean
it.
4. Attach air filter (3) with clamp (2) onto in-
take housing (1).
5. Tighten clamp (2).
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
Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
• Take special care when working on a running engine.
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
Engine noise above 85 dB (A).
Risk of damage to hearing!
• Wear ear protectors.
DANGER
Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
• Take special care when working on a running engine.
WARNING
Engine noise above 85 dB (A).
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.
CAUTION
Damage to component.
Serious damage to plant!
• For filter replacement with the engine running, operate the engine at low engine load.
• The filter which is to be exchanged must be cut out for a brief period only.
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
Risk of injury!
• Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
CAUTION
Unsuitable cleaning tool.
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. Remove strainer (5) from housing and allow
oil to drip into container.
TIM-ID: 0000036227 - 002
Checking strainer
Item Findings Action
Strainer Metallic residues • Clean
• Monitor engine operation
• Check strainer daily
• Contact Service.
Strainer Damaged Fit new part
Square-section ring Damaged Fit new part
O-ring Damaged Fit new part
Installing strainer
1. Coat square-section ring (4) on strainer (5) with engine oil and install strainer (5).
2. Insert strainer into housing.
3. Fill housing with new engine oil.
4. Coat O-ring (3) with engine oil and fit in filter housing.
5. 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
Risk of injury!
• Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
TIM-ID: 0000014256 - 002
24. Tighten cover screw (1) to specified torque using a torque wrench:
Name Size Type Lubricant Value/Standard
Hex nut 1/2” 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 a suitable receptacle to catch the coolant.
2. Switch off preheating unit.
Final steps
1. Seal all open vent and drain points.
2. Set breather valve onto filler neck and close it.
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.
CAUTION
Cold coolant in hot engine can cause thermal stress.
Formation of cracks in components!
• Fill / top up coolant only into cold engine.
Preparatory steps
1. Turn breather valve on expansion tank (for
engines with remote heat exchanger: the
expansion tank is part of the remote cool-
ing system) counterclockwise up to the
first stop and allow pressure to escape.
2. Continue to turn breather valve counter-
clockwise and remove.
TIM-ID: 0000014569 - 002
Final steps
1. Start the engine and run it without load for some minutes.
2. Check coolant level (→ Page 194) and top up engine coolant as required.
TIM-ID: 0000014569 - 002
WARNING
Engine noise above 85 dB (A).
Risk of damage to hearing!
• Wear ear protectors.
DANGER
Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
• Take special care when working on a running engine.
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
Engine noise above 85 dB (A).
Risk of damage to hearing!
• Wear ear protectors.
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.
Function
The preheating unit heats up the engine coolant. The circulating pump (8) ensures the circulation of the
preheated engine coolant through the engine.
The flow heater (5) comprises a heating element. The thermostat (7) switches off the preheating unit via
contactors when the engine coolant temperature has reached the setting of the thermostat (7).
In the event of excessive coolant temperature, the temperature limiter of the thermostat (7) opens the
control loop. The preheating unit is switched off.
The unit must be reset manually after the fault has been rectified.
1 On/Off switch
Cylinders Rated voltage / frequency Heat output kW
12V and 16V 230 V / 50 Hz 9
400 V / 50 Hz 9
230 V / 60 Hz 9
440 V / 60 Hz 9
TIM-ID: 0000014749 - 004
Function
The preheating unit heats up the engine coolant. The circulating pump (6) ensures the circulation of the
preheated engine coolant through the engine.
The flow heater (4) comprises a heating element. A non-return flap (3) prevents engine coolant from
flowing through the preheating unit when the engine is running.
The thermostat (5) switches off the preheating unit via contactors when the engine coolant temperature
has reached the setting of the thermostat (5).
In the event of excessive coolant temperature, the temperature limiter of the thermostat (5) opens the
control loop. The preheating unit is switched off.
The unit must be reset manually after the fault has been rectified. TIM-ID: 0000014749 - 004
WARNING
Engine noise above 85 dB (A).
Risk of damage to hearing!
• Wear ear protectors.
WARNING
Engine noise above 85 dB (A).
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.
CAUTION
Contamination of components.
Damage to component!
• Observe manufacturer's instructions.
• Check components for special cleanness.
CAUTION
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.
CAUTION
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.
CAUTION
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 225)).
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.
Fuse lamp
A second indicator is the fuse lamp SILA
TIM-ID: 0000038009 - 001
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.
Brief description of SILA:
• SILA darkNorma operating state
• SILA flashes orangeOne or more fuses have tripped
The fuse lamp (SILA) signals the following states:
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 - 001
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 at Headquarters: Service-support@mtu-online.com
Feeler gage
Part No.: Y20010128
Qty.: 1
Used in: 7.3.2 Valve clearance – Check and adjustment
(→ Page 140)
Filter wrench
Part No.: F30379104
Qty.: 1
Used in: 7.6.2 Supplementary fuel filter – Replacement
(→ Page 153)
Qty.: 1
Used in: 7.6.3 Fuel filter – Replacement (→ Page 154)
Qty.:
Used in: 7.13.1 Engine oil filter – Replacement (→ Page 183)
Qty.: 1
Used in: 7.13.3 Centrifugal oil filter – Cleaning and filter sleeve
replacement (→ Page 187)
DCL-ID: 0000005757 - 002
Qty.: 1
Used in: 7.14.8 Engine coolant filter – Replacement
(→ Page 203)
Milling cutter
Part No.: F30452739
Qty.: 1
Used in: 7.5.2 Injector – Removal and installation (→ Page 147)
Ratchet
Part No.: F30027340
Qty.: 1
Used in: 7.5.2 Injector – Removal and installation (→ Page 147)
Qty.: 1
Used in: 7.6.7 Fuel prefilter with water separator – Filter ele-
DCL-ID: 0000005757 - 002
Ratchet adapter
Part No.: F30027340
Qty.: 1
Used in: 7.7.1 Compressor wheel – Cleaning (→ Page 165)
Ratchet adapter
Part No.: F30027339
Qty.: 1
Used in: 7.18.5 Coalescer filter element – Replacement
(→ Page 214)
Socket wrench, 24 mm
Part No.: F30039526
Qty.: 1
Used in: 7.3.2 Valve clearance – Check and adjustment
(→ Page 140)
E F
DCL-ID: 0000005757 - 002
T
Maintenance schedule Tasks
– Maintenance task reference table [QL1] 100 – After extended out-of-service periods 90
MTU contact persons 230 Tasks after extended out-of-service periods (>3 weeks) 90
Transport 14
O
Troubleshooting 102
Oil indicator filter – Fuel treatment system 105
– Check 185
Operational checks 89 V
Valve clearance
– Check and adjustment 140
W
Warning notices, standards 13
Water drain valve
– Check 210
Water level probe (3-in-1 rod electrode)
– Check 212
Wiring - engine
– Check 216
DCL-ID: 0000005757 - 002