MTU 16V 4000M73 Operation Instruction Manual PDF

Operating Instructions
Diesel engine with exhaust gas aftertreatment

16V4000M73
16V4000M73L
MS150123/01E
Engine model Power rating Application group
16V4000M73 160 kW/cyl. 1B, continuous operation, variable, high load
16V4000M73L 177 kW/cyl. 1B, continuous operation, variable, high load
Table 1: Applicability
© 2017 Copyright MTU Friedrichshafen GmbH

This publication is protected by copyright and may not be used in any way, whether in whole or in part, without the prior writ-
ten consent of MTU Friedrichshafen GmbH. This particularly applies to its reproduction, distribution, editing, translation, micro-
filming and storage or processing in electronic systems including databases and online services.
All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen GmbH
reserves the right to change, delete or supplement the information provided as and when required.
Table of Contents
1 Safety 5.7 Fuel treatment system control cabinet –
Controls 65
1.1 Important provisions for all products 6 5.8 Checks prior to start-up 66
1.2 Correct use of all products 7 5.9 Fuel treatment system – Initial start-up 67
1.3 Personnel and organizational requirements 8 5.10 Fuel treatment system – Switching on 70
1.4 Safety regulations for initial start-up and 5.11 Engine with exhaust gas aftertreatment –
operation 9 Emergency stop via automation system 71
1.5 Safety regulations for assembly, 5.12 Engagement via LOP 73
maintenance, and repair work 11 5.13 Disengaging from LOP 74
1.6 Fire prevention and environmental 5.14 Waterjet – Flushing from LOP (optional) 75
protection, fluids and lubricants, indirect 5.15 Engine shutdown via the automation
materials 15 system 76
1.7 Standards for safety notices in the text 17 5.16 Engine with exhaust gas aftertreatment –
Stopping via automation system 77
2 Transport 5.17 After shutting down the engine 78
2.1 Transport 18 5.18 Fuel treatment system – Shutdown 79
2.2 Lifting instructions 19 5.19 Plant – Cleaning 80
2.3 Crankshaft transport locking device 22
6 Maintenance
3 General Information 6.1 Maintenance task reference table [QL1] 81
3.1 Engine side and cylinder designations 25
3.2 Product layout 26 7 Troubleshooting
3.3 Engine – Overview 27 7.1 Control cabinet of fuel treatment system –
3.4 SCR catalytic converter – Overview 28 Troubleshooting 83
3.5 Product description 30 7.2 Troubleshooting 84
3.6 Sensors and actuators – Overview 35 7.3 Fault messages of Engine Control Unit (ECU
3.7 Wiring harness, engine with exhaust gas 9) for Series 4000, marine applications, IMO
aftertreatment – Overview 44 III (provisional) 89
4 Technical Data 8 Task Description

4.1 Product data 16V4000M73, 16V4000M73L, 8.1 SOLAS 120
IMO Tier III (preliminary) 51 8.1.1 SOLAS shielding as per MTN 5233 –
4.2 Product data of SCR catalytic converter 55 Installation 120
4.3 Product – Main dimensions 56 8.1.2 Installation locations for SOLAS shielding 121
4.4 Firing order 58 8.1.3 Adhesive tape for SOLAS shielding –
Application 128
5 Operation 8.2 Engine 129
8.2.1 Engine – Barring manually 129
5.1 LOP controls 59
8.2.2 Engine – Barring with starting system 130
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5.2 Putting the engine into operation after

extended out-of-service periods (>3 months) 60 8.3 Cylinder Liner 131
5.3 Putting the engine into operation after 8.3.1 Cylinder liner – Endoscopic examination 131
scheduled out-of-service-period 61 8.3.2 Cylinder liner – Instructions and comments on
endoscopic and visual examination 133
5.4 Starting the engine via the automation
system 62 8.4 Crankcase Breather 135
5.5 Operational checks 63 8.4.1 Crankcase breather – Oil mist separator
5.6 Tasks after extended out-of-service periods replacement 135
(>3 weeks) 64 8.5 Valve Drive 136
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8.5.1 Valve protrusion – Measurement 136 8.16 Oil Filtration / Cooling 207
8.5.2 Valve gear – Lubrication 140 8.16.1 Automatic oil filter – Overview 207
8.5.3 Valve clearance – Check and adjustment 141 8.16.2 Automatic oil filter – Preparatory steps 210
8.5.4 Cylinder head cover – Removal and 8.16.3 Automatic oil filter ‒ Removal 211
installation 145 8.16.4 Automatic oil filter – Disassembly 213
8.16.5 Automatic oil filter – Cleaning 214
8.6 Injection Pump / HP Pump 146
8.16.6 Automatic oil filter – Checking flushing arm
8.6.1 HP fuel pump – Filling with engine oil 146
rotation 215
8.7 Injector 148 8.16.7 Automatic oil filter – Check 216
8.7.1 Injector – Replacement 148 8.16.8 Automatic oil filter – Assembly 217
8.7.2 Injector – Removal and installation (jacketed 8.16.9 Automatic oil filter – Installation 218
fuel system) 149 8.16.10 Automatic oil filter – Final steps 220
8.16.11 Oil filter element – Overview 221
8.8 Fuel Filter 155 8.16.12 Oil filter element – Removal 223
8.8.1 Fuel filter – Replacement 155
8.16.13 Oil filter element – Disassembly 224
8.8.2 Fuel prefilter – Contamination indicator check 157
8.16.14 Oil filter element – Cleaning 226
8.8.3 Fuel prefilter – Draining 159
8.16.15 Oil filter element – Check 227
8.8.4 Fuel prefilter – Flushing 161
8.16.16 Oil filter element – Assembly 228
8.8.5 Fuel prefilter with water separator – Filter
8.16.17 Oil filter element ‒ Installation 232
element replacement 163
8.16.18 Oil indicator filter – Cleaning and check 235
8.9 Exhaust Turbocharger 166 8.16.19 Centrifugal oil filter – Overview 238
8.9.1 Compressor wheel – Cleaning 166 8.16.20 Centrifugal oil filter – Cleaning and filter-
sleeve replacement 239
8.10 Charge-Air Cooling 170 8.16.21 Centrifugal oil filter – Removal and
8.10.1 Intercooler – Check water drain for coolant installation 241
leakage and obstruction 170
8.17 Coolant System, General, High-Temperature
8.11 Air Filter 171 Circuit 242
8.11.1 Air filter – Replacement 171 8.17.1 Engine coolant – Level check 242
8.11.2 Air filter – Removal and installation 172 8.17.2 Engine coolant – Change 243
8.12 Air Intake 173 8.17.3 Engine coolant – Draining 244
8.12.1 Service indicator – Signal ring position check 173 8.17.4 Engine coolant – Filling 245
8.17.5 Engine coolant pump – Relief bore check 248
8.13 Exhaust Gas Aftertreatment 174 8.17.6 Engine coolant – Sample extraction and
8.13.1 Supply unit – Filter element replacement 174 analysis 249
8.13.2 Supply unit – Replacement 177 8.17.7 Preheater – Overview 250
8.13.3 Dosing unit – Replacement 180 8.17.8 Preheater – Removal 251
8.13.4 Urea solution lines – Replacement 183 8.17.9 Preheater – Overhaul 252
8.13.5 Insulation of SCR housing and SCR bypass – 8.17.10 Preheater – Installation 253
Check 184 8.17.11 Preheater – Function and leak-tightness check 254
8.13.6 Pre-feed module – Filter element replacement 185 8.17.12 Heating element(s) – Electrical check 255
8.13.7 Pre-feed module – Replacement 187 8.17.13 Valve cover – Replacement 256
8.13.8 Exhaust pressure sensor – Measuring lines
check 189 8.18 Raw Water Pump with Connections 257
8.13.9 Exhaust pressure sensor – Measuring lines 8.18.1 Raw water pump – Relief bore check 257
cleaning 190 8.19 Battery-Charging Generator 258
8.13.10 SCR catalytic converter – Mounting alignment 191 8.19.1 Battery-charging generator drive – Coupling
8.13.11 SCR catalytic converter – Mounting check 193
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condition check 258

8.13.12 SCR modules – Replacement 194
8.13.13 NOx sensor – Replacement 199 8.20 Engine Mounting / Support 259
8.20.1 Engine mounting – Check 259
8.14 Starting Equipment 202 8.20.2 Engine mounting – Checking securing screws
8.14.1 Starter – Condition check 202 for firm seating 260
8.15 Lube Oil System, Lube Oil Circuit 203 8.21 Auxiliary PTO 261
8.15.1 Engine oil level – Check 203 8.21.1 Bilge pump – Relief bore check 261
8.15.2 Engine oil ‒ Change 204
8.15.3 Engine oil – Sample extraction and analysis 206 8.22 Fuel Supply System 262
8.22.1 Water drain valve – Check 262
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8.22.2 Differential pressure gage – Alarm function 8.24.6 Engine Monitoring Unit EMU 8 – Removal and
check 263 installation 274
8.22.3 Water level probe (3-in-1 rod electrode) – 8.24.7 Engine Interface Module EIM – Removal and
Check 264 installation 275
8.22.4 Pump capacity – Check 265 8.24.8 Engine Interface Module EIM – Diagnostic
8.22.5 Coalescer filter element ‒ Replacement 266 features 276
8.23 Wiring (General) for Engine/Gearbox/Unit 268 8.25 Emergency Instrumentation (Local
8.23.1 Engine cabling – Check 268 Operating Panel) 279
8.25.1 LOP and connectors – Cleaning 279
8.24 Accessories for (Electronic) Engine
Governor / Control System 269
8.24.1 Limit switch for start interlock – Check 269 9 Appendix A
8.24.2 Engine Control Unit ECU 9 – Plug connection
check 270 9.1 List of abbreviations 280
8.24.3 Engine Monitoring Unit EMU 8 – Plug 9.2 MTU Contact/Service Partners 283
connection check 271
8.24.4 Interface module EIM plug connections – 10 Appendix B
Check 272
8.24.5 Engine governor ECU 9 – Removal and 10.1 Special Tools 284
installation 273 10.2 Index 295
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MS150123/01E 2017-05 | Table of Contents | 5

1 Safety
1.1 Important provisions for all products
General information
This product may pose a risk of injury or damage in the following cases:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Changes or modifications which are neither made nor authorized by the manufacturer
• Noncompliance with the safety instructions and warning notices
Nameplates
The product is identified by nameplate, model designation or serial number and must match with the infor-
mation on the title page of this manual.
Nameplates, model designation or serial number can be found on the product.
All EU-certified engines delivered by MTU come with a second nameplate. When operating the machine in the
EU: The second nameplate must be affixed in a prominent position as described in the accompanying specifi-
cations.
Emission regulations and emission labels

Responsibility for compliance with emission regulations
Modification or removal of any mechanical/electronic components or the installation of additional compo-
nents including the execution of calibration processes that might affect the emission characteristics of the
product are prohibited by emission regulations. Emission control units/systems may only be maintained, ex-
changed or repaired if the components used for this purpose are approved by the manufacturer.
Noncompliance with these regulations will invalidate the design type approval issued by the emissions regu-
lation authorities. The manufacturer does not accept any liability for violations of the emission regulations.
The product must be operated over its entire life cycle according to the conditions defined as "Intended use"
(→ Page 7).
Replacing components with emission labels

On all MTU engines fitted with emission labels, these labels must remain on the engine throughout its opera-
tional life.
Exception: Engines used exclusively in land-based, military applications other than by US government agen-
cies.
Please note the following when replacing components with emission labels:
• The relevant emission labels must be affixed to the spare part.
• Emission labels shall not be transferred from the replaced part to the spare part.
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• The emission labels must be removed from the replaced part and destroyed.
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1.2 Correct use of all products
Correct use
The product is intended for use in accordance with its contractually-defined purpose as described in the rele-
vant technical documents only.
Intended use entails operation:
• Within the permissible operating parameters in accordance with the (→ Technical data)
• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubricants
Specifications of the manufacturer)
• With preservation approved by the manufacturer in accordance with the (→ Preservation and Represerva-
tion Specifications of the manufacturer)
• With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU con-
tact/Service partner)
• In the original as-delivered configuration or in a configuration approved by the manufacturer in writing (al-
so applies to engine control/parameters)
• In compliance with all safety regulations and in adherence with all warning notices in this manual
• In compliance with the maintenance work and intervals specified in the (→ Maintenance Schedule)
throughout the useful life of the product
• In compliance with the maintenance and repair instructions contained in this manual, in particular with
regard to the specified tightening torques
• With the exclusive use of technical personnel trained in commissioning, operation, maintenance and re-
pair
• By contracting only workshops authorized by the manufacturer to carry out repair and overhaul
The product must not be operated in explosive atmospheres, unless the engine fulfills the conditions for such
use and approval has been granted.
Any other use, particularly misuse, is considered as being contrary to the intended purpose. Such improper
use increases the risk of injury and damage when working with the product. The manufacturer shall not be
held liable for any damage resulting from improper, non-intended use.
The specifications of the manufacturer will be amended or supplemented as necessary. Prior to operation,
make sure that the latest version is used. The latest version can be found on the websites:
• For drive systems: http://www.mtu-online.com
• For power generation: http://www.mtuonsiteenergy.com
Modifications or conversions
Unauthorized changes to the product represent a contravention of its intended use and compromise safety.
Changes or modifications shall only be considered to comply with the intended use when expressly author-
ized by the manufacturer. The manufacturer shall not be held liable for any damage resulting from unauthor-
ized changes or modifications.
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MS150123/01E 2017-05 | Safety | 7

1.3 Personnel and organizational requirements
Organizational measures of the user/manufacturer
This manual must be issued to all personnel involved in operation, maintenance, repair, assembly, installa-
tion, or transportation.
Keep this manual handy in the vicinity of the product such that it is accessible to operating, maintenance,
repair, assembly, installation, and transport personnel at all times.
Personnel must receive instruction on product handling and repair based on this manual. In particular, per-
sonnel must have read and understood the safety requirements and warnings before starting work.
This is important in the case of personnel who only occasionally perform work on or around the product.
These personnel must be instructed repeatedly.
Personnel requirements
All work on the product must be carried out by trained, instructed and qualified personnel only:
• Training at the Training Center of the manufacturer
• Qualified personnel from the areas mechanical engineering, plant construction, and electrical engineering
The operator must define the responsibilities of the personnel involved in operation, maintenance, repair, as-
sembly, installation, and transport in writing.
Personnel shall not report for duty under the influence of alcohol, drugs or strong medication.
Clothing and personal protective equipment

Always wear appropriate personal protective equipment, e.g. safety shoes, ear protectors, protective gloves,
goggles, breathing mask. Follow the instructions concerning personal protective equipment in the descrip-
tions of the individual activities.
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1.4 Safety regulations for initial start-up and operation
Safety regulations for initial start-up
Install the product correctly and carry out acceptance in accordance with the manufacturer's specifications
before putting the product into service. All necessary approvals must be granted by the relevant authorities
and all requirements for initial startup must be fulfilled.
Whenever the product is subsequently taken into operation ensure that:
• All personnel is clear of the danger zone surrounding moving parts of the machine.
Electrically-actuated linkages may be set in motion when the Engine Control Unit (governor) is switched
on.
• All maintenance and repair work has been completed.
• All loose parts have been removed from rotating machine components.
• All safety equipment is in place.
• All components must be properly grounded. Ground separately by means of a grounding stake as neces-
sary.
• No persons wearing pacemakers or any other technical body aids are present.
• The service room is adequately ventilated.
• In the first few hours of operation, the product emits gases as a result of smoldering e.g. lacquers or oil.
These gases may be hazardous to health. Always wear respiratory protection in the operating room during
this period.
• The exhaust system is leak-tight and that the gases are vented to atmosphere.
• The product must be free of any damage, this applies in particular to lines and cabling.
• Protect battery terminals, generator terminals or cables against accidental contact.
• Check that all connections have been correctly allocated e.g. +/- polarity, fuel line/urea solution line, sup-
ply/return.
Immediately after putting the product into operation, make sure that all control and display instruments as
well as the signaling and alarm systems work properly.
Smoking is prohibited in the area of the product.
Safety regulations during operation

The operator must be familiar with the control and display elements.
The operator must be familiar with the consequences of any operations performed.
During operation, the display instruments and monitoring units must be permanently observed with regard to
present operating status, violation of limit values and warning or alarm messages.
Malfunctions and emergency stop

Practice emergency procedures, especially emergency stopping, at regular intervals.
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,
• respond by taking any necessary emergency action, e.g. emergency stop.
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Operation
Do not remain in the operating room when the product is running unless absolutely necessary. Keep your
stay as short as possible.
Keep a safe distance away from the product if possible. Do not touch the product unless expressly instructed
to do so following a written procedure.
Do not inhale the exhaust gases of the product.
The following requirements must be fulfilled before the product is started:
• Wear ear protectors.
• Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binding agent.
MS150123/01E 2017-05 | Safety | 9

Operation of electrical equipment
When electrical equipment is in operation, certain components of these appliances are electrically live.
Follow the applicable operating and safety instructions when operating the devices and heed warnings at all
times.
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1.5 Safety regulations for assembly, maintenance, and repair
work
Safety regulations for work prior to assembly, maintenance, and repair
Have assembly, maintenance, or repair work carried out by qualified and authorized personnel only.
Allow the product to cool down to less than 50 °C (risk of explosion for oil vapors, fluids and lubricants, risk
of burning).
Relieve pressure in fluid and lubricant systems and compressed-air lines which are to be opened. Use suita-
ble containers of adequate capacity to catch fluids and lubricants.
Release residual pressure before removing or replacing a component in the supply line. To depressurize pres-
surized lines, shut off the lines first, then release the residual pressure.
When changing the oil or working on the fuel system, ensure that the service room is adequately ventilated.
Never carry out assembly, maintenance, or repair work with the product in operation, unless:
• It is expressly permitted to do so following a written procedure.
Lock-out the product to preclude undesired starting, e.g.
• Start interlock
• Key switch
• Close supply line for hydraulic starting.
Attach “Do not operate” sign in the operating area or to control equipment.
Disconnect the battery cables or actuate the battery isolating switch, if fitted. Lock circuit breakers.
Before starting work on CaPoS, if used:
• Switch of the charging system (DC/DC converter).
• Discharge the UltraCap modules using the appropriate discharger.
• Short-circuit the UltraCap modules with a suitable wire jumper.
Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic start-
ers are fitted.
Before working on the exhaust gas treatment system close the shut-off valve on the urea solution tank. Take
into consideration that the urea solution pumps continue to run for a certain period when the engine was
stopped.
Disconnect the control equipment from the product.
Use the recommended special tools or suitable equivalents when instructed to do so.
Safety regulations when performing assembly, maintenance, and repair work

Special tools and lifting equipment
Use only proper and calibrated tools. Observe the specified tightening torques during assembly or disassem-
bly.
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Setting down, lifting and climbing

Carry out work only on assemblies or plants which are properly secured.
Use appropriate lifting equipment for all components. Use all specified attachment points and observe the
center of gravity.
Never work on engines or components when they are held in place by lifting equipment.
Make sure components or assemblies are placed on stable surfaces. Adopt suitable measures to avoid that
components/tools fall down.
Ensure safe stand when performing assembly work.
MS150123/01E 2017-05 | Safety | 11

Never use the product as a climbing aid.
When working high on the equipment, always use suitable ladders and work platforms. Special instructions
for outdoor areas: There must be no risk of slipping e.g. due to icing.
Removing, installing and cleanliness

Pay particular attention to cleanliness at all times.
Take special care when removing ventilation or plug screws from the product.
Ensure that O-rings are not installed in a slanted/twisted condition.
Carry out appropriate cleaning procedures to clean and inspect components requiring special cleanness
(e.g. components carrying oil, fuel, or air).
Note cooling time for components which are heated for installation or removal (risk of burning).
Ensure that all retainers and dampers are installed correctly.
Remove any accumulation of condensate after assembling chilled components. Coat the components with a
suitable corrosion inhibitor as necessary.
Lines
Keep gaseous/liquid fuel injection lines, lines for urea solution and connections clean.
Always seal connections with caps or covers if a line is removed or opened.
Fit new seals when re-installing lines.
Never bend lines and avoid damaging lines, particularly the fuel lines.
Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent contact
with other components. Do not place fuel or oil lines near hot components.
Miscellaneous
Wear a breathing mask offering protection against soot, dust, and mineral fibers (filter class P2) when work-
ing on exhaust components. Wear protective gloves and goggles for protection against acidic condensate.
Do not touch elastomeric seals (e.g. Viton sealing rings) with your bare hands if they have a carbonized or
resinous appearance.
Elastomer components (e.g. engine mounts, damping elements, couplings and V-belts) must not be painted.
Only install them after painting the engine or mask them prior to painting.
The following applies to starters with copper-beryllium alloy pinions:
• Wear a respirator mask (filter class P3). Do not blow out the interior of the flywheel housing or the starter
with compressed air. Clean the flywheel housing inside with a class H dust extraction device.
• Observe the safety data sheet.
Safety regulations after performing assembly, maintenance, and repair work

Before barring the engine, make sure that nobody is standing in the danger zone of the product.
Check that all access ports/apertures which have been opened to facilitate working are closed again.
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Check that all safety equipment has been installed and that all tools and loose parts have been removed
(especially the barring tool).
Ensure that no unattached parts have been left in/on the product (e.g. including rags and cable straps).
Ensure that the grounding system is properly connected.
Welding work
Welding operations on the product or mounted units are not permitted. Cover the product when welding in
its vicinity.
12 | Safety | MS150123/01E 2017-05

Before starting welding work:
• Switch off the power supply master switch.
• Disconnect the battery cables or actuate the battery isolating switch.
• Separate the electrical ground of electronic equipment from the ground of the unit.
No other assembly, maintenance, or repair work must be carried out in the vicinity of the product while weld-
ing is in progress. There is a risk of explosion or fire due to oil vapors or highly flammable fluids and lubri-
cants.
Do not use product as ground terminal.
Never position the welding power supply cable adjacent to, or crossing wiring harnesses of the product. The
welding current can induce interfering voltages in the wiring harnesses which may damage the electrical sys-
tem.
Remove components (e.g. exhaust pipe) from the product before performing necessary welding work.
Hydraulic installation and removal

Check the function and safe operating condition of tools and fixtures to be used. Use only the specified devi-
ces for hydraulic removal/installation procedures.
Observe the max. permissible push-on pressure specified for the equipment.
Do not attempt to bend or apply force to lines which are under pressure.
Before starting work, pay attention to the following:
• Vent the installation/removal device, the pumps and the pipework at the relevant designated points.
• 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 device with central expansion pressure supply, screw spindle into shaft
end until correct sealing is established.
During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of the
component to be installed/removed.
Working with batteries

Observe the safety instructions of the manufacturer when working on batteries.
Gases released from the battery are explosive. Avoid sparks and naked flames.
Do not allow battery acids to come into contact with skin or clothing.
Wear protective clothing, goggles and protective gloves.
Do not place objects on the battery.
Before connecting the cable to the battery, check the battery polarity. The battery may explode and spray
acid if the battery terminals are connected incorrectly.
Working on electrical and electronic assemblies

Always obtain the permission of the person in charge before commencing assembly, maintenance, and repair
work or switching off any part of the electronic system required to do so.
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De-energize the appropriate areas prior to working on assemblies.

ESD: Work on electrostatically endangered components which could be damaged by electrostatic discharge
(ESD) must always be carried out with appropriate equipment. Appropriate equipment is e.g. electrically con-
ductive work surfaces or antistatic wristbands.
Do not damage wiring during removal work. When reconnecting, ensure that cabling cannot be damaged dur-
ing operation by:
• Contact with sharp edges
• Chafing on components
• Contact with hot surfaces.
MS150123/01E 2017-05 | Safety | 13

Do not secure cables on lines carrying fluids.
Do not use cable ties to secure lines.
Always use connector pliers to tighten union nuts on connectors.
Subject the device as well as the product to functional testing on completion of all repair work. The emergen-
cy stop function must be tested in particular.
Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Package
faulty electronic components or assemblies properly before dispatching for repair:
• Moisture-proof
• Shock-proof
• Wrapped in antistatic foil (as necessary)
Working with laser equipment

Work with laser devices shall be carried out by trained and qualified personnel only. Follow the safety in-
structions in the manufacturer's user manual when working with laser equipment.
Wear special laser safety glasses when working with laser equipment (danger of concentrated radiation).
Laser equipment must be fitted with the protective devices necessary for safe operation according to type
and application.
Measuring component dimensions

Workpieces, components and measuring equipment lie in the specified tolerance range at a reference tem-
perature of 20 °C.
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1.6 Fire prevention and environmental protection, fluids and
lubricants, indirect materials
Fire prevention and safety
Flames, naked light and smoking are prohibited.
Ensure the area is well ventilated when working with combustible fluids and lubricants (e.g. cleaning agents).
The resultant steam/air mixture must be sufficiently diluted to prevent a potentially explosive atmosphere.
Rectify any fuel or oil leaks immediately. Oil or fuel on hot components can cause fires so keep the product
clean at all times. Do not leave rags saturated with fluids and lubricants on the product. Do not store com-
bustible materials near the product.
Clean welding points with a non-flammable fluid before welding. Do not carry out welding work on pipes and
components carrying oil or fuel.
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 cable from the external power source to the
ground cable of the engine or to the ground terminal of the starter.
Ensure that suitable extinguishing agents (fire extinguisher) are always available and that staff are familiar
with their correct handling.
Toxic substances may be present following a fire. Always wear protective gloves and other appropriate per-
sonal protective equipment when handling components.
Noise
Wear ear protectors in work areas with a sound pressure level in excess of 85dB (A).
Noise can lead to an increased risk of accident if acoustic signals, warning shouts or noises indicating dan-
ger are drowned.
Environmental protection and disposal

Dispose of used fluids, lubricants and components in accordance with local regulations.
Within the EU, batteries can be returned free of charge to the manufacturer where they will be properly recy-
cled.
Indirect materials, fluids and lubricants

Indirect materials, fluids and lubricants may be hazardous or contain toxic substances. Observe the informa-
tion provided in the safety data sheet for the product when using indirect materials and other chemical sub-
stances. The safety data sheet may be obtained from the relevant manufacturer or from MTU.
Only use fluids and lubricants which have been approved by the manufacture and are specified in the Fluids
and Lubricants Specifications. Request the latest version from the manufacturer.
Contamination of fluids and lubricants with aqueous urea solution (e.g. AdBlue®, DEF): Store fluids and lubri-
cants in separate containers and use different drip trays. Even tiny amounts of aqueous urea solution can
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contaminate sensors and other components leading to malfunction.
Used oil
Used oil contains harmful combustion residue.
Wear protective gloves.
Wash relevant areas after contact with used oil.
MS150123/01E 2017-05 | Safety | 15

Lead
• Adopt suitable measures to avoid the formation of lead dust.
• Switch on extraction system.
• Avoid direct contact with lead or pastes containing lead.
• Do not inhale lead vapors.
• Wash affected areas after contact with lead or substances containing lead.
Compressed air
• Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII and B) out of con-
tainers, risks causing an explosion.
• Wear goggles when blowing off workpieces or blowing away chips.
• Blowing compressed air into thin-walled containers (e.g. containers made of sheet metal, plastic or glass)
for drying purposes or to check for leaks risks bursting them.
• Pay special attention to the pressure level in the compressed air network or pressure vessel.
• Assemblies or products which are to be connected must be designed to withstand this pressure. Install
pressure-reducing or safety valves set to the admissible pressure if this is not the case.
• Hose couplings and connections must be securely attached.
• Provide the snout of the air nozzle with a protective disk (e.g. rubber disk).
• Relieve residual pressure before removing compressed-air equipment from the supply line. To depressu-
rize compressed-air lines, shut off the lines first, then release the residual pressure.
• Perform leak testing in accordance with instructions.
Paints and lacquers

• Observe the relevant safety data sheet for all materials.
• When carrying out painting work outside the spray stands provided with fume extraction systems, ensure
that the area is well ventilated. Make sure that neighboring work areas are not impaired.
• Avoid open flames in the vicinity.
• No smoking.
• Observe fire prevention regulations.
• Always wear a mask providing protection against paint and solvent vapors.
Liquid nitrogen
• Work with liquid nitrogen may be carried out only by qualified personnel.
• 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/alkaline solutions/urea (e.g. AdBlue®, DEF)

• When working with acids and alkaline solutions, wear protective goggles or face mask, gloves and protec-
tive clothing.
TIM-ID: 0000040536 - 013
• Do not inhale vapors.

• If urea solution is swallowed, rinse out mouth and drink plenty of water.
• Remove any wet clothing immediately.
• Wash affected body areas with plenty of water after skin contact.
• Rinse eyes immediately with eyedrops or clean tap water after eye contact. Seek medical attention as
soon as possible.
Contamination of aqueous urea solution with other fluids and lubricants: Store aqueous urea solution in
separate containers and use different drip trays. Even the slightest contamination may cause the exhaust
aftertreatment system to malfunction.
16 | Safety | MS150123/01E 2017-05

1.7 Standards for safety notices in the text
DANGER
In the event of immediate danger.
Consequences: Death, serious or permanent injury!
• Remedial action.
WARNING
In the event of a situation involving potential danger.
Consequences: Death, serious or permanent injury!
CAUTION
In the event of a situation involving potential danger.
Consequences: Minor or moderate injuries!
NOTICE
In the event of a situation involving potentially adverse effects on the product.
Consequences: Material damage!
• Additional product information.
Warning notices
1. This manual with all safety instructions and safety notices must be issued to all personnel involved in opera-
tion, maintenance, repair, assembly, installation, or transportation.
2. The higher level warning notice is used if several hazards apply at the same time. Warnings related to person-
al injury shall be considered to include a warning of potential damage.
TIM-ID: 0000040578 - 005
MS150123/01E 2017-05 | Safety | 17

2 Transport
2.1 Transport
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Crossbeam T80092210 1
Crossbeam T80092360 1
DANGER
Suspended load.
Danger to life!
• Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.
Transport
1. Install the engine mount locking devices and the engine shipping lock prior to transportation (→ Page 22).
2. Remove the horizontal air filter prior to transport (→ Page 172).
3. Only use the lifting eyes provided to transport the engine (→ Page 19).
4. The exhaust gas aftertreatment system (SCR catalytic converter) must be transported separately. i.e. detach-
ed from the engine and without bypass.
5. Only use the lifting points provided to transport the SCR catalytic converter (→ Page 21).
6. Use suitable transport and lifting gear only.
7. The exhaust gas aftertreatment system / engine must only be transported in installation position: Max. ad-
missible diagonal pull 120° (→ Page 20) / 10° (→ Page 19).
8. Remove any loose parts on the exhaust gas aftertreatment system / engine.
9. Always raise/lower the exhaust gas aftertreatment system / engine slowly. The lifting ropes or chains must
not butt against the exhaust gas aftertreatment system / engine or its components during the lifting proce-
dure. Readjust lifting tackle as necessary.
10. For special packaging with aluminum foil: Suspend the engine by the lifting eyes on the bearing pedestal or
transport by means of handling equipment (forklift truck) capable of bearing the load.
11. Secure the exhaust gas aftertreatment system / engine against tipping during transportation. Secure such
as to preclude slipping and tipping when driving up or down inclines and ramps.
Placement after transport

1. Only set down the exhaust gas aftertreatment system / engine on a firm, level surface. The surface must not
have any buckles, steps / platforms and objects lying on it.
2. Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate.
3. Never set the engine down on its oil pan unless expressly authorized to do so by MTU.
4. Set down the exhaust gas aftertreatment system in such a way than only the mounts, not the main body
touch the ground.
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5. Do not set down the exhaust gas aftertreatment system in an inclined position to avoid damaging the system
and the mounts.
18 | Transport | MS150123/01E 2017-05

2.2 Lifting instructions
DANGER
Suspended load.
Danger to life!
DANGER
Falling from great heights.
Risk of serious injury – danger to life!
• When working high on the equipment, always use suitable ladders or work platforms.
• Use personal protective equipment.
DANGER
The load can slip or tip over.
Danger of crushing limbs and body parts!
• Secure the load.
• When securing the load, only used the permitted fastening points and fastening equipment.
WARNING
Heavy part, risk of falling or overturning due to lack of stability.
Risk of crushing body or limbs!
• Use appropriate lifting gear and appliances.
• Wear safety shoes.
Lifting instructions – 16V engine

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1 Max. admissible diagonal B 293.5 mm, right side E 12 mm

pull 10° C 296.5 mm, left side F 368 mm
2 Center of gravity D 1460 mm G 1102 mm
A 1410 mm
MS150123/01E 2017-05 | Transport | 19

Take note of the engine center of gravity
Refer to the installation/arrangement drawings for details of the center of gravity of the engine.
Lifting instructions – SCR catalytic converter without bypass
1 Max. admissible diagonal B 1057 mm F 921 mm

pull 120° C 527 mm G 549 mm
2 Center of gravity D 2 mm H 134 mm
3 Reference point E 253 mm
A 1675 mm
Take note of the center of gravity of SCR catalytic converter

Refer to the installation/arrangement drawings for details of the center of gravity of the SCR catalytic con-
verter.
TIM-ID: 0000071532 - 002
20 | Transport | MS150123/01E 2017-05

Lifting the SCR catalytic converter without bypass
1 Sling 2 Holder 3 Bearing

Follow the instructions below when lifting the SCR catalytic converter:
• When bypass is installed: Do not secure crane to bypass. Bypass must be removed when lifting by crane.
• Attach lifting equipment (1) (chains, ...) to the upper retainers (2) only.
• Always use all four retainers (2) at the same time.
• Use the big opening in the middle (arrowed) as attachment point for the lifting equipment.
• It is recommended to use a dia. 8 4-strand chain (minimum grade 8) (alternatively dia. 10).
• A crossbeam may be used.
• Ensure that the lifting equipment does not damage components.
• The SCR mount catalytic converter must be parallel to the ground when setting it down to ensure that all
four mounts (3) touch the ground at the same time. Setting the box down at excessive inclination could
damage the mounts.
TIM-ID: 0000071532 - 002
MS150123/01E 2017-05 | Transport | 21

2.3 Crankshaft transport locking device
Torque wrench, 10–60 Nm F30452769 1
Ratchet adapter F30027340 1
Engine oil
Transport locking device

Note: The transport locking device on both sides protects the crankshaft bearings from shocks and possible vibra-
tion damage during engine transport.
For installation and removal of the transport locking device, follow the in-
structions below:
1. The transport locking device on both sides must remain installed as long as possible during engine installa-
tion in order to avoid damage.
2. Prior to every engine transport, the transport locking device must be reinstalled on both sides according to
the instructions.
3. If the engine is to be moved together with the generator, the transport locking device for the generator must
also be installed.
4. Always use the screws supplied with or installed in the transport locking device to secure it on the engine.
5. Starting or barring the engine is allowed only with the transport locking device removed. If the generator is
already mounted on the engine, ensure that the transport locking device of the generator is also removed.
Removing guard plates and en-

gine supports (if applicable) on
driving end (KS)
1. Remove screws (2) on both sides and take off
with washers (1), guard plates and engine
supports (3).
2. Store the removed parts of the transport
locking device carefully for possible reuse.
TIM-ID: 0000073120 - 002
22 | Transport | MS150123/01E 2017-05

Fitting the transport locking de-
vice on driving end (KS)
Note: Attach plate (6) only to the upper part of the openings.
1. Secure the plates (6) with screws (4) and washers (5) at the bores on both sides of the flywheel housing and
tighten to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw M16 Tightening torque (Engine oil) 250 Nm +25 Nm
2. Screw locknut (2) onto screw (1) up to the end of the thread.
3. The long side of holder (3) must face downwards. Insert holder (3) through openings in plate (6).
Note: The holder (3) must lock the flywheel only, not the ring gear.
4. Insert screw (1) in bores of holder (3) until holder (3) is secured.
Note: The screw (1) must be tightened alternately on both sides of the flywheel housing.
5. Tighten screw (1) to specified tightening torque.
6. Place locknut (2) of screw (1) on plate (6) and lock it.
Removing the transport locking

device from driving end (KS)
1. Release the locknut (2) on both sides of the
flywheel housing, remove screw (1) and take
off holder (3).
2. Remove screws (4) and take off together with
washers (5) and plates (6).
3. Store the removed parts of the transport
TIM-ID: 0000073120 - 002
locking device carefully for possible reuse to-

gether with this documentation.
MS150123/01E 2017-05 | Transport | 23

Installing guard plates and en-
gine supports (if applicable) on
driving end (KS)
Note: Screw on guard plates and engine support (where applicable) only with the screws supplied or with the
screws removed from the guard plates or engine supports.
u Install engine supports (3) on both sides with guard plates, washers (1) and screws (2) and tighten to speci-
fied tightening torque tightening.
TIM-ID: 0000073120 - 002
24 | Transport | MS150123/01E 2017-05

3 General Information
3.1 Engine side and cylinder designations
1 Left engine side (A-side) 3 Right engine side (B-side)

2 Engine free end in accord- 4 Engine driving end in ac-
ance with DIN ISO 1204 cordance with
(KGS = Kupplungsgegen- DIN ISO 1204 (KS = Kup-
seite) plungsseite)
Engine sides are always designated (in accordance with DIN ISO 1204) as viewed from driving end (4).
For cylinder designation (in accordance with DIN ISO 1204), the letter "Ax" refers to the cylinders on the left-
hand side of the engine (1) and letter "Bx" refers to the cylinders on the right-hand side (3). The cylinders of
each bank are numbered consecutively, starting with x=1 at driving end (4).
The numbering of other engine components also starts with 1 at driving end (4).
TIM-ID: 0000002185 - 013
MS150123/01E 2017-05 | General Information | 25

3.2 Product layout
16V diesel engine with SCR catalytic converter
1 Horizontal air filter 5 SCR catalytic converter 9 Pre-delivery module

2 Exhaust pipe bellows 6 Bypass line (*) 10 Power distribution
3 Exhaust system (optional) 7 Heat shield (*) Shown without insulation
(*) 8 DCM (Distributed Control
4 Connecting pipe (*) Module) control unit
TIM-ID: 0000071545 - 001
26 | General Information | MS150123/01E 2017-05

3.3 Engine – Overview
Engine layout – 16V
1 Oil cooler 7 Cylinder head cover 13 Automatic oil filter

2 Coolant expansion tank 8 Charge-air pipework 14 Fuel filter
3 Crankcase breather 9 Oil filler neck 15 Centrifugal oil filter(s)
4 Air filter 10 Oil pan 16 Engine governor
5 Exhaust turbocharger 11 Engine mounting 17 Raw water cooler
6 Intercooler 12 HP fuel pump
Engine model designation

Key to the engine model designation 16V4000Mxyz
16 Number of cylinders
V Cylinder arrangement: V engine
4000 Series
M Application (M= Marine)
x Application segment (0, 1, 2, 3, ..., 9)
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y Design index (0, 1, 2, 3, ..., 9)

z L (enhanced power / speed)

3.4 SCR catalytic converter – Overview
SCR catalytic converter – Overview
1 SCR catalytic converter 6 Supply units 11 Wiring harness

2 Bypass line (*) 7 Bearing 12 Exhaust inlet flange to after-
3 SOLAS insulation 8 DCM (Distributed Control treatment system (*)
4 Heat shield Module) (*) Shown without insulation
5 Dosing units 9 Pre-feed module
10 Power distribution
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SCR catalytic converter – Overview without SOLAS insulation
1 Exhaust pipe bellows (*) 5 Heat shield 9 Exhaust flap main flow (*)
2 Bypass line (*) 6 Replaceable catalyst mod- 10 Exhaust outlet flange from
3 Dosing units ules aftertreatment system (*)
4 Supply units 7 Bearing 11 Exhaust flap bypass flow (*)
8 Exhaust pipe bellows after (*) Shown without insulation
SCR catalytic converter (*)
TIM-ID: 0000071889 - 002

3.5 Product description
Description of the diesel engine with exhaust gas aftertreatment
Engine
The engine is a liquid-cooled four-stroke diesel engine, rotating counterclockwise (seen from driving end),
with direct injection, sequential turbocharging and charge-air cooling.
The engine is monitored by an engine control and monitoring system (ADEC).
Monitoring in the engine room is carried out by the engine control and monitoring unit (LOP).
Fuel system
Electronically controlled common-rail-injection system with HP pump, pressure accumulator (rail) and single
injectors with integrated individual store.
The electronic control unit controls
• Injection start
• Injection quantity
• Injection pressure
Exhaust system
The exhaust system is equipped with triple-walled, water-cooled exhaust lines.
The triple-walled design permits
• Low surface temperature
• Reduced amount of heat to be dissipated by the coolant
• absolute gas-tightness reached.
Turbocharging
Sequential turbocharging with internal, engine-coolant-controlled charge-air cooling. The right-hand exhaust
turbocharger is cut-in and cut-out on 12V and 16V engines with electronically-controlled, hydraulically-actu-
ated flaps.
Cooling system
Engine cooling as split-circuit cooling system with plate-core heat exchanger.
Heating of the charge-air in idle and low-load operation prevents white smoke formation.
Seawater only flows through engine coolant and fuel heat exchanger as well as the raw water pump.
Service block
The service components are mounted on the auxiliary PTO end.
The layout permits easy access for maintenance.
Service components:
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• Raw water pump, coolant pump

• Fuel duplex filter, switchable
• Automatic oil filter
• Centrifugal lube-oil filter
• Coolant expansion tank
Electronic system
Electronic control and monitoring system with integrated safety and test system, providing interfaces to re-
mote control system (RCS) and monitoring system (MCS).

Engine Interface Module (EIM)
The Engine Interface Module (EIM) is the central connection box on the engine. It covers the entire minimum
scope of a marine engine. It has no controls or parts requiring maintenance.
Functions:
• Start control (start repetition tooth-on-tooth, starter protection)
• Battery-charging generator monitoring
• Emergency stop function with line break monitoring
• Redundant power supply
• Optional control of emergency air-shutoff flaps
• Key switch logic
• Interface to ECU and EMU
• MCS5 dialog interface
• Control of an MTU lube-oil priming pump (power components in separate MTU PPC Box)
• Connection facility for an MTU Local Operating Station (LOS)
The engine interface comprises two parts. The first part is integrated in the engine wiring harness via a Tyco
connector X52, 62-pin. The second part comprises signals at higher current levels. These signals are led out
via M threaded pins and also connected to the engine wiring harness.
Functions
• ECU supply
• EMU supply
• Plant signals (ECU9 connector X1)
• Bus interface (2x MCS5 CAN)
• CAN dialog output (1xMCS5 CAN)
• ECU and EMU emergency stop
• Electric starter
• Terminal 45 of starter A/B (starter engaged)
• Pneumatic starter
• Start-air pressure valve
• Start-air pressure sensor
• Barring gear (barring gear 1 and 2)
• Generator (with excitation control)
Electronic Engine Control Unit (ECU)

Functions:
• Engine speed control with fuel and speed limitation according to engine status and operating conditions
• Control of sequential turbocharging, cylinder bank cut-out and air recirculation function
• Data processing logistics for analog and binary signals
• Interface for data transfer to CAN field bus for remote control and ship-side monitoring
Electronic Engine Monitoring Unit (EMU), optional

Functions:
• Data processing logistics for analog and binary signals
• Interface for data transfer to CAN field bus for remote control and ship-side monitoring
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Electronic Gear Control Unit (GCU), ship-side wall-mounting

Functions:
• Date processing logistics for gear coupling control
• Input/output signals as well as data transfer to CAN field bus for remote control and ship-side monitoring
Monitoring in engine room

Engine control and monitoring unit (LOP)

Functions:
• Alphanumeric, monochrome LCD display for monitoring of measured values as well as alarms when limits
are violated
• Pushbuttons for menu control and dimming unit
• Combined control and display elements for local engine/gear control
• Flashing light and horn for summary alarm in engine room
• Interface to CAN field bus for connected, communicating monitoring system components
Exhaust gas aftertreatment

SCR catalytic converter with partial-flow bypass (HAPS)
Functions:
• Selective catalytic reduction (SCR) of the nitrogen oxides
• Urea solution dosage controlled by Engine Control Unit depending on operating condition of the engine,
exhaust temperature and urea solution concentration
• Homogeneous mixture of urea solution with exhaust gas with built-in mixing channel
• Hydrogen Carbon Adsorption Preventing System (HAPS) to prevent the SCR catalytic converter from over-
heating
• Compliance with the IMO III emissions regulations due to closed loop control with NOx sensor
• Monitoring of NH3 emissions by NH3 sensor
• Urea solution dosage can be deactivated for IMO II operation
Low-load operation
TIM-ID: 0000071553 - 002
1 Low-load operation 2 Cleaning cycle 3 ditto

MTU marine engines of the Series 4000M53R to …M93L are suitable for low-load operation. State-of-the-art
design and equipment features, e.g. TE coolant circuit, sequential turbocharging, jacketed, coolant-cooled
exhaust lines, Common Rail fuel injection and cylinder cutout allow engine operation at low load.
The SCR system was equipped with a partial-flow bypass (HAPS), which prevents inadmissible accumulation
of oil and fuel particles in the system.

Nevertheless, low-load operation at engine load below 15% of the nominal rating is permitted for max.
100 hours. In order to avoid inadmissible oil carbon and/or carbon particle deposits in the engine, it is rec-
ommended to carry out a cleaning cycle for at least 20 minutes after extended low-load operation periods.
During the cleaning cycle, engine speed (power) must be increased step by step until all exhaust turbocharg-
ers are running. The figure illustrates the basic principle for increasing speed/power during the cleaning run.
After longer periods at idle/low-load operation (> 60h) followed by load imposition, avoid shedding load im-
mediately (< 10 minutes ) to prevent the risk of damaging the catalyst substrate.
SOLAS – Fire safety requirements

Installation locations of SOLAS shielding (→ Page 121).
Special connections
In case of leakage, the following connection types are spray-protected even without a cover and have been
confirmed compliant with SOLAS by GL and DNV.
Plugs and sensors (a)

Screw plugs (4) 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 (1).
TIM-ID: 0000071553 - 002
The pressure is so greatly reduced by this and the faulty sealing ring (1) that any leakage is not under pres-
sure.
Plug-in pipe connection (b)

Design precludes lateral spray as the point of separation is shielded by the sleeve (3).
Only seepage along the pipeline is possible whereby the pressure is greatly reduced by a faulty O-ring (2).
The connection is confirmed as being SOLAS-compliant by DNV and GL.

High-pressure connections
1 Jacketed pipe 8 Thrust ring 15 Union nut

2 HP line 9 Union nut 16 Thrust ring
3 O-ring 10 Union nut 17 External pipe of HP line
4 Union nut 11 Connecting piece 18 Internal pipe of HP line
5 Recess for O-ring 12 Snap ring 19 Ball-type seal area
6 Thrust ring 13 Thrust ring 20 Leak-fuel connection
7 Leak-fuel transfer bore 14 Shims
The HP fuel line is sealed by the thrust ring (8).
If leakage in the area of the thrust ring (8) or the HP line (2) occurs, the emerging fuel is routed to the leak-
age chamber.
The leak fuel is drained off without pressure via the leak-fuel transfer bore (7). The leakage chamber is sealed
by the O-rings (3).
This prevents leaking fuel from escaping.
The connection is confirmed as being SOLAS-compliant by DNV and GL.
TIM-ID: 0000071553 - 002

3.6 Sensors and actuators – Overview
Plan view 12V4000M
The following overview drawings also apply to 16V engines.
B4.21 Exhaust bulk temperature, A B7 Lube oil temperature B34.1 Fuel pressure after filter
side B5.3 Lube oil pressure before fil- F33 Coolant level
B3 Intake air temperature ter B4.22 Exhaust bulk temperature, B
B44.1 Turbocharger A speed B48 Fuel pressure (rail) side
B49 Charge air temperature B34.2 Fuel pressure before filter
from air recirculation valve
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Left engine side 12V4000M
B5.1 Lube oil pressure after filter XY1.1 Pneumatic starter B57.6 Main bearing temperature
(B5.2 optional) B57.2 Main bearing temperature B57.7 Main bearing temperature
B50 Crankcase pressure B57.3 Main bearing temperature XG03 Battery-charging generator
B4.A1-Ax Cylinder exhaust tempera- B57.4 Main bearing temperature
ture A1 (optional) B57.5 Main bearing temperature
B10 Charge-air pressure
B57.1 Main bearing temperature
TIM-ID: 0000071648 - 002

Right engine side 12V4000M
B4.A1-Ax Cylinder exhaust tempera- B16 Coolant pressure B9 Charge-air temperature

ture A1 B21 Raw water pressure (option)
B44.2 Turbocharger B speed B77.B1-Bx Splash-oil temperature for
XA80 DCM, SCR connection conrod bearings (option)
TIM-ID: 0000071648 - 002

Free end 12V4000M
F46 H-Fuel Leakage B1 Camshaft speed B6.2 Coolant temperature (op-

B33 Fuel temperature (rail) B54 Oil refill pump pressure tion)
B6 Coolant temperature
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Driving end 12V4000M
B13 Crankshaft speed S37.1 Safety switch

S37.2 Safety switch B13.2 Crankshaft speed (option)
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SCR catalytic converter, free end
X41 DCM connector to ECU B85.1 T-Exhaust before SCR, A X3 Connection to ECU9
X42 DCM connector for power side B85.3 T-Exhaust before SCR, B
supply B102 P-Urea Solution PFM after side
X43 DCM connector for compo- Filter B88.5 NOx before SCR, B side
nents M81.2 PFM pump 2
B91.7 P-Exhaust before SCR M81.1 PFM pump 1
B88.3 NOx before SCR, A side B103 K-T-Urea Solution
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SCR catalytic converter, left side
M81.3 Dosing unit 1.1 M80.1X2 X-VE 1.1 / X2 M80.3X2 X-VE 1.3 / X2
M81.4 Dosing unit 1.2 M80.2X1 X-VE 1.2 / X1 XWA1 Adaptation bypass
M81.5 Dosing unit 1.3 M80.2X2 X-VE 1.2 / X2
M80.1X1 X-VE 1.1 / X1 M80.3X1 X-VE 1.3 / X1
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SCR catalytic converter, right side
M81.6 Dosing unit 2.1 M80.4X1 X-VE 2.1 / X1 M80.5X2 X-VE2.2 / X2

M81.7 Dosing unit 2.2 M80.4X2 X-VE 2.1 / X2 M80.6X1 X-VE 2.3 / X1
M81.8 Dosing unit 2.3 M80.5X1 X-VE2.2 / X1 M80.6X2 X-VE 2.3 / X2
TIM-ID: 0000071648 - 002

SCR catalytic converter, driving end
K100.1X1 Relay 1 connector 1 actua- B85.6 T-Exhaust after SCR M60.1 X-SCR Bypass Flap 1
tor B88.8 NOx after SCR M60.2 X-SCR Bypass Flap 2
K100.1X2 Relay 1 connector 2 actua- B100.2 X-Ammoniac Sensor after XWA1 Adaptation bypass
tor SCR
K100.2X1 Relay 2 connector 1 actua- B91.8 P-Exhaust after SCR
tor
K100.2X2 Relay 2 connector 2 actua-
tor
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3.7 Wiring harness, engine with exhaust gas aftertreatment –
Overview
Engine wiring harness, sensors – connector assignment
X2 Governor ECU B44.1 Exhaust turbocharger A speed
B1 Camshaft speed B44.2 Exhaust turbocharger B speed
B3 Intake air temperature B48 HP fuel pressure
B4.21 Exhaust gas temperature, A-side B49 Charge-air before recirculation
B4.22 Exhaust temperature, B-side B50 Crankcase pressure
B5.1 Lube oil pressure after filter B98 Exhaust pressure after cylinder
B5.3 Lube oil pressure before filter F33 Coolant level
B6 Coolant temperature F46 Leak fuel level
B7 Lube oil temperature M8 Fuel pump
B9 Charge-air temperature S37.1 Start interlock limit switch A
B10 Charge-air pressure S37.2 Start interlock limit switch B
B13 Crankshaft speed X37 Start interlock turning
B16 Coolant pressure XA80 Exhaust gas aftertreatment
B33 Fuel temperature XG03 Battery-charging generator
B34.1 Fuel pressure after filter Y26 Charge-air recirculation
B34.2 Fuel pressure before filter Y27 Turbocharger valve
Engine wiring harness, injectors – connector assignment

X3 Governor ECU Y39Ax Injectors, engine A-side
E4.X KF thermostat heating Y39Bx Injectors, engine B-side
Adaptation – connector assignment

X1 Governor ECU XB19 Starting air pressure
X11 EMU Power XD1 Dialog unit
X37 Start interlock XD1.E Ground XD1
X52 EIM engine box XY1 Starter
Wiring harness, SCR catalytic converter – connector assignment

B85.1 T-Exhaust before SCR, A side M80.4X2 X-VE 2.1 / X2
B85.3 T-Exhaust before SCR, B side M80.5X1 X-VE2.2 / X1
B85.6 T-Exhaust after SCR M80.5X2 X-VE2.2 / X2
B88.3 NOx before SCR, A side M80.6X1 X-VE 2.3 / X1
B88.5 NOx before SCR, B side M80.6X2 X-VE 2.3 / X2
TIM-ID: 0000075361 - 001
B88.8 NOx after SCR M81.1 PFM pump 1 (PFM = pre-feed module)
B91.7 P-Exhaust before SCR M81.2 PFM pump 2
B91.8 P-Exhaust after SCR M81.3 Dosing unit 1.1
B100.2 X-Ammoniac Sensor after SCR M81.4 Dosing unit 1.2
B102 P-Urea Solution PFM after Filter M81.5 Dosing unit 1.3
B103 K-T-Urea Solution M81.6 Dosing unit 2.1
K100.1X1 Relay 1 connector 1 actuator M81.7 Dosing unit 2.2
K100.1X2 Relay 1 connector 2 actuator M81.8 Dosing unit 2.3

Wiring harness, SCR catalytic converter – connector assignment
K100.2X1 Relay 2 connector 1 actuator X41.1 Connector DCM system 1/1
K100.2X2 Relay 2 connector 2 actuator X41.2 Connector DCM system 1/2
M60.1 X-SCR Bypass Flap 1 X41.3 Connector DCM system PFM
M60.2 X-SCR Bypass Flap 2 X41.4 Connector DCM system 2
M80.1X1 X-VE 1.1 / X1 (VE = supply unit) X43.1 Connector DCM sensor 1/1
M80.1X2 X-VE 1.1 / X2 X43.2 Connector DCM sensor 1/2
M80.2X1 X-VE 1.2 / X1 X43.3 Connector DCM sensor PFM
M80.2X2 X-VE 1.2 / X2 X43.4 Connector DCM sensor 2
M80.3X1 X-VE 1.3 / X1 XA80 Exhaust gas aftertreatment
M80.3X2 X-VE 1.3 / X2 XWA1 Adaptation bypass
M80.4X1 X-VE 2.1 / X1
Engine wiring harness for sensors 16V
B50 Crankcase pressure B10 Charge-air pressure M8 Fuel pump

B7 Lube oil temperature B4.21 Exhaust gas temperature A B1 Camshaft speed
B5.1 Lube oil pressure after filter X2 Adaptation governor ECU B16 Coolant pressure
TIM-ID: 0000075361 - 001
B5.3 Lube oil pressure before fil- XA80 Exhaust gas aftertreatment B44.2 Speed, turbocharger B
ter XA80.E Grounding XA80 F33 Coolant level
B34.2 Fuel pressure before filter B6 Coolant temperature Y27 Turbocharger valve
B34.1 Fuel pressure after filter X37 Adaption - Start interlock B3 Intake air temperature
F46 Leak fuel level turning B98 Exhaust pressure after cyl-
B48 HP fuel pressure B4.22 Exhaust gas temperature B inder
B33 Fuel temperature B9 Charge-air temperature Y26 Charge-air recirculation
XG03 Battery-charging generator S37.2 Start interlock limit switch B B49 Charge-air before recircula-
S37.1 Start interlock limit switch A B13 Crankshaft speed tion
B44.1 Speed, turbocharger A

Engine wiring harness for injectors 16V
Y39Ax Injectors, engine A-side E4.x KF thermostat heating

X3 Adaptation governor ECU Y39Bx Injectors, engine B-side
TIM-ID: 0000075361 - 001

Engine wiring harness for EIM
XD1 Adaptation dialog unit XB19 Adaption starting-air pres- X11 Adaption EMU Power
XD1.E Ground XD1 sure X1 Connection to ECU
X37 Connection for start inter- X52 Connection to EIM engine
lock box
XY1 Adaption starting system
TIM-ID: 0000075361 - 001

Engine wiring harness for electric starter
1 EIM terminals 2 Fuse F1 3 Starter terminals
TIM-ID: 0000075361 - 001

Wiring harness for SCR catalytic converter
M81.5 Dosing unit 1.3 M81.7 Dosing unit 2.2 X43.2 Connector DCM sensor 1/2
M81.3 Dosing unit 1.1 M80.4X1 X-VE 2.1 / X1 X41.2 Connector DCM system
M81.4 Dosing unit 1.2 M80.4X2 X-VE 2.1 / X2 1/2
B91.7 P-Exhaust before SCR M80.5X1 X-VE2.2 / X1 X43.3 Connector DCM sensor
M80.1X1 X-VE 1.1 / X1 M80.5X2 X-VE2.2 / X2 PFM
M80.1X2 X-VE 1.1 / X2 M80.6X1 X-VE 2.3 / X1 X41.3 Connector DCM system
M80.2X1 X-VE 1.2 / X1 M80.6X2 X-VE 2.3 / X2 PFM
M80.2X2 X-VE 1.2 / X2 B103 K-T-Urea Solution X43.4 Connector DCM sensor 2
M80.3X2 X-VE 1.3 / X2 M81.1 PFM pump 1 X41.4 Connector DCM system 2
M80.3X1 X-VE 1.3 / X1 M81.2 PFM pump 2 X43.1 Connector DCM sensor 1/1
XWA1 Adaptation bypass B102 P-Urea Solution PFM after X41.1 Connector DCM system
M81.8 Dosing unit 2.3 Filter 1/1
M81.6 Dosing unit 2.1 B88.3 NOx before SCR, A side X3 Connection to ECU9
B85.1 T-Exhaust before SCR, A B85.3 T-Exhaust before SCR, B
side side
B88.5 NOx before SCR, B side
TIM-ID: 0000075361 - 001

Wiring harness for SCR catalytic converter
B100.2 X-Ammoniac Sensor afterK100.2X2 Relay 2 connector 2 actua- B85.6 T-Exhaust after SCR
SCR tor M60.2 X-SCR Bypass Flap 2
XWA1 Adaptation bypass K100.1X2 Relay 1 connector 2 actua- B88.8 NOx after SCR
K100.2X1 Relay 2 connector 1 actuator
tor B91.8 P-Exhaust after SCR
K100.1X1 Relay 1 connector 1 actua- M60.1 X-SCR Bypass Flap 1
tor
TIM-ID: 0000075361 - 001

4 Technical Data
4.1 Product data 16V4000M73, 16V4000M73L, IMO Tier III
(preliminary)
Legend
DL Reference value: Continuous power; Continuously attainable power at standard conditions
BL Reference value: Fuel stop power; Maximum engine power; Not continuously attainable in some appli-
cations (margin for load fluctuations)
A Design value: Value required to design an external system (plant)
R Guideline value: Typical average value for information, only conditionally suitable for design
L Limit value: Value which must not be undershot (lower limit value, min. value) or exceeded (upper lim-
it value, max. value), not suitable for design
N Non-defined value: Value has not yet been defined or will not be defined
- Not applicable: Module does not apply to this product type
X Applicable: Module applies to this product type
> Actual value must be higher than the specified value
< Actual value must be lower than the specified value
* Value not adequately verified (tolerance +/- 10%)
** Value not adequately verified (tolerance +/- 5%)
ID Product type Application Engine speed Listed output

1 16V4000M73 Marine / ship's main 1970 1/min 2560 kW Ref. 25 °C/25 °C;
propulsion 3481 bhp Heat exchanger instal-
1B, continuous opera- led on the engine
tion, variable, high IMO Tier III (Marpol
load convention)
IMO Tier II (Marpol
convention)
2 16V4000M73L Marine / ship's main 2050 1/min 2832 kW Ref. 25 °C/25 °C;
propulsion 3852 bhp Heat exchanger instal-
1B, continuous opera- led on the engine
tion, variable, high IMO Tier III (Marpol
load convention)
IMO Tier II (Marpol
convention)
Reference conditions
ID 1 2
Intake air temperature °C 25 25
Barometric pressure mbar 1000 1000
TIM-ID: 0000071902 - 002
Site altitude above sea level m 100 100

Raw water inlet temperature °C 25 25
Performance data
ID 1 2
Rated engine speed A rpm 1970 2050
Fuel stop power ISO 3046 A kW 2560 2832
MS150123/01E 2017-05 | Technical Data | 51

General conditions (for maximum power)
ID 1 2
Intake depression (new filter) A mbar 27 38
Intake depression, max. L mbar 42 53
Model related data (basic design)

ID 1 2
Cylinder arrangement: V angle Degrees 90 90
(°)
Bore mm 170 170
Stroke mm 190 190
Cylinder displacement Liters 4.31 4.31
Total displacement Liters 68.96 68.96
Number of inlet valves per cylinder 2 2
Number of exhaust valves per cylinder 2 2
Raw-water circuit (open circuit)

ID 1 2
Raw water pump: Inlet pressure, min. L bar -0.2 -0.2
Raw water pump: Inlet pressure, max. L bar 0.5 0.5
Pressure loss in off-engine raw-water system, max. L bar 1.0 1.0
Lube oil system

ID 1 2
Lube oil operating temperature before engine, from R °C 72* 75*
Lube oil operating temperature before engine, to R °C 82 82
Lube oil operating pressure before engine, from R bar 6 6
Lube oil operating pressure before engine, to R bar 8 8
Lube oil operating pressure (low idle) (meas. point: before engine) R bar 2.0 2.0
Fuel system
ID 1 2
Fuel pressure at engine inlet connection, min. (when engine is L bar -0.1 -0.1
starting)
Fuel pressure at engine inlet connection, min. (when engine is L bar -0.3 -0.3
running)
TIM-ID: 0000071902 - 002
Fuel pressure at engine inlet connection, max. (when engine is L bar 1.5 1.5
starting)
Fuel supply flow, max. normal operation R liters/min 14.4 15.8
General operating data

ID 1 2
Firing speed, from R rpm 80 80
Firing speed, to R rpm 120 120
52 | Technical Data | MS150123/01E 2017-05

Starter (electric)
ID 1 2
Rated starter voltage (standard rating) R V= 24 24
Starter (with air/hydraulic starter motor)

ID 1 2
Starting-air pressure before starter motor, min. R bar 8 8
Starting-air pressure before starter motor, max. R bar 9 9
Inclinations, standard oil system (reference: waterline)

ID 1 2
Longitudinal inclination, continuous max. driving end down (Op- L Degrees 17 17
tion: max. operating inclinations) (°)
Longitudinal inclination, temporary max. driving end down (Op- L Degrees 19.5 19.5
tion: max. operating inclinations) (°)
Longitudinal inclination, continuous max. driving end up (Option: L Degrees 12 12
max. operating inclinations) (°)
Longitudinal inclination, temporary max., driving end up (Option: L Degrees 14.5 14.5
max. operating inclinations) (°)
Transverse inclination, continuous max. (Option: max. operating L Degrees 15 15
inclinations) (°)
Transverse inclination, temporary max. (Option: max. operating in- L Degrees 22.5 22.5
clinations) (°)
Capacities
ID 1 2
Engine coolant, engine side (with cooling system) R Liters 400 400
Engine oil capacity, initial filling (standard oil system) (Option: R Liters 330 330
max. operating inclinations)
Oil change quantity, max. (standard oil system) (Option: max. op- R Liters 270 270
erating inclinations)
Oil pan capacity at dipstick mark “min.” (standard oil system) (Op- L Liters 215 215
tion: max. operating inclinations)
Oil pan capacity at dipstick mark “max.” (standard oil system) L Liters 260 260
(Option: max. operating inclinations)
Weights / main dimensions

ID 1 2
TIM-ID: 0000071902 - 002
Engine dry weight (with standard accessories installed, w/o cou- R kg 9600 9600
pling)

Noise
ID 1 2
Exhaust noise, attenuated (EGA 1) - BL (free-field sound pressure R dB(A) 82 82
level Lp, 1 m distance, ISO 6798, +3 dB(A) tolerance)
Engine surface noise with attenuated intake noise (intake silenc- R dB(A) 104 105
er) - BL (free-field sound power level Lp, 1 m distance, ISO 6798,
+2 dB(A) tolerance)
TIM-ID: 0000071902 - 002

4.2 Product data of SCR catalytic converter
SCR catalytic converter – Technical data
Design criteria Unit Value
Max. exhaust mass flow kg/s 6.2
Exhaust temperature in continuous operation °C 550
Max. exhaust temperature °C 580
Max. surface temperature incl. outside insulation acc. to °C 220
SOLAS requirements
Inlet flange (2x) DN300 (DIN 86044-2-300)
Outlet flange (1x) DN450 (DIN 86044-2-450)
Admissible installation position Horizontal
SCR catalytic converter horizontal movement mm Lateral: 15 +2
Axial: 15 +0.5
• Weight of SCR box with periphery and insulation without kg • 2000
partial-flow bypass kg • 300
• Weight of partial-flow bypass
Table 2: Design criteria of SCR catalytic converter

TIM-ID: 0000071917 - 002

4.3 Product – Main dimensions
Engine – Main dimensions
Engine model Length (A) Width (B) Height (C) Height (D)
12V4000M73L 3021 mm 1850 mm 2071 mm 636 mm
16V4000M73L 3610 mm 1850 mm 2071 mm 636 mm
TIM-ID: 0000071782 - 001

SCR catalytic converter – Main dimensions
Width (A) Height (B) Length (C) Length (D)

1736 mm 1885 mm 307 mm 2806 mm
TIM-ID: 0000071782 - 001

4.4 Firing order
Cylinders Firing order
12V A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1
16V A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B7
TIM-ID: 0000023263 - 003

5 Operation
5.1 LOP controls
LOP controls
Item Measure
LOP Start engine via the automation system (→ Automation system Operating In-
structions).
TIM-ID: 0000045323 - 001
MS150123/01E 2017-05 | Operation | 59

5.2 Putting the engine into operation after extended out-of-service
periods (>3 months)
Preconditions
☑ Engine is stopped and starting disabled.
☑ Preservation and Represervation Specifications A001070/.. are available.
Putting into operation after extended out-of-service periods (>3 months)

Item Action
Engine Depreserve (→ MTU Preservation and Represervation Specifications
A001070/..).
Lube oil system Check engine oil level (→ Page 203);
Preheat engine oil as necessary.
Lubricate valve gear (→ Page 140).
Raw water pump (if located Fill with water (approx. 3 to 4 liters).
above waterline)
Coolant circuit If engine is out of service for more than one year, change coolant
(→ Page 243).
Coolant circuit Check coolant level (→ Page 242).
Coolant circuit Heat engine coolant with coolant preheater.
HP fuel pump Only for engines without oil priming pump
Fill HP fuel pump with fresh engine oil (→ Page 146).
Engine Control System Switch master switch to ON;
Press illuminated pushbutton READY FOR OPERATION (→ Page 59).
Engine Control Unit ECU Check plug connections (→ Page 270).
EIM Check plug connections (→ Page 272).
EMU 8 Check plug connections (→ Page 271).
LOP Press illuminated pushbutton LAMP TEST (→ Page 59).
TIM-ID: 0000010093 - 007
60 | Operation | MS150123/01E 2017-05

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

Item Action
Lube oil system Check engine oil level (→ Page 203);
Preheat engine oil as necessary.
Coolant circuit Check coolant level (→ Page 242).
Coolant circuit Heat engine coolant with coolant preheater.
Engine Control System Switch master switch to ON;
Press illuminated pushbutton READY FOR OPERATION (→ Page 59).
LOP Press illuminated pushbutton LAMP TEST (→ Page 59).
ECU Check plug connections (→ Page 270).
EIM Check plug connections (→ Page 272).
EMU 8 Check plug connections (→ Page 271).
Exhaust gas aftertreatment Check urea solution system for leaks.
(SCR system) Check that seal on dosing unit is gas-tight.
Check electrical plug connections on DCM and urea solution components
(→ Page 35).
TIM-ID: 0000075065 - 001
MS150123/01E 2017-05 | Operation | 61

5.4 Starting the engine via the automation system
Starting the engine via the automation system
Item Task
Automation system Start engine via the automation system (→ Automation system Operating In-
structions).
TIM-ID: 0000045316 - 002
62 | Operation | MS150123/01E 2017-05

5.5 Operational checks
DANGER
Components are moving or rotating.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Operate the engine at low load only. Keep clear of the danger zone of the engine.
WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
Operational checks
Item Action
Control and display panels Check readings of operational data (speed, temperature, pressures).
Engine oil Check engine oil level (→ Page 203).
Engine under load, Visually inspect engine for leaks and general condition;
engine at nominal speed Check speed, pressures and temperatures;
Check engine and external lines for leaks;
Check for abnormal running noises and vibration;
Check exhaust color (→ Page 84).
Air filter Check signal ring position of service indicator (→ Page 173);
Replace air filter (→ Page 171) if the signal ring is completely visible in the
service indicator observation window.
Fuel prefilter Drain water and contaminants from fuel prefilter (→ Page 159).
Check pointer position of differential pressure gage at fuel prefilter
(→ Page 157).
HT coolant pump Check relief bore for oil and coolant discharge and contamination
(→ Page 248).
Raw water pump Check relief bore for oil and water discharge and contamination
(→ Page 257).
Exhaust gas aftertreatment Check urea solution level at LOP (→ Automation system Operating Instruc-
(SCR system) tions).
Note: Min. level is monitored by LOP. Circulation cooling is activated when
the tank level drops to 10% and dosing is stopped leading to emission viola-
tion.
TIM-ID: 0000075066 - 001
MS150123/01E 2017-05 | Operation | 63

5.6 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 67).
2. Shut down fuel treatment system (→ Page 79).
TIM-ID: 0000007730 - 006
64 | Operation | MS150123/01E 2017-05

5.7 Fuel treatment system control cabinet – Controls
Item Color Lettering Meaning/function

1 Green Signal lamp Indicates “Pump running”
2 Red Signal lamp Indicates “Pump fault”
3 Yellow Illuminated Indicates “Water drain” / Press to drain water manually
pushbutton
4 Red Illuminated Indicates “Water alarm” / Press to acknowledge
pushbutton
5 Yellow Signal lamp Indicates “Filter warning” due to increased differential pressure
6 Red Illuminated Indicates “Replace filter element” / Press to acknowledge
pushbutton
7 Switch Press to switch pump ON/OFF
8 White Signal lamp Indicates “Control voltage present”
9 Hour meter Indicates runtime of pump
10 Master switch
TIM-ID: 0000031133 - 002
MS150123/01E 2017-05 | Operation | 65

5.8 Checks prior to start-up
Checks prior to start-up

1. 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 70).
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.
TIM-ID: 0000007736 - 005
66 | Operation | MS150123/01E 2017-05

5.9 Fuel treatment system – Initial start-up
Overview of fuel treatment system
1 Pressure-free overflow 9 Ball valve, outlet 17 Automatic water drain

2 Bypass 1 10 Check valve 700 mbar 18 Water level electrode
3 Bypass 2 11 Check valve 5 mbar 19 Ball valve, sample extrac-
4 Safety valve, 3 bar 12 Return to overflow tank tion, inlet
5 Ball valve, inlet 13 Engine 20 Switchgear cabinet
6 Pressure gage 14 Overflow tank 21 Pump
7 Ventilation, sample extrac- 15 Filter water separator 22 Coarse filter
tion 16 Drain ball valve 23 Fuel supply from tank
8 Differential pressure gage 24 Tank
Switching on fuel treatment system

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.
TIM-ID: 0000015773 - 007
1. Remove coalescer filter element (→ Page 266).

2. Check sealing surfaces on coalescer filter element and in the pressure tank.
MS150123/01E 2017-05 | Operation | 67

Initial start-up: HAT
1. Replace fuel filter on engine (→ Page 155).
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 70).
Result: Fuel is drawn from the tank (24). It is then cleaned and dewatered via the filter water separator (15). It is
then returned to the tank (24) via the overflow tank (14). Water settled in the tank is separated.
4. Start engine (→ Page 62).
5. Run engine at idling speed.
6. Check suction pressure (see technical data of the engine) at the engine-mounted fuel delivery pump.
Note: If the suction pressure is within the admissible limits and engine operation is satisfactory.
7. Increase engine speed to 1000 rpm and monitor suction pressure.
8. Check suction pressure at the engine-mounted fuel delivery pump.
Result: If the values are within the limits specified by the manufacturer, the system is ready to start filter replace-
ment simulation with the engine running as part of the Harbor Acceptance Tests.
Simulating filter replacement with the engine running: HAT

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

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).
Result: Simulation was successful if the suction pressure is within the specified limits.
TIM-ID: 0000015773 - 007
68 | Operation | MS150123/01E 2017-05

Simulating power failure (emergency): SAT
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).
6. Operate engine at full load and monitor suction pressure.
Result: Simulation was successful if the suction pressure is within the specified limits.
TIM-ID: 0000015773 - 007
MS150123/01E 2017-05 | Operation | 69

5.10 Fuel treatment system – Switching on
Preconditions
☑ The on-board power supply is switched on.
NOTICE
Risk of damage to engine/system.
Risk of severe damage to property!
• Before switching on, ensure that the engine/system is ready for operation.
• Before switching on, ensure that all housings are closed.
• Before switching on, ensure that no work is in progress anywhere on the entire system.
Fuel treatment system – Switching on

1. Carry out checks prior to start-up (→ Page 66).
2. Switch on master switch on switchgear cabinet.
Result: Signal lamp “Control voltage present” lights up.
3. Switch on switch for pump.
Result: Signal lamp “Pump running” lights up.
TIM-ID: 0000007731 - 006
70 | Operation | MS150123/01E 2017-05

5.11 Engine with exhaust gas aftertreatment – Emergency stop via
automation system
NOTICE
An emergency stop subjects the engine system to an extremely high load.
Risk of overheating, damage to components!
• Trigger an emergency stop only in emergency situations.
Emergency engine stop via automation system

Item Action
Automation system Emergency stop via the automation system (→ Operating Instructions Auto-
mation System).
Overview of emergency stop functions

Normal stop Emergency stop Emergency stop
MTU designa- Higher-level emergency
Emergency stop function
tion "Power-Off SCR"(*) stop function
"Emergency Engine Stop"
"Emergency System Stop"
Function SCR OFF in the event of Emergency engine stop Emergency stop of engine
faults, power supply OFF and EGA
Engine behavior Engine running; no impact Engine at standstill; fuel in- Engine at standstill, power
on engine function jection OFF supply to engine interrupted
Behavior of ex- Sensors/actuators, control Circulation cooling contin- Exhaust gas aftertreatment
haust gas after- units OFF; circulation cool- ues to run OFF, power supply to ex-
treatment sys- ing OFF haust gas aftertreatment
tem (SCR sys- system interrupted; circula-
tem) tion cooling OFF
Implementation Interruption of power supply
to exhaust gas aftertreat-
ment system implemented
by shipyard as color-coded
ON/OFF switch
Comment Pumps and/or actuators to Engine and exhaust gas af-
supply the SCR system with tertreatment system have
urea solution and to be in- separate power supplies.
stalled by the shipyard, Both supplies must be inter-
must be combined with SCR rupted for an “Emergency
Emergency emergency stop System Stop”.
by the shipyard.
CAUTION:
TIM-ID: 0000073589 - 002
Emergency stopping may cause overheating rendering the dosing units inoperable. Dosing system compo-
nents must be consequently replaced. The SCR system does not work any more if the dosing units are dam-
aged by overheating.
(*) Actuate the Power-Off SCR switch:
• When performing maintenance work on the SCR boxes
• When servicing the ECU
• in case of fire in the SCR system
• On taking the entire urea solution system out of operation (e.g. in case of malfunction).
MS150123/01E 2017-05 | Operation | 71

When servicing, wait until the circulation cooling follow-up time has expired (up to 10 hours) before actuating
the “Power-Off SCR” switch to avoid destroying the dosing units as a result of overheating.
TIM-ID: 0000073589 - 002
72 | Operation | MS150123/01E 2017-05

5.12 Engagement via LOP
DANGER
In Local mode, the propulsion plant is controlled from the engine room. The person controlling the ves-
sel has no visual contact with the surrounding area.
Risk of collision and serious injury!
• Only operate the vessel using the LOP when a second person is keeping lookout and is ready to alert
the person at the LOP to any potential hazards. These two persons must remain in direct voice con-
tact at all times, e.g. by radio.
Engagement via LOP

Item Task
LOP Engage via LOP (→ Automation system Operating Instructions).
TIM-ID: 0000045318 - 002
MS150123/01E 2017-05 | Operation | 73

5.13 Disengaging from LOP
DANGER
In Local mode, the propulsion plant is controlled from the engine room. The person controlling the ves-
sel has no visual contact with the surrounding area.
Risk of collision and serious injury!
• Only operate the vessel using the LOP when a second person is keeping lookout and is ready to alert
the person at the LOP to any potential hazards. These two persons must remain in direct voice con-
tact at all times, e.g. by radio.
Disengaging from LOP

Item Task
LOP Disengage via LOP (→ Automation system Operating Instructions).
TIM-ID: 0000045319 - 002
74 | Operation | MS150123/01E 2017-05

5.14 Waterjet – Flushing from LOP (optional)
Preconditions
☑ LOCAL OPERATION illuminated switch is lit brightly (local operating mode is active).
☑ Waterjet-BucketVessel at standstill and waterjet bucket is below the waterline.
☑ Engine speed is in engagement window.
☑ No external engagement interlock is active.
NOTICE
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 mode

Item Measure
LOP Press and hold down FLUSH illuminated pushbutton (→ Page 59).
• FLUSH illuminated pushbutton flashes.
• Gearbox is engaged ASTERN.
• FLUSH illuminated pushbutton is brightly lit after receiving feedback sig-
nal from clutch.
LOP Release FLUSH illuminated pushbutton.
• FLUSH illuminated pushbutton flashes.
• Gearbox is disengaged (neutral position).
• FLUSH illuminated pushbutton goes out after receiving feedback signal
from clutch.
TIM-ID: 0000002330 - 008
MS150123/01E 2017-05 | Operation | 75

5.15 Engine shutdown via the automation system
NOTICE
Stopping the engine when it is running at full load causes extreme stress to the engine.
• Before shutting down, disengage gear and run the engine at idle speed for at least 10 minutes until
engine temperatures have dropped and constant values are displayed.
Engine shutdown via the automation system

Item Measure
Automation system Shut down engine via the automation system (→ Automation system Operat-
ing Instructions).
TIM-ID: 0000045327 - 001
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5.16 Engine with exhaust gas aftertreatment – Stopping via
automation system
NOTICE
Stopping the engine when it is running at full load causes extreme stress to the engine.
• Before shutting down, disengage gear and run the engine at idle speed for at least 10 minutes until
engine temperatures have dropped and constant values are displayed.
Stopping the engine via the automation system

Item Action
Automation system Stopping engine via the automation system (→ Automation system Operating
Instructions).
Overview of operating modes

Operating mode Stopping in normal operation
MTU designa- Manual Switch-Off
tion Engine Stop Key-Switch SCR/IMO II/IMO III (am
LOP)
Function Engine stop Engine stop Manual deactivation of the
urea-solution injection in
IMO II mode or in th event
of faults
Engine behavior Engine at standstill, control Engine at standstill, control Engine running; no impact
units ate active units switch OFF when cir- on engine function. Engine
culation cooling is complet- stop not tripped.
ed.
Behavior of ex- Circulation cooling* contin- Circulation cooling* contin- Circulation cooling* contin-
haust gas after- ues to run ues to run; control units ues to run; IMO II operation
treatment sys- switch OFF when circulation through LOP and bridge
tem (SCR sys- cooling is completed. control console. Engine gov-
tem) ernor monitors circulation
cooling after engine stop.
Implementation LOP display IMO II
(→ Page 59)
Comment (*) The subsystem requires continued circulation cooling with urea solution circulation
after the engine was stopped to avoid thermal damage to the dosing units.
For this purpose, a separate “Power-Off SCR" switch is provided in addition to the"Emer-
gency Engine Stop" button(→ Page 71).
TIM-ID: 0000073590 - 002
MS150123/01E 2017-05 | Operation | 77

5.17 After shutting down the engine
Preconditions
☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.
NOTICE
Engine coolant with inadequate freeze protection. Water remaining in the pressure sensors freezes at
temperatures below 0 °C.
Risk of sensor damage!
• Remove pressure sensors and shake off residual water.
After shutting down the engine

Item Measure
Coolant circuit Drain coolant (→ Page 244) if:
• freezing temperatures are to be expected and the engine is to remain out
of service for an extended period and if no antifreeze has been added to
the coolant;
• the engine room is not heated;
• the coolant is not kept at a suitable temperature;
• the antifreeze concentration is insufficient for the engine-room tempera-
ture;
• antifreeze concentration is 50 % and engine-room temperature is below
-40 °C.
Raw water Drain
• if freezing temperatures are expected and the engine is to remain out of
service for a longer period.
Engine control system Switch off.
Air intake and exhaust sys- Out-of-service-period > 1 week:
tem • Seal engine's air and exhaust sides.
Engine Out-of-service-period > 1 month:
• Carry out engine preservation (→ MTU Preservation and Represervation
Specifications A001070/..)
TIM-ID: 0000002324 - 010
78 | Operation | MS150123/01E 2017-05

5.18 Fuel treatment system – Shutdown
Shutting down fuel treatment system

1. 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.
TIM-ID: 0000007732 - 005
MS150123/01E 2017-05 | Operation | 79

5.19 Plant – Cleaning
Preconditions
☑ No operating voltage applied.

High-pressure cleaner (→ Tools Catalog) 1
Cleaner (Hakupur 50/136) X00056700 1
WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.
WARNING
Water jet from high-pressure cleaning unit.
Risk of eye injury, risk of scalding!
• Do not direct water jet at persons.
• Wear protective clothing, protective gloves, and goggles/safety mask.
NOTICE
Cleaning agents should not be left to take effect for too long.
Damage to components is possible!
• Observe manufacturer's instructions.
NOTICE
Blowing down product with compressed air.
Entry of dirt and damage to components is possible!
• Do not aim compressed air gun directly at seals or electronic components such as connectors or
ECUs.
Cleaning the plant

1. Carry out plant cleaning only in areas where an appropriate oil separator is provided (environmental protec-
tion).
2. Prior to putting the cleaning unit into operation, read the operating instructions of the high-pressure cleaning
units carefully and observe the safety precautions.
3. The following requirements apply for cleaning the plant outside with a high-pressure cleaning unit:
• The pressure of the high-pressure jet (cleaning jet) must not exceed 50 bar.
• A minimum distance between spray nozzle and plant of 1 m must be observed.
TIM-ID: 0000010171 - 034
• The temperature of the cleaning medium must not exceed 80 °C.

4. For external cleaning with high-pressure jet, use a fan jet nozzle only.
Note: Never direct compressed air directly at electronic components.
5. Carry out external cleaning as follows:
a) Seal all openings in a suitable way.
b) Remove coarse dirt.
c) Spray on cleaner sparingly and leave it for 1 to 5 minutes.
d) Use high-pressure jet to remove loosened dirt.
e) Dry engine with compressed air.
80 | Operation | MS150123/01E 2017-05

6 Maintenance
6.1 Maintenance task reference table [QL1]
The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Mainte-
nance Schedule is a standalone publication.
The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance
Schedule.
Option
Task Measures
W0500 Check engine oil level. (→ Page 63)

W0501 Visually inspect engine for leaks and general condition. (→ Page 63)
W0503 X Check signal ring position of maintenance indicator on air filter. (→ Page 63)
W0505 Check relief bores of water pump(s). (→ Page 63)
W0506 Check engine for abnormal running noises, exhaust color and vibrations. (→ Page 63)
W0507 X Drain water and contaminants from fuel prefilter. (→ Page 63)
W0508 X Check reading on differential pressure gauge of fuel prefilter. (→ Page 63)
W1001 Replace fuel filter or fuel filter element. (→ Page 155)
W1005 X Replace air filter. (→ Page 171)
W1006 Replace fuel injectors. (→ Page 148)
W1008 X Replace engine oil filter when changing engine oil, or when the interval (→ Page 207)
(years) is reached, at the latest.
W1009 Measure thickness of oil residue layer, clean, replace filter sleeve - at (→ Page 239)
each engine oil change, at the latest.
W1011 Perform endoscopic examination. (→ Page 131)
W1016 X Battery-charging generator: Check condition of coupling. (→ Page 258)
W1055 X Crankcase breather: Replace oil separator. (→ Page 135)
W1207 Check valve clearance and adjust if necessary. IMPORTANT! First adjust- (→ Page 141)
ment after 1,000 operating hours on a new engine and 1,000 operating
hours following each overhaul of the cylinder heads.
W1244 X Fuel treatment system: Check function of rod electrode. (→ Page 264)
W1245 X Fuel treatment system: Check alarm function of differential pressure (→ Page 263)
gauge.
W1246 X Fuel treatment system: Check pump capacity. (→ Page 265)
W1296 X Coolant expansion tank: Replace valve. (→ Page 256)
W1380 X Fuel treatment system: Replace filter element . (→ Page 266)
TIM-ID: 0000071785 - 001
W1477 X Overhaul preheating unit. (→ Page 250)

W1519 Engine mounting: Check securing screws for secure seating. (→ Page 260)
W1675 X Replace fuel prefilter or filter element of fuel prefilter. (→ Page 163)
W1689 Measure valve protrusion. (→ Page 136)
W1713 Injector: Reset drift correction (CDC) parameters. (→ Page 149)
W1864 X Check and clean oil indicator filter. (→ Page 235)
W4172 Engine mounting: Check general condition of resilient mounts (visual in- (→ Page 259)
spection).
SCR system
MS150123/01E 2017-05 | Maintenance | 81

Option
Task Measures
W1765 X SCR supply unit: Replace filter element. (→ Page 174)

W1766 X Replace reducing agent lines. (→ Page 183)
W1767 X Replace dosing unit. (→ Page 180)
W1768 X Replace supply unit. (→ Page 177)
W1769 X Replace NOx sensor in SCR system. (→ Page 199)
W4179 X Check insulation of housing and bypass, replace as necessary. (→ Page 184)
W4180 X Replace filter on pre-delivery module. (→ Page 185)
W4181 X Check measuring line of exhaust pressure sensor, clean if necessary. (→ Page 189)
W4182 X Replace SCR-GECANNT insert. (→ Page 194)
W4183 X Replace predelivery module. (→ Page 185)
Table 3: Maintenance task reference table [QL1]
TIM-ID: 0000071785 - 001
82 | Maintenance | MS150123/01E 2017-05

7 Troubleshooting
7.1 Control cabinet of fuel treatment system – Troubleshooting
Water alarm
Cause Corrective action
When the maximum water level is 1. Press illuminated pushbutton 'Water alarm' for acknowledgment.
reached, the water level electrode 2. In addition to the automatic water drain function, water can also be
opens the water drain valve and drained manually: Press illuminated pushbutton 'Water drain'.
water is discharged. If the opening The water drain valve opens.
period of the valve exceeds a
preset limit (4 minutes), the pump
will switch off and an alarm is
initiated.
Pump fault
The drive motor is equipped with u Reset motor protection relay.
an overload protection. If the
maximum permissible current
consumption is exceeded, e.g. in
case of a blockage or dry-running,
the motor protection relay
triggers and the pump is switched
off.
Pre-alarm
The differential pressure u Replace coalescer filter element (→ Page 266).
exceeded 1.3 bar.
Replace filter element

The max. permissible differential 1. Replace coalescer filter element (→ Page 266).
pressure exceeded 1.5 bar. If the 2. Press illuminated pushbutton 'Water alarm' for acknowledgment.
coalescer filter element is not
replaced, pressure will increase
further and the safety valve will
TIM-ID: 0000007734 - 009
open. Fuel will be led via the

bypass directly into the overflow
tank.
MS150123/01E 2017-05 | Troubleshooting | 83

7.2 Troubleshooting
Engine does not turn when starter is actuated
Battery low or faulty u Charge or replace (see separate documentation).
Battery: Cable connections faulty u Check firm seating of cable connections (see separate
documentation).
Engine wiring faulty u Check (→ Page 268).
Assemblies or connectors on LOP u Check visually.
loose
Plug-in connections on Engine u Check plug connections (→ Page 270).
Control Unit loose
Plug-in connections on Engine u Check plug connections (→ Page 272).
Interface Module (EIM) loose
Fuse F1 (→ Page 44) in engine u Check fuse, replace as necessary, and re-start the system by
wiring harness faulty (fuse lamp actuating the key switch.
on EIM flashes with relevant
flashing code)
Running gear blocked (engine can 1. Check start interlock (→ Page 269).
not be barred manually) 2. Contact Service.
Engine turns on starting, but does not fire

Poor rotation by starter: Battery u Charge or replace battery (see separate documentation).
low or faulty
Engine Control Unit faulty 1. Replace (→ Page 273).
2. Contact Service.
Engine fires unevenly

Injector faulty u Replace (→ Page 148).
Engine Control Unit faulty 1. Replace (→ Page 273).
2. Contact Service.
TIM-ID: 0000073222 - 002
84 | Troubleshooting | MS150123/01E 2017-05

Engine does not reach nominal speed
Engine: Excessive load u Reduce load.
Air filter clogged 1. Check signal ring position of service indicator (→ Page 173).
2. Replace air filter (→ Page 171).
Fuel prefilter clogged 1. Drain fuel prefilter (→ Page 159).
2. Replace filter element (→ Page 163).
Easy-change fuel filter clogged u Replace (→ Page 155).
Exhaust back pressure too high 1. Check SCR system.
2. Contact Service.
Engine speed not steady

Speed transmitter faulty u Check and replace as necessary (→ Instructions for Exchange of
Sub-assemblies).
Engine Control Unit faulty 1. Check plug connections (→ Page 270).
2. Replace Engine Control Unit (→ Page 273).
3. Contact Service.
Charge-air temperature too high

Engine: Excessive load u Reduce load.
Air intake temperature too high u Check fans and air supply/ventilation ducts for engine room.
Engine coolant mixture incorrect 1. Check engine coolant level (→ Page 242).
2. Check engine coolant (MTU test kit) (→ Page 249).
Charge-air cooler contaminated u Replace (→ Instructions for Exchange of Sub-assemblies).
Charge-air pressure too low

Charge-air cooler contaminated u Replace (→ Instructions for Exchange of Sub-assemblies).
Exhaust turbocharger faulty 1. Clean compressor wheel (→ Page 166).
2. Replace exhaust turbocharger (→ Instructions for Exchange of Sub-
TIM-ID: 0000073222 - 002
assemblies).
Coolant leaks at charge-air cooler

Intercooler leaky, major coolant u Replace intercooler (→ Instructions for Exchange of Sub-
discharge. assemblies).
Note: Escaped coolant burns in SCR system. Visually inspect SCR
system for damage resulting from overheating and signs of sooting.

Exhaust back pressure too high
SCR substrate clogged with: 1. Briefly connect engine load to blow off SCR substrates (soot
• Soot (resulting from engine emission possible).
malfunction, e.g. injector 2. If exhaust back pressure does not fall: Contact Service.
failure)
• Ash (resulting from wrong fuel)
Acrid and pungent smell in engine room or at exhaust outlet

SCR system faulty / leak in urea 1. Switch SCR system off, “Manual Switch-off SCR / IMO II / IMO III”.
solution system • IMO III emissions requirements are no longer complied with.
2. Contact Service.
Black exhaust gas

Excessive load u Reduce load.
Injector faulty 1. Replace (→ Page 148).
2. Check exhaust back pressure.
SCR system clogged 1. Check exhaust back pressure.
2. Briefly connect engine load to blow off SCR substrates (soot
emission possible).
3. If exhaust back pressure does not fall: Contact Service.
Blue exhaust gas

Too much engine oil in the engine u Drain engine oil (→ Page 204).
Note: Engine oil burns in SCR system. Visually inspect SCR system
for damage resulting from overheating, leakage and signs of
sooting.
Oil separator of crankcase u Replace oil separator (→ Page 135).
breather contaminated
Exhaust turbocharger faulty u Replace (→ Instructions for Exchange of Sub-assemblies).
Note: Engine oil burns in SCR system. Visually inspect SCR system
for damage resulting from overheating, leakage and signs of
sooting.
Cylinder head faulty 1. Check cylinder compression.
TIM-ID: 0000073222 - 002
2. Replace cylinder head (→ Instructions for Exchange of Sub-

assemblies).
Piston rings or cylinder liner faulty 1. Check cylinder compression.
2. Carry out endoscopic examination of cylinder liner (→ Page 131).
3. Replace piston rings (→ Instructions for Exchange of Sub-
assemblies).
4. Replace cylinder liner (→ Instructions for Exchange of Sub-
assemblies).
5. Contact Service.

White exhaust gas
Engine is not at operating u Run engine to reach operating temperature.
temperature
Charge-air cooler leaking 1. Check drain for coolant discharge and obstruction (→ Page 170).
2. Replace intercooler (→ Instructions for Exchange of Sub-
assemblies).
Note: Visually inspect SCR system for damage, leakage and signs
of sooting.
Cloud of black exhaust gas (less than 5 min.)

Long low load u Full load, wait.
White smoke, engine room

Initial start-up u Wait, max. ventilation, leave area.
Pungent smell, engine room

Initial start-up u Shut down, check SCR system.
Reduced power due to exhaust gas temperature alarm

Main flow flap faulty 1. Actuate main flow flap via handwheel.
2. Repair main flow flap.
Back pressure too low, emission fault

No baffles installed u Install baffles (→ Page 194).
SCR substrate faulty u Replace SCR substrate (→ Page 194).
High engine room temperature

Leakage in SCR system due to u Re-install SCR system, replace housing as necessary.
TIM-ID: 0000073222 - 002
high back pressures

Leakage in SCR system due to u Replace gaskets
high temperature
Gasket installed incorrectly u Check gasket.

Urea solution escapes from SCR system repeatedly in engine room
Urea solution efflorescence (white u Check peripheral equipment, replace as necessary.
deposit)
Leaks, cracks in urea solution u Check for leakage, replace as necessary (→ Page 183).
system
White crystals on plug connections or urea solution system

Leaks, cracks in urea solution u Check for leakage, replace as necessary (→ Page 183).
system
Yellow smoke on funnel

Wrong coating (DOC) supplied u Install SCR module with right coating (→ Page 194).
TIM-ID: 0000073222 - 002

7.3 Fault messages of Engine Control Unit (ECU 9) for Series
4000, marine applications, IMO III (provisional)
3 – HI T-Fuel

The fuel temperature at sensor 1. Reduce power.
B33 exceeded limit value 1. Fuel 2. Check fuel recooling system (if applicable).
temperature is too high. 3. Contact Service.
4 – SS T-Fuel

The fuel temperature at sensor 1. Reduce power.
B33 exceeded limit value 2. Fuel 2. Check fuel recooling system (if applicable).
temperature is too high. 3. Contact Service.
5 – HI T-Charge Air

The charge-air temperature at 1. Reduce power.
sensor B9 exceeded limit value 1. 2. Check whether alarms 9 and 10 are signaled.
Charge-air temperature is too 3. Contact Service.
high.
6 – SS T-Charge Air

The charge-air temperature at 1. Reduce power.
sensor B9 exceeded limit value 2. 2. Check whether alarms 9 and 10 are signaled.
Charge-air temperature is too 3. Contact Service.
high.
15 – LO P-Lube Oil

The lube oil pressure at sensor 1. Check engine oil level (→ Page 203).
B5.1 went below limit value 1. 2. Contact Service.
Lube oil pressure is too low.
TIM-ID: 0000077157 - 001
16 – SS P-Lube Oil

The lube oil pressure at sensor 1. Check engine oil level (→ Page 203).
B5.1 went below limit value 2. 2. Contact Service.
Lube oil pressure is too low.

19 – HI T-Exhaust A

Exhaust temperature at sensor u Run injector test according to DiaSys description. Contact Service
B4.21 exceeded limit value 1. if no DiaSys is available.
Exhaust temperature is too high.
20 – SS T-Exhaust A

21 – HI T-Exhaust B

22 – SS T-Exhaust B

23 – LO Coolant Level

Coolant level in high temperature 1. Check engine coolant level (→ Page 242).
circuit at switch F33 is too low. 2. Check relief bore of engine coolant pump (→ Page 248).
3. Check cooling circuit visually for leaks.
4. Contact Service.
25 – HI P-Diff-Lube Oil

The differential oil pressure at 1. Replace engine oil filter (→ Page 207).
sensors B5.1 and B5.3 exceeded 2. Contact Service.
TIM-ID: 0000077157 - 001
limit value 1. The differential oil

pressure is too high.

26 – SS P-Diff-Lube Oil

The differential oil pressure at 1. Replace engine oil filter (→ Page 207).
sensors B5.1 and B5.3 exceeded 2. Contact Service.
limit value 2. The differential oil
27 – HI Level Leakage Fuel

Switch F46 in the collecting tank u Contact Service.
has been tripped. A leak has
occurred in the HP fuel system.
30 – SS Engine Overspeed

The engine speed exceeded the 1. Restart the engine if the emergency stop was tripped by the engine
upper limit or the engine overspeed test.
overspeed test was tripped. 2. Contact Service if the emergency stop was tripped by the engine.
Emergency engine stop was
tripped.
31 – HI ETC1 Overspeed

The primary exhaust turbocharger 1. Reduce power.
speed at sensor B44.1 has 2. Contact Service.
exceeded limit value 1. The
exhaust turbocharger speed is too
high.
32 – SS ETC1 Overspeed

The primary exhaust turbocharger 1. Reduce power.
speed at sensor B44.1 has 2. Contact Service.
exceeded limit value 2. The
high.
TIM-ID: 0000077157 - 001
33 – HI P-Diff-Fuel

The differential pressure at 1. Replace fuel filter (→ Page 155).
sensors B34.1 and B34.2 has 2. Contact Service.
violated upper limit value 1. The
differential pressure is too high.

34 – SS P-Diff-Fuel

The differential pressure at 1. Replace fuel filter (→ Page 155).
sensors B34.1 and B34.2 has 2. Contact Service.
violated upper limit value 2. The
differential pressure is too high.

The secondary exhaust 1. Reduce power.
turbocharger speed at sensor 2. Contact Service.
B44.2 has exceeded limit value 1.
The exhaust turbocharger speed
is too high.

is too high.
38 – AL ETC Speed Deviation

The percentual deviation in u Contact Service.
exhaust turbocharger speed
between the primary turbocharger
and the first secondary
turbocharger has exceeded the
limit value. The deviation in
high.
51 – HI T-Lube Oil

The lube oil temperature at sensor 1. Reduce power.
TIM-ID: 0000077157 - 001
B7 exceeded limit value 1. Lube- 2. Check operation of cooler and fan (plant).
oil temperature is too high. 3. Check engine coolant level (→ Page 242).
4. Contact Service.

52 – SS T-Lube Oil

The lube oil temperature at sensor 1. Check operation of cooler and fan (plant).
B7 exceeded limit value 2. Lube- 2. Check engine coolant level (→ Page 242).
oil temperature is too high. 3. Contact Service.
57 – LO P-Coolant

Coolant pressure at sensor B16 1. Check relief bore of engine coolant pump (→ Page 248).
went below limit value 1. Coolant 2. Check engine coolant level (→ Page 242).
pressure is too low. 3. Contact Service.
58 – SS P-Coolant

Coolant pressure at sensor B16 1. Check relief bore of engine coolant pump (→ Page 248).
went below limit value 2. Coolant 2. Check engine coolant level (→ Page 242).
59 – SS T-Coolant L3

The coolant temperature at 1. Check operation of cooler and fan (plant).
sensor B6 exceeded limit value 3. 2. Check engine coolant level (→ Page 242).
Coolant temperature is too high. 3. Contact Service.
60 – SS T-Coolant L4

63 – HI P-Crank Case

The crankcase pressure at sensor 1. Stop engine.
B50 exceeded limit value 1. The 2. Contact Service.
crankcase pressure is too high.
TIM-ID: 0000077157 - 001
64 – SS P-Crank Case

The crankcase pressure at sensor 1. Stop engine.
B50 exceeded limit value 2. The 2. Contact Service.
crankcase pressure is too high.

65 – LO P-Fuel

The fuel pressure at sensor B34.1 1. Replace fuel filter (→ Page 155).
went below limit value 1. Fuel 2. Replace fuel prefilter (→ Page 163).
66 – SS P-Fuel

The fuel pressure at sensor B34.1 1. Replace fuel filter (→ Page 155).
went below limit value 2. Fuel 2. Replace fuel prefilter (→ Page 163).
67 – HI T-Coolant

The coolant temperature at 1. Reduce power.
sensor B6 exceeded limit value 1. 2. Check operation of cooler and fan (plant).
Coolant temperature is too high. 3. Check engine coolant level (→ Page 242).
4. Contact Service.
68 – SS T-Coolant

82 – HI P-Fuel (Common Rail)

The fuel pressure at sensor B48 u Contact Service.
exceeded the limit value. Fuel
83 – LO P-Fuel (Common Rail)

The fuel pressure at sensor B48 u Contact Service.
went below the limit value. Fuel
TIM-ID: 0000077157 - 001
pressure is too low.
89 – SS Engine Speed too low

The engine speed has went below 1. Acknowledge alarm.
the limit value. Emergency engine 2. Observe additional messages.
stop was tripped. 3. Contact Service.

90 – SS Idle Speed Not Reached

The engine has failed to reach idle 1. For hydraulic starter: Check pressure supply (plant) of starter.
speed within the defined time 2. For electric starter: Check the starter power supply (plant).
after reaching starter 3. Check fuel filter, replace as necessary (→ Page 155).
disengagement speed. 4. Check fuel prefilter, replace if required.
5. Observe additional messages.
6. Contact Service.
91 – SS Release Speed Not Reached

The engine has failed to reach 1. For hydraulic starter: Check pressure supply (plant) of starter.
starter disengagement speed 2. For electric starter: Check the starter power supply (plant).
within the defined time after 3. Observe additional messages.
reaching starter speed. 4. Contact Service.
92 – SS Starter Speed Not Reached

The engine has failed to reach the 1. For hydraulic starter: Check pressure supply (plant) of starter.
defined speed threshold within 2. For electric starter: Check the starter power supply (plant).
the defined time. 3. Observe additional messages.
4. Contact Service.
93 – SS T-Preheat

The engine coolant temperature u Contact Service.
has failed to reach the defined
limit value 2. Preheater is out of
order. Start interlock.
94 – LO T-Preheat

The engine coolant temperature u Contact Service.
has failed to reach the defined
limit value 1. Preheater is out of
order.
TIM-ID: 0000077157 - 001
95 – AL Prelubrication Fault

The oil pressure at sensor B5.1 is u Contact Service.
below the specified value. The
specified oil pressure was not
reached. The starting sequence
was terminated.

102 – AL Fuel Cons. Counter Defect

The fuel consumption calculated u Contact Service.
by the ECU and stored on
stopping the engine cannot be
read out properly on restarting the
engine.
104 – AL Eng Hours Counter Defect

The operating hours calculated by u Contact Service.
the ECU and stored on stopping
the engine cannot be read out
properly on restarting the engine.
118 – LO ECU Power Supply Voltage

The ECU supply voltage went 1. Check condition of batteries (plant).
below the defined limit value 1. 2. Check plug connections to engine governor (→ Page 270).
3. Check battery-charging generator (→ Page 258).
4. Contact Service.
119 – LOLO ECU Power Supply Voltage

The ECU supply voltage went 1. Check condition of batteries (plant).
below the defined limit value 2. 2. Check plug connections to engine governor (→ Page 270).
4. Contact Service.
120 – HI ECU Power Supply Voltage

ECU supply voltage exceeded limit 1. Check condition of batteries (plant).
value 1. 2. Check plug connections to engine governor (→ Page 270).
4. Contact Service.
121 – HIHI ECU Power Supply Voltage

TIM-ID: 0000077157 - 001

ECU supply voltage exceeded limit 1. Check condition of batteries (plant).
value 2. 2. Check plug connections to engine governor (→ Page 270).
4. Contact Service.

122 – HI T-ECU

The temperature at the sensor 1. Disconnect power supply.
inside the ECU exceeded the limit 2. Check power supply (plant).
value. The temperature inside the 3. Contact Service.
housing is too high.
141 – AL Power too high

The average power value over the u Contact Service.
last 24 hours has violated the set
maximum value. The average
power demand was too high.
180 – AL CAN1 Node Lost

Connection or communication 1. Check engine wiring (→ Page 268).
with a node on CAN bus 1 has 2. Disconnect power supply, then reconnect.
failed. 3. Contact Service.
181 – AL CAN2 Node Lost

Connection or communication 1. Check engine wiring (→ Page 268).
with a node on CAN bus 2 has 2. Disconnect power supply, then reconnect.
failed. 3. Contact Service.
182 – AL CAN Wrong Parameters

Incorrect parameter values u Contact Service.
entered in data record.
183 – AL CAN No PU-Data

The ECU expects project u Contact Service.
configuration data (PU data) from
TIM-ID: 0000077157 - 001
the Backup Data Module server

(BDM), e.g. SAM or LOP, during
initial start-up.

184 – AL CAN PU-Data Flash Error

The project configuration data (PU u Contact Service.
data) from the Backup Data
Module server (BDM), e.g. SAM or
LOP, saved during initial start-up
cannot be properly read out.
186 – AL CAN1 Bus Off

CAN bus 1 to MTU automation 1. Check plug connections to engine governor (→ Page 270).
system (e.g. ECU/MAU/SAM) is 2. Contact Service.
disrupted or defective.
187 – AL CAN1 Error Passive

CAN bus 1 to MTU automation 1. Check plug connections to engine governor (→ Page 270).
system (e.g. ECU/MAU/SAM) is 2. Contact Service.
disrupted or defective.

CAN bus 2 to plant automation 1. Check connection between plant automation system and MTU
system (e.g. Murphy display) is automation system.
disrupted or defective. 2. Contact Service.

CAN bus 2 to plant automation 1. Check connection between plant automation system and MTU
system (e.g. Murphy display) is automation system.
disrupted or defective. 2. Contact Service.
190 – AL EMU Parameter Not Supported

ECU9-FSW cannot support a later u Contact Service.
TIM-ID: 0000077157 - 001
EMU parameter set version. New

EMU parameters cannot therefore
be set via ECU9.

201 – SD T-Coolant

The signal from the coolant 1. Check engine wiring (→ Page 268).
temperature sensor (B6) on the 2. Contact Service.
coolant distribution housing is
faulty or missing.
202 – SD T-Fuel

The signal from the fuel 1. Check engine wiring (→ Page 268).
temperature sensor (B38) is faulty 2. Contact Service.
or missing.
203 – SD T-Charge Air

The signal from the A side charge- 1. Check engine wiring (→ Page 268).
air temperature sensor (B9) is 2. Contact Service.
faulty or missing.
206 – SD T-Exhaust A

The exhaust gas temperature 1. Check engine wiring (→ Page 268).
sensor (B4.21) in the exhaust pipe 2. Contact Service.
on A side delivers incorrect or no
signal.
207 – SD T-Exhaust B

The charge-air temperature 1. Check engine wiring (→ Page 268).
sensor (B4.22) B side is supplying 2. Contact Service.
a faulty or no signal.
208 – SD P-Charge Air

The signal from the charge-air 1. Check engine wiring (→ Page 268).
TIM-ID: 0000077157 - 001
temperature sensor (B10.1) after 2. Contact Service.

the A side intercooler is faulty or
missing.

211 – SD P-Lube Oil

The signal from the lube oil 1. Check engine wiring (→ Page 268).
pressure sensor after filter (B5.1) 2. Contact Service.
is faulty or missing.
212 – SD P-Coolant

The coolant pressure sensor after 1. Check engine wiring (→ Page 268).
coolant pump (B16) delivers 2. Contact Service.
incorrect or no signal.
214 – SD P-CrankCase

The signal from the crankcase 1. Check engine wiring (→ Page 268).
pressure sensor (B50) is faulty or 2. Contact Service.
missing.
215 – SD P-HD

The signal from the rail pressure 1. Check engine wiring (→ Page 268).
sensor (B48) is faulty or missing. 2. Contact Service.
216 – SD T-Lube Oil

The signal from the lube-oil 1. Check engine wiring (→ Page 268).
temperature sensor (B7.1) is 2. Contact Service.
faulty or missing.
219 – SD T-Intake Air

The signal from the intake air 1. Check engine wiring (→ Page 268).
temperature sensor (B3) is faulty 2. Contact Service.
or missing.
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220 – SD Level Coolant Water

The signal from the coolant level 1. Check engine wiring (→ Page 268).
sensor (F33) is faulty or missing. 2. Contact Service.

221 – SD P-Diff Lube Oil

The signals from lube oil pressure 1. Check engine wiring (→ Page 268).
sensors B5.3 and/or B5.1 are 2. Contact Service.
faulty or missing.
222 – SD Level Leakage Fuel

The signal from the fuel leakage 1. Check engine wiring (→ Page 268).
sensor (F46) is faulty or missing. 2. Contact Service.
227 – SD P-Lube Oil before Filter

The signal from the oil pressure 1. Check engine wiring (→ Page 268).
sensor before filter (B5.3) is faulty 2. Contact Service.
or missing.
228 – SD P-Fuel before Filter

The HP fuel sensor before the 1. Check engine wiring (→ Page 268).
main fuel filter (B34.2) supplies a 2. Contact Service.
faulty signal or no signal.
229 – AL Stop Camshaft Sensor Defect

Emergency engine stop following u Contact Service.
failure of crankshaft sensor and
camshaft sensor.
230 – SD Crankshaft Speed

The signal from the crankshaft 1. Check engine wiring (→ Page 268).
speed sensor (B13) is faulty or 2. Contact Service.
missing.
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231 – SD Camshaft Speed

The signal from the camshaft 1. Check engine wiring (→ Page 268).
speed sensor (B1) is faulty or 2. Contact Service.
missing.

232 – SD Charger 1 Speed

The signal from the A side ETC 1. Check engine wiring (→ Page 268).
speed sensor (B44.1) is faulty or 2. Contact Service.
missing.
233 – SD Charger 2 Speed

The signal from the B side ETC 1. Check engine wiring (→ Page 268).
speed sensor (B44.2) is faulty or 2. Contact Service.
missing.
239 – SD P-Diff Fuel

The pressure sensors B34.1 1. Check engine wiring (→ Page 268).
and/or B34.2 supply a faulty 2. Contact Service.
signal or no signal.
240 – SD P-Fuel

The signal from the fuel pressure 1. Check engine wiring (→ Page 268).
sensor after main fuel filter 2. Contact Service.
(B34.1) is faulty or missing.
241 – SD T-Umblasen

Charge-air temperature sensor 1. Check engine wiring (→ Page 268).
(B49) supplies incorrect signal or 2. Contact Service.
no signal.
245 – SD ECU Power Supply Voltage

The signal from the voltage sensor 1. Check engine wiring (→ Page 268).
in the ECU is faulty or missing. 2. Contact Service.
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266 – SD Speed Demand

The analog nominal speed setting 1. Switch on plant automation.
signal is missing. 2. Contact Service.

270 – SD Frequency Input

Signal at analog frequency input 1. Check engine wiring (→ Page 268).
missing. 2. Contact Service.
321 – AL Wiring Cylinder A1

Short circuit fault in the injector 1. Check wiring of affected injector (→ Page 268).
wiring for cylinder A1 or injector is 2. Replace injector (→ Page 148).
defective. 3. Contact Service.




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wiring for cylinder A10 or injector 2. Replace injector (→ Page 148).
is defective. 3. Contact Service.
331 – AL Wiring Cylinder B1

wiring for cylinder B1 or injector is 2. Replace injector (→ Page 148).

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wiring for cylinder B10 or injector 2. Replace injector (→ Page 148).
is defective. 3. Contact Service.

341 – AL Open Load Cylinder A1

Disruption fault in injector wiring 1. Check wiring of affected injector (→ Page 268).
to cylinder A1. 2. Contact Service.






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351 – AL Open Load Cylinder B1

cylinder B1. 2. Contact Service.




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361 – AL Power Stage Low

The output stage voltage to 1. Check power supply (plant).
control the injectors is too low. 2. Contact Service.
362 – AL Power Stage High

control the injectors is too high. 2. Contact Service.
363 – AL Stop Power Stage

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control the injectors is too low. 2. Contact Service.
Engine stop
365 – AL Stop MV-Wiring Ground

Short circuit of positive or 1. Check cabling (→ Page 268).
negative terminal of one or more 2. Restart engine.
injectors to ground. 3. Contact Service.

371 – AL Wiring TO 1

Short circuit or wire break on 1. Check engine wiring (→ Page 268).
transistor output 1 (TO 1). 2. Contact Service.



381 – AL Wiring TOP 1

Short circuit or wire break at 1. Check cabling (→ Page 268).
transistor output 1, plant (TOP 1). 2. Contact Service.


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400 – AL Open Load Digital Input 1

Open load detected at digital 1. Check cabling (→ Page 268).
input 1 of the ECU. 2. Contact Service.






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408 – AL Open Load Emerg. Stop Input ESI

Open load at emergency stop 1. Check cabling (→ Page 268).
input. 2. Contact Service.
410 – LO U-PDU

The ECU voltage to control the 1. Check power supply (plant).
injectors went below limit value 1. 2. Check cabling (→ Page 268).
3. Contact Service.
411 – LOLO U-PDU

injectors went below limit value 2. 2. Check cabling (→ Page 268).
3. Contact Service.
412 – HI U-PDU

injectors exceeded limit value 1. 2. Check cabling (→ Page 268).
3. Contact Service.
413 – HIHI U-PDU

injectors exceeded limit value 2. 2. Check cabling (→ Page 268).
3. Contact Service.
414 – HI Level Water Fuel Prefilter

Switch F70 in the fuel prefilter has 1. Drain fuel prefilter (→ Page 159).
been tripped by an excessively 2. Replace fuel prefilter (→ Page 163).
high water content in the fuel. 3. Contact Service.
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417 – SD Level Water Fuel Prefilter

The signal from the level sensor 1. Check engine wiring (→ Page 268).
for water in the fuel prefilter (F70) 2. Contact Service.
is faulty or missing.

444 – SD U-PDU

Fault in the internal supply voltage u Contact Service.
for the injector output stage.
445 – SD P-Ambient Air

The signal from the ambient u Contact Service.
pressure sensor in the ECU is
faulty or missing.
454 – SS Power Reduction Active

Power reduction is activated. A 1. Observe additional messages.
main alarm activating power 2. Contact Service.
reduction has been tripped.
470 – SD T-ECU

The signal from the temperature u Contact Service.
sensor in the ECU is faulty or
missing.
472 – AL Stop SD

This fault is output in case of a u Contact Service.
defective sensor which has been
configured to initiate an engine
stop.
474 – AL Wiring FO

Short circuit or wire break at the 1. Check engine wiring (→ Page 268).
frequency output. 2. Contact Service.
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475 – AL CR Trigger Engine Stop

The Crash Recorder is tripped by u Contact Service.
an engine shutdown.

476 – AL Crash Rec. Init. Error

The Crash Recorder data module u Contact Service.
was detected as being faulty after
reading out the flash memory.
478 – AL Comb. Alarm Yel (Plant)

This alarm is raised when a plant 1. Observe additional messages.
device on the PCS5-CAN signals 2. Contact Service.
the ECU to set a yellow summary
alarm.
479 – AL Comb. Alarm Red (Plant)

This alarm is raised when a plant 1. Observe additional messages.
device on the PCS5-CAN signals 2. Contact Service.
the ECU to set a red summary
alarm.
480 – AL Ext. Engine Protection

The external engine protection 1. Check plant signal.
function is active. 2. Contact Service.
482 – SD T-Exhaust C

The signal from the exhaust gas 1. Check engine wiring (→ Page 268).
faulty or missing.
483 – SD T-Exhaust D

The signal from the exhaust gas 1. Check engine wiring (→ Page 268).
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faulty or missing.


is too high. Cause: Fault or
malfunction of another
turbocharger.

turbocharger.

turbocharger.

turbocharger.
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510 – AL Override applied

Override function has been u No action required.
activated. Override suppresses
other alarms.

536 – AL Wiring PWM_CM1

HP fuel control block M8 of the 1. Check engine wiring (→ Page 268).
HP fuel pump cannot be activated. 2. Contact Service.
549 – AL Power Cut-Off detected

The ECU operating voltage was 1. Check engine wiring if the power supply was not disconnected
switched off while the engine was manually (→ Page 268).
running. Do not disconnect the 2. Contact Service.
power supply until the engine is at
standstill.
551 – SS Engine Overspeed Camshaft

The engine speed measured at u Contact Service.
camshaft sensor B1 exceeded
limit value 2 or the engine
overspeed test was tripped.
Emergency engine stop was
tripped.
582 – AL Emergency Stop Failed

This alarm is raised if the engine u Contact Service.
fails to come to a standstill within
a defined time following an
emergency stop signal.
586 – LO P-Oil Refill Pump

The refill pump lube oil pressure 1. Top up engine oil (→ Page 204).
measured at sensor B54 has 2. Contact Service.
fallen below the limit value. The oil
pressure at the refill pump is too
low.
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588 – SD P-Oil Refill Pump

The signal from the refill pump 1. Check engine wiring (→ Page 268).
lube oil pressure sensor (B54) is 2. Contact Service.
faulty or missing.

596 – AL Develop PR Set

The parameter record is used for u No action required.
trials. The alarm remains active
until a series-production
parameter set was installed.
602 – AL CAN Engine Start Lock

The ECU has received a start 1. Check plant controller.
interlock from the plant via the 2. Contact Service.
CAN bus.
606 – AL Double Nodes Lost CAN 1 + 2

Unable to detect one of the 1. Check engine wiring (→ Page 268).
connected and monitored CAN 2. Contact Service.
bus devices on CAN bus 1 and
CAN bus 2.
627 – AL Wiring PWM_CM9

Solenoid valve Y27.1 to cut-in the 1. Check engine wiring (→ Page 268).
A side exhaust turbocharger 2. Contact Service.
cannot be activated.
836 – AL Speed Demand Failure

The ECU is unable to receive a 1. Switch on plant automation.
speed demand signal via the CAN 2. Contact Service.
bus. Alarm 266 is signaled
simultaneously.
947 – AL Invalid LSI Channel Config

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Incorrect LSI channel u Contact Service.

configuration

955 – AL Thermal Management active

Thermal management was u No action required.
activated as soot loading in the
DPF has reached the limit.
Regeneration has been initiated
automatically.
973 – AL Check Sum IIG

The IIG value entered does not 1. Check the IIG input in DiaSys, repeat as necessary.
match the defined input format. 2. Contact Service.

The first engine CAN (CAN 3) for 1. Check engine wiring (→ Page 268).
engine sensors/actuators is 2. Contact Service.
disconnected or faulty.

The first engine CAN (CAN 3) for 1. Check engine wiring (→ Page 268).
engine sensors/actuators is 2. Contact Service.
disrupted.

The second engine CAN (CAN 4) 1. Check engine wiring (→ Page 268).
for engine sensors/actuators is 2. Contact Service.
disconnected or faulty.
983 – AL Stop on Trigger Crashrecorder

This alarm indicates that the u Contact Service.
Crash Recorder has been tripped
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and a start interlock activated as

a result.

1027 – AL Engine Cold Active

This fault is signaled and the 1. Switch on preheater.
“Engine Cold” function initiated if 2. Check preheater, overhaul as necessary (see manufacturer's
one of the temperature values is documentation).
below the defined limit. 3. Contact Service.
1130 – AL Short Circuit Analog Out 1

Incorrect plant value at analog u Contact Service.
output 1 (e.g. moving-coil
instrument, output signal for HT
circuit fan control).
1131 – AL Short Circuit Analog Out 2

Incorrect plant value at analog u Contact Service.
output 2 (e.g. moving-coil
instrument, output signal for LT
circuit fan control).
1139 – AL Communication Error ECU - EXU

Communication error between 1. Check engine wiring (→ Page 268).
ECU and EXU 2. Restart ECU.
3. Contact Service.
1170 – AL Permanent Injection

The ECU has detected continuous u Contact Service.
injection at one or more injectors
based on the pressure gradient in
the HP fuel system (B48).
1178 – AL J1939 Heartbeat1 Lost

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No message via J1939 plant bus u Contact Service.
(CAN2).
1179 – AL J1939 Heartbeat2 Lost

No message via J1939 plant bus u Contact Service.
(CAN2).

1183 – AL Invalid Measurement Config

Selected measuring point not u Contact Service.
activated or configured
incorrectly.
1201 – AL Stop Start Low Power Supply Pow

Engine start is blocked because 1. Check condition of batteries (plant).
the supply voltage is too low. 2. Contact Service.
1370 – SD P-HD Constant Value

The ECU has not detected any u Contact Service.
variation in pressure at HP fuel
sensor B48. HP fuel sensor B48 is
defective.
1376 – AL Refdrive Impossibl Ubat Low

The ECU supply voltage is two low 1. Check condition of batteries (plant).
for successful homing of all flaps 2. Check plug connections to engine governor (→ Page 270).
even when the engine is running. 3. Contact Service.
1377 – AL Refdrive Impossibl Eng Op Point

Homing of one or more flaps 1. Run engine up to idling speed. Result: Homing is executed.
before engine start was not 2. Contact Service.
completed successfully. Homing
the affected flaps is no longer
possible.
1544 – AL Blow Over Temperature Error

The temperature and/or u Contact Service.
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temperature gradient measured at

temperature sensor B49 before
the air recirculation valve is too
high. The air recirculation valve is
not opened.

8 Task Description
8.1 SOLAS
8.1.1 SOLAS shielding as per MTN 5233 – Installation
Preconditions

Shield A5 735233000101 20
Shield A6 735233000102 2
Shield A7 735233000103 3
Shield A8 735233000104 3
Shield B2 735233000200 2
Shield B4 735233000202 1
Shield E5 735233000500 3
Installing SOLAS shielding

1. Pinpoint installation location (→ Page 121).
2. Install suitable shielding.
3. Press shielding until locked.
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120 | Task Description | MS150123/01E 2017-05

8.1.2 Installation locations for SOLAS shielding
General information
Fit SOLAS shielding as per MTN 5233 by way of preference (→ Page 120).
Shield unions with adhesive tape if SOLAS shielding as per MTN 5233 is not possible (→ Page 128).
When affixing adhesive connections ensure that escaping fluid can flow out without pressure (→ Page 128).
Fuel system, fuel lines with fuel pressure >1.8 bar
Item Type of shielding Installation location

1 2 x shield A5 Fuel line to fuel filter head
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1 2 x shield A8 Fuel line from/to fuel filter head
MS150123/01E 2017-05 | SOLAS | 121

1 Shield A8 Fuel line to HP pump
2 Shield E5 Fuel line to HP pump
Lube oil system, oil lines with oil pressure >1.8 bar

1 2 x shield A5 Actuating cylinder exhaust flap ETC B1
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122 | SOLAS | MS150123/01E 2017-05

1 2 x shield A5 Actuating cylinder air flap ETC B1
2 3 x shield A5 T adapter for flap control ETC B1

1 4 x shield A5 Distributor
2 3 x shield A5 Oil return
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MS150123/01E 2017-05 | SOLAS | 123

1* Shield A7 Oil return
* This shield must be installed on the assembly line. This position can no longer be accessed as soon as the
intake housing is installed.

1* Shield A7 Oil line to ETC
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2* Shield A5 Oil line to flap control

3 Shield A5 Oil line to recirculation valve
4* 2 x shield E5 Oil line from main gallery
* These shields must be installed on the assembly line. These positions can no longer be accessed after
assembly intake housing.
124 | SOLAS | MS150123/01E 2017-05

1 2 x shield A5 Air recirculation valve

1 Shield A6 Oil supply line to HP pump: To HP pump
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MS150123/01E 2017-05 | SOLAS | 125

1* Shield B4 Oil supply line to HP pump: On equipment carrier
* This shield must be installed on the assembly line. Assembly in this position is no longer possible after
painting.

1 Shield A7 ETC oil supply
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2 Shield A6 ETC oil supply
126 | SOLAS | MS150123/01E 2017-05

1* Shield B2 Oil line on equipment carrier
1 Shield B2 Oil line on pressure reducing valve
* This shield must be installed on the assembly line. Assembly in this position is no longer possible after
painting.
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MS150123/01E 2017-05 | SOLAS | 127

8.1.3 Adhesive tape for SOLAS shielding – Application
Preconditions

Adhesive tape
Applying adhesive tape – gener-

al information
Note: Use the cable clamp to make a drainage
channel. This allows fluid to flow out without
pressure in case of leakage.
1. Place cable clamp (3) on union.
2. Affix adhesive tape (1) such that lettering (2)
faces out.
3. Wrap adhesive tape without tensioning.
4. Pull out cable clamp (3) after affixing adhe-
sive tape.
Sealing cone unions

Note: For installation positions of sealing cone un-
ions, see (→ Page 121).
1. Wrap three layers of adhesive tape from the
middle of the sealing cone union to area (A)
for at least 30 mm, ensuring that the adhe-
sive tape overlaps at least half its own width.
2. Wrap three layers of adhesive tape from the
middle of the sealing cone union to area (B)
for at least 30 mm, ensuring that the adhe-
sive tape overlaps at least half its own width.
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Plug-in connections
Note: For installation positions of plug-in connections, see (→ Page 121).
1. Apply adhesive tape flush.
2. Apply three layers of adhesive tape such that at least 30 mm are covered from the middle of the screw to the
line.
128 | SOLAS | MS150123/01E 2017-05

8.2 Engine
8.2.1 Engine – Barring manually
Preconditions

Barring gear F6555766 1
Ratchet with extension F30006212 1
DANGER
Rotating and moving engine parts.
• Before cranking the engine with starter system, make sure that there are no persons in the engine's
danger zone.
Barring engine manually

1. Loosen screws (1) and remove end cover (2)
from flywheel housing.
2. Engage barring gear (2) in ring gear of fly-

wheel and mount on flywheel housing.
3. Fit ratchet (1) on barring gear.
Note: No resistance other than compression resist-
ance must be encountered.
4. Rotate crankshaft in engine direction of rota-
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tion.
Result: If the resistance exceeds the normal com-
pression resistance, contact Service.
5. For barring gear removal follow reverse se-
quence of working steps.
MS150123/01E 2017-05 | Engine | 129

8.2.2 Engine – Barring with starting system
BlueLine automation system
Starting barring procedure at LOP 8 (→ BlueLine Operating Instructions)
BlueVision automation system

Starting barring procedure at LOP 8 (→ BlueLine Operating Instructions)
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130 | Engine | MS150123/01E 2017-05

8.3 Cylinder Liner
8.3.1 Cylinder liner – Endoscopic examination
Preconditions
☑ Engine is stopped and starting disabled

Barring tool F6555766 1
Ratchet with extension F30006212 1
Endoscope Y20097353 1
Preparatory steps
1. Remove cylinder head cover (→ Page 145).
2. Remove injector (→ Page 149).
Positioning crankshaft at BDC

1. Using barring tool, turn crankshaft until crankshaft journal of the cylinder to be tested has reached BDC.
2. Insert endoscope into cylinder liner through injector seat.
Endoscopic examination of cylinder liner

Findings Measure
• Thin carbon coating around carbon scraper ring No actions required.
• Slight localized additive deposits at top edge
• Localized smooth areas at bottom edge
• Carbon deposits on entire circumference 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
• Faultless, even honing pattern
• First signs of marks left by lower cooling bores
• Running pattern seems darker
• Dark areas with even or varying degrees of discoloration Further endoscopic examina-
• Beginning and end of the discoloration are not sharply defined and do tion required as part of mainte-
not cover the entire stroke area nance work.
• Dark areas in the upper section of the cooling bore, remaining circum-
ference are faultless
• Piston rings are faultless
• On the entire circumference, apart from light areas of discoloration (do Cylinder liner must be replaced,
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not impair operation) clearly darker stripes that start at the top piston contact Service.
ring
• Heat discoloration in the direction of stroke and honing pattern dam-
age
• Heat discoloration of piston rings
MS150123/01E 2017-05 | Cylinder Liner | 131

1. Compile endoscopic report using the table.
2. Use technical terms to describe the liner surface (→ Page 133).
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.
Final steps
1. Install injector (→ Page 149).
2. Install cylinder head cover (→ Page 145).
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132 | Cylinder Liner | MS150123/01E 2017-05

8.3.2 Cylinder liner – Instructions and comments on endoscopic and visual
examination
Terms used for endoscopic examination
Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic examina-
tion report.
Findings Explanations/Action
Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing products,
particles, broken-off burrs). Removed cylinders clearly show such scoring on the
running surface under endoscope magnification. Cannot be felt with the fingernail.
Findings not critical
Single scores Clearly visible scores caused by hard particles. They usually start in the TDC area
and cross through the honing pattern in the direction of stroke.
Scored area These areas consist of scores of different length and depth next to one another. In
most cases, they are found at the 6-o'clock and 12-o'clock positions (inlet/
exhaust) along the transverse engine axis.
Polished area Polished areas are on the running surface but almost the whole honing pattern is
still visible. Polished areas appear brighter and more shiny than the surrounding
running surface.
Bright area Bright areas are on the running surface and show local removal of the honing pat-
tern. Grooves from the honing process are not visible any more.
Discoloration This is caused by oxidation (surface discoloration through oil or fuel) and tempera-
ture differences around the liner. It appears rather darker within the honed struc-
ture in contrast to the bright metallic running surface. The honing pattern is undis-
turbed. Discolorations extend in stroke direction and may be interrupted.
Corrosion fields / Corrosion fields / spots result from moisture (condensate) with the valves in the
spots overlap (open) position. They are clearly visible due to the dark color of the honing
groove bottom.
This corrosion is not critical unless there is corrosion pitting.
Black lines Black lines are a preliminary stage of burn marks. They are visible as a clear discol-
oration from TDC to BDC in the running surface and the start of localized damage
to the honing pattern.
Cylinder liners with a large number of black lines around the running surface have
limited service life and should be replaced.
Burn mark These are caused by a disturbance in the liner / ring tribo system. Usually they run
over the whole ring-travel area (TDC/BDC), starting at the first TDC-ring and be-
coming more visible from the second TDC-ring 2 onwards and less pronounced
from TDC-ring 1. The honing pattern is usually no longer visible and displays a
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clearly defined (straight) edge to the undisturbed surface. The damaged surface is
usually discolored. The circumferential length varies.
Liners with burn marks starting in TDC ring 1 have to be replaced.
Seizure marks, scuff- Irregular circumference lengths and depths. Can be caused either by the piston
ing skirt or the piston crown. Material deposits on the liner (smear), heavy discolora-
tion. Severe, visible scoring.
Replace liner.
Table 4: Endoscopic examination – Terms used
MS150123/01E 2017-05 | Cylinder Liner | 133

Evaluation of findings and further measures
The findings in the start phase of oxidation discoloration and burn marks are similar. A thorough investigation
and compliance with the above evaluation criteria allow an unambiguous evaluation. To avoid unnecessary
disassembly work, it is recommended that another inspection be carried out after further operation of the
engine.
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134 | Cylinder Liner | MS150123/01E 2017-05

8.4 Crankcase Breather
8.4.1 Crankcase breather – Oil mist separator replacement
Preconditions

Engine oil
Oil mist separator (→ Spare Parts Catalog)
O-ring (→ Spare Parts Catalog)
WARNING
Oil is hot.
Oil can contain residue/substances which are harmful to health.
Risk of injury and poisoning!
• Allow the product to cool to below 50 °C before beginning work.
• Wear protective clothing, protective gloves and goggles/safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.
Oil mist separator – Replace-

ment
1. Remove screws (1) and take off together with
retainer (2).
2. Replace oil mist separator (3).
3. Replace O-ring (4) if necessary.
4. Replace further oil mist separators in the
same way.
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MS150123/01E 2017-05 | Crankcase Breather | 135

8.5 Valve Drive
8.5.1 Valve protrusion – Measurement
Preconditions

Measuring jig 1 Y4350009 1
Depth gage, 200 mm Y20000918 1
Measuring jig 2, optional Y4350010 1
Preparatory steps
1. Remove cylinder head covers (→ Page 145).
2. Install barring tool (→ Page 129).
3. Turn crankshaft in direction of rotation using
barring tool until TDC mark (1) and pointer (2)
are aligned.
Calibrating measuring jigs 1 and

2
1. Place measuring unit (2) on calibration
plate (3).
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136 | Valve Drive | MS150123/01E 2017-05

2. Turn measuring unit screws (1) into the threads and tighten to specified torque using a torque wrench.
Screw M10 Tightening torque 20 Nm
3. Set all dial gages to 0.

4. Unscrew measuring unit (2) from calibration plate (3).
Step 1: Measure valve protrusion at the valve head with measuring jig 1
1. Check TDC position of piston in cylinder A1:
• If rocker arms on cylinder A1 are unloaded, the piston is in firing TDC.
• If rocker arms on cylinder A1 are loaded, the piston is in overlap TDC.
2. Measure valve stem end to cylinder head top distance for each valve in two crankshaft positions (firing TDC
and overlap TDC) according to the diagram. Diagram (→ Page 141).
3. Place measuring unit 1 (2) on the cylinder
head (3).
4. Turn measuring unit screws (1) into the threads provided for the cylinder head cover and tighten to specified
torque using a torque wrench.
5. Determine the values with all dial gages.

• The valve protrusion value must be ≤ 1.5 mm.
• If the value is > 1.5 mm, measure with a depth gage or optionally with measuring jig 2.
6. Unscrew measuring unit (2) from cylinder head (3).
Step 2: Measure valve protrusion at the valve stem with a depth gage
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MS150123/01E 2017-05 | Valve Drive | 137

3. Release adjusting screw (1) and remove valve
bridge. Do not remove rocker arm (2).
4. Measure distance (A) between valve stem

end and cylinder head top at the injector
bore with depth gage.
• The specified value for a new cylinder
head: 93.8 mm.
• Admissible wear: 2 mm.
• Have the affected cylinder head replaced
by expert personnel ahead of schedule if
the measured value is > 95.8 mm.
5. Install valve bridge.
6. Adjusting valve clearance (→ Page 141)
Step 2 optional: Measure valve protrusion at the valve stem with measuring
jig 2
TIM-ID: 0000045593 - 010
138 | Valve Drive | MS150123/01E 2017-05

Note: Do not remove rocker arm (2).
3. Release adjusting screw (1) and remove valve
bridge.
4. Place measuring unit 2 (2) on the cylinder

head (3).
5. Turn measuring unit screws (1) into the threads provided for the cylinder head cover and tighten to specified
torque using a torque wrench.
6. Determine the values with all dial gages.

• The valve protrusion value must be ≤ 2 mm.
• Have the affected cylinder head replaced by expert personnel if the value is > 2 mm.
7. Unscrew measuring unit (2) from cylinder head (3).
TIM-ID: 0000045593 - 010
8. Install valve bridge.

9. Adjusting valve clearance (→ Page 141)
Final steps
1. Remove barring tool (→ Page 129).
MS150123/01E 2017-05 | Valve Drive | 139

8.5.2 Valve gear – Lubrication
Preconditions

Engine oil
Valve gear – Lubrication

2. Fill oil chambers of valve bridges with oil.
3. Fill oil chambers of rocker arms and adjusting
screws with oil.
4. Install cylinder head covers (→ Page 145).
TIM-ID: 0000000921 - 010
140 | Valve Drive | MS150123/01E 2017-05

8.5.3 Valve clearance – Check and adjustment
Preconditions
☑ Engine coolant temperature is max. 40 °C.
☑ Valves are closed.

Feeler gage Y20098771 1
Valve setting gauge Y4349603 1
Angular screw driver F30002815 1
Socket wrench, 24 mm F30039526 1
Engine oil
Preparatory steps
2. Install barring device (→ Page 129).
Note: Pointer (1) is located in the lower opening of
the flywheel housing (arrow).
3. Use barring device to turn crankshaft in di-
rection of rotation until marking OT/A1 on
the rear side of the flywheel housing and
pointer (1) are aligned.
TIM-ID: 0000000922 - 015
MS150123/01E 2017-05 | Valve Drive | 141

Note: Danger of confusion: There might be an addi-
tional OT/A1 mark (1) on the outer perimeter
of the flywheel.
4. The additional OT/A1 mark (1) (if fitted) on
the outer perimeter of the flywheel must not
be used for reference.
Diagram for 8V engines – Two

crankshaft positions

TIM-ID: 0000000922 - 015
142 | Valve Drive | MS150123/01E 2017-05


Checking valve clearance at two crankshaft positions

• If the rocker arms are unloaded on cylinder A1, the piston is in firing TDC.
• If the rocker arms are under load on cylinder A1, the piston is in overlap TDC.
2. Check valve clearance adjustment with cold engine:
• Inlet valves (long rocker arm) = 0.2 mm ±0.05 mm
• Exhaust valves (short rocker arm) = 0.5 mm ±0.05 mm
3. Check all valve clearances in two crankshaft positions (firing TDC and overlap TDC of cylinder A1) as per
diagram:
TIM-ID: 0000000922 - 015
1 Cylinder A1 is in firing TDC

2 Cylinder A1 is in overlap TDC
I Inlet valve
X Exhaust valve
4. Use valve setting gauge or feeler gauge to determine the distance between valve bridge and rocker arm.
5. If the deviation from the set value exceeds 0.1 mm, adjust valve clearance.
MS150123/01E 2017-05 | Valve Drive | 143

Adjusting valve clearance
1. Release locknut (1).
2. Insert valve setting gauge (3) between valve
bridge and rocker arm.
Note: Replace or rectify adjusting screws and/or
locknuts which do not move freely.
3. Using angular screw driver, set adjusting
screw (2) so that the specified valve clear-
ance is provided.
Note: Valve setting gauge must just pass through
the gap.
4. Pass valve setting gauge (3) between valve
bridge and rocker arm.
5. Tighten locknut (1) with torque wrench to the specified tightening torque, holding the adjusting screw (2) to
prevent it from turning.
Locknut M16x1.5 Tightening torque (Engine oil) 90 Nm +9 Nm
6. Check valve clearance, adjust if necessary.
Final steps
1. Remove barring device (→ Page 129).
2. Install cylinder head covers (→ Page 145).
TIM-ID: 0000000922 - 015
144 | Valve Drive | MS150123/01E 2017-05

8.5.4 Cylinder head cover – Removal and installation
Preconditions

Assembly compound (Kluthe Hakuform 30-15) X00067260 1
Removing cylinder head cover

1. Clean very dirty cylinder head covers (1) prior
to removal.
2. Remove screws (3, 4) with washers (2, 5).
3. Take off cylinder head cover with O-ring (6)
from cylinder head (7).
Installing cylinder head cover

1. Clean installation surface.
2. Check O-ring (6) for damage, replace as necessary.
3. Coat O-ring with assembly compound.
4. Insert O-ring in groove on cylinder head cover (1).
5. Fit cylinder head cover on cylinder head (7).
6. Install cylinder head cover with screws (3, 4) and washers (2, 5).
TIM-ID: 0000012309 - 015
MS150123/01E 2017-05 | Valve Drive | 145

8.6 Injection Pump / HP Pump
8.6.1 HP fuel pump – Filling with engine oil
Preconditions

Fuel suction device F30378207 1
Engine oil
WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.
WARNING
Liquid or gaseous media, e.g. fuel, are poisonous.
Escaping vapors of highly volatile media, e.g. fuel or ether.
Risk of fatal injury through swallowing; risk of poisoning through inhalation; irritation to eyes
and skin!
• Seek medical attention immediately; do not induce vomiting.
• Do not inhale vapors or mist.
• Wear protective clothing, protective gloves, and safety glasses.
• If contact is made with skin, wash off with water and soap.
WARNING
Oils/oil vapors are combustible/explosive.
• Avoid open flames, electric sparks and ignition sources.
• Do not smoke.
NOTICE
HP fuel pump not filled with engine oil.
Damage to components, major material damage!
• Ensure that th HP fuel pump is filled with engine oil before it is installed or put into operation.
NOTICE
Contaminated components.
Risk of damage to component!
TIM-ID: 0000001640 - 016
• Check components for special cleanliness and clean if necessary.
146 | Injection Pump / HP Pump | MS150123/01E 2017-05

Preparatory steps
u Loosen nut (2) and remove oil line (1) from
HP pump.
HP pump – Filling
1. Remove union (1).
Note: Excess engine oil runs into gear box.
2. Use fuel suction device to fill HP pump with
2 liters of clean engine oil.
3. Screw in union (1) and use torque wrench to tighten to specified tightening torque.
Neck M16x1.5 Tightening torque 40 Nm
Final steps
u Install oil line.
TIM-ID: 0000001640 - 016
MS150123/01E 2017-05 | Injection Pump / HP Pump | 147

8.7 Injector
8.7.1 Injector – Replacement
Injector (→ Spare Parts Catalog)
Injector – Replacement
u Remove injector and install new one (→ Page 149).
TIM-ID: 0000042329 - 002
148 | Injector | MS150123/01E 2017-05

8.7.2 Injector – Removal and installation (jacketed fuel system)
Preconditions

Installation/removal jig F6789889 1
Milling cutter F30452739 1
Torque screwdriver, 1–5 Nm F30452774 1
Ratchet bit F30027340 1
Assembly compound (Molykote P 37) 50564 1
Multi-purpose grease 40320 1
Engine oil
Damping ring (→ Spare Parts Catalog) 1
O-ring (→ Spare Parts Catalog) 2
Sealing ring (→ Spare Parts Catalog) 1
WARNING
• Do not smoke.
WARNING
and skin!
TIM-ID: 0000000925 - 027
WARNING
Hot components/surfaces.
Risk of burns!
• Allow the engine to cool down to below 50 °C before beginning work.
• Wear suitable protective equipment/thermal gloves.
• Avoid unprotected contact with hot surfaces.
MS150123/01E 2017-05 | Injector | 149

WARNING
Internal tension and residual pressure in the HP fuel system.Parts can be ejected when loosening them.
Risk of injury by ejected parts!
• Only use specified tools and devices.
• Wear goggles/facial protection.
NOTICE
Contamination of components.
Damage to component!
• Check components for special cleanliness.
Preparatory steps
1. Allow HP system to cool down.
2. Shut off fuel supply to engine.
3. Remove cylinder head cover (→ Page 145).
Removing injector
1. Disconnect cable connector on injector.
Note: Observe system pressure.

2. Slowly release union on HP line (4).
3. Remove HP fuel line (4).
Note: When the adapter is unscrewed, the stored
volume of the injector is drained.
4. Remove adapter (3).
5. Remove screw (2) and take off hold-down
clamp (1).
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6. Install installation/removal jig on the cylinder
head.
7. Remove injector with installation/removal jig.
8. Remove the installation/removal jig.
Note: The sealing ring (4) for sealing the combus-

tion chamber must only be used once.
9. Remove sealing ring (4) from injector or use a
self-made wire hook or magnet to take it out
of the cylinder head and dispose properly.
Note: For new assembly:
10. Dispose of injector with O-rings in place.
Note: For repeated assembly:
11. Remove O-rings (3), O-ring (2) and damper
ring (1) from injector.
12. Clean all mating and sealing surfaces.
13. Cover all connections and bores, or seal with
suitable plugs.
Installing injector
Note: • The new sealing ring is included in the
scope of supply of the injector (new part).
• A multi-purpose grease without solids con-
tent must be used.
1. Install new sealing ring (1) abutted to (Multi-
purpose grease) and ensure that the installa-
tion position is correct.
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MS150123/01E 2017-05 | Injector | 151

Note: Remove plugs on HP line only before installa-
tion of the adapter.
2. Remove plug.
3. Use milling cutter to remove oil carbon from
sealing face on cylinder head and protective
sleeve.
Note: The damper ring is already in place for new
assembly.
4. Fit damper ring (1) on injector and apply (As-
sembly compound (Molykote P 37)).
Note: The O-rings are already in place for new as-
sembly.
5. Fit new O-rings (3) on injector (2) and apply
(Assembly compound (Kluthe Hakuform
30-15)).
Note: Make sure that the sealing ring does not fall
into the water sleeve.
6. Ensure that the sealing ring (4) is correctly
seated.
7. Insert injector into cylinder head, ensuring
that the HP line connection is correctly
aligned.
8. Press in injector with installation/removal de-
vice.
9. Remove installation/removal device.
TIM-ID: 0000000925 - 027
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10. Coat screw mating face (2) and thread with
engine oil.
11. Fit hold-down clamp (1) in correct position
and install screw (2) by hand.
Note: Make sure parts are perfectly clean.
12. Apply engine oil to thread, sealing taper and
thrust ring of adapter (3).
13. Apply (Assembly compound (Kluthe Haku-
form 30-15)) to O-rings on adapter (3).
14. Install adapter (3).
15. Tighten screw (2) to specified torque using a torque wrench.

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

Adapter Tightening torque (Engine oil) 100 Nm +10 Nm
Note: Make sure parts are perfectly clean.

17. Coat thread and sealing cone of HP line (5) with engine oil.
18. Coat O-rings with (Assembly compound (Kluthe Hakuform 30-15)).
19. Thread in HP line (5), ensuring that the sealing areas are not damage.
20. Tighten jacketed HP line (5) according to tightening sequence to specified torque using a torque wrench.
Tightening sequence:
1 Adapter (4)
2 Rail (6)
Union nut / thrust Tightening torque (Engine oil) 40 Nm +5 Nm
screw
Note: Do not hold in place by hand.

21. Turn union nuts (4) and (6) back by approx. 45° angle of rotation and – without releasing the tool – tighten
immediately again to the specified tightening torque, following the same sequence. Tightening sequence:
1 Adapter (4)
2 Rail (6)
TIM-ID: 0000000925 - 027

Union nut / thrust Tightening torque (Engine oil) 40 Nm +5 Nm
screw
MS150123/01E 2017-05 | Injector | 153

22. Fit cable connector on injector.
For new assembly: CDC parameters – Reset

Note: Failure to reset drift compensation (CDC) will void the emissions certification of the engine.
u Reset drift compensation (CDC) with DiaSys® (→ Dialog system DiaSys® E531920/..). If DiaSys® is not
available, contact Service.
Final steps
2. Open fuel supply to engine.
TIM-ID: 0000000925 - 027
154 | Injector | MS150123/01E 2017-05

8.8 Fuel Filter
8.8.1 Fuel filter – Replacement
Preconditions

Oil filter wrench F30379104 1
Fuel
Easy-change filter (→ Spare Parts Catalog)
DANGER
WARNING
and skin!
WARNING
• Do not smoke.
WARNING
NOTICE
Severe material damage!
TIM-ID: 0000012705 - 009
• For filter replacement with the engine running, operate the engine at low engine load.
• The filter which is to be replaced must be cut out for a brief period only.
MS150123/01E 2017-05 | Fuel Filter | 155

Replacing fuel filter
Note: • The left fuel filter (5) is cut out when the
lever is in position (3)
• The right fuel filter (4) is cut out when the
lever is in position (7)
1. Cut out fuel filter to be replaced. Pull locking
pin (1) and turn lever (6) to the left or right
stop.
2. Unscrew cut-out fuel filter using an oil filter
wrench.
3. Clean sealing surface on filter head.
4. Check sealing ring of new fuel filter and coat
with fuel.
5. Screw on fuel filter and tighten by hand.
6. Return lever to normal position (6) and lock
with locking pin (1).
7. Replace other fuel filter in the same way.
Note: Venting is omitted on changing filters with
the engine running.
8. Vent fuel system at fuel vent (2).
TIM-ID: 0000012705 - 009
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8.8.2 Fuel prefilter – Contamination indicator check
DANGER
WARNING
Fuel prefilter – Contamination

indicator check
1 Pressure gage
2 Trailing pointer, black
3 Pointer, red
4 Reset button
A Display area, white
B Display area, yellow
C Display area, red
1. With the engine running, read off at pressure gage (1) the vacuum (contamination level) at the filter output
indicated by the red pointer (3).
2. When the red pointer (3) is continuously in the yellow area (B) at the latest, or at a high flow rate moves into
the red area (C):
a) Switch over to second, clean filter.
b) Replace contaminated filter (→ Page 163).
3. The black trailing pointer (2) shows the maximum measured vacuum. It can be reset by turning the but-
ton (4).
TIM-ID: 0000043503 - 003
MS150123/01E 2017-05 | Fuel Filter | 157

Switching over fuel prefilter
1 Filter B in operation
2 Filter A in operation
1. Press button on lever.

2. Turn lever to desired position and engage the button. The tip of the lever with the inscription always faces
the filter that is in operation. When the tip faces downwards, both filters are in operation.
TIM-ID: 0000043503 - 003
158 | Fuel Filter | MS150123/01E 2017-05

8.8.3 Fuel prefilter – Draining
DANGER
WARNING
and skin!
WARNING
• Do not smoke.
WARNING
Draining fuel prefilter

1. Cut out the filter to be drained (A or B):
1 Filter A cut out
2 Filter B cut out
TIM-ID: 0000018510 - 009
MS150123/01E 2017-05 | Fuel Filter | 159

2. Open vent valves (1) of filter to be drained.
3. Open drain valve (2).
4. Drain water and contamination from filter un-
til clean fuel emerges.
5. Close drain valve (2).
6. Open rotary slide valve (2) a little (turning to

approx. 30°) to introduce fuel into the filter
housing with the new filter element.
7. Close vent valve (1) as soon as fuel emerges
from vent pipe (4).
8. Turn the rotary slide valve to the upright posi-
tion (3) until it engages.
Result: Both filters are cut in.
9. Set differential pressure gage (→ Page 157).
TIM-ID: 0000018510 - 009
160 | Fuel Filter | MS150123/01E 2017-05

8.8.4 Fuel prefilter – Flushing
Preconditions
☑ Positive pressure at the prefilter inlet.
DANGER
WARNING
and skin!
WARNING
• Do not smoke.
WARNING
Fuel prefilter – Flushing

1. Cut out contaminated filter (A or B).
1 Filter A cut out
2 Filter B cut out
TIM-ID: 0000012728 - 011
MS150123/01E 2017-05 | Fuel Filter | 161

2. Open threaded vent plug (1) of the filter to be
flushed.
3. Remove drain valve (2) and drain fuel.
Result: Fuel flows from filtered side back to the unfil-
tered side, flushing the filter deposits down-
wards out of the filter.
4. Close threaded vent plug (1) and drain
valve (2).

6. Close vent valves (1) as soon as fuel emerges
from vent pipe (4).
8. Set differential pressure gauge (→ Page 157).
TIM-ID: 0000012728 - 011
162 | Fuel Filter | MS150123/01E 2017-05

8.8.5 Fuel prefilter with water separator – Filter element replacement
Preconditions
☑ Positive pressure at the prefilter inlet

Filter element (→ Spare Parts Catalog)
DANGER
WARNING
Tank is pressurized.
Risk of eye injuries resulting from fluid escaping under high pressure!
• Open tank slowly.
• Wear goggles or safety mask.
WARNING
and skin!
WARNING
• Do not smoke.
WARNING
Risk of burns!
TIM-ID: 0000012750 - 014

NOTICE
MS150123/01E 2017-05 | Fuel Filter | 163

Fuel prefilter with water separa-
tor – Filter element replacement
1. Cut out the filter to be replaced (A or B):
1 Filter A cut out
2 Filter B cut out
2. Open vent valve (3) of the filter to be re-

placed.
3. Unlock drain valve (4) by pressing toggle and
open it.
4. Drain water and contaminants from filter.
5. Close drain valve.
6. Loosen screws (1) and (2).
7. Turn filter housing aside around screw (2) un-
til filter element is accessible.
8. Remove filter element (5) with spring (6).
9. Insert a new filter element in the filter hous-
ing.
10. Insert new O-ring and turn filter housing back
into position.
11. Tighten screws (1) and (2) finger-tight.
12. Tighten screws evenly to specified torque using a torque wrench (max. half a turn per screw).
Screw Tightening torque 40 Nm
TIM-ID: 0000012750 - 014
164 | Fuel Filter | MS150123/01E 2017-05

14. Close vent valve (1) as soon as fuel emerges
from vent pipe (4).
16. Set differential pressure gage (→ Page 157).
TIM-ID: 0000012750 - 014
MS150123/01E 2017-05 | Fuel Filter | 165

8.9 Exhaust Turbocharger
8.9.1 Compressor wheel – Cleaning
Preconditions

Cleaner 40377 1
Engine oil
Sealing rings 007603030101 3
Sealing rings 007603042101 4
WARNING
Chemical substances.
Risk of irritation or burning of eyes, skin and airways!
• Observe information provided in the relevant safety data sheet.
• Wear protective gear as specified in the relevant safety data sheet.
NOTICE
Incorrect installation of components and lines.
• Ensure that components/lines are installed so that they are never under tension or strain.
• Ensure correct installation position of components.
NOTICE
Inappropriate cleaning tool.
• Use appropriate cleaning tool.
Preparatory steps
1. Drain engine coolant (→ Page 244).
2. Remove air filter (→ Page 172).
3. Seal openings with suitable covers.
TIM-ID: 0000018669 - 009
166 | Exhaust Turbocharger | MS150123/01E 2017-05

4. Remove charge-air pipework (1) from exhaust
turbocharger to intercooler.
5. Remove oil lines (2).
6. Loosen clamp (1).

7. Remove intake housing (3) with actuating cyl-
inder (2).
8. Remove coolant lines (1) from compressor

housing (3).
9. Remove coolant vent line (2) from compres-
sor housing (3).
TIM-ID: 0000018669 - 009
MS150123/01E 2017-05 | Exhaust Turbocharger | 167

10. Loosen and remove screws (1).
11. Remove compressor housing (2).
Compressor wheel – Cleaning

Note: Never use a wire brush, scraper or similar ob-
ject for cleaning!
1. Clean compressor housing with a smooth
paint brush or brush.
2. Clean compressor wheel (2) and bearing
housing (1).
3. Thoroughly remove cleaner from all compo-
nents.
4. Replace sealing rings between bearing hous-
ing/compressor housing and plug-in sleeves
as necessary.
Final steps
1. Place compressor housing (2) in position.
TIM-ID: 0000018669 - 009
168 | Exhaust Turbocharger | MS150123/01E 2017-05

2. Screw in screws (1) and tighten to specified tightening torque using a torque wrench .
Screw M10x18 Tightening torque (Engine oil) 20 Nm + 2.5 Nm
3. Install coolant vent line and coolant lines on compressor housing.

4. Install intake housing (3) with actuating cylin-
der (2).
5. Align clamp (1) and tighten to specified torque using a torque wrench.
Clamp Tightening torque 15 Nm + 2 Nm
TIM-ID: 0000018669 - 009
6. Install oil lines (2). Tighten threaded adapter at actuating cylinder to specified torque using a torque wrench.
Threaded adapter 10 G 1/4 Tightening torque (Engine oil) 40 Nm + 4 Nm
A
7. Install charge-air pipework (1) between exhaust turbocharger and intercooler.

8. Install air filter (→ Page 172).
9. Fill with engine coolant (→ Page 245).
MS150123/01E 2017-05 | Exhaust Turbocharger | 169

8.10 Charge-Air Cooling
8.10.1 Intercooler – Check water drain for coolant leakage and obstruction
DANGER
Moving or rotating parts.
Risk of crushing, danger of limbs being caught up or drawn in!
• Operate engine in lower load range only. Keep away from the danger zone of the engine.
WARNING
WARNING
Checking intercooler water

drain for coolant leakage and
obstruction
u With the engine running, verify that air
emerges from the drain bores (arrowed) on
left and right engine sides. If no air emerges:
a) Clean drain bores (arrowed) and blow out
with compressed air.
b) More significant coolant leakage indi-
cates a leaking intercooler. Contact Serv-
ice.
Emergency measures prior to engine start for continued operation with leak-
ing intercooler
1. Remove injectors (→ Page 149).
2. Bar engine manually (→ Page 129).
TIM-ID: 0000013246 - 011
3. Bar engine with starting system to blow out combustion chambers (→ Page 129).
4. Install injectors (→ Page 149).
170 | Charge-Air Cooling | MS150123/01E 2017-05

8.11 Air Filter
8.11.1 Air filter – Replacement
Air filter (→ Spare Parts Catalog)
Replacing air filter

1. Remove old air filter and install new air filter (→ Page 172).
2. Reset signal ring of contamination indicator (→ Page 173).
TIM-ID: 0000005447 - 010
MS150123/01E 2017-05 | Air Filter | 171

8.11.2 Air filter – Removal and installation
Preconditions

Torque screwdriver, 1–5 Nm F30452774 1
Removing and installing air fil-

ter
1. Release clamp (2).
2. Remove air filter (1) and clamp (2) from con-
necting flange of intake housing (3).
3. Verify that there are no objects in the con-
necting flange of the intake housing (3) and
clean it.
4. Place new air filter (1) with clamp (2) onto in-
take housing (3).
5. Tighten screw on clamp (2) with torque wrench to the specified tightening torque.
Screw - Tightening torque 5 Nm
TIM-ID: 0000005457 - 011
172 | Air Filter | MS150123/01E 2017-05

8.12 Air Intake
8.12.1 Service indicator – Signal ring position check
Preconditions
Checking signal ring position

1. When the yellow piston (2) has reached the
red-shaded Service lettering (3), replace air
filter (→ Page 171).
2. After installation of new filter, press reset
button (1).
Result: Signal ring returns to initial position.
TIM-ID: 0000076623 - 001
MS150123/01E 2017-05 | Air Intake | 173

8.13 Exhaust Gas Aftertreatment
8.13.1 Supply unit – Filter element replacement
Preconditions
☑ Engine was stopped with key switch and it was verified that circulation cooling is completed.
☑ SCR system switched off after completion of aftercooling phase.
☑ Shutoff devices for urea solution lines must be provided on-board.

Socket, 46 A/F F30006128 1
Lubricant spray Biolube L Spray
Filter element (→ Spare Parts Catalog)
WARNING
Ammonia is created in case of fire or overheating.
There is a danger of poisoning if urea solution (e.g. AdBlue, DEF) is swallowed.
In case of contact with urea solution (e.g. AdBlue, DEF), there is a danger of skin irritation and eye in-
jury.
• Avoid contact with eyes or skin.
• Do not inhale vapors or smoke.
• When handling urea solution (e.g. AdBlue, DEF), do not eat, drink or smoke.
WARNING
Urea solution (e.g. AdBlue, DEF) is hot.
Risk of injury and scalding!
• Allow product to cool down.
• Slowly open line connections and closures.
• When opening, ensure that the separation points are covered with cloths.
• Wear protective clothing, protective gloves, and safety goggles / safety mask.
NOTICE
TIM-ID: 0000073480 - 002
174 | Exhaust Gas Aftertreatment | MS150123/01E 2017-05

Replacing filter element
Note: Shutoff devices for urea solution lines must
be provided on-board.
1. Shut off supply and return line from pre-feed
module to tank.
Note: Clean with high-pressure cleaner / steam-jet
cleaner as necessary.
2. Clean supply unit prior to opening.
Note: When removing the filter housing, small
amounts of urea solution can escape.
3. Loosen filter housing (5) with built-in seal (4)
using a torque wrench and remove.
Note: When removing the frost compensating dia-
phragm (3), small amounts of urea solution
can emerge.
4. Pull frost compensating diaphragm (3) from
pump housing (1).
5. Remove filter element (2) by turning and
lightly pulling from pump housing (1).
Note: No contamination or other foreign bodies
must enter the supply unit.
6. Clean the supply unit with a dry, clean lint-
free cloth.
Installing filter
Note: Only use new parts.
1. Check parts of spare parts kit for:
• Completeness
• Presence of housing vent in filter housing
bottom (5)
• Presence of frost compensating dia-
phragm (3) and seal (4) in filter housing (5)
• Cleanness of sealing surface on pump
housing (1)
2. Fit filter element (2) via the pin on the pump
housing (1) and press in until it will not go
any further.
Note: The groove on pump housing must be free of
any dirt and debris.
3. Fit the frost compensating diaphragm (3)
over filter cartridge (2) onto pump hous-
ing (1).
4. Sealing bead of the frost compensation dia-
phragm (3) must be seated all-round, com-
TIM-ID: 0000073480 - 002
pletely and firmly in the groove of the pump

housing (1).
5. Spray the full circumference of the frost com-
pensation diaphragm (3) with lubricant spray.
6. Similarly, coat the thread on the pump hous-
ing (1) with lubricant spray.
7. Place filter housing (5) onto pump housing (1)
and screw on.
MS150123/01E 2017-05 | Exhaust Gas Aftertreatment | 175

8. Tighten filter housing (5) to specified torque using a torque wrench.
Filter housing 46A/F Tightening torque (Lubricant spray Bio- 80 Nm ±5 Nm
lube L Spray)
9. Open supply and return line from pre-feed module to tank before starting engine.
TIM-ID: 0000073480 - 002

8.13.2 Supply unit – Replacement
Preconditions

Supply unit (→ Spare Parts Catalog)
WARNING
jury.
WARNING
NOTICE
Removing supply unit

module to tank.
2. Provide suitable containers to collect urea
solution.
TIM-ID: 0000071313 - 002
3. Disconnect HDSC connector of DCM box (3)

and HDSC connector of dosing unit (4).
4. Disconnect connector at urea solution outlet
(1) (pressure line).
5. Disconnect urea solution inlet (2) (intake
line).
6. Seal urea solution connections with the asso-
ciated transport closures.

7. Remove retainer (2) with screws (4).
8. Remove supply unit (3) with screws (1) from
retainer (2).
Installing supply unit

1. Install retainer (2) on supply unit (3).
2. Tighten screws (1) to specified torque using a torque wrench.

Screw M8 Tightening torque 17.5 Nm ±3.5 Nm
3. Install supply unit (3) with retainer (2) on SCR catalytic converter.
TIM-ID: 0000071313 - 002

4. Remove transport closures from urea solu-
tion connections.
5. Connect connector to urea solution inlet (2)
(intake line).
6. Connect connector to urea solution outlet (1)
(pressure line).
7. Connect HDSC connector of DCM box (3)
and HDSC connector of dosing unit (4).
8. Check supply unit connectors for leakage af-
ter initial start-up.
9. Open supply and return line from pre-feed
module to tank before starting engine.
TIM-ID: 0000071313 - 002

8.13.3 Dosing unit – Replacement
Preconditions

Dosing unit (→ Spare Parts Catalog) 6
Insulating molding (→ Spare Parts Catalog) 6
Plate (→ Spare Parts Catalog) 12
Graphite ring seal (→ Spare Parts Catalog) 6
WARNING
jury.
WARNING
NOTICE
TIM-ID: 0000071357 - 002

Removing dosing unit
module to tank.
2. Disconnect connector (1) from dosing unit.
3. Remove urea solution supply line (3) and re-
turn line (2).
4. Remove screws (1, 2, 3).

5. Remove dosing unit together with insulating
molding (4).
Installing dosing unit

1. Fit insulating molding (1) on dosing unit (3).
2. Insert plates (2).
3. Turn the dosing unit a little to press the
graphite ring seal flat.
TIM-ID: 0000071357 - 002

4. Insert dosing unit with insulating molding (4)
into opening in insulation cover.
5. Secure dosing unit with screw (2).
6. Then insert screw (3) and finally screw (1) at
the top.
7. Coat screws (3) with assembly compound.
8. Tighten screws (1, 2, 3) to specified torque using a torque wrench.

Screw M6x20 Tightening torque 10 Nm ±0.85 Nm
9. Install connector (1) on dosing unit.

10. Remove transport closures from the urea sol-
ution connections.
11. Install urea solution supply line (3) and return
line (2).
TIM-ID: 0000071357 - 002

8.13.4 Urea solution lines – Replacement
Preconditions
WARNING
jury.
WARNING
WARNING
Slipping and falling caused by spilled liquids.
Risk of serious injury!
• Immediately clean up spilled liquids with suitable cleaning agents or as defined by the manufacturer’s
specifications.
NOTICE
Replacing urea solution lines

module to tank.
2. Take photos or use the Spare Parts Catalog
to identify and arrange the urea solution
TIM-ID: 0000071335 - 002
lines.
3. Provide suitable containers to collect escap-
ing urea solution.
Note: The Tee fittings (3) cannot be disconnected.
4. Disconnect ring line (1) at disconnectable Tee
folding sleeves (2).
5. Remove urea solution lines.
6. Install urea solution lines.

8.13.5 Insulation of SCR housing and SCR bypass – Check
Insulating moldings/insulating mats (→ Spare Parts Catalog)
Checking insulation of SCR

housing and SCR bypass
Note: • The insulation (1) of the SCR housing
mainly consists of sheet metal (air gap in-
sulation principle), part of the structure is
a sandwich design (sheet metal, insulating
mat, sheet metal). It limits the surface
temperature to max. 220 °C (SOLAS re-
quirements).
• The insulation of the SCR bypass (not
shown) mainly consists of a rubberized
glass-fiber mat (insulation material), which
is fastened with stainless steel wire. It is
fitted to the shape of the SCR bypass and
limits the surface temperature to <
220 °C.
1. Check all individual components of the entire
insulation and their securing elements (2) vis-
ually:
Item Findings Action
Check securing elements for dam- Damaged Replace
age.
Check insulation for signs of wear, • Wear traces Replace
abrasion, deformation and con- • Abrasion
tamination with soot. • Deformation
• Soot
Visible
Note: The insulation complies with SOLAS requirements. If the insulation is modified, compliance with the SOLAS
requirements can no longer be guaranteed.
2. Ensure that no combustible liquids and urea solution may get onto the hot surfaces.
Replacing insulation of SCR housing and SCR bypass

Note: The assembly consisting of SCR catalytic converter and bypass features a continuous insulation. The flange
connections at the interface to the customer's system are not covered by the insulation and must be insulat-
ed on-site.
u All insulating moldings/mats and securing components can be ordered an replaced as single parts.
TIM-ID: 0000071410 - 002

8.13.6 Pre-feed module – Filter element replacement
Preconditions

Filter wrench, 27 A/F (→ Tools Catalog) 1
Easy-change filter (→ Spare Parts Catalog) 1
WARNING
jury.
WARNING
NOTICE
NOTICE
TIM-ID: 0000071380 - 002

Pre-feed module – Filter ele-
ment replacement
module to tank.
2. Provide an appropriate container to collect
the urea solution.
3. Clean pre-feed module (1) before opening it.
4. Undo filter housing (2) with filter wrench and
drain urea solution into a suitable container.
5. Remove filter element by pulling it down-
wards.
6. Replace O-ring.
7. Insert new filter element in filter housing (2).
8. Screw in filter housing (2) up to stop then
turn back a quarter turn.
TIM-ID: 0000071380 - 002

8.13.7 Pre-feed module – Replacement
Preconditions

Pre-feed module (→ Spare Parts Catalog) 1
WARNING
jury.
WARNING
NOTICE
TIM-ID: 0000071385 - 002

Removing pre-feed module
module to tank.
2. Provide suitable containers to collect urea
solution.
3. Disconnect connector from pressure sen-
sor (3).
4. Disconnect solenoid coil connectors (6)
and (7).
5. Disconnect quality sensor (8).
6. Remove pressure line (1) from urea solution
outlet.
7. Remove intake line (2) from urea solution in-
let.
8. Remove tank supply line from urea solution
inlet (4).
9. Remove tank return line from urea solution
outlet (5).
10. Seal urea solution connections with the asso-
ciated transport closures.
11. Remove pre-feed module from SCR catalytic
converter.
Installing pre-feed module

Note: Coat the thread with (Assembly compound
(Molykote P 37)).
1. Install pre-feed module on SCR catalytic con-
verter.
2. Remove transport closures from urea solu-
tion connections.
3. Install tank return line on urea solution outlet
(5).
4. Install tank supply line on urea solution inlet
(4).
5. Install intake line (2) on urea solution inlet.
6. Install pressure line (1) on urea solution out-
let.
7. Connect quality sensor (8).
8. Connect solenoid coil connectors (6) and (7).
9. Connect connector on pressure sensor (3).
TIM-ID: 0000071385 - 002

8.13.8 Exhaust pressure sensor – Measuring lines check
Preconditions
☑ Operating voltage is switched off.

Digital multimeter with test leads, test clips and test prods (→ Tools Catalog) 1
Cable (→ Tools Catalog) 1
DANGER
Rotating, moving engine parts.
Danger of crushing, danger of body parts being drawn in or caught!
• Ensure that the engine can not be started.
• After completion of work, make sure that all protective devices are installed.
Exhaust pressure sensor –

Measuring lines check
1. Switch off engine and engine governor.
2. Pinpoint the applicable connector on SCR
catalytic converter:
• Pressure sensor (1) is connected to SCR
inlet of pipe A via measuring line (3)
• Pressure sensor (2) is connected to SCR
outlet
3. Disconnect connectors from sensors.
4. Connect test adapter between wiring harness
connector and sensor.
5. Switch on system – do not start the engine.
6. Measure voltage, replace sensor if necessary.
TIM-ID: 0000071425 - 001

8.13.9 Exhaust pressure sensor – Measuring lines cleaning
Cleaner (Snow-White 11-0) X00054118 1
WARNING
WARNING
Cleaner is extremely caustic.
Risk of injury and suffocation!
• Avoid contact with eyes and skin.
• Do not inhale vapors and smoke.
• Do not eat, drink, smoke when working with cleaner.
• Wear protective clothing, gloves, and goggles / safety mask.
• Take measures against electrostatic charging.
NOTICE
Exhaust pressure sensor – Measuring lines cleaning

1. Clean all parts.
2. Clean all metallic parts with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 50/136).
3. Blow out all components thoroughly with compressed air.
TIM-ID: 0000071478 - 001

8.13.10 SCR catalytic converter – Mounting alignment
Alignment jig F6794341 1
Engine oil
DANGER
Suspended load.
Danger to life!
DANGER
Electrical voltage.
Risk of serious injury - danger to life!
• Ensure that all grounding straps are installed according to valid specifications.
WARNING
WARNING
Condensation contains acid.
Risk of chemical burns!
• Wear protective goggles.
• Wear protective gloves.
WARNING
Exhaust gases are harmful to health and may cause cancer.
Risk of poisoning and suffocation!
• Keep the engine room well-ventilated at all times.
• Repair leaking exhaust pipework immediately.
NOTICE
Deformation of housing.
• Do not step on the housing.
Note: The SCR catalytic converter is fitted with fixed/movable mounting (with elongated holes) to compensate
TIM-ID: 0000073813 - 003
thermal expansion. The cold mount must be attached at the correct position in the hole to allow movement
under thermal expansion. An alignment jig must be used to position the SCR catalytic converter on the ship's
foundation to avoid damage to the mounts.
SCR catalytic converter – Mounting alignment

1. Attach lifting gear (→ Page 21) and lift SCR catalytic converter with lifting gear.
Note: When lowering, keep equipment as parallel to ship's foundation as possible.
2. Lower SCR catalytic converter until first mount nearly touches ship's foundation.
3. Align inlet/outlet of exhaust aftertreatment system to engine exhaust system connections.

Note: It is sufficient to use one alignment jig, how-
ever, using four devices to align all mounts at
the same time makes the alignment proce-
dure easier.
4. Insert alignment jig (2) in this retainer (4) and
in mount (3). If necessary, move or turn the
mount to the correct position to ensure that
it is properly seated in the retainer.
Note: The ship's foundation must be matched to
the specified positions of the SCR module
mounts to compensate for heat and manufac-
turing tolerances in the exhaust gas after-
treatment system.
5. Match the position of the ship's foundation to
the position of the SCR system mounts.
6. Install foundation screws (arrow) and lower
SCR catalytic converter until mount fully
rests on foundation.
7. Remove alignment jig (2).
8. Loosen connecting screws lightly if alignment
jig is jamming.
Note: Recommended: screw M12, 10.9, ISO4017; washer DIN 433-13-400HV; thread-meshing length >3xD
9. Tighten foundation screws (arrowed, 6 pcs.) to specified tightening torque using a torque wrench.
Screw M12 Tightening torque (Engine oil) 100 Nm
Note: Already tightened to nominal torque on delivery.

10. Check tightening torque of screws (1) as necessary.
Screw M20x90 Tightening torque (Engine oil) 510 Nm
11. Repeat this procedure for the other mounts.
TIM-ID: 0000073813 - 003

8.13.11 SCR catalytic converter – Mounting check
SCR catalytic converter – Mounting check

Visually inspect resilient mounts. • Damage Replace (contact Service)
• Deformation
• Crack formation
TIM-ID: 0000076568 - 001

8.13.12 SCR modules – Replacement
Preconditions

Lifting gear (crane or push-pull cable) (→ Tools Catalog) 1
Cleaner (Loctite 7061) 50518 1
Adhesive (Terokal 2444) 40170 1
SCR module (gecannt) (→ Spare Parts Catalog) 12
V-band clamp (→ Spare Parts Catalog) 12
Gasket (→ Spare Parts Catalog) 36
Metal profile (→ Spare Parts Catalog) 12
DANGER
Suspended load.
Danger to life!
WARNING
WARNING
Risk of burns!
WARNING
Condensation contains acid.
Risk of chemical burns!
TIM-ID: 0000071397 - 003
WARNING
Dust and fibers in filter elements.
Risk of poisoning!
• Wear breathing protection.
• Use vacuum cleaner of dust class H.

WARNING
Exhaust gases are harmful to health and may cause cancer.
Risk of poisoning and suffocation!
• Keep the engine room well-ventilated at all times.
• Repair leaking exhaust pipework immediately.
WARNING
Components have sharp edges.
Risk of injury!
CAUTION
Restricted freedom of movement when performing maintenance work.
Risk of injury, joint and back disorders!
• Leave adequate space for assembly and maintenance.
• Ensure that assemblies are easily accessible.
• Ensure that maintenance personnel can stand safely.
NOTICE
Deformation of housing.
• Do not step on the housing.
Removing maintenance access

doors
Note: The maintenance access doors are part of
the sheet-metal insulation of the SCR catalyt-
ic converter. Removal can be done with the
assistance of a mechanic.
1. Unclip the clamps (arrowed) of maintenance
access door (1) first.
2. Pull maintenance access door (1) out of up-
per and lower clamps (in the direction of the
arrow, see magnified detail).
3. Unclip the clamps (arrowed) of maintenance
access door (2).
4. Pull maintenance access door (2) out of up-
per and lower clamps (in the direction of the
arrow, see magnified detail).
TIM-ID: 0000071397 - 003

Removing SCR modules
1. Undo V-band clamp (2) while holding cover
(1).
Note: Weight of cover: approx. 4 kg.
2. Remove cover (1) with seal (3).
Note: Risk of crushing! Weight of SCR module: ap-
prox. 26 kg.
3. Carefully pull SCR module (4) out of retaining
pipe (7) by gently jiggling.
4. Dispose of SCR module (4), seals (3, 5, 6)
and V-band clamp (2).
Installing SCR modules

1. Check new SCR modules for damage.
Note: Do not allow cleaner to come into contact
with the surface of the catalytic converter.
2. Clean flange bottom (2) of SCR module (6)
with a lint-free cloth and (Cleaner (Loctite
7061)) to ensure that it is free from grease.
Note: (Adhesive (Terokal 2444)) Apply to the seal
only!
3. Glue seal (1) onto flange bottom (2).
Note: Seal (7) is already glued at the factory.
4. If seal (7) becomes loose, glue it manually on-
to the contoured bearing/sealing area by
wrapping it in preloaded state in two rows
around the perimeter.
Result: The joint of the two ends of the seal (ar-
rowed) may be arranged at any position on
the perimeter.
5. Clean metal profile (4) and glue seals (3, 5)
onto both sides.
6. Fit seal assembly (3, 4, 5) over SCR module
(6) and glue optionally onto rear side of
flange bottom (2).
TIM-ID: 0000071397 - 003

Note: There is no need to center the spaces be-
tween the recesses.
7. The recesses (arrowed) in the metal profile
must engage precisely in the recesses on the
SCR module.
Note: • Do not throw, roll or drop SCR module.

• Document SCR module markings and
batch number.
• Ensure that the seal (2) does not touch,
damage or alter the position of the perfo-
ration (B) in the retaining pipe (1) when in-
serting the SCR module. Seal (2) and re-
taining pipe (1) may only come into con-
tact after passing the perforated area (B)!
8. Align the SCR module (3) such that the un-
perforated areas (A) (longitudinal welds, ar-
rowed) are aligned with retaining pipe (1) and
SCR module (3). An offset amounting to ±10°
of twist is still acceptable in this case.
Note: Risk of crushing or pinching fingers especially

in the perforated area!
9. Push SCR module (3) into retaining pipe (4)
by hand, jiggling gently but without using any
additional expedients, until it makes contact
with the knurled area.
10. Position new V-band clamp (2) over knurled
area on retaining pipe (4) and cover (1).
TIM-ID: 0000071397 - 003

Note: • Do not use lubricants to expediate assembly!
• The maximum tightening torque of 25 Nm must not be exceeded!
11. Tighten V-band clamp (2) to specified torque using a torque wrench.
Nut M8 Tightening torque 20 Nm
12. Check that the clamp has settled into position, tap lightly all around with a rubber mallet then tighten once
again to specified tightening torque.
Installing maintenance access

doors
Note: If possible, two mechanics should install the
maintenance access doors.
1. Push maintenance access door (2) into upper
and lower clamps (in the direction of the ar-
row, see magnified detail).
Note: Make sure to establish the upper and lower
clamping connections when pushing the door
through the clamps into place.
2. Close the clamps (arrowed) of maintenance
access door (2).
3. Push maintenance access door (1) into upper
and lower clamps (in the same direction of
the arrow, see magnified detail).
Note: Make sure to establish the upper and lower
clamping connections when pushing the door
through the clamps into place.
4. Close the clamps (arrowed) of maintenance
access door (1).
5. Use the outside clamps (arrows on the left
side) to fasten the maintenance access door
at the housing.
Note: If the CDC parameters are not reset, the
emission certification of the engine becomes
invalid.
6. Reset using DiaSys®, see (→ dialog system
DiaSys® E531920/..).
TIM-ID: 0000071397 - 003

8.13.13 NOx sensor – Replacement
Preconditions
☑ Engine was stopped with key switch.

NOx sensor (→ Spare Parts Catalog) 3
WARNING
Risk of burns!
NOTICE
High voltage.
Risk of damage to components!
• Switch off ignition before replacing components.
NOTICE
Ceramic cell breakage due to shock or impact.
Risk of damage to components!
• Avoid shocks and impacts.
• Exercise extreme care when handling sensors.
Preparatory steps
1. Remove screws (1) and open clamps (3).
2. Remove metal plate segment (2).
Note: Insulating molding (4) is split in two and
serves as a seal.
3. Remove front insulating molding (4).
TIM-ID: 0000071388 - 002

Removing NOx sensors before
and after SCR
Note: Always replace the complete NOx sensor as-
sembly including the evaluation unit.
1. Loosen and disconnect connectors on the
evaluation units (1).
2. Unscrew NOx sensors (2) before SCR.
3. Remove evaluation units (1).
Note: Always replace the complete NOx sensor as-

sembly including the evaluation unit.
4. Loosen and disconnect connector at evalua-
tion unit.
5. Unscrew NOx sensor (1) after SCR.
6. Remove evaluation unit.
Installing NOx sensors before

and after SCR – new sensors
1. Install evaluation units before and after SCR.
Note: Do not wipe off thread grease of manufactur-
er. Do not apply any other lubricant.
2. Only remove protective cap from thread im-
mediately before assembly.
3. Screw in sensors by hand.
TIM-ID: 0000071388 - 002

4. Tighten hexagon (2) to specified torque using a torque wrench.
Nut M20x1.5 Tightening torque 50 Nm ±10 Nm
5. Connect connector (1) to all evaluation units latch it.
Installing NOx sensors before

and after SCR – used sensors
Note: • Sensors may only be used twice.
• After being exposed to any impact, the
sensor is considered to be faulty and may
not be used.
1. Install evaluation units before and after SCR.
2. Only remove protective cap from thread im-
mediately before assembly.
Note: Apply assembly compound sparingly and en-
sure that lubricant does not drip or run down
onto the sensor.
3. Apply specified assembly compound to sen-
sor thread as necessary.
4. Screw in sensors by hand.
5. Tighten hexagon (2) to specified torque using a torque wrench.

Nut M20x1.5 Tightening torque (Assembly compound 50 Nm ±10 Nm
(Molykote P 37))
6. Connect connector (1) to all evaluation units latch it.
Final steps
Note: Replace insulating moldings as necessary
(front and rear).
1. Insert front insulating molding (4).
2. Install metal plate segment (2).
TIM-ID: 0000071388 - 002
3. Tighten screws (1) to specified torque using a torque wrench.

Screw Tightening torque (Assembly compound 34 Nm ±3 Nm
(Molykote P 37))
4. Close clamps (3).

8.14 Starting Equipment
8.14.1 Starter – Condition check
Preconditions
Checking starter condition

1. Check securing screws of starter for secure seating and tighten if required.
2. Check wiring (→ Page 268).
TIM-ID: 0000000905 - 018
202 | Starting Equipment | MS150123/01E 2017-05

8.15 Lube Oil System, Lube Oil Circuit
8.15.1 Engine oil level – Check
Preconditions
WARNING
Oil is hot.
Checking engine oil level after

extended standstill
1. Pull out dipstick from guide tube and wipe it.
2. Insert oil dipstick into guide tube up to the
stop, pull it out after approx. 10 seconds and
check oil level.
Note: After extended standstill, the oil level may be
up to 2 cm above mark (1). This may be
caused e.g. by oil from oil filters and heat ex-
changers flowing back into the oil pan. After
extended standstill, the oil level "2 cm above
mark (2)" is the minimum oil level.
3. Oil level must be at least 2 cm above
mark (2).
4. If necessary, top up with oil, maximum to
mark (1) (→ Page 204).
5. Insert oil dipstick into guide tube up to the
stop.
Checking oil level immediately after engine stop

1. 5 minutes after stopping the engine, pull out oil dipstick from guide tube and wipe it.
2. Insert oil dipstick into guide tube up to the stop, pull it out after approx. 10 seconds and check oil level.
3. Oil level must be between marks (1) and (2).
4. If necessary, top up with oil, maximum to mark (1) (→ Page 204).
5. Insert oil dipstick into guide tube up to the stop.
TIM-ID: 0000000931 - 016
MS150123/01E 2017-05 | Lube Oil System, Lube Oil Circuit | 203

8.15.2 Engine oil ‒ Change
Preconditions
☑ Engine is at operating temperature.

Engine oil
Sealing ring (→ Spare Parts Catalog)
WARNING
Oil is hot.
Oil change without semirotary hand pump: Draining oil via drain plug(s) on oil
pan
1. Provide a suitable container to collect the oil.
2. Remove drain plug(s) and drain oil.
3. Install drain plug(s) with new sealing ring.
Oil change using semirotary hand pump: Oil extraction

2. Extract all oil from oil pan using the semirotary hand pump.
Draining residual oil at equip-

ment carrier
2. Remove drain plugs (1) and (2) and drain oil:
• Approx. 12 liters at (1)
• Approx. 5 liters at (2)
3. Check oil indicator filter (→ Page 235).
TIM-ID: 0000014100 - 006
4. Install drain plug(s) with new sealing ring.
204 | Lube Oil System, Lube Oil Circuit | MS150123/01E 2017-05

5. Tighten drain plugs (1) and (2) to specified torque using a torque wrench:
Screw M26x1.5 Tightening torque 100 Nm+10 Nm
Filling with new oil

1. Open cover (1) on filler neck.
2. Pour oil in at filler neck up to “max.” mark at
oil dipstick.
3. Close cap (1) on filler neck.
4. Check engine oil level (→ Page 203).
5. After oil change, bar engine with starting sys-
tem (→ Page 130).
TIM-ID: 0000014100 - 006
MS150123/01E 2017-05 | Lube Oil System, Lube Oil Circuit | 205

8.15.3 Engine oil – Sample extraction and analysis
Preconditions

MTU test kit 5605892099/00 1
DANGER
WARNING
Oil is hot.
WARNING
Take engine oil sample and ana-

lyze
1. With the engine running at operating temper-
ature, loosen screw on automatic oil filter by
1 to 2 turns.
2. Drain approx. 2 liters engine oil to flush out
the oil sludge.
3. Drain approx. 1 liter engine oil into a clean
container.
4. Close screw.
5. Using the equipment and chemicals in the
MTU test kit, analyze the engine oil for:
• Dispersing capacity (spot test);
• Water content;
TIM-ID: 0000014114 - 008
• Dilution with fuel
206 | Lube Oil System, Lube Oil Circuit | MS150123/01E 2017-05

8.16 Oil Filtration / Cooling
8.16.1 Automatic oil filter – Overview
Automatic oil filter
1 Filter housing 9 O-ring 17 Screw

2 Oil filter element 10 Cover 18 Gearbox flange
3 O-ring 11 Screw 19 O-ring
4 Cover 12 Sealing ring 20 Sealing ring
5 Nut 13 Screw-fitting union 21 Union
6 Strainer 14 Sealing ring 22 Vent line
7 O-ring 15 Union 23 Nut
8 Spring 16 Scavenge oil line 24 Screw
TIM-ID: 0000014226 - 007
MS150123/01E 2017-05 | Oil Filtration / Cooling | 207

1 Sealing ring 8 Plug screw 15 Sealing ring
2 Plug screw 9 Sealing ring 16 Sealing ring
3 Sealing ring 10 Plug screw 17 Bypass valve
4 Plug screw 11 Sealing ring 18 O-ring
5 Sealing ring 12 Threaded bushing 19 Cover
6 Plug screw 13 Plug screw 20 Screw
7 Sealing ring 14 Plug screw
TIM-ID: 0000014226 - 007
208 | Oil Filtration / Cooling | MS150123/01E 2017-05

1 Screw 8 O-ring 15 Turbine housing
2 Securing bushing 9 Clamping ring 16 Impeller
3 Compression spring 10 Spring washer 17 Washer
4 Scavenge bushing 11 Screw 18 Stud
5 Sight glass 12 Screw 19 Nut
6 Flat gasket 13 Worm gear
7 O-ring 14 Grooved pin
TIM-ID: 0000014226 - 007

8.16.2 Automatic oil filter – Preparatory steps
Preconditions
Automatic oil filter preparatory steps

1. Observe safety instructions.
2. Remove centrifugal oil filter (→ Page 238).
TIM-ID: 0000014233 - 005

8.16.3 Automatic oil filter ‒ Removal
Preconditions
☑ Preparatory steps have been completed.
DANGER
Suspended load.
Danger to life!
WARNING
WARNING
Oil is hot.
WARNING
• Do not smoke.
NOTICE
Ingress of contamination from automatic oil filter in the engine oil system.
Severe engine damage possible!
• Remove the automatic oil filter before changing the oil filter candles.
• Keep everything scrupulously clean when performing maintenance and repair work.
• Cover all exposed openings when opening assemblies.
NOTICE
TIM-ID: 0000014231 - 011

Draining oil
u Remove plug screw (2) with sealing ring (1)
and drain off oil into a suitable container.
Removing automatic oil filter

Note: Clean interface between automatic oil filter
and coolant distribution housing.
1. Attach automatic oil filter (1) to crane with a
lightly tensioned lifting strap.
2. Remove screws (2).
3. Remove automatic oil filter from coolant dis-
tribution housing (3).
4. Collect any oil that runs out.
5. Remove O-rings (4).
6. Seal openings on coolant distribution housing
with suitable covers.
TIM-ID: 0000014231 - 011

8.16.4 Automatic oil filter – Disassembly
Preconditions
☑ Automatic oil filter has been removed from engine.
Automatic oil filter – Disassembly

1. Observe safety instructions.
2. Disassemble automatic oil filter as per overview drawing (→ Page 207).
TIM-ID: 0000014232 - 004

8.16.5 Automatic oil filter – Cleaning
WARNING
WARNING
Chemical substances in cleaners.
Risk of irritation and chemical burns!
• Always obey manufacturer's instructions for use.
WARNING
NOTICE
Automatic oil filter – Cleaning

1. Carefully clean all components and connections.
• Clean all metallic parts with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 50/136).
• Flush all oil ducts thoroughly with cleaner.
• Blow out all components thoroughly with compressed air.
2. Wipe all sealing and mating faces dry with a clean, lint-free cloth.
3. Inspect visually to ensure that all sealing and mating faces are clean. If not, repeat cleaning procedure.
4. Remove corrosion inhibitor from new components with cleaner (Hakupur 50/136).
TIM-ID: 0000014228 - 007

8.16.6 Automatic oil filter – Checking flushing arm rotation
Preconditions
☑ Engine is running.
WARNING
Rotating parts.
Risk of injury!
• Keep sufficiently clear off rotating parts.
Automatic oil filter – Checking

flushing arm rotation
1. Check at sight glass that plastic spinner (1)
turns.
2. If the plastic spinner turns irregularly or if it
does not turn at all, check the whole auto-
matic oil filter (→ Page 207).
TIM-ID: 0000071222 - 001

8.16.7 Automatic oil filter – Check
Oilstone F30454308/03 1
Checking automatic oil filter

Visually check all components for • Wear traces • Smooth with crocus cloth or oil-
wear, impact marks, and damage. • Pressure marks stone.
• Damage visible • Replace
Check gearwheel on worm gear • Indentations • Smooth minor wear traces and
for indentations, signs of wear and • Signs of wear damage with crocus cloth or oil-
damage. • Damage visible stone.
• Replace
Check flushing arms on oil filter el- • Flushing arms do not rotate. • Check worm gear and replace
ement for easy movement as necessary (→ Page 207).
(→ Page 232). Blow compressed
air into the oil supply aperture to
make the impeller rotate.
Check oil filter element (→ Page 227).
TIM-ID: 0000014230 - 006

8.16.8 Automatic oil filter – Assembly
Engine oil
Seal kit (→ Spare Parts Catalog)
WARNING
NOTICE
NOTICE
Assembling automatic oil filter

1. The assembly procedure is identical with that described for disassembly, but in reverse sequence of work
steps.
2. Additionally, the following instructions are to be observed:
a) Replace all sealing elements.
b) Coat O-rings with assembly compound.
c) Insert O-rings in grooves.
TIM-ID: 0000069537 - 001

8.16.9 Automatic oil filter – Installation
Preconditions

Engine oil
DANGER
Suspended load.
Danger to life!
WARNING
WARNING
• Do not smoke.
NOTICE
NOTICE
NOTICE
TIM-ID: 0000014235 - 010

Automatic oil filter – Installation
1. Remove all covers.
Note: Replace all O-rings.
2. Coat O-rings (4) with assembly compound.
3. Insert O-rings in ring groove.
4. Attach automatic oil filter (1) with lifting strap
to crane.
5. Install automatic oil filter on coolant distribu-
tion housing (3).
6. Coat screws (2) with engine oil.
7. Insert and tighten screws.
TIM-ID: 0000014235 - 010

8.16.10 Automatic oil filter – Final steps
Final steps
1. Install centrifugal oil filter (→ Page 238).
2. Check engine oil level and fill up as necessary (→ Page 203).
3. Enable engine start.
TIM-ID: 0000014237 - 006

8.16.11 Oil filter element – Overview
Oil filter candle element
1 Plastic spinner 5 Washer 9 O-ring

2 Screw 6 O-ring 10 Filter candles
3 Sealing nut 7 Upper flushing arm
4 Spring washer 8 Screw
TIM-ID: 0000069540 - 002

1 O-ring 4 Grooved ball bearing 7 Overflow valve
2 Top strainer plate 5 Grooved ball bearing 8 Bottom strainer plate
3 Screw 6 Connecting pipe 9 Protective screen
TIM-ID: 0000069540 - 002
1 O-ring 3 Lower flushing arm 5 Screw

2 Flushing arm shaft 4 Gear 6 Screw

8.16.12 Oil filter element – Removal
Preconditions
☑ Automatic oil filter is removed from engine.
WARNING
Oil is hot.
WARNING
• Do not smoke.
Removing oil filter element

1. Remove nuts (2) from oil filter cover (1).
2. Remove oil filter cover.
3. Loop cable ties (2) around the flushing arm

and close loosely.
4. Take filter element (1) out of automatic oil fil-
ter housing by pulling the cable ties.
5. Remove O-ring.
TIM-ID: 0000069541 - 004

8.16.13 Oil filter element – Disassembly
Removal tool XP52699100138 1
Oil filter element – Disassembly

1. Remove screw (2).
2. Pull out plastic spinner (1) with spring.
3. Lock flushing arm (6) in position and remove
sealing nut (3).
4. Remove spring washer (4) and washer (5).
5. Remove screw (8).
6. Remove flushing arm from strainer plate (7).
7. Remove filter element (1) from flushing arm

shaft (2).
TIM-ID: 0000070293 - 002

8. Turn filter element through 180° and press
filter candles (1) out towards top strainer
plate using removal tool (2).
9. Remove filter candles.

11. Remove top strainer plate (2).
12. Take off O-ring (3).
13. Remove protective strainer (4) from connect-
ing pipe (5) with bottom strainer plate attach-
ed.
14. Remove O-ring from bottom strainer plate.
Removing overflow valve

u Unscrew overflow valves (1) and remove from
connecting pipe (2).
TIM-ID: 0000070293 - 002

8.16.14 Oil filter element – Cleaning
WARNING
WARNING
Chemical substances in cleaners.
Risk of irritation and chemical burns!
• Always obey manufacturer's instructions for use.
WARNING
NOTICE
Oil filter element – Cleaning

Note: • The outer side and the inner side of the protective strainer are installed in the filtered-oil side.
• Do not place the oil filter element on the jacket surface.
1. Carefully clean all components and connections.
• Clean all metallic parts with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 50/136).
• Flush all oil ducts thoroughly with cleaner.
• Blow out all components thoroughly with compressed air.
2. Wipe all sealing and mating faces dry with a clean, lint-free cloth.
3. Inspect visually to ensure that all sealing and mating faces are clean. If not, repeat cleaning procedure.
4. Remove corrosion inhibitor from new components with cleaner (Hakupur 50/136).
TIM-ID: 0000069544 - 003

8.16.15 Oil filter element – Check
Feeler gauge Y20098771
Oil filter candles (→ Spare Parts Catalog)
Grooved ball bearing (→ Spare Parts Catalog)
Grooved ball bearing (→ Spare Parts Catalog)
Gear (→ Spare Parts Catalog)
Oil filter element – Check

Item Findings Measure
Check grooved ball bearing on • Damage Replace
flushing arm shaft. • Sluggish
Check flushing arm gap (between Gap incorrect Oil filter insert - Replacement
flushing arm and strainer plate).
Gap: 0.05 to 0.3 mm
Check gear • Indentations • Smooth minor wear traces and
• Signs of wear damage with crocus cloth or oil-
• Damage visible stone.
• Replace
TIM-ID: 0000069539 - 003

8.16.16 Oil filter element – Assembly
Feeler gauge Y20098771 1
Engine oil
Screw locking compound (Loctite 243) 40573 1
Oil filter candles (→ Spare Parts Catalog) 36
Overflow valve (→ Spare Parts Catalog) 6
NOTICE
NOTICE
Installing overflow valve
TIM-ID: 0000070295 - 003
Note: The overflow valves must be replaced in any case.

u Screw overflow valves (1) in connecting pipe (2) and tighten to the specified tightening torque.
Overflow valve Tightening torque (Engine oil) 8 Nm

Assembling oil filter element
1. O-ring with assembly compound and insert
into groove of bottom strainer plate.
2. Install protective strainer (4) on connecting
pipe (5) with bottom strainer plate attached.
3. Coat O-ring (3) with assembly compound and
insert in groove of top strainer plate (2).
4. Install top strainer plate.
5. Coat thread of screws (1) with screw-locking
compound (Loctite 243).
6. Insert screws (1) and tighten.
7. Coat O-rings (1) with assembly compound

and insert in ring grooves on both ends of fil-
ter candles.
8. Insert new filter candles (2) through top
strainer plate with chamfer facing down.
9. Insert flushing arm shaft (2) in filter ele-

ment (1) through bottom strainer plate.
TIM-ID: 0000070295 - 003

10. Coat O-ring (2) with assembly compound and
insert in groove on upper flushing arm (7).
11. Fit top flushing arm on flushing arm shaft and
top strainer plate (6).
12. Install washer (3) and spring washer (4).
Note: Note position of screw in relation to elongat-
ed hole on shaft.
13. Screw in screw (1) loosely.
14. Screw on sealing nut (5).
15. Lock flushing arm (4) in position and tighten sealing nut (5) with torque wrench to the specified torque.
Sealing nut Tightening torque (Engine oil) 40 Nm
Note: Tolerances for gap on both sides: 0.05 to 0.3 mm.

16. Check gap (1) between flushing arm (4) and strainer plate (2) with feeler gauge . If the tolerances are not
met, replace oil filter element.
17. Tighten screw (3).
TIM-ID: 0000070295 - 003

18. Insert screw (3) and tighten to specified torque using a torque wrench.
Screw Tightening torque (Engine oil) 9 Nm
19. Fit plastic spinner (2) with spring on sealing nut (1).
TIM-ID: 0000070295 - 003

8.16.17 Oil filter element ‒ Installation
Preconditions
☑ Automatic oil filter is removed from engine.

Engine oil
WARNING
NOTICE
Blowing through lines (gas lines, supply lines, etc.) with compressed air will result in airborne particles.
Risk of penetration of contaminants leading to component damage!
• Disconnect the engine from the cooling water network by fitting blanking plates at the connecting
flanges.
• Seal off connecting flanges, so that no dirt particles are blown into the engine.
NOTICE
NOTICE
TIM-ID: 0000069547 - 003

Oil filter element ‒ Installation
1. Coat new O-ring with assembly compound
and insert in groove of bottom strainer plate.
2. Insert oil filter element (1) into housing.
3. Insert new gasket in oil filter cover (1).

4. Install oil filter cover.
5. Screw on nuts (2) and tighten with torque wrench to the specified tightening torque .
Nut Tightening torque (Engine oil) 65 Nm
TIM-ID: 0000069547 - 003

Checking flushing arms on oil
filter element for ease of move-
ment
Note: Opening (2) is located on the filtered-oil side.
Ensure particular cleanness.
1. Cover opening (2).
Note: Constrict opening with a suitable cover.
2. Blow compressed air into aperture (1).
3. Check that flushing arm turns at sight glass
(3).
4. If flushing arm does not turn, remove oil filter
element, disassemble, check again
(→ Page 227) and replace if necessary.
TIM-ID: 0000069547 - 003

8.16.18 Oil indicator filter – Cleaning and check
Preconditions

Engine oil
Strainer (→ Spare Parts Catalog)
Square-section ring (→ Spare Parts Catalog)
Spring (→ Spare Parts Catalog)
WARNING
WARNING
Oil is hot.
WARNING
NOTICE
Inappropriate cleaning tool.
• Use appropriate cleaning tool.
TIM-ID: 0000067939 - 003

Removing basket strainer – var-
iant A
1. Clean oil indicator filter before disassembling
it.
3. Take off cover (2) and O-ring (3).
4. Remove strainer (5) from filter housing and
allow oil to drip into container.
Cleaning strainer
1. Shake coarse contamination out of strainer (5).
Note: Do not damage the fabric of the strainer.
3. Use a soft brush to remove stubborn deposits from strainer as necessary.
4. Blow out strainer (5) with compressed air from outside to inside.
Checking strainer
Strainer Metallic residues • Clean
• Monitor engine operation
• Check strainer daily
• Contact Service
Strainer Damaged Replace
Square-section ring Damaged Replace
O-ring Damaged Replace
Installing strainer
1. Coat square-section ring (4) on strainer (5) with engine oil and install strainer (5).
2. Insert strainer into housing.
3. Fill housing with new engine oil.
4. Coat O-ring (3) with engine oil and install in filter housing.
5. Install cover (2) and secure with screws (1) and washers.
TIM-ID: 0000067939 - 003

Removing basket strainer – var-
iant B
Note: Cover (2) is under tension due to spring (4).
2. Take off cover (2) and O-ring (3).
3. Remove spring (4).
4. Take strainer (5) out of filter housing.
Cleaning strainer
1. Shake coarse contamination out of strainer (5).
Note: Do not damage the fabric of the strainer.
3. Use a soft brush to remove stubborn deposits from strainer as necessary.
4. Blow out strainer (5) with compressed air from outside to inside.
Checking strainer
Strainer Metallic residues • Clean
• Monitor engine operation
• Check strainer daily
• Contact Service
Strainer Damaged Replace
Square section ring Damaged Replace
Spring Damaged Replace
O-ring Damaged Replace
Installing strainer
1. Coat square section ring on basket strainer (5) with engine oil and install basket strainer (5).
2. Coat O-ring (3) with engine and install in filter housing.
3. Move spring (4) into fitting position.
4. Install cover (2) and secure with screws (1).
TIM-ID: 0000067939 - 003

8.16.19 Centrifugal oil filter – Overview
Centrifugal oil filter
1 Centrifugal oil filter 7 Socket pipe 13 Flange

2 O-ring 8 O-ring 14 Socket pipe
3 Flange 9 Threaded adapter 15 Washer
4 Washer 10 Sealing ring 16 Nut
5 Screw 11 O-ring
6 O-ring 12 Stud
TIM-ID: 0000044377 - 003

8.16.20 Centrifugal oil filter – Cleaning and filter-sleeve replacement
Preconditions

Cold cleaner (Hakutex 60) X00056750 1
Filter sleeve (→ Spare Parts Catalog)
WARNING
Oil is hot.
WARNING
Centrifugal oil filter – Cleaning

and filter-sleeve replacement
1. Remove clamp (17).
2. Release cover nut (2) and take off cover (1).
3. Carefully lift rotor (14), allow oil to drain and
remove from housing.
4. Holding the rotor (14) firmly, release rotor
cover nut (3).
5. Take off rotor cover (3).
6. Remove filter sleeve (6).
7. Measure thickness of oil residues on filter
sleeve (6).
Result: Shorten maintenance interval if the oil resi-
dues exceed the maximum thickness of
TIM-ID: 0000060251 - 004
45 mm.
8. Disassemble rotor tube (7), conical disk (8)
and rotor base (13).

1. Wash rotor cover (3), rotor tube (7), conical disk (8) and rotor base (13) with cold cleaner.
2. Blow out with compressed air.
3. Check sealing rings (9, 10, 12), fit new ones if necessary.
4. Apply assembly compound to sealing rings (9, 10) and insert them in grooves of bearing axle (11).
5. Assemble rotor tube (7), conical disk (8) and rotor base (13) with sealing ring (12).
Note: Observe marks and notices on the paper sleeve!
6. Insert new filter sleeve (6) in rotor tube (7) with the smooth paper surface facing the outer wall.
7. Check sealing rings (4, 5), fit new ones if necessary.
8. Fit sealing ring (5) in rotor tube (7) and sealing ring (4) in rotor cover (3).
9. Install rotor cover (3) and tighten nut of rotor cover (3) to specified torque using a torque wrench.
Nut M12 Tightening torque 80 Nm ±12 Nm
10. Place rotor (14) in housing (15) and check for ease of movement.
11. Check sealing ring (16), fit new one if necessary.
12. Fit sealing ring (16) on housing (15).
13. Fit cover (1).
14. Tighten cover nut (2) by hand.
15. Install clamp (17) and tighten to specified torque using a torque wrench.
Clamp Tightening torque 20 Nm ±3 Nm
16. Tighten cover nut (2) tighten to specified torque using a torque wrench.
Screw Tightening torque 7 Nm ±1 Nm
TIM-ID: 0000060251 - 004

8.16.21 Centrifugal oil filter – Removal and installation
Preconditions
☑ Engine oil has been drained from centrifugal oil filter.

Sealing ring (→ Spare Parts Catalog) 3
NOTICE
NOTICE
Removing centrifugal oil filter

1. Remove centrifugal oil filter as shown in overview drawing (→ Page 238).
2. Seal openings with suitable covers.
Installing centrifugal oil filter

1. Remove all covers.
2. Coat new O-rings with assembly compound and install.
3. Install centrifugal oil filter as shown in overview drawing (→ Page 238).
4. Fill with engine oil, if necessary (→ Page 204).
5. Enable engine start.
TIM-ID: 0000071180 - 001

8.17 Coolant System, General, High-Temperature Circuit
8.17.1 Engine coolant – Level check
Preconditions
WARNING
Coolant is hot and under pressure.
• Let the engine cool down.
Checking coolant level at filler neck:

1. Turn breather valve of coolant expansion tank counterclockwise until the first stop and allow pressure to es-
cape.
2. Continue to turn breather valve counterclockwise and remove.
3. Check coolant level (coolant must be visible at the bottom edge of the cast-in eye of the filler neck).
Checking coolant level at exter-

nal cooler:
1. Check coolant level (coolant must be visible
at marker plate).
2. Top up coolant if necessary (→ Page 245).
3. Check and clean breather valve.
4. Position breather valve on filler neck and
close.
Coolant-level check by means of level sensor:

1. Switch on engine control system and check readings on the display.
2. Top up coolant if necessary (→ Page 245).
TIM-ID: 0000043936 - 001
242 | Coolant System, General, High-Temperature Circuit | MS150123/01E 2017-05

8.17.2 Engine coolant – Change
Coolant
Engine coolant change

1. Drain engine coolant (→ Page 244).
2. Fill with engine coolant (→ Page 245).
TIM-ID: 0000000036 - 031
MS150123/01E 2017-05 | Coolant System, General, High-Temperature Circuit | 243

8.17.3 Engine coolant – Draining
Preconditions
WARNING
Preparatory steps
1. Provide a suitable receptacle to catch the coolant.
2. Switch off preheater.
Draining engine coolant

1. Turn valve cover on filler neck of expansion tank counterclockwise to first stop and allow pressure to escape.
2. Continue to turn valve cover counterclockwise and remove.
3. Draw off separated corrosion inhibitor oil in expansion tank through the filler neck.
4. Open drain valves and/or drain plugs and
drain coolant at the following points:
• Elbow of the engine coolant pump (2)
• Crankcase, left and right side (1)
• On tee under flywheel housing
• At preheater
5. Tighten drain valves on elbow of engine coolant pump (2) and on crankcase (1) to specified torque using a
torque wrench.
Spindle A/F11 Tightening torque 12 Nm
TIM-ID: 0000073243 - 002
Final steps
1. Close all remaining open drain points.
2. Position valve cover on filler neck and close.

8.17.4 Engine coolant – Filling
Preconditions
☑ Engine is cold.

Engine coolant
WARNING
NOTICE
Cold coolant in hot engine can cause thermal stress.
Possible formation of cracks in the engine!
• Fill / top up coolant only into cold engine.
Variant 1: Filling coolant

through filler neck on expansion
tank
1. Turn valve cover (1) on expansion tank on the
left to the first lock and release pressure.
2. Continue to turn valve cover counterclock-
wise and remove.
TIM-ID: 0000014571 - 005

3. Open vent points on intercooler, exhaust tur-
bochargers, and on plate-core heat exchang-
er (arrowed).
4. Fill coolant through filler neck on expansion
tank.
5. When coolant escapes at the vent points,
close vent points one by one, proceeding
from the lowest point upwards.
6. Fill expansion tank until overflow edge is
reached.
7. Start engine with open expansion tank
(→ Page 62) and operate it in idle mode.
8. Open vent points one by one, starting at the
lowest point and proceeding upwards.
9. Close vent points.
10. Fill expansion tank until overflow edge is
reached.
11. When coolant temperature (T-Coolant)
reached 40 °C, increase the engine speed to
1000 rpm for approx. 2 minutes.
12. With the engine idling, fill expansion tank un-
til overflow edge is reached.
13. With the expansion tank open, run the engine
up to nominal speed (full load) under load.
14. Leave the engine idling for approx. 5 minutes
until the coolant temperature stabilizes.
15. Check coolant level in expansion tank:
• Level ≥ 50%: Close valve cover.
• Level ≤ 50%: Stop engine and fill expan-
sion tank until overflow edge is reached.
16. Close valve cover on expansion tank and run
engine up to full load again.
17. After the engine has cooled down, top up
coolant up to overflow edge in expansion
tank.
18. Check proper condition of valve cover and
clean sealing faces if required.
19. Fit and close valve cover on expansion tank.
Variant 2: Filling with coolant

using a pump
1. Connect appropriate pump (pressure at least
0.5 bar) with hose to filling connection (ar-
rowed) on A side or B side. Alternatively:
TIM-ID: 0000014571 - 005

2. Connect appropriate pump (pressure at least
0.5 bar) with a hose to the drain valve (ar-
rowed).
3. Open vent points on intercooler, exhaust tur-
bochargers, and on plate-core heat exchang-
er, see variant 1 (→ Step 3).
4. Ensure that the valve cover on the expansion
tank is closed.
5. Pump coolant into engine at 0.5 bar minimum
until air no longer emerges at the vent points.
6. When coolant escapes at the vent points,
close vent points one by one, proceeding
from the lowest point upwards.
7. Open valve cover (1) and fill expansion tank

until overflow edge is reached.
8. Start engine with open expansion tank
(→ Page 62) and operate it in idle mode.
9. Open the vent points in sequence from bot-
tom to top until air stops emerging, then
close them again.
10. When coolant temperature is 40 °C (T-Cool-
ant), increase engine speed to 1,000 rpm for
approx. 2 minutes, then reduce engine speed
to idle speed.
11. With the engine idling, fill expansion tank un-
til overflow edge is reached.
12. Stop engine (→ Page 76) and remove pump.
13. With the expansion tank open, start the en-
gine and run it up to nominal speed (full load)
under load.
14. Leave the engine idling for approx. 5 minutes
until the coolant temperature stabilizes.
15. Check coolant level in expansion tank:
• Level ≥ 50%: Close valve cover.
• Level ≤ 50%: Stop engine and fill expan-
sion tank until overflow edge is reached.
16. Close valve cover on expansion tank and run
engine up to full load again.
17. Stop engine (→ Page 76).
18. After the engine has cooled down, fill the ex-
pansion tank until the overflow edge is
reached.
TIM-ID: 0000014571 - 005
19. Check proper condition of valve cover and

clean sealing faces if required.
20. Fit and close valve cover on expansion tank.
Final steps
1. Start the engine and run it without load for some minutes.
2. Check coolant level (→ Page 242) and top up engine coolant as required.

8.17.5 Engine coolant pump – Relief bore check
DANGER
WARNING
Engine coolant pump – Relief

bore check
1. Check relief bore for oil and coolant dis-
charge.
• Permissible coolant discharge: up to 10
drops per hour
• Permissible oil discharge: up to 5 drops
per hour
• If discharge exceeds the specified limits:
Contact Service.
2. If the relief bore is dirty, stop the engine
(→ Page 76) and disable engine start, observe
general safety instructions for maintenance
and repair.
3. Clean relief bore with a wire.
TIM-ID: 0000000961 - 014

8.17.6 Engine coolant – Sample extraction and analysis
Preconditions

MTU test kit 5605892099/00 1
DANGER
WARNING
WARNING
Engine coolant – Sample extrac-

tion and analysis
1. Open drain valve on engine coolant pump el-
bow with the engine running.
2. Drain off approx. 1 liter engine coolant.
Result: Sampling point is clean.
3. Drain approx. 1 liter engine oil into a clean
container.
TIM-ID: 0000014608 - 009
4. Tighten shut-off cock (arrow) with torque wrench to the specified tightening torque.
Spindle SW11 Tightening torque 12 Nm
5. Using the equipment and chemicals of the MTU test kit, examine engine coolant for:
• antifreeze concentration
• concentration of corrosion protection oil
• pH value
6. For engine coolant change intervals, see (→ MTU Fluids and Lubricants Specifications).

8.17.7 Preheater – Overview
1 Outlet 5 Junction box 9 Nonmetallic cover and cap

2 Non-return valve 6 ON/OFF switch 10 Circulating pump
3 24 VDC connection 7 Inlet Arrow Flow direction
4 Connection to ship's power 8 Thermostat
supply system
TIM-ID: 0000073942 - 001

8.17.8 Preheater – Removal
DANGER
Electric voltage supply for operation.
Danger of burns and fatal electric shock!
• Make certain that the power supply to the product is switched off before starting work. Secure
against unintentional switching on!
WARNING
WARNING
Preheater – Removal
1. Switch off preheater (3) at switch (4) and dis-
connect from power supply.
2. Close shut-off valves in coolant circuit be-
tween preheater and engine.
3. Attach preheater (3) to crane with a lightly
tensioned rope.
4. Loosen and remove screw s on mounting
plate (6).
5. Loosen adapter flanges (1) and (5).
6. Remove gaskets from flanges (1) and (5).
7. Use crane to lift preheater (3) and set it
down.
8. Protect openings from dirt by fitting sealing
caps.
TIM-ID: 0000073943 - 001

8.17.9 Preheater – Overhaul
Preconditions
DANGER
WARNING
Preheater – Overhaul
1. Disconnect power supply to heating element.
2. Close shut-off valves in coolant lines upstream and downstream of preheating unit.
3. Drain coolant at drain valve into a clean vessel.
4. Clean and flush coolant circuit.
5. Check hoses for cracks and other damage. Replace as necessary.
6. Check wiring for damage and overheating.
7. Allow heating element to cool down.
8. Remove housing cover (7).
9. Remove screws of connection housing (4)
and remove connection housing (4) and O-
ring (3).
10. Loosen thermostat clip (6).
11. Remove terminals on thermostat (5) from
blade terminals of measuring unit.
12. Replace thermostat (5) if necessary.
13. Remove screws of heating element plate (2).
14. Remove heating element plate (2) with heat-
ing element (8) from tank (9).
Note: Make sure the O-ring (1) is properly installed.
15. Clean heating element (8) and tank (9).
16. Install heating element plate (2) with heating
element (8).
17. Install connection housing (4) and O-ring (3).
18. Install housing cover (7).
19. Connect heating element to power supply.
20. Remove pump from volute and check for resi-
dues in impeller and lines.
TIM-ID: 0000073695 - 001
21. Connect hoses and open shut-off valves.

22. Check preheater for leakage and correct op-
eration (→ Page 254).
23. Check coolant level (→ Page 242).

8.17.10 Preheater – Installation
Gasket (→ Spare Parts Catalog)
DANGER
WARNING
Preheater – Installation
1. Remove sealing caps from flanges (1) and (5).
Note: Observe flow direction as marked with arrows
on pump and non-return flap.
2. Attach preheater (3) to crane and position it
on the flanges (1) and (5).
3. Insert gaskets in flanges (1) and (5).
4. Screw on mounting plate (6).
5. Check position of non-return valve (2).
6. Screw on flanges (1) and (5).
7. Detach preheater (3) from crane.
8. Connect preheater (3) to power supply.
9. Open shut-off valves in coolant circuit be-
tween preheater and engine.
10. Vent coolant circuit.
11. Switch on preheater (3) at switch (4).
12. Check for leaks in operation.
TIM-ID: 0000073944 - 001

8.17.11 Preheater – Function and leak-tightness check
Preconditions
☑ Preheater is switched on.
Checking operation
Note: The coolant temperature must be within the range of the thermostat when the preheater is ready for opera-
tion.
1. Check coolant preheating temperature.
2. Set the thermostat to the relevant temperatures if they are out of range.
Checking heating element(s) (electrical)

u (→ Page 255)
Checking for leaks

1. Check leak-tightness at coolant inlet and outlet.
2. Tighten any leaking unions.
TIM-ID: 0000030251 - 003

8.17.12 Heating element(s) – Electrical check
Preconditions
☑ Preheater must be switched on.
Note: Work on electrical systems must only be carried out by qualified personnel.
Heating element(s) – Electrical check

1. Use a clip-on measuring instrument at an accessible point (e.g. in switchgear cabinet) to carry out one cur-
rent measurement per phase.
2. For power consumption, see electrical systems documentation or use formula: I = P / (√3 * U), I in Ampere,
P in Watt, U in Volt.
• lt is only permissible for the actual power consumption to be slightly less than the specified value. No
other deviations are permissible.
• If power consumption is significantly less, the heating element(s) must be replaced, contact Service
TIM-ID: 0000030452 - 001

8.17.13 Valve cover – Replacement
Preconditions

Valve cover (→ Spare Parts Catalog) 1
WARNING
Preparatory steps
u Switch off preheater.
Replacing valve cover

Note: Schematic diagram. Design may deviate.
1. Turn valve cover (1) on coolant expansion
tank counterclockwise until the first stop and
release pressure.
2. Continue to turn valve cover counterclock-
wise and remove.
3. Remove chain with screw (4) and washer (3).
4. Draw off separated corrosion inhibitor oil in
expansion tank via filler neck (2).
5. Fit new valve cover and close it.
6. Install chain.
TIM-ID: 0000065495 - 004

8.18 Raw Water Pump with Connections
8.18.1 Raw water pump – Relief bore check
Preconditions
DANGER
WARNING
Raw water pump – Relief bore

check
1. Check relief bore (1) for oil and coolant dis-
charge.
2. Clean the relief bore with a wire if it is dirty.
• Permissible coolant discharge: Up to 10
drops/hour.
• Permissible oil discharge: Up to 5 drops/
hour.
3. If discharge exceeds the specified limits, con-
tact Service.
TIM-ID: 0000064541 - 002
MS150123/01E 2017-05 | Raw Water Pump with Connections | 257

8.19 Battery-Charging Generator
8.19.1 Battery-charging generator drive – Coupling condition check
Preconditions

Engine oil
Battery-charging generator
drive – Coupling condition
check
2. Remove protective cover (2).
3. Check resilient coupling (3) for cracks and
plastic deformation.
4. If there is serious deformation or crack for-
mation, contact Service.
5. Install protective cover (2) with screws (1).
6. Use torque wrench to tighten screws (1) to specified tightening torque.

Screw M8x60 Tightening torque (Engine oil) 21 Nm +2 Nm
TIM-ID: 0000007390 - 009
258 | Battery-Charging Generator | MS150123/01E 2017-05

8.20 Engine Mounting / Support
8.20.1 Engine mounting – Check
Engine mounting – Check

Visually inspect resilient mounts. • Damage Replace (contact Service).
• Brittleness
• Deformation
• Crack formation
• Swelling
TIM-ID: 0000015370 - 005
MS150123/01E 2017-05 | Engine Mounting / Support | 259

8.20.2 Engine mounting – Checking securing screws for firm seating
Preconditions

Engine oil
Checking securing screws for

firm seating
1. Check security of securing screws (1 to 3).
2. Tighten loose screw connections (1) to specified torque using a torque wrench.
Screw M10x28 Control torque (Engine oil) 42 Nm +4 Nm
TIM-ID: 0000073162 - 001

260 | Engine Mounting / Support | MS150123/01E 2017-05

8.21 Auxiliary PTO
8.21.1 Bilge pump – Relief bore check
DANGER
WARNING
Bilge pump – Relief bore check

1. Check relief bores for oil and water dis-
charge.
2. Stop engine (→ Page 76) and disable engine
start.
3. Clean relief bores with a wire if dirty.
• Permissible 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.
TIM-ID: 0000015791 - 007
MS150123/01E 2017-05 | Auxiliary PTO | 261

8.22 Fuel Supply System
8.22.1 Water drain valve – Check
Water drain valve – Check

1. Open water drain valve.
2. Check water outlet for obstructions.
3. Close water drain valve.
TIM-ID: 0000007733 - 007
262 | Fuel Supply System | MS150123/01E 2017-05

8.22.2 Differential pressure gage – Alarm function check
WARNING
• Do not smoke.
Checking differential pressure gage alarm function

2. Set the alarm points at the differential pressure gage to zero.
Result: Alarm is issued after preset time.
3. Reset alarm points at differential pressure gage.
TIM-ID: 0000007737 - 007
MS150123/01E 2017-05 | Fuel Supply System | 263

8.22.3 Water level probe (3-in-1 rod electrode) – Check
Preconditions
☑ System is put out of service and emptied.
WARNING
• Do not smoke.
Checking water level probe (3-in-1 rod electrode)

1. Disconnect plug from water level probe.
2. Unscrew water level probe.
4. Immerse water level probe into a tank filled with water until water level reaches the thread.
5. Switch on plant.
Result: Water drain valve opens.
6. Leave water level probe in tank.
Result: Alarm must be issued after the preset time.
7. Switch off the system.
9. Remove water level probe from tank.
10. Screw in water level probe.
11. Connect plug for water level probe.
12. Fill system, vent and put into operation.
TIM-ID: 0000007739 - 009

8.22.4 Pump capacity – Check
WARNING
• Do not smoke.
Checking pump capacity

1. Install suitable pressure gauge in the intake connection of the pump.
2. Check pump pressure.
a) Switch on fuel treatment system (→ Page 70).
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 suction.
a) Reduce suction pressure of pump to -0.8 bar with the shut-off valve at the pump intake side.
b) Check pressure at the pressure gauge in the inlet to the fuel treatment system and note down.
c) Open ball valve at inlet and outlet of fuel treatment system.
4. Calculate wear limit.
Example:
Measured value (normal condition). 3 bar
Measured value (reduced suction condition). 2.6 bar
The wear limit has been reached when the measured value (reduced suction) is 10% lower than the meas-
ured pressure (normal). Repair pump (Contact Service).
TIM-ID: 0000007740 - 009

8.22.5 Coalescer filter element ‒ Replacement
Preconditions
☑ System is stopped and starting disabled.

Fuel
Engine oil
Coalescer filter element (→ Spare Parts Catalog)
Gasket (→ Spare Parts Catalog)
WARNING
• Do not smoke.
NOTICE
NOTICE
Replacing coalescer filter ele-

ment
1. Close ball valve at the inlet and outlet of the
fuel treatment system.
2. Open drain ball valve.
3. Drain fuel.
4. Close drain ball valve.
5. Remove nuts (9) with washers (2).
TIM-ID: 0000007735 - 013
7. Remove cover with seal (10).

8. Remove nut (3), washer (8) and end plate (4).
9. Remove coalescer filter element (5).
10. Catch fuel as it runs out.
11. Clean housing with a lint-free cloth. Rinse
with fuel as necessary.
12. Check housing for corrosion.
13. Clean housing sealing faces.
14. Install coalescer filter element (5).
15. Install end plate (4), washer (8) and nut (3).

16. Tighten nut (3) to specified torque using a torque wrench.
Nut M16 Tightening torque (Engine oil) 30 Nm +3 Nm
17. Fit seal (10).

18. Install cover.
19. Install screws (1), washers (2) and nuts (9).
20. Tighten nuts (9).
21. Open ball valve at the inlet and outlet of the fuel treatment system.
Result: The fuel treatment system is ready for operation.
TIM-ID: 0000007735 - 013

8.23 Wiring (General) for Engine/Gearbox/Unit
8.23.1 Engine cabling – Check
Preconditions

Solvent (isopropyl alcohol) X00058037 1
Engine cabling – Check

1. Check securing screws of cable clamps on engine and tighten loose screw connections.
2. Ensure that cables are securely seated in clamps and cannot move freely.
3. Check if all cable clips are closed and intact.
4. Replace faulty cable clips.
5. Check cable clamps for secure fit, tighten loose clamps.
6. Replace faulty cable clamps.
7. Visually inspect the following electrical components for damage:
• Connector housings
• Contacts
• Plug connectors
• Cables and terminals
• Plug-in contacts
Result: If cable conductors are damaged, contact Service.
Note: Close connectors that are not plugged in with the protective cap supplied.
8. Use isopropyl alcohol to clean dirty connector housings, plug connectors and contacts.
9. Ensure that all connecting plugs of the sensors are correctly engaged.
TIM-ID: 0000000029 - 024
268 | Wiring (General) for Engine/Gearbox/Unit | MS150123/01E 2017-05

8.24 Accessories for (Electronic) Engine Governor / Control System
8.24.1 Limit switch for start interlock – Check
Preconditions
Note: In the OFF position, the limit switch activates a start interlock, i.e. the engine cannot be started.
Limit switch for start interlock –
Check
1. Check whether switches (3) and guard
plate (2) with engine support (1) are installed
on both sides of flywheel housing (4).
2. Check whether both switches (3) are actuat-
ed.
3. If switches (3) and/or guard plate (2) with en-
gine support (1) is/are not installed:
• Screw on guard plate (2) with engine sup-
port (1).
• Then screw on switch (3), ensuring that
the switch (3) is actuated by the guard
plate (2).
4. If switch (3) and guard plate (2) are installed,
but switch (3) is in the OFF position:
• Make certain that the guard plate (2) at
the side of the switch (3) is not distorted.
• Loosen guard plate (2) and screw on such
that the switch (3) is actuated.
TIM-ID: 0000016782 - 007
MS150123/01E 2017-05 | Accessories for (Electronic) Engine Governor / Control System | 269
8.24.2 Engine Control Unit ECU 9 – Plug connection check
Preconditions
Checking plug connections on

ECU 9
1. Check all connectors on ECU for firm seating.
Ensure that the clips (1) are engaged.
2. Check screws of cable clamps (2) on ECU for
firm seating. Ensure that cable clamps are
not faulty.
TIM-ID: 0000075262 - 001
270 | Accessories for (Electronic) Engine Governor / Control System | MS150123/01E 2017-05
8.24.3 Engine Monitoring Unit EMU 8 – Plug connection check
Preconditions
Checking plug connections on

EMU
1. Check both connectors on EMU (2) for firm
seating. Ensure that the clips (1) are engag-
ed.
2. Check screws of cable clamps (3) on EMU (2)
for firm seating. Ensure that cable clamps are
not faulty.
TIM-ID: 0000075263 - 001
8.24.4 Interface module EIM plug connections – Check
Preconditions
Checking EIM plug connections

1. Check both Tyco plugs (62-pole) (2) on EIM
for firm seating. Ensure that clips (3) are en-
gaged.
2. Check screws (1) of cable clamps on EIM for
firm seating. Ensure that cable clamps are
not faulty.
TIM-ID: 0000017034 - 004
8.24.5 Engine governor ECU 9 – Removal and installation
Preconditions
NOTICE
Wrong engine governor installed.
Engine damage!
• When reassembling an engine, make sure that the governor with the data record for the given engine
is installed.
Removing engine governor from

engine
1. Note or mark assignment of cables and
plugs.
2. Remove all screws (2).
3. Release latches (3) of male connectors.
4. Remove all connectors.
6. Take off engine governor.
Installing engine governor on engine

1. Install in reverse order. Ensure correct assignment of plugs and sockets.
2. Check resilient mount before installing.
Result: If resilient mount is porous or defective then replace it.
TIM-ID: 0000062341 - 003
8.24.6 Engine Monitoring Unit EMU 8 – Removal and installation
Preconditions
NOTICE
Wrong engine governor installed.
Engine damage!
• When reassembling an engine, make sure that the governor with the data record for the given engine
is installed.
Removing Engine Control Unit

with Engine Monitoring Unit
from engine
1. Note or mark assignment of cables and con-
nectors.
2. Remove all screws from cable clamps (3).
3. Undo clips (4) on connectors.
4. Disconnect all connectors.
6. Remove Engine Control Unit (1) with Engine
Monitoring Unit (2).
Removing Engine Monitoring Unit

1. Unscrew screws on base of EMU (2).
2. Remove EMU 8 (2) from ECU (1).
Installing Engine Monitoring Unit

1. Place EMU 8 (2) on ECU (1).
2. Screw in and tighten screws on base of EMU (2).
Installing Engine Control Unit with Engine Monitoring Unit on engine

1. Install in reverse order ensuring correct assignment of connectors and sockets.
2. Check resilient mount before installing.
Result: If resilient mount is porous or faulty then replace it.
TIM-ID: 0000075264 - 001
8.24.7 Engine Interface Module EIM – Removal and installation
Preconditions
Removing EIM from the engine

1. Note or mark assignment of cables and con-
nectors.
2. Unscrew all screws (1).
3. Undo clips (2) on connectors.
4. Disconnect all connectors.
5. Unscrew power and starter cable.
7. Take off EIM.
Installing EIM on the engine

1. Install in reverse order. When doing so, observe correct assignment between cables and connectors.
2. Check seal before installing.
Result: Replace seal if porous or defective.
Downloading software
1. The new EIM still does not have appropriate FSW and parameter/descriptor module (the diagnostic lamp (DI-
LA) indicates flashing code 4 when the power supply is connected, (→ Page 276)).
2. The FSW and the parameter/descriptor module must first be downloaded from the central database (CDB)
based on the relevant engine number using the Diasys software tool, and then loaded in the EIM.
TIM-ID: 0000061227 - 001
8.24.8 Engine Interface Module EIM – Diagnostic features
Diagnostic lamp (DILA)
A diagnostic lamp (LED, blue) is integrated in the housing of the Engine Interface Module (EIM).
It indicates the operating status of the EIM.
Functions of diagnostic lamp DILA
DILA lit Engine Interface Module (EIM) is OK.
DILA dark EIM supply voltage missing or diagnostic lamp activation is faulty.
DILA flashes Hardware or software fault in the Engine Interface Module
The diagnostic lamp (DILA) signals the following states:
1 Time in seconds 4 Application loader active 7 No firmware

2 Timing: 1/8 s 5 External RAM faulty 8 Application crashed
3 Ready for operation 6 External FLASH faulty
Fuse lamp (SILA)

A second indicator is the fuse lamp.
TIM-ID: 0000075045 - 001
This is also integrated in the housing of the Engine Interface Module. It indicates the status of the fuses.
An orange LED is provided to allow diagnosis of a “tripped fuse” fault directly at the unit as it is often difficult
to pinpoint a fault in the field without cabling diagrams.
This LED is activated by the controller.
Functions of fuse lamp SILA
SILA dark Normal operating state
SILA flashes orange One or more fuses have tripped.
The fuse lamp (SILA) signals the following states:
1 Preamble 6VSP current path failed (S5) 11 ES pushbutton current path
2 Engine Control Unit current 7SLD current path failed (S6) failed – 24 V external (S10)
path failed (S1) 8DDV current path failed (S7) 12 Key switch current path
3 MCS current path failed 9Gear monitoring current failed (S11)
(S2) path failed (S8) 13 SDAF 1 and 2 current path
4 EMU current path failed 10 Emergency stop current failed (S12)
(S3) path failed – 24 V internal 14 PIM current path failed
5 Starter voltage: Terminal (S9) (S13)
30, 31 not connected and 15 Spare current path failed
PR 10.0600.001 has value (S14) (for EIM with ECU 9
1 or 2 (S4) only)
The failed current paths are signaled consecutively following the preamble (1) (LED on for 4 seconds). There
is a pause lasting 4 seconds in between.
TIM-ID: 0000075045 - 001
Sample flashing sequences
A Fuse S5 failure (1/2 second B Fuse S1 and fuse S4 failure

steps) (1/2 second steps)
Note:
These bit patterns are continuously transmitted.
The CAN message “Status of internal power supply” also contains information on the current path states of
the EIM.
TIM-ID: 0000075045 - 001
8.25 Emergency Instrumentation (Local Operating Panel)
8.25.1 LOP and connectors – Cleaning
Preconditions

Solvent (isopropyl alcohol) X00058037 1
Cleaning LOP
1. Wipe LCD screen with dry cloth, without applying excessive pressure.
2. Remove dirt from pushbuttons using solvent.
3. Remove coarse dirt on housing surface using solvent.
Cleaning connectors on LOP

1. Remove dirt from connector and socket surfaces using solvent.
2. Check legibility of cable labels. Clean or replace illegible labels.
TIM-ID: 0000008867 - 007
MS150123/01E 2017-05 | Emergency Instrumentation (Local Operating Panel) | 279

9 Appendix A
9.1 List of abbreviations
Abbrevia- Meaning Explanation
tion
ADEC Advanced Diesel Engine Control Engine governor
AGN Abgasnachbehandlung Exhaust gas aftertreatment
AL Alarm Alarm (general)
ANSI American National Standards Institute Association of American standardization organiza-
tions
BR Baureihe Series
BV Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU Publication
No. A01061/..
CAN Controller Area Network Data bus system, bus standard
CDC Calibration Drift Compensation Setting for drift correction with DiaSys in engine gov-
ernor
CO2 Carbon Dioxide
CPP Controllable Pitch Propeller
DCM Distributed Control Module
DU Dosing Unit
DEF Diesel Exhaust Fluid Also referred to as "aqueous urea solution" and "re-
ducing agent"
DILA Diagnostic lamp on EIM
DIN Deutsches Institut für Normung e. V. German standardization association; at the same
time identifier of German standards (DIN = “Deutsche
Industrie-Norm”)
DIS Display Unit Display panel
DL Default Lost Alarm: Default CAN bus failure
DPF Diesel Particulate Filter
ECS Engine Control System Engine management system
ECU Engine Control Unit Engine governor
EDM Engine Data Module Memory module for engine data
EIM Engine Interface Module Interface to engine monitoring system
EMU Engine Monitoring Unit
EPA Environmental Protection Agency US regulator which implements and enforces federal
laws to protect the environment and sets out stand-
TIM-ID: 0000071898 - 001
ards aimed at ensuring compliance with such laws

ETC Exhaust turbocharger
FPP Fixed Pitch Propeller
GCU Gear Control Unit
GMU Gear Monitoring Unit
HAPS Hydrogen Carbon Adsorption Preven-
tion System
HAT Harbour Acceptance Test
280 | Appendix A | MS150123/01E 2017-05

tion
HI High Alarm: Measured value exceeds 1st maximum limit
HIHI High High Alarm: Measured value exceeds 2nd maximum limit
value
HNBR Hydrogenated Nitrile Butadiene Rubber
HT High Temperature
H2O Water
ICFN ISO – Continuous rating – Fuel stop Power specification in accordance with DIN-ISO
power – Net 3046-7
IDM Interface Data Module Memory module for interface data
IIG Initial Injector Equalization Entering of injector code with DiaSys in engine gover-
nor
IMO International Maritime Organization
IP International Protection
ISO International Organization for Stand- International umbrella organization for all national
ardization standardization institutes
KGS Kraftgegenseite Engine free end in accordance with DIN ISO 1204
KS Kraftseite Engine driving end in accordance with DIN ISO 1204
LCD Liquid Crystal Display, Liquid Crystal
Device
LCU Local Control Unit LOP subassembly
LED Light Emitting Diode
LMU Local Monitoring Unit LOP subassembly
LO Low Alarm: Measured value lower than 1st minimum limit
value
LOLO Low Low Alarm: Measured value lower than 2nd minimum limit
value
LOP Local Operating Panel Control console, control panel
LOS Local Operating Station
MCS Monitoring and Control System
MG Message
MPU Microprocessor Unit, Microprocessing
Unit
NH3 Ammonia
NOx Nitrous Oxides - NO and NO22 Nitrous gases
N2 Nitrogen
O2 Oxygen
TIM-ID: 0000071898 - 001
OT Oberer Totpunkt Top Dead Center

P-xyz Pressure-xyz Pressure measuring point xyz
PAN Panel Control panel
PCU Propeller Control Unit
PDM Pre-Delivery Module
PIM Peripheral Interface Module
PM Particulate Matter
PTFE Polytetrafluoroethylene
MS150123/01E 2017-05 | Appendix A | 281

tion
RM Reduktionsmittel Reducing agent, also referred to as "DEF" and "aque-
ous urea solution"
RCS Remote Control System
RL Redundancy Lost Alarm: Redundant CAN bus failure
S Sulfur
SAE Society of Automotive Engineers U.S. standardization organization
SAM Service and Application Module
SAT Sea Acceptance Test
SCR Selective Catalytic Reduction
SD Sensor Defect Alarm: Sensor failure
SDAF Shut Down Air Flaps
SILA Sicherungslampe Fuse lamp on EIM
SOLAS International Convention for the Safety
of Life at Sea
SPC Spare Parts Catalog
SS Safety System Safety system alarm
SSK Schnellschlussklappe(n) German Abbreviation for SDAF
SU Supply Unit
T-xyz Temperature-xyz Temperature measuring point xyz
TC Tool Catalog
TD Transmitter Deviation Alarm: Deviation in transmitter values
UT Unterer Totpunkt Bottom Dead Center (BDC)
VE Versorgungseinheit Supply unit (SU)
VFM Vorfördermodul Predelivery Module (PDM)
VS Voith Schneider Voith-Schneider drive
WJ Water jet Water jet drive
ZKP Zugehörigkeit-Kategorie-Parameter Assignment category parameter; number scheme for
signals from the ADEC engine governor
TIM-ID: 0000071898 - 001
282 | Appendix A | MS150123/01E 2017-05

9.2 MTU Contact/Service Partners
The worldwide network of the sales organization with subsidiaries, sales offices, representatives and custom-
er service centers ensure fast and direct support on site and ensure the high availability of our products.
Local Support
Experienced and qualified specialists place their knowledge and expertise at your disposal.
For locally available support, go to the MTU Internet site: http://www.mtu-online.com
24h Hotline
With our 24h hotline and high flexibility, we're your contact around the clock: during each operating phase,
preventive maintenance and corrective operations in case of a malfunction, for information on changes in
conditions of use and for supplying spare parts.
Your contact person in our Customer Assistance Center:
E-mail: info@mtu-online.com
Tel.: +49 7541 9077777
Fax.: +49 7541 9077778
Asia/Pacific: +65 6100 2688
North and Latin America: +1 248 560 8000
Spare Parts Service

Fast, simple and correct identification of spare parts for your drive system or vehicle fleet. The right spare
part at the right time at the right place.
With this aim in mind, we can call on a globally networked spares logistics system, a central warehouse at
headquarters and on-site stores at our subsidiary companies, agencies and service workshops.
Your contact at Headquarters:
E-mail: spare.parts@mtu-online.com
Tel.: +49 7541 9077777
Fax.: +49 7541 9077778
TIM-ID: 0000000873 - 016
MS150123/01E 2017-05 | Appendix A | 283

10 Appendix B
10.1 Special Tools
Alignment jig
Part No.: F6794341
Qty.: 1
Used in: 8.13.10 SCR catalytic converter – Mounting alignment
(→ Page 191)
Angular screw driver

Part No.: F30002815
Qty.: 1
Used in: 8.5.3 Valve clearance – Check and adjustment
(→ Page 141)
Barring gear
Part No.: F6555766
Qty.: 1
Used in: 8.2.1 Engine – Barring manually (→ Page 129) DCL-ID: 0000043366 - 002
284 | Appendix B | MS150123/01E 2017-05

Barring tool
Part No.: F6555766
Qty.: 1
Used in: 8.3.1 Cylinder liner – Endoscopic examination
(→ Page 131)
Cable
Part No.:
Qty.: 1
Used in: 8.13.8 Exhaust pressure sensor – Measuring lines check
(→ Page 189)
Crossbeam
Part No.: T80092210
Qty.: 1
Used in: 2.1 Transport (→ Page 18)
Crossbeam
Part No.: T80092360
Qty.: 1
Used in: 2.1 Transport (→ Page 18)
DCL-ID: 0000043366 - 002
MS150123/01E 2017-05 | Special Tools | 285

Depth gage, 200 mm
Part No.: Y20000918
Qty.: 1
Used in: 8.5.1 Valve protrusion – Measurement (→ Page 136)
Digital multimeter with test leads, test clips and test prods
Part No.:
Qty.: 1
Used in: 8.13.8 Exhaust pressure sensor – Measuring lines check
(→ Page 189)
Endoscope
Part No.: Y20097353
Qty.: 1
(→ Page 131)
Feeler gage
Part No.: Y20098771
Qty.: 1
(→ Page 141)
DCL-ID: 0000043366 - 002
286 | Special Tools | MS150123/01E 2017-05

Feeler gauge
Part No.: Y20098771
Qty.:
Used in: 8.16.15 Oil filter element – Check (→ Page 227)
Qty.: 1
Used in: 8.16.16 Oil filter element – Assembly (→ Page 228)
Filter wrench, 27 A/F

Part No.:
Qty.: 1
Used in: 8.13.6 Pre-feed module – Filter element replacement
(→ Page 185)
Fuel suction device

Part No.: F30378207
Qty.: 1
Used in: 8.6.1 HP fuel pump – Filling with engine oil (→ Page 146)
High-pressure cleaner
Part No.:
Qty.: 1
Used in: 5.19 Plant – Cleaning (→ Page 80)
Installation/removal jig
Part No.: F6789889
Qty.: 1
Used in: 8.7.2 Injector – Removal and installation (jacketed fuel
system) (→ Page 149)
DCL-ID: 0000043366 - 002

Lifting gear (crane or push-pull cable)
Part No.:
Qty.: 1
Used in: 8.13.12 SCR modules – Replacement (→ Page 194)
Measuring jig 1
Part No.: Y4350009
Qty.: 1
Measuring jig 2, optional

Part No.: Y4350010
Qty.: 1
Milling cutter
Part No.: F30452739
Qty.: 1
system) (→ Page 149) DCL-ID: 0000043366 - 002

MTU test kit
Part No.: 5605892099/00
Qty.: 1
Used in: 8.15.3 Engine oil – Sample extraction and analysis
(→ Page 206)
Qty.: 1
Used in: 8.17.6 Engine coolant – Sample extraction and analysis
(→ Page 249)
Oil filter wrench

Part No.: F30379104
Qty.: 1
Used in: 8.8.1 Fuel filter – Replacement (→ Page 155)
Oilstone
Part No.: F30454308/03
Qty.: 1
Used in: 8.16.7 Automatic oil filter – Check (→ Page 216)
Ratchet adapter
Part No.: F30027340
Qty.: 1
Used in: 2.3 Crankshaft transport locking device (→ Page 22)
Qty.: 1
Used in: 8.9.1 Compressor wheel – Cleaning (→ Page 166)
DCL-ID: 0000043366 - 002
Qty.: 1
Qty.: 1
Used in: 8.22.5 Coalescer filter element ‒ Replacement
(→ Page 266)

Ratchet adapter
Part No.: F30027341
Qty.: 1
Qty.: 1
Used in: 8.20.2 Engine mounting – Checking securing screws for
firm seating (→ Page 260)
Ratchet bit
Part No.: F30027340
Qty.: 1
Qty.: 1
Used in: 8.8.5 Fuel prefilter with water separator – Filter element
replacement (→ Page 163)
Qty.: 1
Used in: 8.13.3 Dosing unit – Replacement (→ Page 180)
Qty.: 1
Ratchet bit
Part No.: F30027341
Qty.: 1
Qty.: 1
Used in: 8.15.2 Engine oil ‒ Change (→ Page 204)
Ratchet bit
Part No.: F30450902
Qty.: 1
Used in: 8.13.1 Supply unit – Filter element replacement
DCL-ID: 0000043366 - 002
(→ Page 174)

Ratchet with extension
Part No.: F30006212
Qty.: 1
Used in: 8.2.1 Engine – Barring manually (→ Page 129)
Qty.: 1
(→ Page 131)
Removal tool
Part No.: XP52699100138
Qty.: 1
Used in: 8.16.13 Oil filter element – Disassembly (→ Page 224)
Socket wrench, 24 mm
Part No.: F30039526
Qty.: 1
(→ Page 141)
Socket, 46 A/F
Part No.: F30006128
Qty.: 1
(→ Page 174)
DCL-ID: 0000043366 - 002

Torque screwdriver, 1–5 Nm
Part No.: F30452774
Qty.: 1
Qty.: 1
Used in: 8.11.2 Air filter – Removal and installation (→ Page 172)
Torque wrench, 10–60 Nm

Part No.: F30452769
Qty.: 1
Qty.: 1
Used in: 8.6.1 HP fuel pump – Filling with engine oil (→ Page 146)
Qty.: 1
Qty.: 1
Used in: 8.8.5 Fuel prefilter with water separator – Filter element
Qty.: 1
Used in: 8.9.1 Compressor wheel – Cleaning (→ Page 166)
Qty.: 1
Used in: 8.13.13 NOx sensor – Replacement (→ Page 199)
Qty.: 1
Used in: 8.16.20 Centrifugal oil filter – Cleaning and filter-sleeve
Qty.: 1
Used in: 8.19.1 Battery-charging generator drive – Coupling condi-
tion check (→ Page 258)
Qty.: 1

Part No.: F30047798
Qty.: 1
DCL-ID: 0000043366 - 002

(→ Page 191)
Qty.: 1

Part No.: F30044239
Qty.: 1
Used in: 8.16.20 Centrifugal oil filter – Cleaning and filter-sleeve

Part No.: F30452768
Qty.: 1
Qty.: 1
(→ Page 141)
Qty.: 1
Qty.: 1
(→ Page 174)
Qty.: 1
(→ Page 191)
Qty.: 1
Used in: 8.15.2 Engine oil ‒ Change (→ Page 204)
Qty.: 1

Part No.: F30027336
Qty.: 1
Qty.: 1
DCL-ID: 0000043366 - 002

Part No.: F30043446
Qty.: 1
Used in: 8.13.3 Dosing unit – Replacement (→ Page 180)
Qty.: 1
Used in: 8.22.5 Coalescer filter element ‒ Replacement
(→ Page 266)
Valve setting gauge

Part No.: Y4349603
Qty.: 1
(→ Page 141)
DCL-ID: 0000043366 - 002

10.2 Index
A Cylinder
Actuators – Designation 25
– Overview 35 Cylinder head cover
Adhesive tape for SOLAS shielding – Installation 145
– Application 128 – Removal 145
After stopping the engine 78 Cylinder liner
Air filter – Endoscopic examination 131
– Installation 172 – Instructions and comments on endoscopic and visual
– Removal 172 examination 133
– Replacement 171
D
– Service indicator check 173
Automatic oil filter Diagnostic lamp (DILA)
– Assembly 217 – EIM 276
– Check 216 Diagnostics
– Checking flushing arm rotation 215 – EIM 276
– Cleaning 214 Differential pressure gage
– Disassembly 213 – Alarm function check 263
– Final steps 220 Disengaging
– Installation 218 – From LOP 74
– Overview 207 Dosing unit
– Preparatory steps 210 – Replacement 180
– Removal 211
E
B ECS
Battery-charging generator drive – Fault messages 89
– Coupling condition check 258 ECU9
Bilge pump – Fault messages 89
– Relief bore check 261 Emergency engine stop
– Via automation system 71
C EMU 8
Cabling – Installation 274
– Check – Plug connection check 271
– On engine 268 – Removal 274
Centrifugal oil filter Engagement
– Cleaning 239 – Via LOP 73
– Installation 241 Engine
– Overview 238 – Barring
– Removal 241 – Manually 129
Checks – Main dimensions 56
– Prior to start-up 66 – Shutdown
Coalescer filter element – Via the automation system 76
– Replacement 266 – Starting
Compressor wheel – Via the automation system 62
Engine cabling
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– Cleaning 166
Contact persons 283 – Check 268
Coolant Engine Control Unit ECU 9
– Change 243 – Plug connection check 270
– Engine Engine coolant
– Draining 244 – Change 243
Crankcase breather – Draining 244
– Oil mist separator – Filling 245
– Replacement 135 – Level check 242
Crankshaft – Sample analysis 249
– Transport locking device – Sample extraction 249
– Installation/removal 22
MS150123/01E 2017-05 | Index | 295

Engine coolant pump Fuel prefilter with water separator
– Relief bore check 248 – Draining 159
Engine driving end – Filter element
– Definition 25 – Flushing 161
Engine free end – Replacement 163
– Definition 25 Fuel treatment system
Engine Interface Module EIM – Control cabinet
– Removal and installation 275 – Controls 65
Engine mounting – Initial start-up 67
– Check 259 – Shutdown 79
– Checking securing screws for firm seating 260 – Switching on 70
Engine oil Fuse lamp (SILA)
– Centrifugal oil filter – EIM 276
– Cleaning 239
– Change 204 H
– Filter sleeve Heating element(s)
– Replacement 239 – Electrical check 255
– Sample analysis 206 Hotline 283
– Sample extraction 206 HP pump
Engine oil level – Filling with engine oil 146
– Check 203
Engine sides I
– Designation 25 Injector
Engine with exhaust gas aftertreatment – Installation 149
– Stopping – Removal 149
– Via automation system 77 – Replacement 148
Engine – Barring with starting system 130 Insulation
Engine – Overview 27 – Check
Exhaust gas aftertreatment – SCR housing and SCR bypass 184
– Overview 28 Intercooler
Exhaust pressure sensor – Check water drain for coolant discharge and obstruc-
– Measuring lines check 189 tion 170
– Measuring lines cleaning 190 Interface module EIM
– Check 272
F
Fault messages L
– ECS with ECU9 89 Lifting instructions 19
Filter Limit switch for start interlock
– Fuel – Check 269
– Replacement 155 List of abbreviations 280
Filter element LOP
– Replacement – Cleaning 279
– Pre-feed module 185 – Connector cleaning 279
– Supply unit 174 LOP controls
Filter sleeve – Starting 59
– Replacement 239
M
Firing order 58
Mounting
DCL-ID: 0000043366 - 002
Fuel
– Treatment system – Alignment 191
– Switching on 70 – Check 193
– Troubleshooting 83 MTU contact persons 283
– treatment system
N
– Shutdown 79
Fuel filter NOx sensor
– Replacement 155 – Replacement 199
Fuel prefilter
– Contamination indicator check 157
296 | Index | MS150123/01E 2017-05

O R
Oil filter Raw water pump
– Final steps 220 – Relief bore check 257
– Preparatory steps 210
Oil filter candles S
– Check 227 Safety notices, standards 17
– Cleaning 226 Safety regulations
Oil filter element – Assembly work 11
– Assembly 228 – Environmental protection 15
– Check 227 – Fire prevention 15
– Checking easy movement 232 – Fluids and lubricants 15
– Cleaning 226 – Important provisions 6, 7
– Disassembly 224 – Indirect materials 15
– Installation 232 – Initial start-up 9
– Overview 221 – Maintenance work 11
– Removal 223 – Operation 9
Oil indicator filter – Organizational requirements 8
– Check 235 – Personnel requirements 8
– Cleaning 235 – Repair work 11
Operational checks 63 Safety requirements
Overflow valve – Safety notices, standards 17
– Removal 224 SCR catalytic converter
Overflow valves – Mounting alignment 191
– Installation 228 – Mounting check 193
– Overview 28
P – Product data 55
Plant SCR modules
– Cleaning 80 – Replacement 194
Plug connections Sensors
– Check 272 – NOx
Preheater – Replacement 199
– Overhaul 252 – Overview 35
– Function and leak-tightness check 254 Service indicator
– Installation 253 – Check 173
– Overview 250 Service partners 283
– Removal 251 SOLAS shielding
Pre-feed module – Adhesive tape application 128
– Filter element – Installation locations 121
– Replacement 185 SOLAS shielding
– Replacement 187 – Installation
Product – As per MTN 5233 120
– Layout 26 Spare parts service 283
Product data Starter
– 16V4000M73, IMO Tier III 51 – Condition check 202
– 16V4000M73L, IMO Tier III 51 Supply unit
Product description 30 – Replacement 177
Pump
DCL-ID: 0000043366 - 002
– Engine coolant T
– Relief bore check 248 Tasks after extended out-of-service periods (>3 weeks) 64
Pump capacity Transport
– Check 265 – Description 18
Putting the engine into operation after extended out-of- – Lifting instructions 19
service periods (>3 months) 60 Transport locking device
Putting the engine into operation after scheduled out-of- – Crankshaft
service-period 61 – Installation/removal 22
Troubleshooting 84
– Fuel treatment system 83
MS150123/01E 2017-05 | Index | 297

U
Urea solution lines
– Replacement 183
V
Valve clearance
– Adjustment 141
– Check 141
Valve cover
– Replacement 256
Valve gear
– Lubrication 140
Valve protrusion
– Measurement 136
W
Water drain valve
– Check 262
Water level probe (3-in-1 rod electrode)
– Check 264
Waterjet
– Flushing
– From LOP (option) 75
Wiring harness
– Overview 44
DCL-ID: 0000043366 - 002
298 | Index | MS150123/01E 2017-05

MTU 16V 4000M73 Operation Instruction Manual PDF

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MTU 16V 4000M73 Operation Instruction Manual PDF

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Operating Instructions

Diesel engine with exhaust gas aftertreatment

© 2017 Copyright MTU Friedrichshafen GmbH

4 Technical Data 8 Task Description

5.2 Putting the engine into operation after

MS150123/01E 2017-05 | Table of Contents | 3

condition check 258

4 | Table of Contents | MS150123/01E 2017-05

MS150123/01E 2017-05 | Table of Contents | 5

Emission regulations and emission labels

Replacing components with emission labels

6 | Safety | MS150123/01E 2017-05

MS150123/01E 2017-05 | Safety | 7

Clothing and personal protective equipment

TIM-ID: 0000040531 - 010

8 | Safety | MS150123/01E 2017-05

Safety regulations during operation

Malfunctions and emergency stop

MS150123/01E 2017-05 | Safety | 9

TIM-ID: 0000040533 - 016

10 | Safety | MS150123/01E 2017-05

Safety regulations when performing assembly, maintenance, and repair work

Setting down, lifting and climbing

MS150123/01E 2017-05 | Safety | 11

Removing, installing and cleanliness

Safety regulations after performing assembly, maintenance, and repair work

12 | Safety | MS150123/01E 2017-05

Hydraulic installation and removal

Working with batteries

Working on electrical and electronic assemblies

De-energize the appropriate areas prior to working on assemblies.

MS150123/01E 2017-05 | Safety | 13

Working with laser equipment

Measuring component dimensions

TIM-ID: 0000040535 - 017

14 | Safety | MS150123/01E 2017-05

Environmental protection and disposal

Indirect materials, fluids and lubricants

contaminate sensors and other components leading to malfunction.

MS150123/01E 2017-05 | Safety | 15

Paints and lacquers

Acids/alkaline solutions/urea (e.g. AdBlue®, DEF)

• Do not inhale vapors.

16 | Safety | MS150123/01E 2017-05

MS150123/01E 2017-05 | Safety | 17

Placement after transport

18 | Transport | MS150123/01E 2017-05

Lifting instructions – 16V engine

1 Max. admissible diagonal B 293.5 mm, right side E 12 mm

MS150123/01E 2017-05 | Transport | 19

Lifting instructions – SCR catalytic converter without bypass

1 Max. admissible diagonal B 1057 mm F 921 mm

Take note of the center of gravity of SCR catalytic converter

20 | Transport | MS150123/01E 2017-05

1 Sling 2 Holder 3 Bearing

MS150123/01E 2017-05 | Transport | 21

Transport locking device

Removing guard plates and en-

22 | Transport | MS150123/01E 2017-05

Removing the transport locking

locking device carefully for possible reuse to-

MS150123/01E 2017-05 | Transport | 23

TIM-ID: 0000073120 - 002