20V 4000M 93, M93L (PDF, 22 MB) - MTU

Operating InstructionsDiesel Engine20 V 4000 M9320 V 4000 M93L

MS150048/03E

Printed in Germany© 2012 Copyright MTU Friedrichshafen GmbHThis Publication is protected by copyright and may not be used in any way whether in whole or in part without the priorwritten permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, micro‐filming 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 damageduring operation.Subject to alterations and amendments.

Table of Contents1 Safety

1.1 General conditions 51.2 Personnel and organizational requirements 61.3 Transport 71.4 Crankshaft transport locking device 81.5 Safety regulations for startup and operation 111.6 Explosion hazard when removing

inspection port cover on engine 121.7 Safety regulations for maintenance and

repair work 131.8 Auxiliary materials, fluids and lubricants,

fire prevention and environmentalprotection 16

1.9 Conventions for safety instructions in thetext 18

2 General Information

2.1 Engine side and cylinder designations 192.2 Product description 202.3 Engine overview 292.4 Sensors, actuators and injectors –

Overview 30

3 Technical Data

3.1 20V 4000 M93 engine data: IMO, engine-mounted heat exchanger, intercooler madeof copper-based alloy 35

3.2 20V 4000 M93 engine data: EPA 2, engine-mounted heat exchanger 38

3.3 20V 4000 M93L engine data: IMO, engine-mounted heat exchanger, intercooler madeof copper-based alloy 41

3.4 20V 4000 M93L engine data: EPA 2,engine-mounted heat exchanger 44

3.5 Firing order 47

4 Operation

4.1 Controls 484.2 Tasks after extended out-of-service periods

(>3 weeks) 494.3 Checks prior to start-up 504.4 Fuel treatment system – Putting into

operation 51

4.5 Starting the engine 534.6 Fuel treatment system – Switching on 544.7 Starting the engine 554.8 Engine emergency stop at BlueLine

automation system (control stand) 564.9 Operational checks 57

4.10 Coupling – Engaging from LOP 584.11 Coupling – Disengaging from LOP 594.12 Waterjet – Flushing from LOP (optional) 604.13 Stopping the engine from LOP 614.14 Stopping the engine at the BlueLine

automation system (control stand) 624.15 Emergency stop from LOP 634.16 After stopping the engine 644.17 Fuel treatment system – Shutdown 654.18 Plant cleaning 66

5 Maintenance

5.1 Maintenance schedule task reference table[QL1] 67

6 Troubleshooting

6.1 Fuel treatment system – Troubleshooting 686.2 Troubleshooting 69

7 Task Description

7.1 Engine 727.1.1 Engine – Barring manually 727.1.2 Engine – Barring with starting system 73

7.2 Cylinder Liner 747.2.1 Cylinder liner – Endoscopic examination 747.2.2 Cylinder liner – Instructions and comments on

endoscopic and visual examination 76

7.3 Valve Drive 787.3.1 Valve gear – Lubrication 787.3.2 Valve clearance – Check and adjustment 797.3.3 Cylinder head cover – Removal and

installation 83

7.4 Injection Valve / Injector 847.4.1 Injector – Replacement 847.4.2 Injector – Removal and installation 85

7.5 Fuel Filter 907.5.1 Fuel filter – Replacement 90

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7.5.2 Fuel prefilter – Differential pressure gaugecheck and adjustment 92

7.5.3 Fuel prefilter – Draining 937.5.4 Fuel prefilter ‒ Flushing 947.5.5 Fuel prefilter – Filter element replacement 96

7.6 Charge-Air Cooling 987.6.1 Compressor wheel – Cleaning 987.6.2 Intercooler – Check water drain for coolant

discharge and obstruction 100

7.7 Air Filter 1017.7.1 Air filter – Replacement 1017.7.2 Air filter – Removal and installation 102

7.8 Air Intake 1037.8.1 Contamination indicator – Signal ring position

check (optional) 1037.8.2 Air flap – Check for ease of movement 104

7.9 Exhaust Flap with Actuator 1057.9.1 Exhaust flap – Check for easy movement 105

7.10 Starting Equipment 1067.10.1 Starter – Condition check 106

7.11 Lube Oil System, Lube Oil Circuit 1077.11.1 Engine oil level – Check 1077.11.2 Engine oil – Change 1087.11.3 Engine oil – Sample extraction and analysis 110

7.12 Oil Filtration / Cooling 1117.12.1 Engine oil filter – Replacement 1117.12.2 Automatic oil filter – Oil filter candle

replacement 1137.12.3 Oil indicator filter – Check 1167.12.4 Centrifugal oil filter – Cleaning and filter

sleeve replacement 118

7.13 Coolant Circuit, General, High-Temperature Circuit 120

7.13.1 Ventilation points 1207.13.2 Engine coolant – Level check 1217.13.3 Engine coolant – Change 1227.13.4 Engine coolant draining 1237.13.5 Engine coolant – Filling 1247.13.6 Engine coolant pump – Relief bore check 1277.13.7 Engine coolant – Sample extraction and

analysis 1287.13.8 Coolant filter – Replacement 129

7.14 Low-Temperature Circuit 1307.14.1 Charge-air coolant – Draining 130

7.15 Raw Water Pump with Connections 1317.15.1 Raw water pump – Relief bore check 131

7.16 Battery-Charging Generator 1327.16.1 Battery-charging generator drive – Coupling

condition check 132

7.17 Engine Mounting / Support 1337.17.1 Engine mounts – Checking securing screws

for firm seating 1337.17.2 Engine mounts – Resilient element check 134

7.18 Drive Systems, Driving End and Free End(Coupling) 136

7.18.1 Coupling – Condition check 136

7.19 Fuel Supply System 1377.19.1 Water drain valve – Check 1377.19.2 Differential pressure gauge – Check 1387.19.3 Water level probe (3-in-1 rod electrode) –

Check 1397.19.4 Pump capacity – Check 1407.19.5 Coalescer filter element – Replacement 141

7.20 Wiring (General) for Engine/Gearbox/Unit 1437.20.1 Engine wiring – Check 143

7.21 Accessories for (Electronic) EngineGovernor / Control System 144

7.21.1 CDC parameters – Reset with DiaSys® 1447.21.2 Engine governor and connectors – Cleaning 1457.21.3 EMU and connectors – Cleaning 1467.21.4 Engine Monitoring Unit EMU 7 – Plug

connection check 1477.21.5 Engine governor – Checking plug-in

connections 1487.21.6 ECU 7 engine governor – Removal and

installation 149

7.22 Emergency Instrumentation (LocalOperating Panel) 150

7.22.1 LOP and connectors – Cleaning 150

8 Appendix A

8.1 Abbreviations 1518.2 MTU contact persons/service partners 153

9 Appendix B

9.1 Special Tools 1549.2 Index 161

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1 Safety1.1 General conditions

GeneralIn addition to the instructions in this publication, the applicable country-specific legislation and other com‐pulsory regulations regarding accident prevention and environmental protection must be observed. Thisstate-of-the-art engine has been designed to meet all applicable laws and regulations. The engine maynevertheless present 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

Correct useThe engine is intended solely for use in accordance with contractual agreements and the purpose envis‐aged for it on delivery. Any other use is considered improper use. The engine manufacturer accepts noliability whatsoever for resultant damage or injury in such case. The responsibility is borne by the useralone.Correct use also includes observation of and compliance with the maintenance specifications.

Modifications or conversionsUnauthorized modifications to the engine represent a safety risk.MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications orconversions.

Spare partsOnly genuine MTU spare parts must be used to replace components or assemblies. MTU accepts noliability whatsoever for damage or injury resulting from the use of other spare parts and the warranty shallbe voided in such case.

Reworking componentsRepair or engine overhaul must be carried out in workshops authorized by MTU.

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1.2 Personnel and organizational requirements

Personnel requirementsAll work on the engine shall be carried out by trained and qualified personnel only.The specified legal minimum age must be observed.The operator must specify the responsibilities of the operating, maintenance and repair personnel.

Organizational measuresThis publication must be issued to all personnel involved in operation, maintenance, repair or transporta‐tion.Keep it at hand at the operating site of the engine so that it is available to operating, maintenance, repairand transport personnel at all times.Use the manual as a basis for instructing personnel on engine operation and repair with an emphasis onexplaining safety-relevant instructions.This is particularly important in the case of personnel who only occasionally perform work on or aroundthe engine. This personnel must be instructed repeatedly.For the identification and layout of the spare parts during maintenance or repair work, take photos or usethe spare parts catalog.

Working clothes and protective equipmentWear proper protective clothing for all work.Use the necessary protective equipment for the given work to be done.

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1.3 Transport

Transport

Lift the engine only with the lifting eyes provided.The lifting eyes are designed for engine transport only, not for the transport of propulsion units (engineand gearbox).Use only the transport and lifting equipment 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 trans‐port pallet or transport with equipment for heavy loads (forklift truck).Prior to transporting the engine, it is imperative to install transportation locking devices for crankshaft andengine mounts.Secure the engine against tilting during transportation. The engine must be especially secured againstslipping 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 todo so.

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1.4 Crankshaft transport locking device

Special tools, Material, Spare partsDesignation / Use Part No. Qty.Torque wrench, 10-60 Nm F30510423 1Torque wrench, 60-320 Nm F30047446 1Engine oil

Transport locking device

Note: The locking device protects the crankshaft bearings from shocks and vibration damage during enginetransport.

For installation and removal of the transport locking device, follow the instructionsbelow:

1. The transport locking device must remain installed as long as possible during engine installation in orderto avoid damage.

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

3. If the engine is to be moved together with the generator, the transport locking device for the generatormust 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 generatoris already mounted on the engine, ensure that the transport locking device of the generator is also re‐moved.

6. Attach these instructions, clearly visible, to the engine.

Removing guard plates and enginemounting brackets (if applicable)on driving end (KS)

1. Remove screws (4) om both sides and takeoff with washers (3), guard plates (1) andengine mounting brackets (2).

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

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Fitting the transport locking deviceon driving end (KS)

Note: Attach plates (2) only to the upper part of the openings.1. Secure the two plates (2) with screws (6) 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 nut (3) onto screws (4) up to the end of the thread.3. The long end of retainers (1) must face downwards. Push retainers (1) with the round front face through

the plate openings (2).Note: The retainers (1) must lock the flywheel only, not the ring gear.

4. Install screws (4) into the bores of retainers (1) until the retainers (1) are locked in position.5. Tighten screws (4) alternately with torque wrench to the specified tightening torque.


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

6. Screw on nuts (3) of both screws (4) at plates (2) and secure.

Removing the transport lockingdevice from driving end (KS)

1. Release the locknuts (3) on both sides ofthe flywheel housing, remove screws (4)and take off the two locks (1).

2. Unscrew screws (6) and remove togetherwith washers (5) and plates (2).

3. Store the removed parts of the transportlocking device together with this documen‐tation carefully for possible reuse.

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Installing guard plates and enginemounting brackets (if applicable)on driving end (KS)

Note: Always use the screws supplied with the orremoved from the guard plates and enginemounting brackets to secure them on theengine.

1. Install engine mounting brackets (2) on bothsides with guard plates (1) washers (3), andscrews (4).

2. Tighten screws (4).

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1.5 Safety regulations for startup and operation

Safety precautions when putting the equipment into operationPrior to initial operation of the assembly or plant, install the assembly or unit according to the specifica‐tions and check the installation according to the MTU specifications.Before putting the device or plant into operation, always ensure:• that all maintenance and repair work is completed,• that all loose parts have been removed from rotating machine components,• that all persons are clear of the danger zone of moving machine components.Immediately after putting the device or plant into operation, make sure that all control and display instru‐ments as well as the monitoring, signaling and alarm systems are working properly.

Safety regulations for equipment operationEmergency procedures must be practiced regularly.The operator must be familiar with the controls and displays.The operator must be familiar with the consequences of all operations to be performed.During operation, the display instruments and monitoring units must be permanently observed with re‐gard to present operating status, violation of limit values and warning or alarm messages.The following steps must be taken if a malfunction of the system is recognized or reported by the system:• inform supervisor(s) in charge,• analyze the message,• if required, carry out emergency operations e.g. emergency engine stop.

Engine operationThe following conditions must be fulfilled before starting the engine:• Wear ear protectors.• Ensure that the engine room is well ventilated.• Do not inhale engine exhaust gases.• Ensure that the exhaust system is free of leaks and that the gases are discharged to atmosphere.• Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binding

agent.• Protect battery terminals, battery-charger terminals and cables against accidental contact.• When the engine is running, never release coolant, oil, fuel, compressed-air or hydraulic lines.

Operation of electrical equipmentWhen operating electrical equipment, certain components of this equipment are live.Observe the safety instructions for these devices.

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1.6 Explosion hazard when removing inspection port cover onengine

DANGER Explosion hazard due to oil vapors.Risk of serious injury – danger to life!• Allow the engine to cool down before opening the crankcase!• Avoid open flames, electrical sparks and ignition sources.

Safety instructionsu Before starting maintenance work, allow the engine to cool down for at least 10 min. (danger of explosion

due to oil vapors).

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1.7 Safety regulations for maintenance and repair work

Safety regulations for maintenance and repair workHave maintenance and repair work carried out by qualified and authorized personnel only.Allow the engine to cool down before starting maintenance work (risk of explosion of oil vapors).Before starting work, relieve pressure in systems and compressed-air lines which are to be opened.Take special care when removing ventilation or plug screws from the engine. Cover the screw or plugwith a rag to prevent fluids escaping under pressure.Take special care when draining hot fluids ⇒ Risk of injury.When changing the engine oil or working on the fuel system, ensure that the engine room is adequatelyventilated.Allow the engine / system to cool down before starting to work.Observe the maintenance and repair instructions.Never carry out maintenance and repair work with the engine running unless expressly instructed to doso.Secure the engine against accidental starting.Disconnect the battery when electrical starters are fitted.Close the main valve on the compressed-air system and vent the compressed-air line when pneumaticstarters are fitted.Disconnect the control equipment from the assembly or system.Use only proper, calibrated tools. Observe the specified tightening torques during assembly/disassembly.Carry out work only on assembles and/or units which are properly secured.Never use lines for climbing.Keep fuel injection lines and connections clean.Always seal connections with caps or covers if a line is removed or opened.Take care not to damage lines, in particular fuel lines, during maintenance and repair work.Ensure that all retainers and dampers are installed correctly.Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent con‐tact 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 proper‐ly protected.Note cooling time for components which are heated for installation or removal ⇒ Risk of burning.When working high on the engine, always use suitable ladders and work platforms. Make sure compo‐nents are placed on stable surfaces.Observe special cleanness when conducting maintenance and repair work on the assembly or system.After completion of maintenance and repair work, make sure that no loose objects are in/on the assem‐bly or system.Before barring the engine, make sure that nobody is standing in the danger zone. Check that all guardshave been reinstalled and that all tools and loose parts have been removed after working on the engine.The following additional instructions apply to starters with beryllium copper pinion:• Breathing protection of filter class P2 must be applied during maintenance work to avoid health haz‐

ards caused by the beryllium-containing pinion. Do not blow out the interior of the flywheel housing orthe starter with compressed air. Clean the flywheel housing inside with a class H dust extraction de‐vice as an additional measure.

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Welding workNever carry out welding work on the assembly, system, or engine-mounted units. Cover the engine whenwelding in its vicinity.Do not use the assembly or system as ground terminal.Do not route the welding lead over or near the wiring harnesses of MTU systems. The welding currentmay otherwise induce an interference voltage in the wiring harnesses which could conceivably damagethe electrical system.Remove parts (e.g. exhaust pipes) which are to be welded from the engine beforehand.

Hydraulic installation and removalCheck the function and safe operating condition of tools and fixtures to be used. Use only the specifieddevices 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.Before starting work, pay attention to the following:• Vent the hydraulic installation/removal tool, the pumps and the lines at the relevant points for the

equipment to be used (e.g. open vent plugs, pump until bubble-free air emerges, close vent plugs).• For hydraulic installation, screw on the tool with the piston retracted.• For hydraulic removal, screw on the tool with the piston extended.For a hydraulic installation/removal tool with central expansion pressure supply, screw spindle into shaftend until correct sealing is established.During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of thecomponent to be installed/removed.

Working on electrical/electronic assembliesAlways obtain the permission of the person in charge before commencing maintenance and repair workor switching off any part of the electronic system required to do so.De-energize the appropriate areas prior to working on assemblies.Do not damage cabling during removal work. When reinstalling ensure that wiring is not damaged duringoperation by contact with sharp objects, by rubbing against other components or by a hot surface.Do not secure cables on lines carrying fluids.Do not use cable binders to secure cables.Always use connector pliers to tighten connectors.Subject the device or system to a function check on completion of all repair work.Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Pack de‐fective electronic components and assemblies in a suitable manner when dispatched for repair, i.e. par‐ticularly protected against moisture and impact and wrapped in antistatic foil if necessary.

Working with laser equipmentWhen working with laser equipment, always wear special laser-protection goggles ⇒ Heavily focused ra‐diation.Laser equipment must be fitted with the protective devices necessary for safe operation according totype and application.

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For conducting light-beam procedures and measurement work, only the following laser devices must beused:• Laser devices of classes 1, 2 or 3A.• Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700

nm), a maximum output of 5 mW, and in which the beam axis and surface are designed to preventany risk to the eyes.

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1.8 Auxiliary materials, fluids and lubricants, fire prevention andenvironmental protection

Fire preventionRectify any fuel or oil leaks immediately; even splashes of oil or fuel on hot components can cause fires –therefore always keep the engine in a clean condition. Do not leave cloths soaked with fluids and lubri‐cants lying on or near the assembly or unit. Do not store inflammable material near the assembly or unit.Do not weld pipes and components carrying oil or fuel! Before welding, clean with a nonflammable fluid.When starting the engine with an external power source, connect the ground lead last and remove it first.To avoid sparks in the vicinity of the battery, connect the ground lead from the external power source tothe ground lead of the engine or to the ground terminal of the starter.Always keep suitable firefighting equipment (fire extinguishers) at hand and familiarize yourself with theiruse.

NoiseNoise can lead to an increased risk of accident if acoustic signals, warning shouts or noises indicatingdanger are drowned.Wear ear protectors in work areas with a sound pressure level in excess of 85 dB (A).

Environmental protection and disposalModification or removal of mechanical or electronic components or the installation of additional compo‐nents as well as the execution of calibration processes that might affect the emission characteristics ofthe engine are prohibited by emission regulations. Emission control units/systems may only be main‐tained, exchanged or repaired if the components used for this purpose are approved by MTU or equiva‐lent components. Noncompliance with these guidelines might represent a violation of the Clean Air Actand involves the termination of the operating license by the emission authorities. MTU does not acceptany liability for violations of the emission regulations. MTU will provide assistance and advice if emission-relevant components are intended to be modified. The MTU Maintenance Schedules ensure the reliabili‐ty and performance of MTU engines and must be complied with over the entire life cycle of the engine.Use only fuel of prescribed quality to comply with emission limit values.Dispose of used fluids, lubricants and filters in accordance with local regulations.Within the EU, batteries can be returned free of charge to MTU FN / MTU Onsite Energy where they aresubjected to proper recycling procedures.

Auxiliary materials, fluids and lubricantsUse only fluids and lubricants that have been tested and approved by MTU.The Fluids and Lubricants Specifications will be amended or supplemented as necessary. Before usingthem, make sure you have the latest version. The latest version is also available at: http://www.mtu-on‐line.com/mtu/mtu-valuecare/mtu-valueservice-Technische-Dokumentation.Keep fluids and lubricants in suitable, properly designated containers. When using fluids, lubricants andother chemical substances, follow the safety instructions that apply to the product. Take special carewhen using hot, chilled or caustic materials. When using flammable materials, avoid all sparks and donot smoke.

Used oilUsed oil contains harmful combustion residues.Rub barrier cream into hands.Wash hands after contact with used oil.

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Lead• When working with lead or lead-containing compounds, avoid direct contact to the skin and do not

inhale lead vapors.• Adopt suitable measures to avoid the formation of lead dust.• Switch on extraction system.• Wash hands after contact with lead or lead-containing substances.

Compressed airObserve special safety precautions when working with compressed air:• Pay special attention to the pressure level in the compressed air network and pressure vessel.• Assemblies and equipment to be connected must either be designed for this pressure, or, if the per‐

mitted pressure for the connecting elements is lower than the pressure required, a pressure reducingvalve and safety valve (set to permitted pressure) must form an intermediate connection.

• Hose couplings and connections must be securely attached.• Wear goggles when blowing off components or blowing away chips.• 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 equipment or tool is to be replaced.• 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.• 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.• Carry out leak test in accordance with the specifications.

Paints and lacquers• When carrying out painting work outside the spray stands provided with fume extraction systems, en‐

sure that the area is well ventilated. Make sure that neighboring work areas are not impaired.• No open flames.• No smoking.• Observe fire prevention regulations.• Always wear a mask providing protection against paint and solvent vapors.

Liquid nitrogen• Store liquid nitrogen only in small quantities and always in regulation containers without fixed covers.• Avoid body contact (eyes, hands).• Wear protective clothing, protective gloves, closed shoes and protective goggles / safety mask.• Make sure that working area is well ventilated.• Avoid all knocks and jars to the containers, fixtures or workpieces.

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

protective clothing.• If such solutions are spilled onto clothing, remove the affected clothing immediately.• Rinse injured parts of the body thoroughly with clean water.• Rinse eyes immediately with eyedrops or clean tap water.

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1.9 Conventions for safety instructions in the text

DANGER In the event of immediate danger.Consequences: Death or serious injury• Remedial action

WARNING In the event of potentially dangerous situations.Consequences: Death or serious injury• Remedial action

CAUTION In the event of dangerous situations.Consequences: Minor injury or material damage• Remedial action

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

Note: This manual contains highlighted safety warnings in accordance with the US ANSI Z535 standard whichbegin with one of the signal words listed above depending on the severity of the hazard.

Safety instructions1. Read and familiarize yourself with all safety notices before starting up or repairing the product.2. Pass on all safety instructions to your operating, maintenance, repair and transport personnel.

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2 General Information2.1 Engine side and cylinder designations

Engine sides are always designated as viewed from the driving end (KS).The cylinders of the left engine side are designated "A" and those of the right side "B" (as per DIN ISO1204). The cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end.Other components are numbered in the same way, i.e. starting with No. 1 on driving end.

1 Left engine side2 KGS = Free end

3 Right engine side4 KS = Driving end

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2.2 Product description

Description of the engine

EngineThe engine is a liquid-cooled four-stroke cycle diesel engine, rotating counterclockwise (seen from driv‐ing end), with direct injection, sequential exhaust turbocharging and charge-air cooling.The engine is monitored by an engine control and monitoring system (ADEC).The 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) andsingle injectors with integrated individual store.The electronic control unit controls• Injection timing• Injection amount• Injection pressure

Exhaust systemThe 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.

TurbochargingSequential 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, hydrauli‐cally-actuated flaps. ETC B1 A2 and B2 on 20V engines.

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 at 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• Coolant expansion tank (20V 4000 M03 only, not installed on engine).

Electronic systemElectronic control and monitoring system with integrated security and test system with interfaces to re‐mote control system (RCS) and to monitoring system (MCS).

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Electronic engine governor (ECU)Functions:• Engine speed control with fuel and speed limitation dependent on engine status and operating condi‐

tions;• 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 monitor‐

ing.

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 combined alarm in engine room;• Interface to CAN field bus for connected, communicating monitoring system components.

SOLAS – Fire protection specifications

Fuel system, fuel lines with fuel pressures exceeding 1.8 barAll lines with SOLAS-compliant covers for pipe connections, according to MTU standard MTN5233, areshown.

1 Fuel line to fuel filter head


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1 Fuel line from fuel filter head

1 Fuel line to HP pump

Lube oil system, oil lines with oil pressures exceeding 1.8 barAll lines with SOLAS-compliant covers for pipe connections, according to MTU standard MTN5233, areshown.


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1 Parting line ETC oil supply free end

1 Parting line ETC oil supply drivingend

1 Oil line to equipment carrier


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1 Oil supply to HP pump

1 Oil supply to flap control free end

1 ETC oil supply on main oil gallery


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1 Switching cylinder air flap A2

1 Oil line connection2 Switching cylinder exhaust flap tur‐

bocharger A23 T piece flap control

1 Connection oil line to turbochargerB1

2 Switching cylinder exhaust flap tur‐bocharger B1

3 T piece flap control turbocharger B1


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1 Switching cylinder air flap turbo‐charger B1

1 Connection oil line to turbochargerB2

2 Switching cylinder exhaust flap tur‐bocharger B2

3 Switching cylinder air flap turbo‐charger B2

4 T piece flap control turbocharger B2

1 Flap control distributor


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Special connectionsThe following types of union are spray-proof in case of leakage even without covers and have been con‐firmed as being SOLAS-compliant by GL and DNV.

Plug-in pipe connectionDesign precludes lateral spray as the point of separation is shielded by the sleeve (4).Only seepage along the pipeline is possible whereby the pressure is greatly reduced by a faulty O-ring(3).The connection is confirmed as compliant with SOLAS by DNV and GL.

Plugs and sensorsScrew plugs (2) are either sealed with copper sealing rings (1) as per DIN or O-rings (ISO).The fluid must first pass the thread in case of a loose threaded union or faulty sealing ring (2).The pressure is so greatly reduced by this and the faulty sealing ring (2) that any leakage is not underpressure.


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HP connections

1 Jacket tube2 HP line3 O-ring4 Union nut5 Recess for O-ring6 Thrust ring7 Leakage-overflow bore

8 Thrust ring9 Union nut

10 Union nut11 Connecting piece12 Circlip13 Thrust ring14 Shims

15 Union nut16 Thrust ring17 HP line outer pipe18 HP line inner19 Ball retaining area20 Leak fuel connection

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 cavity chamber.Leak fuel is allowed to escape without pressure via the leakage overflow bore (7). The cavity chamber issealed by the O-rings (3).This prevents leakage egress.The connection is confirmed as compliant with SOLAS by DNV and GL.


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2.3 Engine overview

1 Oil cooler2 Crankcase breather3 Air filter4 Exhaust turbocharger5 Intercooler

6 Charge-air pipework7 Cylinder head8 Oil filler neck9 Engine mounting

10 Oil pan

11 Automatic oil filter12 HP fuel pump13 Fuel filter14 Centrifugal oil filter(s)15 Coolant cooler

Engine model designationKey to the engine model designations 20V 4000 Mxyz20 Number of cylindersV Cylinder arrangement: V engine4000 SeriesM ApplicationX Application segmenty Design indexz R (reduced power/speed)

L (enhanced power/speed)


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2.4 Sensors, actuators and injectors – Overview

Top view 20V 4000 M

1 B4.A1 (exhaust temper‐ature cyl. A1)









10 B4.A10 (exhaust tem‐perature cyl. A10)

11 B5.2 (lube oil pressureafter filter)

12 B34.2 (fuel pressure be‐fore filter)

13 B34.1 (fuel pressure af‐ter filter)

14 B5.3 (lube oil pressurebefore filter)

15 B48 (fuel pressure incommon rail)

16 B4.B10 (exhaust tem‐perature cyl. B10)

17 B4.B9 (exhaust temper‐ature cyl. B9)










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20V 4000 M left side

1 B7 (lube oil tempera‐ture)

2 B50 (crankcase pres‐sure)

3 B44.3 (turbocharger Cspeed)

4 B4.23 (temperature, tur‐bocharger C)

5 B4.21 (temperature, tur‐bocharger A)

6 B3 (intake air tempera‐ture)

7 B44.1 (turbocharger Aspeed)

8 B10 (charge-air pres‐sure)

9 B57.1 (main bearingtemperature)











20 B5.1 (lube-oil pressureafter filter)


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20V 4000 M free end

1 B6 (coolant tempera‐ture)

2 F46 (leak fuel level)

3 B33 (fuel temperature)4 B1 (camshaft speed)

5 B54 (oil refill pumppressure)

6 B6.2 (coolant tempera‐ture)


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20V 4000 M right side

1 B44.2 (turbocharger Bspeed)

2 B4.22 (temperature, tur‐bocharger B)

3 B49 (charge-air temper‐ature, recirculationvalve)

4 B4.24 (temperature, tur‐bocharger D)

5 B44.4 (turbocharger Dspeed)

6 B16 (coolant pressure)

7 B21 (raw water pres‐sure)

8 B77.B10 (spray oil temp.conrod bearing)











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20 V 4000 M driving end

1 B13.2 (crankshaftspeed)

2 B13 (crankshaft speed)

3 S37.2 (safety switch)4 S37.1 (safety switch)


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3 Technical Data3.1 20V 4000 M93 engine data: IMO, engine-mounted heat

exchanger, intercooler made of copper-based alloy

EXPLANATIONAbbr. 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 20V 4000

M93Application group 1DSIntake air temperature °C 25Raw water inlet temperature °C 25Barometric pressure mbar 1000Site 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 2100Fuel stop power, ISO 3046 A kW 3900

GENERAL CONDITIONS (for maximum power)Number of cylinders 20Intake depression (new filter) A mbar 15Intake depression, max. L mbar 30

MODEL-RELATED DATA (basic design)Number of cylinders 20Cylinder arrangement: V angle Degrees 90Bore mm 170Stroke mm 190

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Number of cylinders 20Cylinder displacement Liters 4.31Total displacement Liters 86.2Number of inlet valves per cylinder 2Number of exhaust valves per cylinder 2

RAW WATER CIRCUIT (open circuit)Number of cylinders 20Raw water pump: Inlet pressure, min. L bar -0.2Raw water pump: Inlet pressure, max. L bar 0.5Pressure 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 6Lube oil operating pressure before engine, to R bar 8Lube 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 -0.1Fuel pressure at engine inlet connection, min. (during engine operation) L bar -0.3Fuel pressure at engine inlet connection, max. (during engine start) L bar 1.5Fuel supply rate, max. R liters/min 30

GENERAL OPERATING DATANumber of cylinders 20Firing speed, from R rpm 80Firing 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 8Starting-air pressure before starter motor, max. R bar 10

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

L Degrees 15

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

L Degrees 22.5

Longitudinal inclination, continuous max., driving end up (Option: max. op‐erating inclinations)

L Degrees 10

Longitudinal inclination, temporary max., driving end up (Option: max. oper‐ating inclinations)

L Degrees NN

Transverse inclination, continuous max. (Option: max. operating inclina‐tions)

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 440Engine oil on initial filling (standard oil system) (Option: max. operating incli‐nations)

R Liters 365

Oil change quantity, max. (standard oil system) (Option: max. operating in‐clinations)

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-fieldsound-pressure level Lp, 1m distance, ISO 6798+2dB(A) tolerance)

R dB(A) 106


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3.2 20V 4000 M93 engine data: EPA 2, engine-mounted heatexchanger



M93Application group 1DSIntake air temperature °C 25Raw water inlet temperature °C 25Barometric pressure mbar 1000Site altitude above sea level m 100



MODEL-RELATED DATA (basic design)Number of cylinders 20Cylinder arrangement: V angle Degrees 90Bore mm 170Stroke mm 190Cylinder displacement Liters 4.31Total displacement Liters 86.2


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Number of cylinders 20Number of inlet valves per cylinder 2Number of exhaust valves per cylinder 2








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L Degrees 15


L Degrees 22.5


L Degrees 10


L Degrees NN


L Degrees 22.5

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


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3.3 20V 4000 M93L engine data: IMO, engine-mounted heatexchanger, intercooler made of copper-based alloy



M93LApplication group 1DSIntake air temperature °C 25Raw water inlet temperature °C 25Barometric pressure mbar 1000Site altitude above sea level m 100





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L Degrees 15


L Degrees 22.5


L Degrees 10


L Degrees NN


L Degrees 22.5


R Liters 365


R Liters 320


L Liters 255


L Liters 300



R dB(A) 118


R dB(A) 107


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3.4 20V 4000 M93L engine data: EPA 2, engine-mounted heatexchanger



M93LApplication group 1DSIntake air temperature °C 25Raw water inlet temperature °C 25Barometric pressure mbar 1000Site altitude above sea level m 100





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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**Lube oil operating pressure before engine, from R bar 6Lube oil operating pressure before engine, to R bar 8Lube oil operating pressure (low idle) (measuring point: before engine) R bar 2.0






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L Degrees 15


L Degrees 22.5


L Degrees 10


L Degrees NN


L Degrees 22.5


R Liters 365


R Liters 320


L Liters 255


L Liters 300



R dB(A) 118


R dB(A) 107


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3.5 Firing order

Firing orderNum‐ber ofcylin‐ders

Firing order

8V A1-B4-A4-A2-B3-A3-B2-B112V A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B116 V A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B720 V A1-B5-A8-B7-A5-B2-A7-B10-A2-B3-A10-B6-A3-B4-A6-B9-A4-B1-A9-B8


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4 Operation4.1 Controls

Automation system controlsRefer to automation system operating instructions

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4.2 Tasks after extended out-of-service periods (>3 weeks)

Tasks after extended out-of-service periods (>3 weeks)Note: Operate fuel treatment system for at least 5 minutes.

1. Start up fuel treatment system (→ Page 51).2. Shut down fuel treatment system (→ Page 65).

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4.3 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 54).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.

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4.4 Fuel treatment system – Putting into operation

Overview of fuel treatment system1 Pressure-free overflow2 Bypass 13 Bypass 24 Safety valve, 3 bar5 Ball valve, inlet6 Pressure gage7 Ventilation, sample extraction8 Differential pressure gage9 Ball valve, outlet

10 Check valve 700 mbar11 Check valve 5 mbar12 Return to overflow container13 Engine14 Overflow container15 Water separator filter16 Ball valve, drain17 Automatic water drain18 Water level electrode19 Ball valve, sample extraction, inlet20 Switchgear cabinet21 Pump22 Coarse filter23 Fuel supply from tank24 Tank

Switching on fuel treatment system1. Switch on fuel treatment system (→ Page 54).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 141).2. Check sealing surfaces on coalescer filter element and in the pressure tank.

Initial operation: HAT1. Replace fuel filter on engine (→ Page 90).

Note: Determine the suction pressure upstream of the engine-mounted fuel delivery pump.2. Install pressure gage in fuel supply line from Yard fuel system to engine.3. Switch on fuel treatment system and operate it for some minutes (→ Page 54).

Result: The fuel is drawn from tank (24), cleaned by the water separator filter (15) and then routed via overflowtank (14) back to tank (24). Water that collects in the tank is separated.

4. Start engine (→ Page 53).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 replace‐ment simulation with the engine running as part of the Harbor Acceptance Tests.

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Simulation of filter replacement with the engine running: HAT1. Switch on fuel treatment system (→ Page 54).2. Start engine (→ Page 53).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 permissible 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

system.

Simulation of power failure (emergency): HAT1. Switch on fuel treatment system (→ Page 54).2. Start engine (→ Page 53).3. Run engine at idling speed.4. Switch off pump (21) on 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 permissible limits and engine operation is satisfactory.6. Increase engine speed to 1000 rpm and monitor suction pressure.

Result: If the suction pressure is within the specified limits, simulation was successful.

Simulation of power failure (emergency): SAT1. Switch on fuel treatment system (→ Page 54).2. Start engine (→ Page 53).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 permissible limits and engine operation is satisfactory.6. Operate engine at full load and monitor suction pressure.

Result: If the suction pressure is within the specified limits, simulation was successful.

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4.5 Starting the engine

Preconditions☑ External start interlock is not active.☑ Emergency air shut-off flaps (if fitted) are open.

DANGER Unguarded rotating and moving engine components.Risk of serious injury – danger to life!• Before barring or starting the engine, make sure that nobody is in the danger zone.

WARNING Engine noise above 85 dB (A).Risk of damage to hearing!• Wear ear protectors.

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 Operation StationLOS

(→ Operating instructions for electronic system)

CCU (→ Operating instructions for electronic system)

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4.6 Fuel treatment system – Switching on

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

CAUTION Damage to engine/plant.Major material damage!• Before switching on, ensure that the engine/plant is ready for operation.• Before switching on, ensure that all housings are closed.• Before switching on, ensure that no work is in progress anywhere on the entire system.

Switching on fuel treatment system1. Carry out checks prior to start-up (→ Page 50).2. Switch on master switch on switch cabinet.

Result: Signal lamp “Control voltage present” lights up.3. Switch on switch for pump.

Result: Signal lamp “Pump running” lights up.

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4.7 Starting the engine

BlueLine automation system

Starting the engine at LOS or at LOP 8 (with display)(→ BlueLine Operating Instructions)

Starting the engine at LOP 6 (without display)(→ BlueLine Operating Instructions)

Starting the engine at control stand(→ BlueLine Operating Instructions)

BlueVision automation system

Starting the engine at LOP 8 (without oil priming pump option)(→ BlueVision ECS-5 Operating Instructions )

Starting the engine at LOP 8 (with oil priming pump option)(→ BlueVision ECS-5 Operating Instructions )

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4.8 Engine emergency stop at BlueLine automation system(control stand)

CAUTION An emergency stop causes extreme stress to the engine.Risk of overheating, damage to components!• Initiate emergency stop only in emergency situations.

Engine emergency stop at BlueLine automation systemItem MeasureEngine Emergency shutdown at automation system BlueLine (→ Operating In‐

structions for BlueLine).

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4.9 Operational checks

DANGER Unguarded rotating and moving engine components.Risk of serious injury – danger to life!• Take special care when working on a running engine.


Operational checksItem ActionEngine oil Check engine oil level (→ Page 107).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 69).

Air filter Check signal ring position of service indicator (→ Page 103);Replace air filter (→ Page 101) if the signal ring is completely visible in theservice indicator observation window.

Intercooler Check condensate drain(s) for water discharge and obstruction(→ Page 100).

Exhaust gas system Check condensate drain for obstructions.Fuel prefilter(s) Drain water and contamination from fuel prefilter (if fitted) (→ Page 93).

Check pointer position of differential pressure gage at fuel prefilter (if ap‐plicable).

HT coolant pump Check relief bore for oil and coolant discharge and contamination(→ Page 127).

Raw water pump Check relief bore for oil and water discharge and contamination(→ Page 131).

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4.10 Coupling – Engaging from LOP

Preconditions☑ LOCAL OPERATION illuminated pushbutton lights up brightly (local operating mode is active).☑ Engine speed in engagement window.☑ No external engagement interlock active.

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.

Engaging coupling without reversing gearbox (CPP, WJ, VS)Item MeasureLOP Press COUPLING IN illuminated pushbutton (→ Page 48).

• COUPLING IN button flashes.• Coupling is engaged.• After receiving the feedback signal from coupling, the COUPLING IN

button is illuminated brightly.

Engaging coupling in ahead direction with reversing gearbox (FPP, WJ)Item MeasureLOP Press COUPLING AHEAD illuminated pushbutton (→ Page 48).

• COUPLING AHEAD button flashes.• Gearbox is engaged in AHEAD direction.• After receiving the feedback signal from coupling, the COUPLING

AHEAD button is illuminated brightly.

Engaging coupling in astern direction with reversing gearbox (FPP)Item MeasureLOP Press COUPLING ASTERN illuminated pushbutton (→ Page 48).

• COUPLING ASTERN button flashes.• Gearbox is engaged astern.• After receiving the feedback signal from coupling, the COUPLING AS‐

TERN button is illuminated brightly.

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4.11 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 48).

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

button is illuminated brightly.

Disengaging coupling with reversing gearbox (FPP, WJ)Item MeasureLOP Press COUPLING NEUTRAL illuminated pushbutton (→ Page 48).

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

NEUTRAL button is illuminated brightly.

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4.12 Waterjet – Flushing from LOP (optional)

Preconditions☑ LOCAL OPERATION illuminated pushbutton lights up brightly (local operating mode is active).☑ Vessel at a standstill and Waterjet bucket below the waterline.☑ Engine speed in engagement window.☑ No external engagement interlock active.

CAUTION Waterjet 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 FLUSH illuminated pushbutton and keep pressed (→ Page 48).

• FLUSH pushbutton flashes.• Gearbox is engaged astern.• After receiving the feedback signal from coupling, the FLUSH pushbut‐

ton is illuminated brightly.LOP Release FLUSH illuminated pushbutton.

• FLUSH pushbutton flashes.• Gearbox is disengaged (neutral position).• Illumination of FLUSH pushbutton is switched off as soon as the feed‐

back signal from coupling is received.

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4.13 Stopping the engine from LOP

Preconditions☑ Engine is running in local mode.

CAUTION Stopping the engine when it is running at full load causes extreme stress to the engine.Risk of overheating, damage to components!• Before shutting down, disengage gear and run the engine at idle speed for at least 10 mins. until

engine temperatures have dropped and constant values are displayed.

Stopping the engine from LOPItem MeasureLOP Disengage gearbox (→ Page 48).LOP Operate engine at idle speed (→ Page 48).Temperature indications Wait until engine temperatures do not fall any further.LOP Press STOP illuminated pushbutton (→ Page 48).

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

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

CAUTION Stopping the engine when it is running at full load causes extreme stress to the engine.Risk of overheating, damage to components!• Before shutting down, disengage gear and run the engine at idle speed for at least 10 mins. until

engine temperatures have dropped and constant values are displayed.

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

(→ BlueLine Operating Instructions).

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4.15 Emergency stop from LOP

CAUTION An emergency stop causes extreme stress to the engine.Risk of overheating, damage to components!• Initiate emergency stop only in emergency situations.

Emergency stop from LOPItem MeasureLOP Open cap of illuminated EMERGENCY STOP pushbutton (→ Page 48).LOP Press EMERGENCY STOP illuminated pushbutton.

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

lamp etc. are tripped.

After emergency stop from LOPItem MeasureLOP Press ALARM ACKNOWLEDGE illuminated pushbutton (→ Page 48).

• Audible and visual signalization stops.LOP Press ALARM ACKNOWLEDGE button again.

• Power supply to ECU is provided;• Alarm has been acknowledged.

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

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4.16 After stopping the engine

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

After stopping the engineItem ActionCoolant circuit Drain coolant (→ Page 123) if:

• freezing temperatures are expected and the engine is to remain out ofservice for an extended period, but engine coolant has no antifreezeadditive;

• 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 to be expected and the engine is to remainout of service for an extended 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• Preserve engine (→ MTU Fluids and Lubricants Specifications

A001061/.. )

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4.17 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.

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4.18 Plant cleaning

Preconditions☑ Engine is stopped and starting disabled.☑ Operating voltage is not present.

Special tools, Material, Spare partsDesignation / Use Part No. Qty.Steam jet cleaner - 1Cleaner (Hakupur 312) 30390 1

WARNING Compressed airRisk 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 cleaning1. Carry out plant cleaning only in areas where an appropriate oil separator is provided (environmental pro‐

tection).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 mustbe observed. The temperature of the cleaning medium must not exceed 80 °C.

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.

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5 Maintenance5.1 Maintenance schedule task reference table [QL1]

The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. TheMaintenance Schedule is a stand-alone publication.The task numbers in this table provide reference to the maintenance tasks specified in the MaintenanceSchedule.

Task Maintenance tasksW0500 Check engine oil level (→ Page 107)W0501 Visually inspect engine for leaks and general condition (→ Page 57)W0502 Check intercooler drain (if applicable) (→ Page 100)W0503 Check maintenance indicator of air filter (→ Page 103)W0504 Check telltale bores of HP fuel pump (→ Page 57)W0505 Check relief bores of coolant pump(s) (→ Page 127)W0506 Check engine for abnormal running noises, exhaust color

and vibrations(→ Page 57)

W0507 Drain water and dirt from fuel prefilter (if applicable) (→ Page 57)W0508 Check reading on differential pressure gage of fuel prefilter (if

applicable)(→ Page 57)

W1001 Replace fuel filter or fuel filter element (→ Page 90)W1005 Replace air filter (→ Page 101)W1006 Replace fuel injectors (→ Page 84)W1008 Replace engine oil filter at each oil change or when the time

limit (years) is reached, at the latest(→ Page 111)

W1009 Check layer thickness of oil residues, clean and replace filtersleeve (if applicable) at each oil change, at the latest

(→ Page 118)

W1011 Perform endoscopic inspection of combustion chambers (→ Page 74)W1016 Generator: Check condition of coupling (→ Page 132)W1036 Replace coolant filter (→ Page 129)W1047 Check and clean oil indicator filter (→ Page 116)W1076 Exhaust turbocharger: Clean compressor wheel (→ Page 98)W1207 Check and adjust valve clearance. ATTENTION! First adjust‐

ment after 1,000 operating hours!(→ Page 79)

W1244 Check operation of rod electrode (if applicable) (→ Page 139)W1245 Differential-pressure gage, check alarm function (if applica‐

ble)(→ Page 138)

W1246 Check pump performance (if applicable) (→ Page 140)W1463 Check general condition of engine mounting (visual inspec‐

tion)(→ Page 133)

W1713 Injector: Reset drift correction (CDC) parameters (→ Page 144)

Table 1: Maintenance schedule task reference table [QL1]

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6 Troubleshooting6.1 Fuel treatment system – Troubleshooting

Illuminated pushbutton “Water alarm” is lit.Cause Corrective action

When the maximum water levelis reached, the water level elec‐trode opens the water drainvalve and water is discharged. Ifthe opening period of the valveexceeds a preset limit (4 mi‐nutes), the pump will switch offand an alarm is initiated.

1. Press illuminated pushbutton “Water alarm” to acknowledge.2. In addition to the automatic water drain function, water can also

be drained manually. To do so, press the illuminated pushbutton“Water drain” to open the drain valve.

Signal lamp “Pump fault” is lit.Cause Corrective action

The drive motor is equipped withan overload protection. If themaximum permissible currentconsumption is exceeded, e.g. incase of a blockage or dry-run‐ning, the motor protection relaytriggers and the pump is switch‐ed off.

u Reset motor protection relay.

Signal lamp “Warning filter” is lit.Cause Corrective action

The differential pressure exceed‐ed 1.3 bar.

u Replace coalescer filter element (→ Page 141).

Illuminated pushbutton “Replace filter element” is lit.Cause Corrective action

The max. permissible differentialpressure of 1.5 bar was exceed‐ed. If the coalescer filter elementis not replaced, pressure will in‐crease further and the safetyvalve will open. Fuel will be ledvia the bypass directly into theoverflow tank.

1. Replace coalescer filter element (→ Page 141).2. Press illuminated pushbutton “Replace filter element” to ac‐

knowledge.

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6.2 Troubleshooting

Engine does not turn when starter is actuatedComponent Probable cause TaskBattery Low or defective Charge or replace (see manufacturer's

documentation).Cable connections defective Check whether cable connections are

properly secured (see manufacturer'sdocumentation).

Starter Engine wiring or starter defective Check whether cable connections areproperly secured, contact Service.

Engine wiring Defective Check (→ Page 143).LOP Seating of assemblies or connectors

possibly looseInspect visually.

ECU Plug-in connections possibly loose Check plug connections (→ Page 148).Engine Running gear blocked (engine cannot

be barred manually)Contact Service.

Engine turns on starting but does not fireComponent Probable cause TaskStarter Poor rotation by starter: Battery low or

defectiveCharge or replace battery (see manu‐facturer's documentation).

Engine wiring Defective Check (→ Page 143).ECU Defective Contact Service.

Engine fires unevenlyComponent Probable cause TaskFuel injection equip‐ment

Injector defective Replace (→ Page 84).

Engine wiring Defective Check (→ Page 143).ECU Defective Contact Service.

Engine does not reach rated speedComponent Probable cause TaskFuel supply Easy-change fuel filter clogged Replace (→ Page 90).Air supply Air filter clogged Check signal ring position of service in‐

dicator (→ Page 103).Fuel injection equip‐ment


Engine wiring Defective Check (→ Page 143).Engine Overload Contact Service.

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Engine speed not steadyComponent Probable cause TaskFuel injection equip‐ment


Speed sensor Defective Contact Service.ECU Defective Contact Service.

Charge-air temperature too highComponent Probable cause TaskEngine coolant Incorrect engine coolant concentration Check (MTU test kit).Intercooler Contaminated Contact Service.Engine room Air-intake temperature too high Check fans and air supply / ventilation

ducts.

Charge-air pressure too lowComponent Probable cause TaskAir supply Air filter clogged Check signal ring position of service in‐

dicator (→ Page 103).Intercooler Contaminated Contact Service.Exhaust turbocharger Defective Contact Service.

Coolant leaks on intercoolerComponent Probable cause TaskIntercooler Leaking, major coolant discharge Contact Service.

Exhaust gas blackComponent Probable cause TaskAir supply Air filter clogged Check signal ring position of service in‐

dicator (→ Page 103).Fuel injection equip‐ment


Engine Overload Contact Service.

Exhaust gas blueComponent Probable cause TaskEngine oil Too much oil in engine Drain engine oil (→ Page 108).

Oil separator or oil preseparator ofcrankcase breather clogged

Replace.

Exhaust turbocharg‐er, cylinder head, pis‐ton rings, cylinder lin‐er

Defective Contact Service.

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Exhaust gas whiteComponent Probable cause TaskEngine Not at operating temperature Run engine to reach operating temper‐

ature.Intercooler Leaking Contact Service.

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7 Task Description7.1 Engine

7.1.1 Engine – Barring manually

Preconditions☑ Engine is stopped and starting disabled.

Special tools, Material, Spare partsDesignation / Use Part No. Qty.Barring device F6555766 1Ratchet head with extension F30006212 1

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.

Engine – Barring manually1. Remove guard plate.

Result: Safety switch preventing engine starting ac‐tivated.

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

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

tation. Apart from the normal compressionresistance, there should be no resistance.

5. For barring device removal, follow reversesequence of working steps.

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7.1.2 Engine – Barring with starting system

Barring using the automation systemRefer to automation system operating instructions

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7.2 Cylinder Liner7.2.1 Cylinder liner – Endoscopic examination

Preconditions☑ Engine is stopped and starting disabled

Special tools, Material, Spare partsDesignation / Use Part No. Qty.Rigid endoscope Y20097353 1

Preparatory steps1. Remove cylinder head cover (→ Page 83).2. Remove injector (→ Page 85).

Positioning crankshaft at BDC1. Using barring gear, turn crankshaft until crankshaft journal of the cylinder to be inspected has reached

BDC.2. Insert endoscope into cylinder liner through injector seat.

Endoscopic examination of cylinder linerFindings Action• Thin carbon coating on circumference of carbon scraper ring• Slight localized additive deposits at top edge• Localized smooth areas on bottom edge• Carbon deposits on circumference in clearance 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• Consistent honing pattern without objections• 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 cir‐

cumference without objections• Piston rings without objections

Further endoscopic examina‐tion required as part of main‐tenance work

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

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

• Heat discoloration of piston rings

Cylinder liner must be re‐placed; Service must be con‐tacted

1. Compile endoscopy report using the table.2. Use technical terms for description of the liner surface (→ Page 76).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.


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Final steps1. Install injector (→ Page 85).2. Install cylinder head cover (→ Page 83).


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7.2.2 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 exami‐nation report.

Findings MeasureMinor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing prod‐

ucts, particles, broken-off burrs). Removed cylinders clearly show such scoringon the running surface under endoscope magnification. Cannot be felt with thefingernail.Findings not critical.

Single scores Clearly visible scores caused by hard particles. They usually start in the TDCarea and cross through the hone pattern in the direction of stroke.Findings not critical.

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

Smoothened area Smoothened areas are on the running surface but almost the whole honingpattern is still visible. Smoothened areas appear brighter and more brilliantthan the surrounding running surface.Findings not critical.

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

Discoloration This is caused by oxidation (surface discoloration through oil or fuel) and tem‐perature differences around the liner. It appears rather darker within the honedstructure in contrast to the bright metallic running surface. The honing patternis undisturbed. Discolorations extend in stroke direction and may be interrupt‐ed.Findings not critical.

Corrosion fields / spots Corrosion fields / spots result from water (condensed water) with the valves inthe overlap (open) position. They are clearly visible due to the dark color of thehoning groove bottom.This corrosion is not critical unless there is corrosion pitting.

Black lines Black lines are a step towards heat discoloration. They are visible as a cleardiscoloration from TDC to BDC in the running surface and the start of localizeddamage to the honing pattern.Cylinder liners with a large number of black lines around the running surfacehave limited service life and should be replaced.


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Findings MeasureBurn mark This is caused by a malfunction in the liner / ring tribosystem. Usually they run

over the whole ring-travel area (TDC/BDC), starting at the first TDC-ring andbecoming more visible from the second TDC-ring 2 onwards and less pro‐nounced from TDC-ring 1. The honing pattern is usually no longer visible anddisplays a clearly defined (straight) edge to the undisturbed surface. The dam‐aged surface is usually discolored. The circumferential length varies.Liners with burn marks, or heat discoloration, starting in TDC ring 1 have to bereplaced.

Seizure marks, scuff‐ing

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

Evaluation of findings and further measuresThe findings in the start phase of oxidation discoloration and heat discoloration are similar. A thoroughinvestigation and compliance with the above evaluation criteria allow an unambiguous evaluation. Toavoid unnecessary disassembly work, it is recommended that another inspection be carried out after fur‐ther operation of the engine.


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7.3 Valve Drive7.3.1 Valve gear – Lubrication


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

Valve gear – Lubrication1. Remove cylinder head covers (→ Page 83).2. Fill oil chambers of valve bridges with oil.3. Fill oil chambers of rocker arms and adjust‐

ing screws with oil.4. Install cylinder head covers (→ Page 83).


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7.3.2 Valve clearance – Check and adjustment

Preconditions☑ Engine is stopped and starting disabled.☑ Engine coolant temperature is max. 40 °C.☑ Valves are closed.

Special tools, Material, Spare partsDesignation / Use Part No. Qty.Feeler gauge Y20098771 1Torque wrench, 60-320 Nm F30452768 1Box wrench socket, 24 mm F30039526 1Ratchet adapter F30027341 1Engine oil

Preparatory steps1. Remove cylinder head cover (→ Page 83).2. Install barring device (→ Page 72).3. The TDC marking (1) (if fitted) on the fly‐

wheel must not be used for reference.


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4. Rotate crankshaft with barring device in di‐rection of engine rotation until TDC-A1marking and pointer are aligned.

Diagram for 8V engines (twocrankshaft positions)

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

X Exhaust valve



X Exhaust valve


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X Exhaust valve



X Exhaust valve

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 (long rocker arm) = 0.2 mm• Exhaust (short rocker arm) = 0.5 mm

3. Check all valve clearances in two crankshaft positions (firing TDC and overlap TDC of cylinder A1) asper diagram.

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.


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Adjusting valve clearance1. Release locknut (1).2. Insert feeler gauge between valve bridge

and rocker arm.3. Use Allen key to set adjusting screw (2) so

that the specified valve clearance is estab‐lished.

4. Feeler gauge must just pass through thegap.

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


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 steps1. Remove barring device (→ Page 72).2. Install cylinder head cover (→ Page 83).


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7.3.3 Cylinder head cover – Removal and installation


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Grease (Kluthe Hakuform 30-10/Emulgier) X00058061O-ring (→ Spare Parts Catalog)

Removing cylinder head cover1. Clean very dirty cylinder head covers (3)

prior to removal.2. Remove screws (1) and washers (2).3. Take off cylinder head cover (3) with O-

ring (4) from cylinder head (5).

Installing cylinder head cover1. Clean mounting surface.2. Check O-ring (4) for damage, replace if necessary.3. Coat O-ring (4) with grease.4. Position O-ring (4) in groove of cylinder head cover (3).5. Fit cylinder head cover (3) on cylinder head (5).6. Install cylinder head cover (3) with screws (1) and washers (2).


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7.4 Injection Valve / Injector7.4.1 Injector – Replacement

Special tools, Material, Spare partsDesignation / Use Part No. Qty.Injector (→ Spare Parts Catalog)

Replacing injectoru Remove injector and install new injector (→ Page 85).


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7.4.2 Injector – Removal and installation


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Installation/removal tool F6789889 1Milling cutter F30452739 1Torque wrench, 0.5-5 Nm 0015384230 1Torque wrench, 10-60 Nm F30452769 1Torque wrench, 60-320 Nm F30452768 1Assembly paste (Optimoly Paste White T) 40477 1Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 1Engine oilO-ring (→ Spare Parts Catalog)

WARNING Fuels are combustible.Risk of fire and explosion!• Avoid open flames, electrical sparks and ignition sources.• Do not smoke.

Preparatory steps1. Shut off fuel supply to engine.2. Remove cylinder head cover (→ Page 83).

Removing injector1. Disconnect cable connector on injector.


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2. Remove HP fuel line (4).3. Remove return line (5).

Note: The injector accumulator will be emptiedwhen removing the adapter.

4. Remove adapter (3).5. Remove screw (2) and take off hold-down

clamp (1).

6. Install installation/removal tool on cylinderhead.

7. Remove injector with installation/removaltool.

8. Remove installation/removal tool.

9. Remove sealing ring (4) from injector or usea self-made hook to take it out of the cylin‐der head.

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

11. Clean all mating and sealing surfaces.12. Cover all connections and bores, or seal

with suitable plugs.


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Installing injector1. Remove plug before installing the injector.

(Do not remove the plug from the HP linebefore installing the adapter.)

2. Coat injector with assembly paste at theseat of the nozzle clamping nut.

3. Fit new sealing ring (4) (included in thescope of supply of the injector) with greaseon injector, observe installation position ofsealing ring (4).

4. Fit new O-rings (3) (included in the scope ofsupply of the injector), O-ring (2) and damp‐ing ring (1) onto the injector and coat withgrease.

5. Clean sealing face on cylinder head andprotective sleeve with milling cutter.

6. Insert injector into cylinder head, ensuringthat the HP line adapter is correctly aligned.

7. Use installation/removal tool to press in in‐jector.

8. Remove installation/removal tool.


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9. Coat screw head mating face (2) andthread with engine oil.

10. Fit hold-down clamp (1) in the correct position and use torque wrench to tighten screw (2) to the specifiedinitial tightening torque.


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.


Adapter Preload torque (Engine oil) 5 Nm to 10 Nm

13. Tighten screw (2) with torque wrench to the specified tightening torque.


Screw M12 Tightening torque 100 Nm + 10 Nm

14. Tighten adapter (3) with torque wrench to the specified tightening torque.


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 se‐quence:

1 Rail (6)2 Adapter (4)


Union nut / thrustscrew

Tightening torque 30 Nm + 5 Nm


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18. Mount double-walled HP line (5) and use torque wrench to tighten to the specified torque. Tighteningsequence:

1 Adapter (4)2 Rail (6)


Union nut / thrustscrew

Tightening torque 40 Nm + 5 Nm

19. Fit cable connector onto injector.Note: If the CDC parameters are not reset, the

exhaust emissions certification of the en‐gine will become null and void.

20. Reset CDC parameters (→ Page 144).

Final steps1. Install cylinder head cover (→ Page 83).2. Open fuel supply to engine.


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7.5 Fuel Filter7.5.1 Fuel filter – Replacement


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Oil filter wrench F30379104 1Diesel fuelEasy-change filter (→ Spare Parts Catalog)Synthetic ring (→ Spare Parts Catalog)




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.


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Fuel filter replacement with theengine stopped

A Both filters operatingB Left filter cut outC Right filter cut out1 Fuel vent2 Fuel filter

1. Cut out the filter to be replaced.2. Remove cut-out easy-change filter using the oil filter wrench.3. Clean the sealing face of the filter head.4. Check sealing ring of the new easy-change filter and coat it with fuel.5. Install SOLAS shielding (→ Page 20).6. Install and tighten easy-change filter by hand.7. Set three-way cock to operating position (both filters cut in).8. Replace further fuel filters in the same way.9. Vent fuel system (1).

Fuel filter replacement with theengine running

1. Cut out the filter to be replaced.2. Remove cut-out easy-change filter using

the oil filter wrench.3. Clean the sealing face of the filter head.4. Check sealing ring of the new easy-change

filter and coat it with fuel.5. Install SOLAS shielding (→ Page 20).6. Install and tighten easy-change filter by

hand.7. Set three-way cock to operating position

(both filters cut in).8. Replace further fuel filters in the same way.


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7.5.2 Fuel prefilter – Differential pressure gauge check and adjustment



Adjusting differential pressuregauge

1. When installing the new filter element: alignadjustable pointer (2) with pressure-indicat‐ing pointer (3) of pressure gauge (1).

2. Check differential pressure.

Checking differential pressure of fuel prefilter1. With the engine running at full load or rated power, read off pressure at gauge (1).2. If differential pressure as indicated between position of adjustable pointer (2) and pressure-indicating

pointer (3) of pressure gauge is ≥ 0.3 bar, flush filter element of the cut-in filter (→ Page 94).


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7.5.3 Fuel prefilter – Draining


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Diesel fuelGasket (→ Spare Parts Catalog)


Fuel prefilter – Draining1. Cut out filter to be drained.

I Left filter cut inII Right filter cut in

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

3. Unlock drain valve (6) by pressing toggleand open it.

4. Drain water and contaminants from filter un‐til pure 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.10. Cut in the cut-out filter again.11. Close threaded vent plug (5) when fuel

emerges.


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7.5.4 Fuel prefilter ‒ Flushing

Special tools, Material, Spare partsDesignation / Use Part No. Qty.FuelGasket (→ Spare Parts Catalog)




Fuel prefilter ‒ Flushing1. Cut out clogged filter.



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

3. Unlock drain valve (6) by pressing valvetoggle, open it and drain fuel.

Result: Fuel flows from filtered side back to the un‐filtered side, flushing the filter depositsdownwards out of the filter.

4. Close threaded vent plug (5) and drainvalve (6).

Fuel prefilter – Topping up with fuel1. Stop engine (→ Page 61) and disable engine start.2. Remove screws for cover and take off cover (2).3. Fill filter housing with clean fuel.4. Place new gasket in cover (2).5. Fit cover with gasket and secure it with screws.6. Check differential pressure (→ Page 92).

Result: If flushing did not lead to an improvement of the differential pressure, replace filter element of fuel prefil‐ter (→ Page 96).


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7.5.5 Fuel prefilter – Filter element replacement


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Diesel fuelFilter element (→ Spare Parts Catalog)Gasket (→ Spare Parts Catalog)


Replacing filter element1. Cut out filter to be drained.



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2. Open threaded vent plug (5) of contaminat‐ed filter.

3. Unlock drain valve (6) by pressing toggleand open it.

4. Drain water and dirt from filter.5. Close drain valve (6).6. Remove screws securing the cover and

take off cover (2).7. Remove spring housing (4) and filter ele‐

ment (3).8. Insert new filter element (3) and spring

housing (4).9. Fill filter housing with clean fuel.

10. Place new gasket in cover (2).11. Fit cover with gasket and secure it with

screws.12. Cut in the cut-out filter again.13. Close threaded vent plug (5) when fuel

emerges.14. Adjust the differential pressure gauge

(→ Page 92).


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7.6 Charge-Air Cooling7.6.1 Compressor wheel – Cleaning


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Cold cleaner X00056750 1


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.

Preparatory steps1. Drain engine coolant.(→ Page 123)2. Remove air filter.(→ Page 102)3. Remove exhaust system after exhaust turbocharger.4. Remove exhaust flap with actuators.5. Remove air intake.

Compressor wheel – CleaningNote: 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.


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Final steps1. Install air intake.2. Install exhaust flap with actuators.3. Install exhaust system after exhaust turbocharger.4. Install air filter.(→ Page 102)5. Fill with engine coolant.(→ Page 124)


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7.6.2 Intercooler – Check water drain for coolant discharge and obstruction




Checking intercooler water drainfor coolant discharge andobstruction

1. With the engine running check the drainbore(s) on the right and left of the enginefor emerging air (at driving end). If no airemerges:

2. Clean drain bore(s) and blow out with com‐pressed air.

3. Significant coolant discharge indicates aleaking intercooler. Contact Service.

Emergency measures prior to engine start with a leaking intercooler1. Remove injectors (→ Page 85).2. Bar engine manually (→ Page 72).3. Bar engine with starting system to blow out cylinder chambers (→ Page 72).4. Install injectors (→ Page 85).


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7.7 Air Filter7.7.1 Air filter – Replacement

Special tools, Material, Spare partsDesignation / Use Part No. Qty.Air filter (→ Spare Parts Catalog)

Replacing the air filter1. Remove old air filter and install new air filter (→ Page 102).2. Reset signal ring of contamination indicator (→ Page 103).


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7.7.2 Air filter – Removal and installation


Removing and installing air filter1. Release clamp (2).2. Remove air filter (3) and clamp (2) from

connecting flange of intake housing (1).3. Verify that there are no objects in the con‐

necting flange of the intake housing (1) andclean it.

4. Place new air filter (3) with clamp (2) ontointake housing (1).

5. Tighten clamp (2).


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7.8 Air Intake7.8.1 Contamination indicator – Signal ring position check (optional)


Checking signal ring position1. If the signal ring is completely visible in the

observation window (2), replace air filter(→ Page 101).

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

Result: Engaged piston with signal ring moves backto initial position.


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7.8.2 Air flap – Check for ease of movement


DANGER Unguarded rotating and moving engine components.Risk of serious injury — danger to life!• Before working on the engine, disable engine start.

Checking air flap for ease ofmovement

1. Open air flap by moving the lever in the di‐rection of the arrow.

2. Release lever.Result: The air flap returns to the original position.

3. Contact Service if the air flap does not fullyreturn to the original position.


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7.9 Exhaust Flap with Actuator7.9.1 Exhaust flap – Check for easy movement


Checking exhaust flap for easymovement

1. Actuate control linkage and actuating cylin‐der several times by hand to check for easymovement.

2. If it does not move freely, contact Service.


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7.10 Starting Equipment7.10.1 Starter – Condition check


Checking starter condition1. Check securing screws of starter for secure seating and tighten if required.2. Check wiring (→ Page 143).


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7.11 Lube Oil System, Lube Oil Circuit7.11.1 Engine oil level – Check

Preconditions☑ Engine shut down and starting disabled.

Checking oil level prior to enginestart

1. Withdraw oil dipstick from guide tube andwipe it.

2. Insert oil dipstick into guide tube up to stop,withdraw after approx. 10 seconds andcheck oil level.

Note: After extended standstill, the oil level mayexceed the mark (1) by up to 2 cm. Thiscan be caused by oil flowing from e.g. oil fil‐ter or heat exchanger back to the oil pan.

3. The oil level must reach mark (1) or exceedmark (1) by up to 2 cm.

4. Top up with oil to mark (1) as necessary(→ Page 108).

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

Checking oil level after the engine is stopped1. 5 minutes after stopping the engine, remove oil dipstick from the guide tube and wipe it.2. Insert oil dipstick into guide tube up to stop, withdraw after approx. 10 seconds and check oil level.3. Oil level must be between marks (1) and (2).4. Top up with oil to mark (1) as necessary (→ Page 108).5. Insert oil dipstick into guide tube up to the stop.


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7.11.2 Engine oil – Change

Preconditions☑ Engine is stopped and starting disabled.☑ Engine is at operating temperature.☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.

Special tools, Material, Spare partsDesignation / Use Part No. Qty.Torque wrench F30027337 1Ratchet adapter F30027341 1Engine oilSealing ring (→ Spare Parts Catalog)

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 at drain plug(s) on oil pan1. Provide a suitable container in which 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 in which to collect the oil.2. Extract all oil from oil pan using the semirotary hand pump.

Draining residual oil at theequipment carrier

1. Provide a suitable container in which to col‐lect the oil.

2. Remove drain plugs (1) and (2) and drainoil:• Approx. 12 liters at (1)• Approx. 5 liters at (2)

3. Check oil indicator filter (→ Page 116).4. Install drain plug(s) with new sealing ring.


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5. Tighten drain plugs (1) and (2) with torque wrench to the specified torque:


Tightening torque 100 Nm+10Nm

Filling new oil1. Open cover of filler neck.2. Pour oil in at filler neck up to "max." mark at

oil dipstick.3. Close cover of filler neck.4. Check engine oil level (→ Page 107).5. After oil change, bar engine with starting

system (→ Page 73).


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7.11.3 Engine oil – Sample extraction and analysis


Special tools, Material, Spare partsDesignation / Use Part No. Qty.MTU test kit 5605892099/00 1




Engine oil sample extraction andanalysis

1. With the engine running at operating tem‐perature, open screw on automatic oil filterby 1 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 of the

MTU test kit, check engine oil for:• Dispersing capacity (spot test);• Water content;• Dilution by fuel.


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7.12 Oil Filtration / Cooling7.12.1 Engine oil filter – Replacement

Special tools, Material, Spare partsDesignation / Use Part No. Qty.Filter wrench F30379104Engine oilOil filter (→ Spare Parts Catalog)




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.

Replacing engine oil filter1. Stop engine (→ Page 61) and disable en‐

gine start.2. Unscrew oil filter using filter wrench.3. Clean sealing surface on connecting piece.4. Check condition of new oil filter sealing ring

and moisten it with oil.5. Screw on and tighten new oil filter by hand.6. Replace other oil filters in the same way.7. Turn engine with starting system after every

oil change and filter replacement(→ Page 73).

8. Check oil level (→ Page 107).


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Oil filter with diverter (option): Oilfilter replacement with the enginestopped

1. Stop engine (→ Page 61) and disable en‐gine start.

2. Unscrew oil filter using oil filter wrench.3. Clean sealing surface on connecting piece.4. Check condition of new oil filter sealing ring

and moisten it with oil.5. Fit SOLAS shield (→ Page 20).6. Screw on and tighten new oil filter by hand.7. Replace other oil filters in the same way.8. Turn engine with starting system after every

oil change and filter replacement(→ Page 73).

9. Check oil level (→ Page 107).

Oil filter with diverter (option): Oilfilter replacement with the enginerunning

1. To cut out the filter to be replaced, set thethree-way cock to the corresponding posi‐tion.• Position A: Lower filters cut out• Position B: Both filters cut in (normal op‐

erating position)• Position C: Upper filters cut out.

2. Unscrew oil filter using oil filter wrench.3. Clean sealing surface on connecting piece.4. Check condition of new oil filter sealing ring

and moisten it with oil.5. Fit SOLAS shield (→ Page 20).6. Screw on and tighten new oil filter by hand.7. Replace other oil filters in the same way.8. Check oil level (→ Page 107).


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7.12.2 Automatic oil filter – Oil filter candle replacement


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 1Engine oilO-ring (→ Spare Parts Catalog)Oil filter candles (→ Spare Parts Catalog)


CAUTION Contamination of components.Damage to component!• Observe manufacturer's instructions.• Check components for special cleanness.

Removing oil filter candles1. Remove nuts (2) from oil filter cover (1).2. Remove oil filter cover.


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3. Withdraw filter insert (1).4. Remove O-ring.

5. Remove screw (2).6. Withdraw plastic spinner (1) with spring.7. Unscrew nut (3).8. Take off spring washer and washer.9. Remove screw (4).

10. Remove flushing arm (5) from screenplate (6).

11. Turn filter element through 180° and useappropriate tool to push out filter can‐dles (1).

12. Turn filter element through 180° and insertnew filter candles (1) with chamfer facingdownwards.


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Installing oil filter candles1. For installation follow reverse sequence of working steps.2. Additionally, the following instructions are to be observed:

• Replace all sealing elements with new parts• Coat O-rings with grease• Insert O-rings in grooves• Pay attention to installation position of fillister-head screw to elongated hole in shaft


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7.12.3 Oil indicator filter – Check


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Strainer (→ Spare Parts Catalog)Square-section ring (→ Spare Parts Catalog)O-ring (→ Spare Parts Catalog)



CAUTION Unsuitable cleaning tool.Damage to component!• Observe manufacturer's instructions.• Use appropriate cleaning tool.

Removing strainer1. 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.


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Checking strainerItem Findings TaskStrainer 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 (5) with cleaner.2. Remove stubborn deposits with soft brush.3. Blow out strainer (5) with compressed air from inside.

Installing strainer1. 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.


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7.12.4 Centrifugal oil filter – Cleaning and filter sleeve replacement


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Torque wrench, 6-50 Nm F30027336 1Cold cleaner (Hakutex 60) X00056750 1Filter sleeve (→ Spare Parts Catalog)Sealing ring (→ Spare Parts Catalog)Sealing ring (→ Spare Parts Catalog)




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Centrifugal oil filter cleaning andfilter sleeve replacement

1. Remove clamp (14).2. Release cover screw (2) and take off cov‐

er (1).3. Carefully lift rotor (11), allow oil to drain and

remove from housing.4. Holding the rotor (11) firmly, release 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).8. If maximum layer thickness of oil residues

exceeds 45 mm, shorten maintenance in‐terval.

9. Disassemble rotor tube (7), conical disk (8)and rotor base (10).

10. Wash rotor cover (4), rotor tube (7), conicaldisk (8) and rotor base (10) with cold clean‐er.

11. Blow out with compressed air.12. Check sealing ring (9), fit new one if neces‐

sary.13. Assemble rotor tube (7), conical disk (8)

and rotor base (10) with sealing ring (9).14. Insert new filter sleeve (6) in rotor tube (7)

with the smooth paper surface facing theouter wall.

15. Check sealing ring (5), fit new one if neces‐sary.

16. Mount rotor cover (4) with sealing ring (5).17. Tighten rotor cover nut (3) with torque wrench to the specified torque.


Nut Tightening torque 35 Nm to 45 Nm

18. Place rotor (11) in housing (12) and check for ease of movement.19. Check sealing ring (13), fit new one if necessary.20. Fit sealing ring (13) on housing (12).21. Fit cover (1).22. Fit cover screw (2) by hand.23. Install clamp (14) and tighten with torque wrench to the specified torque.


Clamp Tightening torque 8 Nm to 10 Nm

24. Tighten cover nut (2) with torque wrench to the specified torque.


Screw Tightening torque 5 Nm to 7 Nm


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7.13 Coolant Circuit, General, High-Temperature Circuit7.13.1 Ventilation points

Coolant lines on exhaust turbocharger

1 Ventilation point


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7.13.2 Engine coolant – Level check

Preconditions☑ Engine is stopped and starting disabled.☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.

WARNING Coolant is hot and under pressure.Risk of injury and scalding!• Let the engine cool down.• Wear protective clothing, gloves, and goggles / safety mask.

Checking engine coolant level at filler neck:1. Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to

escape.2. Continue to turn breather valve counterclockwise and remove.3. Check engine coolant level (coolant must be visible at the bottom edge of the filler neck's cast eye).

Checking engine coolant level atremote cooler:

1. Check engine coolant level (coolant mustbe visible at marker plate).

2. Top up engine coolant if necessary(→ Page 124).

3. Check and clean breather valve.4. Place breather valve on filler neck and

close.

Checking engine coolant level via level sensor:1. Switch on engine control system and check readings on the display.2. Top up engine coolant if necessary (→ Page 124).


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7.13.3 Engine coolant – Change

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

Engine coolant – Change1. Drain engine coolant (→ Page 123).2. Fill with engine coolant (→ Page 124).


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7.13.4 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 counter‐clockwise and remove.

3. Draw off precipitated corrosion inhibitor oilfrom the expansion tank through filler neck.

4. Open drain valves and drain plugs anddrain coolant 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.


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7.13.5 Engine coolant – Filling

Preconditions☑ Engine is stopped and starting disabled.☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.

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


CAUTION Cold coolant in hot engine can cause thermal stress.Formation of cracks in components!• Fill / top up coolant only into cold engine.

Preparatory steps1. Turn breather valve of coolant expansion

tank counterclockwise to first stop and allowpressure to escape.


3. Release the coolant line union on both tur‐bochargers (→ Page 120).

4. Release the coolant line union at the cool‐ant distributor (→ Page 120).


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Filling with coolant using a pump1. Connect appropriate pump with hose to fill‐

ing connection (arrow) on A side or B side.Alternatively:

2. Connect a suitable pump with a hose todrain valve (arrowed).

3. Pump coolant into engine at 0.5 bar mini‐mum until coolant emerges from the loos‐ened unions at the coolant distributor.

4. Tighten the union for coolant line at thecoolant distributor (→ Page 120).

5. Fill expansion tank until overflow edge isreached.

6. Check proper condition of breather valveand clean sealing faces if required.

7. Place breather valve on filler neck andclose.

8. Continue filling process until coolant emerg‐es from the loosened unions at the two tur‐bochargers.

9. Tighten the coolant line union on both tur‐bochargers (→ Page 120).

10. Start engine (→ Page 53).11. After the engine has run at idling speed for

10 seconds, stop engine (→ Page 61).12. Turn breather valve of coolant expansion

tank counterclockwise to first stop and allowpressure to escape.


14. Check coolant level (→ Page 121) and topup engine coolant as required:

a) Fill in coolant in expansion tank until thecoolant level at top edge of filler neckremains constant.

b) Place breather valve on filler neck andclose.

c) Repeat the steps from "Start engine"(→ Step 10) until coolant no longerneeds to be topped up.

d) Disconnect pump and hose.


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Filling with coolant through filler neck1. Alternatively: Fill coolant through filler neck on expansion tank until coolant emerges from the loosened

unions at the coolant distribution.2. Tighten the union for coolant line at the coolant distributor (→ Page 120).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 120).5. Check proper condition of breather valve and clean sealing faces if required.6. Set breather valve onto filler neck and turn until the first stop to close.7. Start engine (→ Page 53).8. After the engine has run at idling speed for 10 seconds, stop engine (→ Page 61).9. Turn breather valve counterclockwise and remove.

10. Check coolant level (→ Page 121) and top up engine coolant as required:a) Repeat the steps from "Start engine" (→ Step 7) until coolant no longer needs to be topped up.b) Check proper condition of breather valve and clean sealing faces if required.c) Place breather valve on filler neck and close.


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7.13.6 Engine coolant pump – Relief bore check



Engine coolant pump – Relief borecheck

1. Check relief bore for oil and coolant dis‐charge.

2. Shut down engine (→ Page 53) and disableengine start, observe general safety instruc‐tions “Maintenance 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 hour.4. If discharge exceeds the specified limits:

Contact Service.


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7.13.7 Engine coolant – Sample extraction and analysis


Special tools, Material, Spare partsDesignation / Use Part No. Qty.MTU test kit 5605892099/00 1




Engine coolant – Sample extractionand analysis

1. With the engine running, open drain valve(1).

2. Rinse extraction point by draining approx. 1liter of engine coolant.

3. Drain approx. 1 liter of engine coolant into aclean container.

4. Close drain valve (1).5. Use the equipment and chemicals of the

MTU test kit to check the engine coolantfor:• Antifreeze concentration• Corrosion inhibitor concentration• pH value

6. Engine coolant change intervals (→ MTUFluids and Lubricants Specifications).


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7.13.8 Coolant filter – Replacement


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Filter wrench F30379104 1Engine oilCoolant filter (→ Spare Parts Catalog)


Coolant filter – Replacement1. Close shut-off cocks (1).2. Remove coolant filter (2) with filter wrench.3. Clean sealing surface on connecting piece.4. Coat seal on new coolant filter with engine

oil.5. Screw on coolant filter and tighten hand-

tight.6. Open shut-off cocks (1).


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7.14 Low-Temperature Circuit7.14.1 Charge-air coolant – Draining


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Sealing ring (→ Spare Parts Catalog)


Charge-air coolant – Draining1. Provide an appropriate container to drain

the coolant into.2. Turn breather valve of filler neck on coolant

expansion tank counterclockwise to firststop and allow pressure to escape.


4. Draw off separated corrosion inhibitor oil inexpansion tank through the filler neck.

5. Open drain valves and/or drain plugs anddrain coolant at the following points:• at the LT coolant pump• at the LT thermostat housing.

6. Draining of residual coolant:• at the intercooler

7. Close all drain valves and screw in drainplugs with new sealing rings.

8. Place breather valve on filler neck andclose.


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7.15 Raw Water Pump with Connections7.15.1 Raw water pump – Relief bore check



Raw water pump – Relief borecheck

1. Check relief bore for oil and raw water dis‐charge.

2. Shut down engine (→ Page 53) and disableengine start, observe general safety instruc‐tions “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 hour.4. If discharge exceeds the specified limits:

Contact Service.


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7.16 Battery-Charging Generator7.16.1 Battery-charging generator drive – Coupling condition check


Checking condition of battery-charging generator drive coupling

1. Remove protective cover.2. Check resilient coupling for cracks and de‐

formation (arrow).3. Contact Service in case of severe deforma‐

tion or cracking.4. Install protective cover.


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7.17 Engine Mounting / Support7.17.1 Engine mounts – Checking securing screws for firm seating


Engine mounts – Checking securing screws for firm seating1. Check securing screws for firm seating.2. Tighten loose threaded connections.


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7.17.2 Engine mounts – Resilient element check

Preconditions☑ Engine is stopped and starting disabled.☑ Engine is filled with coolant and engine oil.

Special tools, Material, Spare partsDesignation / Use Part No. Qty.Feeler gauge Y20010128 1Calipers Y20001743 1Box wrench F30379609 1Engine oil

Engine mounts – Checking thecondition of resilient elements

1. Wipe rubber surface with dry cloth, do notuse organic detergents.

2. Check resilient elements for crack formationand deformation by visual inspection.

3. Have cracked mounts replaced, contactService.

Engine mounts – Measuring adjustment dimension1. Measure dimension (a) with Vernier caliper.

Note: On new blocked mounts, the adjustment dimension is approx. 28 mm.2. If the measured value of dimension a = 20 mm is lower than the specified value, the resilient element

must be replaced, contact Service.


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Engine mounts – Checking bufferclearance

1. Take off protective cap (2).2. Check marking (1):

• With marking 30: a = 3 mm +0,3 mm.• With marking 40: a = 4 mm +0,3 mm.

3. Check dimension (a) with feeler gauge onmeasuring groove (4).

4. If dimension (a) deviates from the abovespecifications, adjust buffer clearance.

Engine mounts – Buffer clearance adjustment1. Undo nut (3).2. Adjust buffer clearance by turning the central buffer (1).3. Coat mating face of nut (3) and thread of central buffer (1) with a little engine oil. Engine oil must not get

in contact with the rubber elements of the resilient mount.4. Tighten nut (3) to the specified tightening torque securing the central buffer (1) to prevent it turning.


Nut M27 x 2 Tightening torque (Engine oil) 580 Nm +50 Nm

5. Fit protective cap (2).


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7.18 Drive Systems, Driving End and Free End (Coupling)7.18.1 Coupling – Condition check


Coupling condition check1. Remove perforated plate(s).2. Wipe rubber element with dry cloth, do not use organic detergents.3. Check condition of coupling through assembly hole(s) using an inspection lamp. Hair cracks in the rubber

elements are permissible.4. If a considerable number of deeper cracks or places with broken-off rubber are found, contact Service.5. Install perforated plate(s).


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7.19 Fuel Supply System7.19.1 Water drain valve – Check

Water drain valve – Check1. Open water drain valve.2. Check water outlet for obstructions.3. Close water drain valve.


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7.19.2 Differential pressure gauge – Check


Checking differential pressure gauge1. Switch on fuel treatment system (→ Page 54).2. Set the alarm points at the differential pressure gauge to zero.

Result: Alarm is initiated with preset delay.3. Reset the alarm points at the differential pressure gauge to the specified values.


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

Preconditions☑ System is put out of operation and emptied.


Checking water level probe (3-in-1 rod electrode)1. Disconnect connector from water level probe.2. Unscrew water level probe.3. Disconnect connector from water level probe.4. Immerse water level probe into a tank filled with water until water level reaches the thread.5. Switch system on.

Result: Water drain valve opens.6. Leave water level probe in tank.

Result: Alarm must be triggered with the preset delay.7. Switch off the system.8. Disconnect connector from water level probe.9. Remove water level probe from tank.

10. Screw in water level probe.11. Connect connector for water level probe.12. Fill and vent the system then put it into operation.


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7.19.4 Pump capacity – Check


Pump capacity – Check1. Install suitable pressure gauge in the intake connection of the pump.2. Check pump pressure.

a) Switch on fuel treatment system (→ Page 54).Note: The pressure limiting valve at the pump might respond and open. Audible noise is caused by overflowing

fuel and can be disregarded.b) Close ball valve at the outlet of the fuel treatment system.c) Check pressure at the pressure gauge in the inlet to the fuel treatment system and note down.

3. Checking pump pressure with reduced 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 barMeasured value (reduced suction condition). 2.6 barIf the measured value (reduced suction condition) is 10% lower than the measured value (normal con‐dition), the wear limit is reached. Repair pump (contact Service).


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7.19.5 Coalescer filter element – Replacement

Preconditions☑ System is switched off and starting disabled.

Special tools, Material, Spare partsDesignation / Use Part No. Qty.Torque wrench, 6-50 Nm F30027336 1Ratchet adapter F30027339 1Diesel fuelEngine oilCoalescer filter element (→ Spare Parts Catalog)Gasket (→ Spare Parts Catalog)


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.

Coalescer filter element –Replacement

1. Close ball valve at the inlet and outlet of thefuel treatment system.

2. Open drain valve.3. Drain fuel.4. Close drain valve.5. Remove nut (9) with washer (2).6. Remove screws (1).7. Remove cover with gasket (10).8. Remove nut (3), washer (8) and end

plate (7).9. Remove coalescer filter element (4).

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.15. Install end plate (7), washer (8) and nut (3).


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16. Tighten nut (3) to specified tightening torque using a torque wrench.


Nut M16 Tightening torque (Engine oil) 30 Nm +3 Nm

17. Fit gasket (10).18. Install cover.19. Install screw (1), washer (2) and nut (9).20. Tighten nut (9).21. Open ball valve at the inlet and outlet of the fuel treatment system.

Result: The fuel treatment system is ready for operation.


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7.20 Wiring (General) for Engine/Gearbox/Unit7.20.1 Engine wiring – Check


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Isopropyl alcohol X00058037 1

Engine wiring – Check1. Check securing screws of cable clamps on engine and tighten loose threaded connections.2. Ensure that cables are fixed in their clamps and cannot swing freely.3. Check that cable ties are firm, tighten loose cable ties.4. Replace faulty cable ties.5. Visually inspect the following electrical line components for damage:

• connector housings;• contacts;• sockets;• cables and terminals;• plug-in contacts.

6. (→ Contact Service) if cable conductors are damaged.Note: Close male connectors that are not plugged in with the protective cap supplied.

7. Clean dirty connector housings, sockets and contacts with isopropyl alcohol.8. Ensure that all sensor connectors are securely engaged.


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7.21 Accessories for (Electronic) Engine Governor / ControlSystem

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 appli‐

cable.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 appli‐

cable.u Contact Service.


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7.21.2 Engine governor and connectors – Cleaning



Note: Always use test connectors to enter the connectors. Never use test leads for this purpose.Otherwise thecontacts could be bent.

Engine governor and connectors – Cleaning1. Remove coarse dirt from housing surface with isopropyl alcohol.2. Remove dirt from connector and cable surfaces with isopropyl alcohol.3. Check legibility of cable labels. Clean or replace illegible labels.

Cleaning severely contaminated connectors on the engine governorNote: Seal unused connectors with the supplied protective cap.

1. Release the latch and pull off 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 lock them.


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7.21.3 EMU and connectors – Cleaning


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

EMU and connectors – Cleaning1. Remove coarse dirt from housing surface using a cloth moistened with isopropyl alcohol.2. Remove dirt from connector and cable surfaces with isopropyl alcohol.3. Check legibility of cable labels. Clean or replace illegible labels.

Cleaning severely contaminated EMU connectors1. 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 secure latches.


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7.21.4 Engine Monitoring Unit EMU 7 – Plug connection check


Checking EMU plug connections1. Check both connectors on EMU (2) for firm

seating. Ensure that clips (3) are engaged.2. Check screws (1) of cable clamps on EMU

(2) for firm seating. Ensure that cableclamps are not faulty.


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7.21.5 Engine governor – Checking plug-in connections


Note: Always use test connectors to enter the connectors. Never use test leads for this purpose.Otherwise thecontacts could be bent.

Checking plug-in connections on engine governor1. Check all plug-in connections for secure seating.2. Latch connectors if loose.


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7.21.6 ECU 7 engine governor – Removal and installation


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 engine governor fromengine

1. Note or mark assignment of cables andconnectors.

2. Remove all screws (2).3. Undo latches (3) of the connectors.4. Remove all connectors.5. Remove screws (1).6. Take off engine governor.

Installing engine governor on engine1. Install in reverse order. In doing so, ensure correct assignment of connectors and sockets.2. Check rubber mount before installation.

Result: If the rubber mount is porous or defective, replace it.


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7.22 Emergency Instrumentation (Local Operating Panel)7.22.1 LOP and connectors – Cleaning



Cleaning LOP1. 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.

Cleaning connectors on LOP1. Remove dirt from connector and socket surfaces using isopropyl alcohol.2. Check legibility of cable labels. Clean or replace illegible labels.


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8 Appendix A8.1 Abbreviations

Abbrevia‐tion

Meaning Explanation

ADEC Advanced Diesel Engine Control Engine governorAL Alarm Alarm (general)ANSI American National Standards Institute Association of American standardization organiza‐

tionsETC Exhaust turbochargerBR SeriesBV Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU Publica‐

tion No. A01061/..CAN Controller Area Network Data bus system, bus standardCPP Controllable Pitch Propeller Controllable pitch propellerDIN Deutsches Institut für Normung e. V. At the same time identifier of German standards

(DIN = “Deutsche Industrie-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 systemEMU Engine Monitoring Unit Engine monitoring unitSPC Spare Parts CatalogFPP Fixed Pitch Propeller Fixed pitch propellerGCU Gear Control Unit Gear control unitGMU Gear Monitoring Unit Gear monitoring unitHAT Harbour Acceptance TestHI High Alarm: Measured value exceeds 1st maximum limitHIHI High High Alarm: Measured value exceeds 2nd maximum lim‐

it valueHT High Temperature High temperatureICFN ISO - Continuous rating - Fuel stop

power - NetPower specification in accordance with DIN-ISO3046-7

IDM Interface Data Module Memory module for interface dataIMO International Maritime Organization International maritime organisationISO International Organization for Stand‐

ardizationInternational umbrella organization for all nationalstandardization institutes

KGS Kraftgegenseite Engine free end in accordance with DIN ISO 1204

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Abbrevia‐tion

Meaning Explanation

KS Driving end Engine driving end in accordance with DIN ISO1204

LCD Liquid Crystal Display, Liquid CrystalDevice

Liquid-crystal display

LCU Local Control Unit Local control unit (LOP subassembly)LED Light Emitting Diode Light emitting diodeLMU Local Monitoring Unit Local monitoring unit (LOP subassembly)LO Low Alarm: Measured value lower than 1st minimum

limit valueLOLO Low Low Alarm: Measured value lower than 2nd minimum

limit valueLOP Local Operating Panel Control console, control panelLOS Local Operating Station Local operating stationMCS Monitoring and Control System Monitoring and Control SystemMG Message MessageMPU Microprocessor Unit, Microprocessing

UnitMicroprocessor (unit)

OT Oberer TotpunktP-xyz Pressure-xyz Pressure measuring point xyzPAN Panel Control panelPCU Propeller Control Unit Propeller control unitPIM Peripheral Interface Module Peripheral interface moduleRCS Remote Control System 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 Flaps Emergency-air shutoff flap(s)SOLAS International Convention for the Safe‐

ty of Life at SeaInternational Convention for the Safety of Life atSea

SS Safety System Safety system alarmSSK Emergency-air shutoff flap(s)T-xyz Temperature-xyz Temperature measuring point xyzTD Transmitter Deviation Alarm: Sensor comparison faultUT Unterer TotpunktVS Voith Schneider Voith Schneider driveWJ Water Jet Water jet driveTC Tool CatalogZKP Zugehörigkeit-Kategorie-Parameter Assignment category parameter, number scheme

for signals from the ADEC engine governor

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8.2 MTU contact persons/service partners

Our worldwide sales network with its subsidiaries, sales offices, representatives and customer servicecenters ensures fast and direct support on site and 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 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 changedoperating conditions, or for spare parts supply.Your contact at Headquarters: [email protected]

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 warehouseat headquarters and on-site stores at our subsidiary companies, agencies and service workshops.Your contact at Headquarters:E-mail: [email protected]: +49 7541 908555Fax: +49 7541 908121

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9 Appendix B9.1 Special Tools

Barring device

Part No.: F6555766Qty.:Used in:

1 7.1.1 Engine – Barring manually (→ Page 72)

Box wrench


1 7.17.2 Engine mounts – Resilient element check (→Page 134)

Box wrench socket, 24 mm


1 7.3.2 Valve clearance – Check and adjustment (→ Page79)

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Calipers

Part No.: Y20001743Qty.:Used in:


Feeler gauge



Feeler gauge



Filter wrench


7.12.1 Engine oil filter – Replacement (→ Page 111)

Qty.:Used in:

1 7.13.8 Coolant filter – Replacement (→ Page 129)

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Installation/removal tool


1 7.4.2 Injector – Removal and installation (→ Page 85)

Milling cutter



MTU test kit

Part No.: 5605892099/00Qty.:Used in:

1 7.11.3 Engine oil – Sample extraction and analysis (→Page 110)

Qty.:Used in:

1 7.13.7 Engine coolant – Sample extraction and analysis(→ Page 128)

Oil filter wrench


1 7.5.1 Fuel filter – Replacement (→ Page 90)

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Ratchet adapter



Qty.:Used in:

1 7.11.2 Engine oil – Change (→ Page 108)

Ratchet adapter


1 7.19.5 Coalescer filter element – Replacement (→ Page141)

Ratchet head with extension


1 7.1.1 Engine – Barring manually (→ Page 72)

Rigid endoscope


1 7.2.1 Cylinder liner – Endoscopic examination (→ Page74)

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Steam jet cleaner

Part No.: -Qty.:Used in:

1 4.18 Plant cleaning (→ Page 66)

Torque wrench


1 7.11.2 Engine oil – Change (→ Page 108)

Torque wrench, 0.5-5 Nm

Part No.: 0015384230Qty.:Used in:


Torque wrench, 10-60 Nm


1 1.4 Crankshaft transport locking device (→ Page 8)




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1 7.19.5 Coalescer filter element – Replacement (→ Page141)



1 7.12.4 Centrifugal oil filter – Cleaning and filter sleevereplacement (→ Page 118)



1 1.4 Crankshaft transport locking device (→ Page 8)




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9.2 Index20V 4000 M93 engine data: EPA 2, engine-mounted

heat exchanger 3820V 4000 M93 engine data: IMO, engine-mounted heat

exchanger, intercooler made of copper-based alloy 3520V 4000 M93L engine data: EPA 2, engine-mounted

heat exchanger 4420V 4000 M93L engine data: IMO, engine-mounted heat

exchanger, intercooler made of copper-based alloy 41

AAbbreviations 151Actuators– Overview 30After stopping the engine 64Air filter– Removal and installation 102– Replacement 101Air flap – Check for ease of movement 104Automatic oil filter– Filter candles

– Replacement 113Auxiliary materials 16

BBattery-charging generator drive– Coupling condition check 132

CCDC parameters– Reset 144Centrifugal oil filter– Cleaning and filter sleeve replacement 118Charge-air coolant – Draining 130Checks– Prior to start-up 50Coalescer filter element– Replacement 141Compressor wheel– Cleaning 98Connectors– Cleaning 145Contact persons 153Contamination indicator– Signal ring position check 103Controls 48Coolant filter– Replacement 129Coupling– Condition check 136– From LOP 58Crankshaft transport locking device– Removal/installation 8Cylinder– Designation 19Cylinder head cover– Removal and installation 83

Cylinder liner– Endoscopic examination 74– Instructions and comments on endoscopic and visual

examination 76

DDifferential pressure gauge– Check 138Disengaging– from LOP 59

EECU 7 engine governor– Removal and installation 149Emergency stop– From LOP 63EMU 7– Plug connection check 147EMU and connectors – Cleaning 146Engine– Barring with starting system 73– Overview 29– Start 53– Stopping

– At the BlueLine automation system (control stand) 62

– From LOP 61– Wiring check 143Engine coolant– Change 122– Filling 124– Level check 121– Sample extraction and analysis 128Engine coolant draining 123Engine coolant pump – Relief bore check 127Engine emergency stop– At BlueLine automation system (control stand) 56Engine governor– Checking plug-in connections 148– Cleaning 145Engine Monitoring Unit EMU 7– Plug connection check 147Engine mounts– Resilient element check 134Engine mounts– Checking securing screws for firm seating 133Engine oil– Centrifugal oil filter – Cleaning and filter sleeve re‐

placement 118Engine oil filter– Replacement 111Engine oil level– Check 107Engine oil – Change 108Engine oil – Sample extraction and analysis 110

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Engine side– Designation 19Engine wiring– Check 143Engine – barring manually 72Environmental protection 16Exhaust flap– Check for easy movement 105

FFilter– Automatic oil filter

– Filter candles - Replacement 113– Coalescer Element

– Replacement 141Fire prevention 16Firing order 47Fluids and lubricants 16Fuel– prefilter

– Flushing 94– Treatment system

– Troubleshooting 68– treatment system

– Shutdown 65– Switching on 54

Fuel filter – Replacement 90Fuel prefilter– Differential pressure gauge

– Check and adjustment 92– Draining 93– Filter element

– Replacement 96– Flushing 94

– From LOP (option) 60Fuel treatment system– Putting into operation 51– Shutdown 65– Switching on 54

GGeneral conditions 5

HHotline 153

IInjector– Removal and installation 85– Replacement 84Injectors– Overview 30Inspection port cover– Explosion hazard 12Intercooler– Check water drain for coolant discharge and obstruc‐

tion 100

LLOP– Cleaning 150– Connector cleaning 150

MMaintenance work– Safety regulations 13MTU contact persons 153

OOil indicator filter – Check 116Operation– Safety regulations 11Operational checks 57Overview– Engine 29

PPersonnel and organizational requirements 6Plant– Cleaning 66Product description 20Pump capacity– Check 140

RRaw water pump – Relief bore check 131Repair work– Safety regulations 13

SSafety instructions 18Safety regulations 11, 13Sensors– Overview 30Service partners 153Spare parts service 153Starter– Condition check 106Starting the engine 55Startup– Safety regulations 11

TTasks– After extended out-of-service periods 49Tasks after extended out-of-service periods (>3 weeks)

49Transport 7Troubleshooting 69– Fuel treatment system 68

VValve clearance– Adjustment 79– Check 79Valve gear– Lubrication 78

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Ventilation points 120

WWater drain valve– Check 137Water level probe (3-in-1 rod electrode)– Check 139Waterjet– Flushing

– From LOP (option) 60Wiring - engine– Check 143

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20V 4000M 93, M93L (PDF, 22 MB) - MTU

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