Operating Instructions: Diesel Engine 8V4000Mx3x

Operating Instructions
Diesel engine
8V4000Mx3x
MS15034/00E
Engine model kW/cyl. rpm Application group
8V4000M53 115 kW/cyl. 1800 1A, continuous operation, unrestricted
8V4000M63 125 kW/cyl. 1800 1A, continuous operation, unrestricted
8V4000M53R 93 kW/cyl. 1600 1A, continuous operation, unrestricted
Table 1: Applicability
© 2018 Copyright MTU Friedrichshafen GmbH

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ten consent of MTU Friedrichshafen GmbH. This particularly applies to its reproduction, distribution, editing, translation, micro-
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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 5.10 Fuel treatment system – Switching on 90
5.11 Fuel treatment system – Shutdown 91
1.1 Important provisions for all products 5 5.12 Stopping the engine 92
1.2 Correct use of all products 7 5.13 Emergency engine stop 93
1.3 Personnel and organizational requirements 8 5.14 After shutdown 94
1.4 Initial start-up and operation – Safety 5.15 Plant – Cleaning 95
regulations 9
1.5 Assembly, maintenance, and repair work –
6 Maintenance
Safety regulations 11
1.6 Fire and environmental protection, fluids 6.1 Maintenance task reference table [QL1] for
and lubricants 15 EPA regions 96
1.7 Standards for warning notices in the text 6.2 Maintenance task reference table [QL1] for
and highlighted information 17 Non EPA regions 98
2 Transport 7 Troubleshooting
2.1 Transport 18 7.1 Troubleshooting 100
2.2 Lifting requirements 19 7.2 Control cabinet of fuel treatment system –
Troubleshooting 103
3 General Information 7.3 Engine governor ADEC (ECU 7) fault
messages for Series 4000 engines, marine
3.1 Engine layout 21 application 104
3.2 Product description 25 7.4 ADEC engine governor – Fault codes 105
3.3 Tightening specifications for screws, nuts
and bolts 39
8 Task Description
3.4 Engine side and cylinder designations 52
3.5 Sensors and actuators – Overview 53 8.1 SOLAS 131
8.1.1 SOLAS shielding as per MTN 5233 –
4 Technical Data Installation 131
8.1.2 SOLAS shielding – Installation 132
4.1 ENGINE DATA 8V4000M53R (provisional) 63 8.1.3 Installation locations for SOLAS shielding 133
4.2 Product data 8V4000M53 67 8.1.4 Adhesive tape for SOLAS shielding –
4.3 Product data 8V4000M63 72 Application 140
4.4 Firing order 77 8.2 Engine 141
4.5 Engine – Main dimensions 78 8.2.1 Engine – Barring manually 141
8.2.2 Barring engine with starting system 143
5 Operation 8.3 Cylinder Liner 144
5.1 Controls 79 8.3.1 Cylinder liner – Endoscopic examination 144
8.3.2 Cylinder liner – Instructions and comments on
5.2 Putting the engine into operation after
endoscopic and visual examination 146
extended out-of-service periods (>3 months) 80
5.3 Putting the engine into operation after 8.4 Crankcase Breather 148
DCL-ID: 0000051756 - 001
scheduled out-of-service-period 81 8.4.1 Crankcase breather – Oil mist fine separator

5.4 Re-starting the engine following an replacement 148
automatic safety shutdown 82 8.5 Valve Drive 149
5.5 Starting the engine 83 8.5.1 Valve gear – Lubrication 149
5.6 Operational checks 84 8.5.2 Valve clearance – Check and adjustment 150
5.7 Tasks after extended out-of-service periods 8.5.3 Cylinder head cover – Removal and
(>3 weeks) 85 installation 153
5.8 Checks prior to start-up 86 8.5.4 Cylinder head cover – Removal and
installation 154
5.9 Fuel treatment system – Initial start-up 87
MS15034/00E 2018-08 | Table of Contents | 3

8.6 Injection Pump / HP Pump 155 8.16.8 Engine coolant filter – Replacement 212
8.6.1 HP fuel pump – Filling with engine oil 155 8.16.9 Preheater – Function and leak-tightness check 213
8.6.2 HP fuel pump – Relief bore check 157 8.16.10 Preheating unit 214
8.16.11 Preheater – Overhaul 217
8.7 Injection Valve / Injector 158
8.7.1 Injector – Replacement 158 8.17 Raw Water Pump with Connections 218
8.7.2 Injector – Removal and installation (jacketed 8.17.1 Raw water pump – Relief bore check 218
fuel system) 159
8.18 Battery-Charging Generator 219
8.8 Fuel Filter 166 8.18.1 Battery-charging generator drive – Coupling
8.8.1 Additional fuel filter – Overview 166 condition check 219
8.8.2 Additional fuel filter – Replacement 167
8.19 Engine Mounting / Support 220
8.8.3 Fuel filter – Replacement 168
8.19.1 Engine mounting – Checking resilient element 220
8.8.4 Fuel prefilter – Differential pressure gage
check and adjustment 170 8.20 Auxiliary PTO 221
8.8.5 Fuel prefilter – Draining 171 8.20.1 Bilge pump – Relief bore check 221
8.8.6 Fuel prefilter – Flushing 173
8.8.7 Fuel prefilter with water separator – Filter
8.21 Fuel Supply System 222
8.21.1 Water drain valve – Check 222
element replacement 175
8.21.2 Differential pressure gage – Alarm function
8.8.8 Fuel prefilter with water separator – O-ring
check 223
replacement in rotary slide valve 178
8.21.3 Water level probe (3-in-1 rod electrode) –
8.9 Exhaust Turbocharger 179 Check 224
8.9.1 Compressor wheel – Cleaning 179 8.21.4 Pump capacity – Check 225
8.21.5 Coalescer filter element ‒ Replacement 226
8.10 Charge-Air Cooling 184
8.10.1 Intercooler – Check water drain for coolant 8.22 Wiring (General) for Engine/Gearbox/Unit 228
leakage and obstruction 184 8.22.1 Engine wiring harness and mounts – Overview 228
8.22.2 Engine cabling – Check 234
8.11 Air Filter 185
8.11.1 Air filter – Replacement 185 8.23 Accessories for (Electronic) Engine
8.11.2 Air filter – Removal and installation 186 Governor / Control System 235
8.23.1 Limit switch for start interlock – Check 235
8.12 Air Intake 187
8.23.2 Engine Control Unit ECU 7 – Checking plug
8.12.1 Contamination indicator – Signal ring position
connections 236
check 187
8.23.3 Engine Monitoring Unit EMU 7 – Plug
8.13 Starting Equipment 188 connection check 237
8.13.1 Starter – Condition check 188 8.23.4 Interface module EIM plug connections –
Check 238
8.14 Lube Oil System, Lube Oil Circuit 189 8.23.5 Engine governor ECU 7 – Removal and
8.14.1 Engine oil level – Check 189
installation 239
8.14.2 Engine oil – Change 190
8.23.6 Engine Interface Module EIM 2 – Removal and
8.14.3 Engine oil – Sample extraction and analysis 192
installation 240
8.15 Oil Filtration / Cooling 194 8.23.7 Engine Interface Module EIM 2 – Diagnostic
8.15.1 Engine oil filter – Replacement 194 features 241
8.15.2 Oil indicator filter – Cleaning and check 196 8.23.8 EMU 7 – Removal and installation 244
8.15.3 Centrifugal oil filter – Cleaning and filter 8.23.9 CDC parameters – Reset 245
sleeve replacement 199
8.16 Coolant Circuit, General, High-Temperature 9 Appendix A

DCL-ID: 0000051756 - 001
Circuit 202
8.16.1 Drain and vent points 202 9.1 List of abbreviations 246
8.16.2 Engine coolant level – Check 205 9.2 MTU Contact/Service Partners 248
8.16.3 Engine coolant – Change 206
8.16.4 Engine coolant – Draining 207 10 Appendix B
8.16.5 Engine coolant, filling 208
8.16.6 HT coolant pump – Relief bore check 210 10.1 Special Tools 249
8.16.7 Engine coolant – Sample extraction and 10.2 Index 256
analysis 211
4 | Table of Contents | MS15034/00E 2018-08

1 Safety
1.1 Important provisions for all products
General
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. This data must match the speci-
fications in these instructions.
Nameplates, model designation or serial number can be found on the product.
All EU-certified engines delivered by MTU come with a second nameplate. This second nameplate is deliv-
ered "loosely" with the engine. If the nameplate secured to the engine after installation in the vehicle/system
is not visible without the removal of components, the system integrator must install the second nameplate in
a clearly visible area on the vehicle/system.
Emission specifications and emission label

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-related components must only be serviced, ex-
changed or repaired if the components used for this purpose are approved by the manufacturer.
Noncompliance with these specifications will invalidate the design type approval or certification issued by
the emissions regulation 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).
Emission certification applicable to engines with EPA Nonroad Tier 4 emission

certification in accordance with 40 CFR 1039
Extract from the standard:
Failing to follow these instructions when installing a certified engine in a piece of nonroad equipment violates
federal law (40 CFR 1068.105(b)), subject to fines or other penalties as described in the Clean Air Act.
Extract from the standard:
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If you install the engine in a way that makes the engine's emission control information label hard to read
during normal engine maintenance, you must place a duplicate label on the equipment, as described in 40
CFR 1068.105.
When fitting the second label, the requirements of 40 CFR 1068.105(c) must be followed and observed. This
paragraph describes the process for requesting and fitting the label, the documentation obligations and stor-
age obligations for the required documents.
MS15034/00E 2018-08 | Safety | 5

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.
• The emission labels must be removed from the replaced part and destroyed.
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6 | Safety | MS15034/00E 2018-08

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
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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MS15034/00E 2018-08 | 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.
Such 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
and also for work with live parts
The operator must define the responsibilities of the personnel involved in operation, maintenance, repair, as-
sembly, installation, and transport in writing.
Personnel shall not report for duty under the influence of alcohol, drugs or strong medication.
Clothing and personal protective 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.
Safe handling of Substances of Very High Concern pursuant to the REACH regulation (Registration, Evalua-
tion, Authorization and restriction of Chemicals): We recommend wearing protective gloves at all times in
order to reduce risk when working.
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8 | Safety | MS15034/00E 2018-08

1.4 Initial start-up and operation – Safety regulations
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 safeguards are in place.
• All components must be properly grounded. Ground separately by means of a grounding stake as neces-
sary.
• No persons wearing pacemakers or any other technical body aids are present.
• The service room is adequately ventilated.
• In the first few hours of operation, the product emits gases as a result of smoldering e.g. lacquers or oil.
These gases may be hazardous to health. Always wear respiratory protection in the operating room 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/reduction agent line,
supply/return.
Immediately after putting the product into operation, make sure that all control and display instruments as
well as the monitoring, 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.
Take the following steps if any system malfunctions are detected or signaled by the system:
• Inform supervisor(s) in charge.
• Analyze the message.
• Respond by taking any necessary emergency action, e.g. emergency stop.
TIM-ID: 0000040533 - 020
After a safety shutdown, the engine must only be started after the cause of the shutdown has been eliminat-
ed.
Contact Service if the root cause of the malfunction cannot be clearly identified.
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.
MS15034/00E 2018-08 | Safety | 9

Do not inhale the exhaust gases of the product.
The following requirements must be fulfilled before the product is started:
• Wear ear protectors.
• Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binding agent.
Operation of electrical 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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10 | Safety | MS15034/00E 2018-08

1.5 Assembly, maintenance, and repair work – Safety regulations
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 from oil vapors, fluids and lubricants,
risk of burning).
Relieve pressure in fluid and lubricant systems and compressed-air lines which are to be opened. Use suita-
ble containers of adequate capacity to catch fluids and lubricants.
Release residual pressure before removing or replacing a component in the supply line. To depressurize pres-
surized lines, shut off the lines first, then release the residual pressure.
Work must only be carried out on lines when they are free of fluids and lubricants.
When changing the oil or working on the fuel system, ensure that the service room is adequately ventilated.
Never carry out assembly, maintenance, or repair work with the product in operation, unless:
• It is expressly permitted to do so following a written procedure.
Lock-out the product to preclude undesired starting, e.g.
• Start interlock
• Key switch
• Close supply line for hydraulic starting.
Attach “Do not operate” sign in the operating area or to control equipment.
Disconnect the battery cables or actuate the battery isolating switch, if fitted. Lock circuit breakers.
Before starting work on CaPoS, if used:
• Switch off the charging system (DC/DC converter).
• Discharge the UltraCap modules using the appropriate discharger.
• Short-circuit the UltraCap modules with a suitable wire jumper.
Close the main valve on the compressed-air system and vent the compressed-air line when air starters are
fitted.
Before working on the exhaust gas aftertreatment system, close the shutoff valve on the reducing agent
tank. Note that the reducing agent pumps continue to run for a certain period when the engine is stopped.
Disconnect the control equipment from the product.
Use the recommended special tools or suitable equivalents when instructed to do so.
Safety regulations when performing assembly, maintenance, and repair work

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

TIM-ID: 0000040535 - 021
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 prevent
components/tools from falling down.
Assume a safe standing position when performing assembly work.
Never use the product as a climbing aid.
MS15034/00E 2018-08 | Safety | 11

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.
Completely wipe up escaped fluids and lubricants due to the risk of slipping.
Take special care when removing ventilation or plug screws from the product.
Ensure that O-rings are not installed in a slanted/twisted condition.
Carry out appropriate cleaning procedures to clean and inspect components requiring special cleanness
(e.g. components carrying oil, fuel, or air).
Note cooling time for components which are heated for installation or removal (risk of burning).
Ensure that all mounts and dampers are installed correctly.
Remove any accumulation of condensate after assembling chilled components. Coat the components with a
suitable corrosion inhibitor as necessary.
Lines
Ensure that lines for all fluids and lubricants and their connections are clean.
Always seal connections with caps or covers if a line is removed or opened.
Fit new seals when re-installing lines.
Never bend lines and avoid damaging lines, particularly the fuel lines.
Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent contact
with other components. Do not place fuel or oil lines near hot components.
Miscellaneous
Sufficient ventilation must be guaranteed during the work.
Wear a breathing mask offering protection against soot, dust, and mineral fibers (filter class P3) when work-
ing on exhaust components. Clean the work area with a dust extraction machine of class H. Wear 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

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Before barring the engine, make sure no one is in the danger zone of the engine.
Check that all access ports/apertures which have been opened to facilitate working are closed again.
Check that all safeguards have been installed and that all tools and loose parts have been removed (especial-
ly the barring tool).
Ensure that no unattached parts have been left in/on the product (e.g. including rags and cable straps).
Ensure that the grounding system is properly connected.
12 | Safety | MS15034/00E 2018-08

Welding work
Welding operations on the product or mounted units are not permitted. Cover the product when welding in
its vicinity.
Before starting welding work:
• Switch off the power supply master switch.
• Disconnect the battery cables or actuate the battery isolating switch.
• Separate the electrical ground of electronic equipment from the ground of the unit.
No other assembly, maintenance, or repair work must be carried out in the vicinity of the product while weld-
ing is in progress. There is a risk of explosion or fire due to oil vapors or highly flammable fluids and lubri-
cants.
Do not use product as ground terminal.
Never position the welding power supply cable adjacent to, or crossing wiring harnesses of the product. 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 jig, the pumps and the pipework at the relevant designated points.
• For hydraulic installation, screw on the jig with the piston retracted.
• For hydraulic removal, screw on the jig with the piston extended.
For a hydraulic installation/removal jig with central expansion pressure supply, screw spindle into shaft end
until correct sealing is established.
During hydraulic installation and removal of components, 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.
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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.
De-energize the relevant areas prior to working on assemblies.
ESD (Electrostatic Discharge): Work on components which could be damaged by electrostatic discharge
must always be carried out with appropriate equipment. Appropriate equipment is e.g. electrically conductive
work surfaces or antistatic wristbands.
MS15034/00E 2018-08 | Safety | 13

Do not damage wiring during removal work. When reconnecting, ensure that cabling cannot be damaged dur-
ing operation by:
• Contact with sharp edges
• Chafing on components
• Contact with hot surfaces.
Do not secure cables on lines carrying fluids.
Do not use cable ties to secure lines.
Always use connector pliers to tighten union nuts on connectors.
Subject the device as well as the product to functional testing on completion of all repair work. The emergen-
cy stop function must be tested in particular. The functional check of the emergency stop, during which the
voltage supply of the ECU is switched off, must only be carried out when the product is cold.
Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. 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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14 | Safety | MS15034/00E 2018-08

1.6 Fire and environmental protection, fluids and lubricants
Fire prevention and fire
Fire, naked light and smoking are prohibited.
In case of a fire, stop the fuel supply if this is possible without endangering personnel.
The product has hot surfaces that can ignite combustible gases and other substances in the immediate area.
The operating company must install and operate the product a safe distance away from danger sources and
observe any relevant safety regulations or recommendations. Products that comply with the SOLAS Conven-
tion do not constitute such as danger.
After working with combustible fluids and lubricants (e.g. cleaning agents), ensure the area is well ventilated.
The resultant steam/air mixture must be sufficiently diluted to prevent a potentially explosive atmosphere.
Eliminate leaks of fluids and lubricants immediately. Fluids and lubricants on hot components can 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 combustible materials near the product.
Incorrect refueling of the reducing agent system with fuel can result in fire.
Before welding, clean the area to be welded with a nonflammable fluid. Do not carry out welding work 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 extinguishers) are always available and that staff are familiar
with their correct handling.
A fire can result in the creation of toxic substances. Always wear protective gloves when handling compo-
nents and wear additional personal protective equipment is necessary.
Noise
Wear ear protectors in workplaces with a sound pressure level in excess of 85 dB (A).
Noise can lead to an increased risk of accidents if acoustic signals, warning shouts or sounds indicating dan-
ger are compromised.
Environmental protection and 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.
Fluids and lubricants/auxiliary materials (process materials)

Process materials can also be or contain hazardous or toxic substances. When using process materials and
other chemical substances, observe the associated safety data sheet. The safety data sheet may be obtained
from the relevant manufacturer or from MTU.
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Only process materials approved by the manufacturer in accordance with the Fluids and Lubricants Specifi-
cations must be used. The most recent respective version must be requested from the manufacturer.
Contamination of process materials with reducing agent (e.g. AdBlue®, DEF): Store process materials in sep-
arate containers and their own drip trays. Even extremely small amounts of reducing agent contamination
can result in malfunctions in sensors and other components.
Used oil contains combustion residues that are harmful to health.
When handling used oil, protective gloves must be used.
Wash relevant areas after contact with used oil.
MS15034/00E 2018-08 | Safety | 15

Registration, evaluation, approval and restriction of chemicals (REACH
ordinance)
Particularly hazardous substances used with our products are named in a list:
www.mtu-online.com/mtu/technische-info → SVHC as per REACH in MTU products
Compressed air
• Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII and B) out of con-
tainers, risks causing an explosion.
• Wear goggles when blowing dirt off workpieces or blowing away chips.
• Blowing compressed air into thin-walled containers (e.g. containers made of sheet metal, plastic or glass)
for drying purposes or to check for leaks risks bursting them.
• Pay special attention to the pressure in the compressed air system or pressure vessel.
• Assemblies or products which are to be connected must be designed to withstand this pressure. Install
pressure-reducing or safety valves set to the admissible pressure if this is not the case.
• Hose couplings and connections must be securely attached.
• Provide the snout of the air nozzle with a protective disk (e.g. rubber disk).
• Release residual pressure before removing a compressed air device from the supply line. To depressurize
compressed-air lines, shut off the lines first, then release the residual pressure.
• Carry out a leak test in the specified manner.
Painting
• Observe the relevant safety data sheet for all materials.
• When carrying out painting work outside the spray stands provided with fume extraction systems, ensure
that the area is well ventilated. Make sure that neighboring work areas are not adversely affected.
• Avoid open flames in the surrounding area.
• No smoking.
• Observe fire-prevention regulations.
• Always wear a mask providing protection against paint and solvent vapors.
Liquid nitrogen
• Work with liquid nitrogen may be carried out only by qualified personnel.
• Store liquid nitrogen only in small quantities and always in specified containers without fixed covers.
• Avoid body contact (eyes, hands).
• Wear protective clothing, protective gloves, closed shoes and safety goggles.
• Make sure that the working area is well ventilated.
• Avoid knocking or jolting the containers, valves and fittings or workpieces in any way.
Acids/alkalines/reducing agents (e.g. AdBlue®, DEF)

• When working with acids and alkaline solutions, wear goggles or face mask, gloves and protective cloth-
ing.
• Do not inhale vapors.
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• If reducing agent is swallowed, rinse out mouth and drink plenty of water.
• Remove any wet clothing immediately.
• After skin contact, wash affected body areas with plenty of water.
• Rinse eyes immediately with eyedrops or clean mains water. Consult a doctor as soon as possible.
Contamination of reducing agent with other process materials: Store reducing agent in separate contain-
ers and use separate drip trays. Even extremely slight contamination can lead to malfunctions in the ex-
haust aftertreatment system.
Mistakenly filling the tank of the reducing agent system with fuel can cause leakage at the seals and in
the hoses.
16 | Safety | MS15034/00E 2018-08

1.7 Standards for warning notices in the text and highlighted
information
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 warning notices must be issued to all personnel involved in oper-
ation, maintenance, repair, assembly, installation, or transportation.
2. The highest level warning notice is used if several hazards apply at the same time. Warnings related to per-
sonal injury shall be considered to include a warning of potential damage.
Highlighted information
Important
This field contains product information which is important or useful for the user.
This information must not refer to hazards related to personal injury or material damage.
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MS15034/00E 2018-08 | Safety | 17

2 Transport
2.1 Transport
Transport
Attach the engine at the lifting eyes provided only.

The lifting eyes are designed for engine transport only, not for the transport of propulsion units (engine and
gearbox).
Use only the transport and lifting gear approved by MTU.
The engine must only be transported in installation position, max. permissible diagonal pull 10°.
Take note of the engine center of gravity.
In the case of special packaging with aluminum foil, suspend the engine on the lifting eyes of the transport
pallet or transport with equipment for heavy loads (forklift truck).
Prior to transporting the engine, it is imperative to install transportation locking devices for crankshaft and
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engine mounts.
Secure the engine against tilting during transportation. The engine must be especially secured against slip-
ping or tilting when going up or down inclines and ramps.
Setting the engine down after transport

Place the engine only on an even, firm surface.
Ensure appropriate consistency and load-bearing capacity of the ground or support surface.
Never place an engine on the oil pan, unless expressively authorized by MTU on a case-to-case basis to do
so.
18 | Transport | MS15034/00E 2018-08

2.2 Lifting requirements
DANGER
Suspended load.
Danger to life!
• Use suitable equipment and lifting devices.
• Never stand beneath a suspended load and keep a safe distance.
• Wear personal protective equipment (e.g. protective helmet, safety shoes).
Lifting requirements for installed heat exchanger
1 Maximum permissible diag- 2 Center of gravity

onal pull 10° (*)
(*) Max. permissible diagonal pull must be observed:
• Max. permissible diagonal pull in longitudinal direction is 10 degrees; simultaneous diagonal pull in trans-
verse direction is impermissible.
• Max. permissible diagonal pull in transverse direction is 10 degrees; simultaneous diagonal pull in longitu-
dinal direction is impermissible.
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MS15034/00E 2018-08 | Transport | 19

Lifting requirements for remote heat exchanger
1 Maximum permissible diag- 2 Center of gravity

onal pull 10° (*)
(*) Max. permissible diagonal pull must be observed:
• Max. permissible diagonal pull in longitudinal direction is 10 degrees; simultaneous diagonal pull in trans-
verse direction is impermissible.
• Max. permissible diagonal pull in transverse direction is 10 degrees; simultaneous diagonal pull in longitu-
dinal direction is impermissible.
Take note of the engine center of gravity

Refer to the installation/arrangement drawings for details of the center of gravity of the system or engine. TIM-ID: 0000067782 - 002
20 | Transport | MS15034/00E 2018-08

3 General Information
3.1 Engine layout
Overview with remote heat exchanger, free end
1 Centrifugal oil filter 5 Fuel filter 9 Bilge pump (option)

2 Dry-type air filter 6 Oil filter 10 Raw water pump (option for
3 Exhaust manifold 7 Battery-charging generator engines with remote heat
4 Cylinder head (option) exchanger)
8 HP fuel pump 11 Engine management and
monitoring
KGS Free end
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MS15034/00E 2018-08 | General Information | 21

Overview with remote heat exchanger, driving end
1 Exhaust outlet 6 Engine mounting 11 Compressor housing

2 Recirculation line 7 Oil filler neck 12 Charge-air cooler
3 Crankcase breather coolant 8 Oil pan 13 Exhaust turbocharger carri-
expansion tank 9 Crankcase er housing
4 Oil cooler 10 Charge-air line 14 Air pipe to charge-air cooler
5 Coolant pump KS Driving end
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22 | General Information | MS15034/00E 2018-08

Overview with engine-mounted heat exchanger, free end
1 Raw-water outlet 6 Cylinder head 11 Raw water pump

2 Coolant expansion tank 7 Fuel filter 12 Heat exchanger
3 Centrifugal oil filter 8 Oil filter 13 Engine management and
4 Dry-type air filter 9 Battery-charging generator monitoring
5 Exhaust manifold (option) KGS Free end
10 HP fuel pump
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Overview with engine-mounted heat exchanger, driving end
1 Exhaust outlet 6 Oil filler neck 11 Charge-air cooler

2 Crankcase breather 7 Oil pan 12 Air pipe to charge-air cooler
3 Oil cooler 8 Crankcase 13 Exhaust turbocharger carri-
4 Coolant pump 9 Charge-air line er housing
5 Engine mounting 10 Compressor housing KS Driving end
Engine model designation

Key to engine model designation 8V 4000 Mxyz
8 Number of cylinders
V Cylinder arrangement: V-engine
4000 Series
M Application (M= Marine)
x Application load profile (0, 1, 2, 3...9)
y Design status (0, 1, 2, 3...9)
z R (reduced power/speed)
L (enhanced power/speed)
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S (60 Hz)
F (50 Hz)

3.2 Product description
Engine description
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).
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 offers
• low surface temperature,
• reduced amount of heat to be dissipated by the coolant,
• absolute gas-tightness.
Turbocharging system
Sequential turbocharging with internal, engine-coolant-controlled charge air cooling. The left-hand exhaust
turbocharger is cut-in and cut-out with electronically controlled, hydraulically actuated flaps.
Cooling system
Split-circuit engine cooling system with remote or engine-mounted heat exchanger.
Heating of the charge-air in idle and low-load operation prevents white smoke formation.
Seawater only flows through engine coolant and fuel heat exchanger as well as the raw water pump (if appli-
cable)..
Service block
The service components are mounted on the auxiliary PTO end.
The arrangement permits easy access for maintenance.
Service components:
• Raw water pump (if fitted), coolant pump
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• Centrifugal lube oil filter

• Coolant expansion tank (only on engines with engine-mounted heat exchanger)
• Coolant filter
Intermittent oil priming for on-board power generating engines (M23-M43)

The engines are equipped with intermittent oil priming as standard.
Oil priming is activated every 30 minutes. The oil priming process ends as soon as oil pressure in the main oil
gallery reaches 0.4 bar or after 180 seconds, at the latest.
If at least 0.2 bar has not been reached in 180 seconds, an alarm is issued.

To prevent engine damage through hydraulic impact due to excessive oiling of the combustion chamber, the
engine must be started at least once a month as a countermeasure.
Electronic system
Electronic control and monitoring system with integrated safety and test system, providing interfaces to Re-
mote Control System (RCS) and Monitoring and Control System (MCS).
Engine Interface Module (EIM)

The Engine Interface Module (EIM) is the central connection box on the engine. It covers the complete mini-
mum scope of a marine engine. It does not have any controls or components requiring maintenance.
Functions:
• Starter control (start repetition, tooth alignment, starter protection)
• Battery-charging generator monitoring
• Open bus interface to the plant (SAE J1939)
• Emergency stop function with wire break monitoring
• Redundant power supply
• Optional control of emergency-air shutoff flaps
• Key switch logic
• Interface to ECU and EMU
• MCS5 dialog interface
• Control of an MTU lube oil priming pump (power components in separate MTU PPC Box)
• Connection facility for an MTU Local Operating Station (LOS)
Serial RS422 interface for diagnosis

The engine interface comprises two parts. The first section is integrated in the engine cable harness via a
Tyco male connector X52, 62-pin. The second part refers to signals associated with higher currents. These
signals are guided out via M-threaded pins and are also integrated in the engine wiring harness.
Functions
• Power supply of ECU
• Power supply of EMU
• Plant signals (ECU7 connector X1)
• Bus interface (2x MCS5 CAN)
• CAN dialog output (1xMCS5 CAN)
• Emergency stop from EMU and ECU
• Electric starter
• Terminal 45 starter A/B (engaged)
• Pneumatic starter
• Starting-air pressure valve
• Starting-air pressure sensor
• Barring gear (Barring Gear 1 and 2)
• Battery-charging generator (with exciter control)
• Optional emergency air-shutoff flaps
• Activation of emergency-air shutoff flaps 1+2
• Feedback from emergency-air shutoff flaps 1+2
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Electronic engine governor (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)
Functions:
• Data processing logistics for analog and binary signals
• Interface for data transfer to CAN field bus for remote control and ship-side monitoring
Low-load operation
8V4000M53/M53R/M63 engines
1 Low-load operation 2 Cleaning cycle 3 ditto

MTU marine engine Series 4000M53R to …M93L may be operated in low-load operation. State-of-the-art de-
sign and equipment features, e.g. TE coolant circuit, sequential turbocharging, jacketed, coolant-cooled ex-
haust lines, Common Rail fuel injection and cylinder cutout allow engine operation at low load.
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 recom-
mended to carry out a cleaning cycle for at least 20 minutes after extended low-load operation periods. Dur-
ing the cleaning cycle, engine speed (power) must be increased step by step until all exhaust turbochargers
are running. The figure shows the basic speed/power run-up procedure for the cleaning cycle to be carried
out.
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8V4000M23/M33/M43 engines
A Engine power B Engine speed ETC Exhaust turbocharger

MTU marine genset engine Series 4000M23/M33/M43 may be operated in low-load operation. State-of-the-
art design and equipment features e.g. TE coolant circuit, jacketed, coolant-cooled exhaust lines, Common
Rail fuel injection and cylinder cutout allow engine operation at low load.
Low-load operation (engine power up to approx. 20% of rated power) takes place in single-ETC mode (with
only one exhaust turbocharger running). To ensure the functionality of the control mechanism and of the ex-
haust flap of the turbocharger which does not run in low-load operation, it is recommended to operate the
engine with both exhaust turbochargers running after 100 operating hours in low-load operation, at the lat-
est.
SOLAS – Fire protection specifications

Fuel system, fuel lines with fuel pressure >1.8 bar
All lines with SOLAS-compliant covers for pipe joints, according to MTU standard MTN5233, are shown.
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1 Fuel line after LP pump
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1 Fuel line to fuel filter head

retainer

1 Fuel line from fuel filter
head
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1 Fuel line on HP pump

1 Fuel line on fuel filter head
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1 Fuel line on fuel filter head
Lube oil system, oil lines with oil pressure >1.8 bar
All lines with SOLAS-compliant covers for pipe joints, according to MTU standard MTN5233, are shown.

1 Oil supply to actuating cylinder and air
flap - Turbocharger A1
1 Actuating cylinder of exhaust flap -

Turbocharger A1
2 Oil line to actuating cylinder of ex-
haust flap - Turbocharger A1
3 4/2-way valve
4 From distributor
5 Oil return from 4/2-way directional
control valve
1 Oil return from 4/2-way directional

control valve
2 Oil supply for 4/2-way directional con-
trol valve and exhaust turbocharger
3 Oil from main oil gallery
4 Oil return to crankcase
5 Air recirculation valve
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Item Type of shielding Comments
1 Shields (A4) Exhaust turbocharger oil supply, A
side
2 Shields (A5) (2 x) Exhaust turbocharger oil supply, A
side
1 Oil supply for exhaust turbocharger

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Item Type of shielding Comments
1 Shields (A6) Oil supply to HP pump
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1 Oil supply line of HP pump
on equipment carrier
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1 Oil supply on equipment

carrier

1 Cover on oil filter cartridge
Special connections
The following types of connections are spray-proof in case of leakage even without covers and have been
confirmed as being SOLAS-compliant by GL and DnV.
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Plug-in pipe connection
The sleeve (4) covers the joint to prevent lateral spray.
Only leak-off along the line is possible, the pressure is decreased significantly if an O-ring (3) defect occurs.
The union is confirmed as being SOLAS-compliant by DnV and GL.
Plugs and sensors

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

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

2 HP line 9 Union nut 16 Thrust ring
3 O-ring 10 Union nut 17 Outer high-pressure line
4 Union nut 11 Connecting piece pipe
5 Recess for O-ring 12 Snap ring 18 Internal pipe of HP line
6 Thrust ring 13 Thrust ring 19 Ball-type seal area
7 Leakage overflow bore 14 Compensating disks 20 Leak fuel connection
The HP fuel line is sealed by the thrust ring (8).
In case of leakage around the thrust ring (8) or the HP line (5) fuel escapes into the leakage chamber.
The leaking fuel is drained off without pressure via the leakage overflow-bore (7). The leakage chamber is
sealed toward the outside by the O-rings (3).
This prevents leakage egress.
The union is confirmed as being SOLAS-compliant by DnV and GL.
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3.3 Tightening specifications for screws, nuts and bolts
Tightening torques for setscrew and connections as per MTN 5008 standard
This standard applies to setscrews not subject to dynamic loads and the associated nuts according to:
• MMN 384
• ISO 4762 (DIN 912)
• ISO 4014 (DIN 931-1)
• ISO 4017 (DIN 933)
• DIN EN ISO 8765 (EN 28765; DIN 960)
• DIN EN ISO 8676 (EN 28676; DIN 961)
• DIN 6912
This standard applies to studs not subject to dynamic loads and the associated nuts according to:
• DIN 833
• DIN 835
• DIN EN ISO 5395 (DIN 836)
• DIN 938
• DIN 939
This standard applies to screws with hexalobular heads according to:
• DIN 34800
• DIN 34801
The standard does not apply to heat-resistant screws in the hot component zone.
Tightening torques MA are specified for screws of strength class 8.8 (surface condition bare, phosphatized or
galvanized) and 10.9 (surface condition bare or phosphatized).
The values in the table are based on a friction coefficient µtot = 0.125.
Threads and mating faces of screws and nuts must be coated with engine oil prior to assembly.
When hand-tightening (defined torque), an assembly tolerance of -5+15% of the figures in the table is permit-
ted.
When machine-tightening, the permissible assembly tolerance is ±15%.
Tightening torques for setscrews

Hand-tightening Machine-tightening
Thread
8.8 MA (Nm) 10.9 M A (Nm) 8.8 MA (Nm) 10.9 M A (Nm)
M6 9 12 8 11
M8 21 31 20 28
M8 x 1 23 32 21 30
M10 42 60 40 57
M10 x 1.25 45 63 42 60
M12 74 100 70 92
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M12 x 1.25 80 110 75 105

M12 x 1.5 76 105 72 100
M14 115 160 110 150
M14 x 1.5 125 180 120 170
M16 180 250 170 235
M16 x 1.5 190 270 180 255
M18 250 350 240 330
M18 x 1.5 280 400 270 380
M20 350 500 330 475

Hand-tightening Machine-tightening
Thread
8.8 MA (Nm) 10.9 M A (Nm) 8.8 MA (Nm) 10.9 M A (Nm)
M20 x 1.5 390 550 350 520
M22 480 680 450 650
M22 x 1.5 520 730 490 700
M24 600 850 570 810
M24 x 1.5 680 950 640 900
M24 x 2 660 900 620 850
M27 900 1250 850 1175
M27 x 2 960 1350 900 1275
M30 1200 1700 1100 1600
M30 x 2 1350 1900 1250 1800
MA = tightening torques
Tightening torques for studs

screwed into
Thread Steel M A Gray cast iron MA AI alloy MA
(Nm) (Nm) (Nm)
M6 9 6 6
M8 11 9 10
M10 17 13 13
M12 27 23 18
M14 37 33 33
M16 55 45 –
Tightening torques for setscrews and nuts made of stainless steel

The values in the table are based on a friction coefficient µtot = 0.12, lubricated with Molykote on the thread
and under the screw head.
Strength class
70 80
Basic size Material
MA MA
(Nm) (Nm)
M5 3.7 4.9 A2 / A4
M6 6.4 8.5 A2 / A4
M8 15.3 20.4 A2 / A4
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M10 31 41 A2 / A4
M12 52 70 A2 / A4
M16 126 167 A2 / A4
M20 254 326 A2 / A4

Tightening torque for self-locking hex nuts
Thread MA (Nm) Lubricants
M6 7.5 +1 –
M8 17 +2 –
M10 35 +4 –
M12 59 +6 –
M14 100 +10 –
M16 140 +14 –
M20 290 +29 –
Tightening torque for stress bolt connections as per MTN 5007 standard
This standard applies to stress pin bolts and stress bolts which are subjected to static and dynamic load of
strength class 10.9 as well as to the associated nuts.
Shaft and transition dimensions as per MMN 209 standard and material and machining as per MMN 389
standard (bright surface or phosphatized).
The values in the table are based on a friction coefficient µtot = 0.125.
Threads and mating faces of screws and nuts must be coated with engine oil prior to assembly.
An assembly tolerance of +10% of the figures in the table is permitted due to unavoidable deviations during
the tightening process.
The values in the tables are for manual tightening using a torque wrench.
Thread Not torsion-protected MA(Nm) Torsion-protected MA (Nm)

M6 9 12
M8 21 28
M8 x 1 24 30
M10 42 55
M10 x 1.25 46 60
M12 75 93
M12 x 1.5 78 99
M14 120 150
M14 x 1.5 135 160
M16 180 225
M16 x 1.5 200 245
M18 250 315
M18 x 1.5 300 360
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M20 350 450

M20 x 1.5 430 495
M22 500 620
M22 x 1.5 560 675
M24 640 790
M24 x 2 700 850
M27 900 1170
M27 x 2 1000 1230

Thread Not torsion-protected MA(Nm) Torsion-protected MA (Nm)
M30 1250 1575
*Protect screw shaft from torsion when tightening.
MA= tightening torques.
Tightening torques for plug screws as per MTN 5183-1 standard

This standard applies to plug screws to DIN 908, DIN 910 and DIN 7604 with threaded end to DIN 3852
Form A (sealed with sealing ring to DIN 7603-Cu).
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Tightening torques MA are given for screw plugs made of steel (St) with surface protected by a phosphate
coating and oiled or galvanized.
Threads and mating faces beneath heads must be coated with engine oil prior to assembly.
Tightening torques for plug screws to DIN 908, DIN 910 and DIN 7604A (with short threaded end).
screwed into
Thread Steel/gray cast iron MA AI alloy MA
(Nm) (Nm)
M10 x 1 15 15
M12 x 1.5 25 25
M14 x 1.5 35 30
M16 x 1.5 40 35
M18 x 1.5 50 40
M20 x 1.5 60 50
M22 x 1.5 70 70
M24 x 1.5 85 80
M26 x 1.5 100 100
M27 x 2 100 100
M30 x 1.5 110 110
M30 x 2 120 120
M33 x 2 160 160
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M36 x 1.5 190 180

M38 x 1.5 220 200
M42 x 1.5 260 240
M45 x 1.5 290 270
M48 x 1.5 310 300
M52 x 1.5 325 320
M56 x 2 380 360

screwed into
(Nm) (Nm)
M64 x 2 400 400
Tightening torque for plug screws DIN 7604C (with long screwed end)
screwed into
Thread Steel/gray cast iron M A AI alloy MA
(Nm) (Nm)
M8 x 1 10 10
M22 x 1.5 80 65
M26 x 1.5 105 90
M30 x 1.5 130 130
M38 x 1.5 140 120
M45 x 1.5 160 140
Tightening torque for banjo screws as per MTN 5183-2 standard

This standard applies to banjo screws to MMN 223 and N 15011 sealed with sealing ring to DIN 7603-Cu.
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The stated tightening torques MA apply to steel (St) banjo screws with a phosphatized surface and oiled or
galvanized and for copper-aluminum alloy.
Tightening torques for steel banjo screws

inserted in steel/gray cast iron/aluminum alloy
Thread MA
(Nm)
M8 x 1 10
M10 x 1 15
M12 x 1.5 20
M14 x 1.5 25
M16 x 1.5 25
M18 x 1.5 30
M22 x 1.5 60
M26 x 1.5 90
M30 x 1.5 130
M38 x 1.5 140
M45 x 1.5 160
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Tightening torques for copper-aluminum alloy banjo screws

inserted in steel/gray cast iron/aluminum alloy
Thread MA
(Nm)
M10 x 1 15
M16 x 1.5 30

Tightening torques for male connectors as per MTN 5183-3 standard
This standard applies to male unions to DIN 2353 Series L with threaded end to DIN 3852 Form A (sealed by
sealing ring to DIN 7603-Cu).
Tightening torques MA are given for male unions made of steel (St) with phosphatized surface coating and
oiled, or galvanized.
inserted in steel/gray cast iron MA
Thread
(Nm)
M10 x 1 15
M12 x 1.5 20
M14 x 1.5 35
M16 x 1.5 50
M18 x 1.5 60
M22 x 1.5 70
M26 x 1.5 100
M32 x 2 160
M42 x 2 260
M48 x 2 320
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Tightening torques for union nuts as per DIN 3859-2
1 Union nut
2 Screw fixture
3 O-ring
4 Linear ball bearing
Union nut: On installing the ball-type union, after tightening the union nut firmly by hand (noticeable increase
in force), it should be tightened another 1/4 turn (90°) past this point.
Tightening torques for spigot unions with O-ring to ISO 6149-2
Thread Torque (Nm) +10%

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M8 x 1 10
M10 x 1 20
M12 x 1.5 35
M14 x 1.5 45
M16 x 1.5 55
M18 x 1.5 70
M20 x 1.5 1) 80
M22 x 1.5 100

M27 x 2 170
M33 x 2 310
M42 x 2 330
M48 x 2 420
M60 x 2 500
1)
Only for sealing off installation spaces for screw-in valves (see ISO 6149-47 and ISO 7789)
Tightening torques for screwed plugs with O-ring as per ISO 6149-3

M8 x 1 8
M10 x 1 15
M12 x 1.5 25
M14 x 1.5 35
M16 x 1.5 40
M18 x 1.5 45
M22 x 1.5 60
M27 x 2 100
M33 x 2 160
M42 x 2 210
M48 x 2 260
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M60 x 2 315

Tightening torques for plug screw joints as per MTN 5183-6
screwed into
(Nm) (Nm)
M10 x 1 20 10 +2
M12 x 1.5 35 14 +2
M14 x 1.5 45 15 +3
M16 x 1.5 55 18 +3
M18 x 1.5 70 23 +3
M22 x 1.5 100 33 +4
M27 x 2 170 57 +5
M33 x 2 310 103 +10
M42 x 2 330 110 +11
M48 x 2 420 140 +14
M60 x 2 – 200 +20
Assembly instructions and tightening torque for hose fittings with union nuts
These instructions do not apply to ORFS fittings. In contrast to the instructions for pipe unions, hose fittings
with sealing heads and the matching adapters must be fitted and connected as follows.
Hose fitting, metallic sealing with union nut: tighten union nut by hand then tighten a further max. 1/4 of a
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turn with a wrench.

Hose fitting with O-ring and union nut: tighten union nut by hand then tighten a further max. 1/2 of a turn
with a wrench.
Hoses must be properly aligned before tightening the union nuts.
Sealing head/sealing cone with metric union nut
Metric thread Pipe outer dia. Torque (Nm)
M12 x 1.5 6 20
M14 x 1.5 8 38

Sealing head/sealing cone with metric union nut
Metric thread Pipe outer dia. Torque (Nm)
M16 x 1.5 8 45
10
M18 x 1.5 10 51
12
M20 x 1.5 12 58
M22 x 1.5 14 74
15
M24 x 1.5 16 74
M26 x 1.5 18 105
M30 x 2 20 135
22
M36 x 2 25 166
28
M42 x 2 30 240
M45 x 2 35 290
M52 x 2 38 330
42
Sealing head with BSP union nut

BSPP thread Torque (Nm)
G1/4 20
G3/8 34
G1/2 60
G5/8 69
G3/4 115
G1 140
G1.1/4 210
G1.1/2 290
G2 400
SAE sealing cone with union nut JIC 37°

UNF thread Size Torque (Nm)
7/16–20 –4 15
1/2–20 –5 20
9/16–18 –6 30
3/4–16 –8 50
TIM-ID: 0000002333 - 018
7/8–14 –10 69
1.1/16–12 –12 98
1.3/16–12 –14 118
1.5/16–12 –16 140
1.5/8–12 –20 210
1.7/8–12 –24 290
2.1/2–12 –32 450

ORFS – flat sealing with union nut
UNF thread Size Torque (Nm)
9/16–18 –4 14 +2
11/16–16 –6 24 +3
13/16–16 –8 43 +4
1–14 –10 60 +8
1.3/16–12 –12 90 +5
1.3/16–12 –14 90 +5
1.7/16–12 –16 125 +10
1.11/16–12 –20 170 +20
2–12 –24 200 +25
2–1/2–20 –32 460 +30
TIM-ID: 0000002333 - 018

3.4 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 - 014

3.5 Sensors and actuators – Overview
Remote heat exchanger
Left engine side 8V4000Mx3
1 B44.2 (N-Turbocharger B) 4 B34.2 (P-Fuel before filter) 7 F46 (H fuel leakage)

2 B4.21 (T-Exhaust, A side) 5 B34.3 (P-Fuel before filter)
3 B10 (P-Charge air) 6 B34.1 (P-Fuel after filter)
TIM-ID: 0000012942 - 004

Engine free end (KGS) 8V4000Mx3
1 B33 (T-Fuel, rail) 5 B5.3 (P-Lube oil before fil- 9 B6.2 (T-Coolant)
2 B7 (T-Lube oil) ter) 10 B6 (T-Coolant)
3 B5.2 (P-Lube oil after filter), 6 B48 (P-Fuel in common rail) 11 Connector XD1 – Dialog
only with switchable oil fil- 7 B1 (N-Camshaft) unit
ter 8 B54 (P-Oil refill pump)
4 B5.1 (P-Lube oil after filter)
TIM-ID: 0000012942 - 004

Right engine side 8V4000Mx3
1 B16 (P-Coolant) 3 B4.22 (T-Exhaust, B bank)

2 B9 (T-Charge Air) 4 B44.1 (N-Turbocharger A)
TIM-ID: 0000012942 - 004

Driving end (KS) 8V4000Mx3
1 S37.1 (S-Safety switch) 3 B13 (N-Crankshaft)

2 B13.2 (N-Crankshaft) 4 S37.2 (safety switch)
TIM-ID: 0000012942 - 004

Plan view 8V4000Mx3
1 Y27 (turbocharger control 3 B50 (P-Crankcase) 5 B49 (T-Charge-air, air recir-

valve) 4 B4.A1-B4B4 (T-Individual ex- culation valve)
2 Y26 (A-Air recirculation haust A1-A4, B1-B4) 6 B3 (T-Intake air)
valve)
TIM-ID: 0000012942 - 004

Engine-mounted heat exchanger
Left engine side 8V4000Mx3
1 B44.2 (N-Turbocharger B) 4 B34.2 (P-Fuel before filter) 7 F46 (H-Fuel leakage)

2 B4.21 (T-Exhaust, A side) 5 B34.3 (P-Fuel before filter) 8 B33 (T-Fuel in common rail)
3 B10 (P-Charge air) 6 B34.1 (P-Fuel after filter)
TIM-ID: 0000012942 - 004

Engine free end (KGS) 8V4000Mx3
1 B48 (P-Fuel in common rail) 5 B5.3 (P-Lube oil before of 9 B6 (T-Coolant)

2 B7 (T-Lube oil) filter) 10 Connector XD1 – Dialog
3 B5.2 (P-Lube oil after filter), 6 B1 (N-Camshaft) unit
only with switchable oil fil- 7 B54 (P-Oil refill pump)
ter 8 B6.2 (T-Coolant)
4 B5.1 (P-Lube oil after filter)
TIM-ID: 0000012942 - 004

Right engine side 8V4000Mx3
1 F33 (H-Coolant) 3 B21 (P-Raw water) 5 B4.22 (T-Exhaust, B bank)

2 B16 (P-Coolant) 4 B9 (T-Charge Air) 6 B44.1 (N-Turbocharger A)
TIM-ID: 0000012942 - 004

Driving end (KS) 8V4000Mx3
1 S37.1 (S-Safety switch) 3 B13 (N-Crankshaft)

2 B13.2 (N-Crankshaft) 4 S37.2 (S-Safety switch)
TIM-ID: 0000012942 - 004

Plan view 8V4000Mx3
1 Y27 (turbocharger control 3 B4.A1-B4B4 (T-Individual ex- 5 B49 (T-Charge-air, air recir-
valve) haust A1-A4, B1-B4) culation valve)
2 B50 (P-Crankcase) 4 Y26 (A-Air recirculation 6 B3 (T-Intake air)
valve)
TIM-ID: 0000012942 - 004

4 Technical Data
4.1 ENGINE DATA 8V4000M53R (provisional)
Explanation:
DL Ref. value: Continuous power
BL Ref. value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power settings).
N Value not yet defined
- Not applicable
X Applicable
Engine model Engine-mounted heat Remote heat ex-

exchanger changer
Application group 1A 1A 1A 1A
Intake air temperature °C 25 45 25 45
Charge-air coolant temperature °C - - - -
Raw water inlet temperature °C 25 32 25 32
Barometric pressure mbar 1000 1000 1000 1000
Site altitude above sea level m 100 100 100 100
POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)
Number of cylinders Engine-mounted heat Remote heat ex-
exchanger changer
Rated engine speed A rpm 1600 1600 1600 1600
Fuel stop power ISO 3046 A kW 746 746 746 746
GENERAL CONDITIONS (for maximum power)

exchanger changer
Intake depression (new filter) A mbar 15 15 15 15
Intake depression, max. L mbar 30 30 30 30
MODEL RELATED DATA (basic design)

TIM-ID: 0000018973 - 002

exchanger changer
Cylinder arrangement: V-angle Degrees 90 90 90 90
(°)
Bore mm 170 170 170 170
Stroke mm 210 210 210 210
Cylinder displacement Liters 4.77 4.77 4.77 4.77
Total displacement Liters 38.1 38.1 38.1 38.1
MS15034/00E 2018-08 | Technical Data | 63

exchanger changer
Inlet valves per cylinder 2 2 2 2
Number of exhaust valves per cylinder 2 2 2 2
RAW WATER CIRCUIT (open circuit)

exchanger changer
Raw water pump: Inlet pressure, min. L bar -0.4 -0.4 -- --
Raw water pump: Inlet pressure, max. L bar 1.0 1.0 -- --
Pressure loss in engine-external raw water L bar 1.0 1.0 -- --
system, max.
LUBE-OIL SYSTEM
exchanger changer
Lube oil operating temperature before en- R °C 80** 81** 80** 81**
gine, from
Lube-oil operating temperature before en- R °C 88** 89** 88** 89**
gine, to
Lube-oil operating pressure before engine, R bar 6.3 6.3 6.3 6.3
from
Lube oil operating pressure before engine, R bar 5.3 5.3 5.3 5.3
to
Lube oil operating pressure (low idle) R bar 2.2 2.2 2.2 2.2
(meas. point: before engine)
FUEL SYSTEM
exchanger changer
Fuel pressure at engine inlet connection, L bar -0.1 -0.1 -0.1 -0.1
min. (when engine is starting)
Fuel pressure at supply connection to en- L bar -0.3 -0.3 -0.3 -0.3
gine, min. (when engine is running),
Fuel pressure at supply connection to en- L bar 1.5 1.5 1.5 1.5
gine (when engine is starting), max.
Fuel supply flow, max. A Liters/mi
n
TIM-ID: 0000018973 - 002
GENERAL OPERATING DATA

exchanger changer
Firing speed, from R rpm 80 80 80 80
Firing speed, to R rpm 120 120 120 120
64 | Technical Data | MS15034/00E 2018-08

STARTING SYSTEM (electric)
exchanger changer
Rated starter voltage (standard design) R V= 24 24 24 24
STARTING (with compressed air/hydraulic starter)

exchanger changer
Starting-air pressure before starter motor, R bar 8 8 8 8
min.
Starting-air pressure before starter, max. R bar 9 9 9 9
INCLINATIONS, STANDARD OIL SYSTEM (reference: waterline)

exchanger changer
Longitudinal inclination, continuous max. L Degrees 15 15 15 15
driving end down (Option: max. operating (°)
inclinations)
Longitudinal inclination, temporary max. L Degrees 22.5 22.5 22.5 22.5
driving end down (Option: max. operating (°)
inclinations)
driving end up (Option: max. operating in- (°)
clinations)
Longitudinal inclination, temporary max., L Degrees
driving end up (Option: max. operating in- (°)
clinations)
Transverse inclination, continuous max. L Degrees 22.5 22.5 22.5 22.5
(option: max. operating inclinations) (°)
Transverse inclination, temporary max. L Degrees
CAPACITIES
exchanger changer
Engine coolant, engine side (with cooling R Liters 230 230 -- --
system)
Engine oil, total, for initial filling (standard R Liters 190 190 190 190
oil system) (option: max. operating incli-
TIM-ID: 0000018973 - 002
nations)
Oil change quantity, max. (standard oil R Liters
system) (Option: max. operating inclina-
tions)
Oil pan capacity at dipstick mark “min.” L Liters 120* 120* 120* 120*
(standard oil system) (Option: max. oper-
ating inclinations)
Oil pan capacity at dipstick mark “max.” L Liters 160* 160* 160* 160*
(standard oil system) (Option: max. oper-
ating inclinations)

WEIGHTS / MAIN DIMENSIONS
exchanger changer
Engine dry weight (with attached standard R kg 5875 5875 5505* 5505*
accessories, without coupling)
ACOUSTICS
exchanger changer
Exhaust noise, unsilenced - BL (free-field R dB(A) 108* 108* 108* 108*
sound pressure level Lp, 1m distance, ISO
6798, +3dB(A) tolerance)
Engine surface noise with attenuated in- R dB(A) 103* 103* 103* 103*
take noise (filter) - BL (free-field sound
power level Lp, 1 m distance, ISO 6798,
+2dB(A) tolerance)
TIM-ID: 0000018973 - 002

4.2 Product data 8V4000M53
Legend
DL Reference value: Continuous power. Continuous driving performance under standard conditions
BL Reference value: Fuel stop power. Maximum engine power. With some applications, not drivable on
continuous basis (adjustment reserve)
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 Not yet defined value. Value not yet named/will not be named
- Not applicable
X Applicable
> Actual value must be greater than the specified value.
< Actual value must be smaller than the specified value.
* Insufficiently guaranteed value (tolerance +/- 10%).
** Insufficiently guaranteed value (tolerance +/- 5%).
ID Product type Application Engine speed Listed output

1 8V4000M53 Marine / ship main 1800 rpm 920 kW Ref. 25 °C/25 °C;
propulsion 1234 bhp heat exchanger instal-
1A continuous power, led on the engine
unlimited IMO Tier II (Marpol
convention)
EU Nonroad St IIIA
(97/68/EC)
IMO Tier I Marpol
Comp
IMO Tier II Marpol
Comp
EPA Marine T2 Comp
(40CFR94)
propulsion 1234 bhp Heat exchanger sepa-
1A continuous power, rate from engine
convention)
EU Nonroad St IIIA
(97/68/EC)
IMO Tier I Marpol
Comp
IMO Tier II Marpol
Comp
EPA Marine T2 Comp
(40CFR94)
TIM-ID: 0000026879 - 002

3 8V4000M53 Marine / ship main 1800 rpm 920 kW Ref. 45 °C/32; heat
propulsion 1234 bhp exchanger installed on
1A continuous power, engine
convention)
EU Nonroad St IIIA
(97/68/EC)
IMO Tier I Marpol
Comp
IMO Tier II Marpol
Comp
EPA Marine T2 Comp
(40CFR94)
convention)
EU Nonroad St IIIA
(97/68/EC)
IMO Tier I Marpol
Comp
IMO Tier II Marpol
Comp
EPA Marine T2 Comp
(40CFR94)
Reference conditions
ID 1 2 3 4
Performance data
ID 1 2 3 4
General conditions (for max. power)

TIM-ID: 0000026879 - 002
ID 1 2 3 4
Exhaust overpressure A mbar 30 30 30 30
Exhaust overpressure, max. L mbar 85 85 85 85

ID 1 2 3 4
Fuel temperature at engine inlet connec- R °C 25 25 25 25
tion
Fuel temperature at engine supply con- L °C 55 55 55 55
nection, max.
Model related data (basic design)

ID 1 2 3 4
Cylinder arrangement: V angle Degrees 90 90 90 90
(°)
Bore mm 170 170 170 170
Stroke mm 210 210 210 210
Displacement of a cylinder Liters 4.77 4.77 4.77 4.77
Raw-water circuit (open circuit)

ID 1 2 3 4
Raw water pump: Inlet pressure, min. L bar -0.2 -0.2
Raw water pump: inlet pressure, max. L bar 1.0 1.0
Pressure loss in off-engine raw water sys- L bar 1.0 1.0
tem, max.
Lube oil system

ID 1 2 3 4
Lube oil operating pressure before en- R bar 6.5 6.5 6.5 6.5
gine, from
gine, to
Fuel system
ID 1 2 3 4
min. (when engine is running)
Fuel pressure at engine inlet connection, L bar 1.5 1.5 1.5 1.5
TIM-ID: 0000026879 - 002
max. (when engine is starting)

Fuel supply flow, max. normal operation R liters/min 5.5 7.5 5.5 7.5

ID 1 2 3 4

Starter (electric)
ID 1 2 3 4
Rated starter voltage (standard rating) R V= 24 24 24 24
Starter (with air/hydraulic starter motor)

ID 1 2 3 4
Starting-air pressure before starter mo- R bar 8 8 8 8
tor, min.
tor, max.
Inclinations, standard oil system (reference: waterline)

ID 1 2 3 4
driving end down (option: max. operating (°)
inclinations)
inclinations)
driving end up (option: max. operating in- (°)
clinations)
Longitudinal inclination, temporary max., L Degrees 17.5 17.5 17.5 17.5
clinations)
Transverse inclination, continuous max. L Degrees 15 15 15 15
Transverse inclination, temporary max. L Degrees 22.5 22.5 22.5 22.5
Capacities
ID 1 2 3 4
Engine coolant, engine side (with cooling R Liters 230 - 230 -
system)
Engine oil capacity, initial filling (standard R Liters 190 190 190 190
nations)
Oil pan capacity at dipstick mark “min.” L Liters 100 100 100 100
(standard oil system) (option: max. oper-
ating inclinations)
TIM-ID: 0000026879 - 002
Oil pan capacity at dipstick mark “max.” L Liters 130 130 130 130
ating inclinations)
Weights / main dimensions

ID 1 2 3 4
Engine dry weight (with standard acces- R kg 6030 5610 6030 5610
sories installed, w/o coupling)

Sound
ID 1 2 3 4
Exhaust noise, unsilenced - BL (free-field R dB(A) 107 107 107 107
sound pressure level Lp, 1m distance,
ISO 6798, +3dB(A) tolerance)
Engine surface noise with attenuated in- R dB(A) 104 104 104 104
+2dB(A) tolerance)
TIM-ID: 0000026879 - 002

4.3 Product data 8V4000M63
Legend
DL Reference value: Continuous power. Continuous driving performance under standard conditions
BL Reference value: Fuel stop power. Maximum engine power. With some applications, not drivable on
continuous basis (adjustment reserve)
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 Not yet defined value. Value not yet named/will not be named
- Not applicable
X Applicable
> Actual value must be greater than the specified value.
< Actual value must be smaller than the specified value.
* Insufficiently guaranteed value (tolerance +/- 10%).
** Insufficiently guaranteed value (tolerance +/- 5%).

convention)
EU Nonroad St IIIA
(97/68/EC)
IMO Tier I Marpol
Comp
IMO Tier II Marpol
Comp
EPA Marine T2 Comp
(40CFR94)
convention)
EU Nonroad St IIIA
(97/68/EC)
IMO Tier I Marpol
Comp
IMO Tier II Marpol
Comp
EPA Marine T2 Comp
(40CFR94)
TIM-ID: 0000018974 - 002

convention)
EU Nonroad St IIIA
(97/68/EC)
IMO Tier I Marpol
Comp
IMO Tier II Marpol
Comp
EPA Marine T2 Comp
(40CFR94)
convention)
EU Nonroad St IIIA
(97/68/EC)
IMO Tier I Marpol
Comp
IMO Tier II Marpol
Comp
EPA Marine T2 Comp
(40CFR94)
Reference conditions
ID 1 2 3 4
Performance data
ID 1 2 3 4
General conditions (for max. power)

TIM-ID: 0000018974 - 002
ID 1 2 3 4

Model related data (basic design)
ID 1 2 3 4
Cylinder arrangement: V angle Degrees 90 90 90 90
(°)
Bore mm 170 170 170 170
Stroke mm 210 210 210 210
Displacement of a cylinder Liters 4.77 4.77 4.77 4.77
Raw-water circuit (open circuit)

ID 1 2 3 4
Raw water pump: Inlet pressure, min. L bar -0.2 -0.2
Raw water pump: inlet pressure, max. L bar 1.0 1.0
Pressure loss in off-engine raw water sys- L bar 1.0 1.0
tem, max.
Lube oil system

ID 1 2 3 4
gine, from
gine, to
Fuel system
ID 1 2 3 4
min. (when engine is running)
Fuel pressure at engine inlet connection, L bar 1.5 1.5 1.5 1.5
max. (when engine is starting)
Fuel supply flow, max. normal operation R liters/min 5.8 7.8 5.8 7.8

ID 1 2 3 4
TIM-ID: 0000018974 - 002

Starter (electric)
ID 1 2 3 4
Rated starter voltage (standard rating) R V= 24 24 24 24

Starter (with air/hydraulic starter motor)
ID 1 2 3 4
tor, min.
tor, max.
Inclinations, standard oil system (reference: waterline)

ID 1 2 3 4
inclinations)
inclinations)
clinations)
Longitudinal inclination, temporary max., L Degrees 17.5 17.5 17.5 17.5
clinations)
Transverse inclination, continuous max. L Degrees 15 15 15 15
Transverse inclination, temporary max. L Degrees 22.5 22.5 22.5 22.5
Capacities
ID 1 2 3 4
Engine coolant, engine side (with cooling R Liters 230 230
system)
Engine oil capacity, initial filling (standard R Liters 190 190 190 190
nations)
Oil pan capacity at dipstick mark “min.” L Liters 100 100 100 100
ating inclinations)
Oil pan capacity at dipstick mark “max.” L Liters 130 130 130 130
ating inclinations)
TIM-ID: 0000018974 - 002
Weights / main dimensions

ID 1 2 3 4
Engine dry weight (with standard acces- R kg 6120 5710 6120 5710
sories installed, w/o coupling)

22. Sound
ID 1 2 3 4
Exhaust noise, unsilenced - BL (free-field R dB(A) 107 107 107 107
sound pressure level Lp, 1m distance,
ISO 6798, +3dB(A) tolerance)
Engine surface noise with attenuated in- R dB(A) 104 104 104 104
+2dB(A) tolerance)
TIM-ID: 0000018974 - 002

4.4 Firing order
8V A1-B4-A4-A2-B3-A3-B2-B1
12 V A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1
16 V A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B7
TIM-ID: 0000010713 - 002

4.5 Engine – Main dimensions
Main engine dimensions
Engines with remote heat exchanger

Engine model Length (A) Width (B) Height (C)
8V4000 M23S/23F/33S/33S/53/53R/63 approx. 2386 approx. 1613 approx. 1959
mm mm mm
Engines with engine-mounted heat exchanger
Engine model Length (A) Width (B) Height (C)

8V4000 M23S/23F/33S/33S/53/53R/63 approx. 2590 approx. 1613 approx. 2060
mm mm mm
TIM-ID: 0000018218 - 002

5 Operation
5.1 Controls
Automation system controls
Refer to automation system operating instructions
TIM-ID: 0000016959 - 003
MS15034/00E 2018-08 | Operation | 79

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

months)
Item Task
Engine Depreserve (→ Preservation and Represervation Specifications A001070/..).
Valve drive Lubricate valve gear every ≥ 6 months (→ Page 149).
Lube oil system Check engine oil level (→ Page 189);
Preheat engine oil if required.
Fuel prefilter Prime with fuel (→ Page 175)
Fuel prefilter, pressure Align adjustable pointer with position of pressure indicator (→ Page 170).
gauge
HP fuel pump Only for engines without oil priming pump:
Fill HP fuel pump with fresh engine oil (→ Page 155).
Raw water pump (if located Prime with water (approx. 3 to 4 liters).
above waterline (only appli-
cable to engines with en-
gine-mounted heat exchang-
er or with optional remote
heat exchanger))
Coolant circuit If engine is out of service for more than one year, change engine coolant
(→ Page 206).
Coolant circuit Check coolant level (→ Page 205).
Coolant circuit Preheat coolant with preheating unit.
Engine control system Refer to automation system operating instructions.
ECU Check plug connections (→ Page 236).
EMU Check plug connections (→ Page 237)
EIM Check plug connections (→ Page 238).
TIM-ID: 0000010092 - 006
80 | Operation | MS15034/00E 2018-08

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

Item Task
Lube oil system Check engine oil level (→ Page 189);
Preheat engine oil if required.
Coolant system Check coolant level (→ Page 205).
Coolant system Preheat coolant with preheating unit.
Fuel prefilter Drain (→ Page 171);
Check that suction-side pressure indicated at the fuel prefilter pressure
gauge is within the limit (→ Page 170).
Engine control system Refer to automation system operating instructions.
ECU Check plug connections (→ Page 236).
EIM Check plug connections (→ Page 238).
EMU Check plug connections (→ Page 237).
TIM-ID: 0000010655 - 004
MS15034/00E 2018-08 | Operation | 81

5.4 Re-starting the engine following an automatic safety
shutdown
NOTICE
Re-starting the engine following an automatic safety shutdown.
Risk of severe engine damage!
• Before starting the engine, make sure the root cause of the safety shutdown was eliminated.
• If the root cause cannot be identified or eliminated, contact Service.
Note: • If an engine has been shutdown by a fault (red alarm), the engine may only be re-started when the fault
has been identified and eliminated.
Procedure following an automatic safety shutdown

1. Eliminate fault.
2. If the root cause cannot be identified or eliminated, contact Service.
Important
The function "Overdrive safety system" (if fitted), which is only used in emergency situations, is not affect-
ed.
TIM-ID: 0000081383 - 001
82 | Operation | MS15034/00E 2018-08

5.5 Starting the engine
Start the engine via the automation system
TIM-ID: 0000017525 - 003
MS15034/00E 2018-08 | Operation | 83

5.6 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 Task
Engine under load Check engine visually for leaks and general condition; Check air pipework be-
Engine at nominal speed tween air filter and exhaust turbocharger for leaks and damage.
Check for abnormal running noise, vibration, and exhaust color (→ Page 100).
Air filter Check signal ring position of service indicator (→ Page 187).
Replace air filter (→ Page 185), if the signal ring is completely visible in the
service indicator control window.
HP fuel pump Check relief bores for fuel discharge (→ Page 157).
HT coolant pump Check relief bore for oil and coolant discharge and obstructions
(→ Page 210).
Fuel prefilter (optional) Check reading on differential pressure gage (→ Page 170);
Drain water and contaminants (→ Page 171).
Raw water pump (only on Check relief bore for oil and coolant discharge and obstructions
engines with engine-mount- (→ Page 218).
ed or optional remote heat
exchanger)
Bilge pump (optional) Check relief bore for oil and coolant discharge and obstructions
(→ Page 221).
TIM-ID: 0000018474 - 005
84 | Operation | MS15034/00E 2018-08

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

Note: Operate fuel treatment system for at least 5 minutes.
1. Start up fuel treatment system (→ Page 87).
2. Shut down fuel treatment system (→ Page 91).
TIM-ID: 0000007730 - 006
MS15034/00E 2018-08 | Operation | 85

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 90).
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
86 | Operation | MS15034/00E 2018-08

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 226).

2. Check sealing surfaces on coalescer filter element and in the pressure tank.
MS15034/00E 2018-08 | Operation | 87

Initial start-up: HAT
1. Replace fuel filter on engine (→ Page 168).
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 90).
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 83).
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
88 | Operation | MS15034/00E 2018-08

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
MS15034/00E 2018-08 | Operation | 89

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 86).
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
90 | Operation | MS15034/00E 2018-08

5.11 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
MS15034/00E 2018-08 | Operation | 91

5.12 Stopping the engine
Stopping the engine via the automation system
TIM-ID: 0000017528 - 004
92 | Operation | MS15034/00E 2018-08

5.13 Emergency engine stop
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 stop
1. Refer to automation system operating instructions.
2. Follow instructions.
TIM-ID: 0000017530 - 006
MS15034/00E 2018-08 | Operation | 93

5.14 After shutdown
Preconditions
☑ MTU Preservation and Represervation Specifications (A001070/..) are available.
After shutdown
Item Task
Coolant circuit Drain coolant (→ Page 207) if:
• freezing temperatures are to be expected and the engine is to remain out
of service for an extended period but the coolant has no antifreeze addi-
tive;
• engine room is not heated;
• coolant is not kept at a suitable temperature;
• antifreeze concentration is insufficient for the engine-room temperature;
• antifreeze concentration is 50% and engine-room temperature is below
-40 °C.
Raw water (only on engines Drain
with engine-mounted heat • if freezing temperatures are to be expected and the engine is to remain
exchanger) out of service for an extended period.
Engine control system Switch off.
Air intake and exhaust sys- Out-of-service-period > 1 week
tem
• Seal engine on air and exhaust sides.
Out-of-service-period > 1 month
• Carry out engine preservation (→ MTU Preservation and Represervation
Specifications A001070/..).
TIM-ID: 0000010168 - 005
94 | Operation | MS15034/00E 2018-08

5.15 Plant – Cleaning
Preconditions
☑ No operating voltage applied.
Special tools, Material, Spare parts

Designation / Use Part No. Qty.
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.
MS15034/00E 2018-08 | Operation | 95

6 Maintenance
6.1 Maintenance task reference table [QL1] for EPA regions
The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Mainte-
nance Schedule is a stand-alone publication.
The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance
Schedule.
Option
Task Maintenance tasks
W0500 Check engine oil level. (→ Page 189)

W0501 Carry out visual inspection of engine for general condition (→ Page 84)
and leaks.
W0503 Inspect service indicator of air filter. (→ Page 187)
W0504 Check the inspection bores of the HP fuel pump. (→ Page 84)
W0505 Check relief bores of coolant pump(s). (→ Page 210)
W0506 Check for abnormal running noises, exhaust gas color and (→ Page 84)
vibration.
W0507 Drain off water and contamination from fuel prefilter. (→ Page 84)
W0508 X Check differential pressure gauge of fuel prefilter. (→ Page 84)
W1001 Fit new fuel filter or new fuel filter insert. (→ Page 168)
W1005 X Fit new air filters. (→ Page 185)
W1006 Replace fuel injectors. (→ Page 158)
W1008 X Fit new engine oil filters each time the engine oil is changed (→ Page 194)
or, at the latest, on expiry of the time limit (given in years).
W1009 Check thickness of oil residue layer. Clean. Fit new sleeve, (→ Page 199)
at the latest, each time the engine oil is changed.
W1011 Inspect cylinder chambers using endoscope. (→ Page 144)
W1016 X Check condition of coupling. (→ Page 219)
W1055 X Fit new oil separators. (→ Page 148)
W1076 Clean compressor wheel. (→ Page 179)
W1207 Check valve clearance, adjust if required. ATTENTION! Initial (→ Page 150)
adjustment after 1,000 operating hours and subsequently
1,000 operating hours after each cylinder-head overhaul..
W1244 X Check function of bar electrode. (→ Page 224)
TIM-ID: 0000083706 - 001
W1245 X Check alarm function of differential pressure gauge. (→ Page 223)

W1246 X Check pump capacity. (→ Page 225)
W1463 Carry out visual inspection of engine mounts for general (→ Page 220)
condition.
W1477 X Overhaul preheater / jacket water heater. (→ Page 217)
W1481 Replace intermediate fuel filter of filter element of inter- (→ Page 167)
mediate fuel filter.
W1675 X Fit new fuel prefilter or new fuel prefilter insert. (→ Page 175)
96 | Maintenance | MS15034/00E 2018-08

Option
W1713 Injector: reset drift compensation parameters (CDC). (→ Page 245)

W1864 X Check and clean oil indicator filter. (REFDM TARGET NOT FOUND)
Table 2: Maintenance task reference table [QL1]

TIM-ID: 0000083706 - 001
MS15034/00E 2018-08 | Maintenance | 97

6.2 Maintenance task reference table [QL1] for Non EPA regions
The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Mainte-
nance Schedule is a stand-alone publication.
The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance
Schedule.
Option
W0500 Check engine oil level. (→ Page 189)

W0501 Carry out visual inspection of engine for general condition (→ Page 84)
and leaks.
W0502 Inspect intercooler drain system. (→ Page 184)
W0503 Inspect service indicator of air filter. (→ Page 187)
W0504 Check the inspection bores of the HP fuel pump. (→ Page 84)
W0505 Check relief bores of coolant pump(s). (→ Page 210)
W0506 Check for abnormal running noises, exhaust gas color and (→ Page 84)
vibration.
W0507 Drain off water and contamination from fuel prefilter. (→ Page 84)
W0508 X Check differential pressure gauge of fuel prefilter. (→ Page 84)
W1001 Fit new fuel filter or new fuel filter insert. (→ Page 168)
W1005 X Fit new air filters. (→ Page 185)
W1006 Replace fuel injectors. (→ Page 158)
W1008 X Fit new engine oil filters each time the engine oil is changed (→ Page 194)
or, at the latest, on expiry of the time limit (given in years).
W1009 Check thickness of oil residue layer. Clean. Fit new sleeve, (→ Page 199)
at the latest, each time the engine oil is changed.
W1011 Inspect cylinder chambers using endoscope. (→ Page 144)
W1016 X Check condition of coupling. (→ Page 219)
W1047 X Check and clean oil indicator filter. (REFDM TARGET NOT FOUND)
W1076 Clean compressor wheel. (→ Page 179)
W1207 Check valve clearance, adjust if required. ATTENTION! Initial (→ Page 150)
adjustment after 1,000 operating hours and subsequently
1,000 operating hours after each cylinder-head overhaul..
W1244 X Check function of bar electrode. (→ Page 224)
W1245 X Check alarm function of differential pressure gauge. (→ Page 223)
W1246 X Check pump capacity. (→ Page 225)
TIM-ID: 0000083734 - 001
W1463 Carry out visual inspection of engine mounts for general (→ Page 220)
condition.
W1477 X Overhaul preheater / jacket water heater.
W1481 Replace intermediate fuel filter of filter element of inter-
mediate fuel filter.
W1581 X Replace impactor.
98 | Maintenance | MS15034/00E 2018-08

Option
W1675 X Fit new fuel prefilter or new fuel prefilter insert.

W1713 Injector: reset drift compensation parameters (CDC). (→ Page 245)
Table 3: Maintenance task reference table [QL1]

TIM-ID: 0000083734 - 001
MS15034/00E 2018-08 | Maintenance | 99

7 Troubleshooting
7.1 Troubleshooting
Engine does not turn when starter is actuated
Cause Corrective action
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 cabling or starter faulty u Check firm seating of cable connections, contact Service.
Engine cabling faulty u Check (→ Page 234).
Loose plug connections on Engine u Check plug connections (→ Page 236).
Control Unit
Loose plug connections on Engine u Check plug connections (→ Page 238).
Interface Module (EIM)
Fuse F1 (→ Page 228)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)
Engine blocked (engine cannot be u Contact Service.
barred manually)
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 u Contact Service.
Engine fires unevenly

Injector faulty u Replace (→ Page 158).
Engine does not reach nominal speed

TIM-ID: 0000010520 - 005

Fuel filter clogged u Replace (→ Page 168).
Air supply: Air filter clogged u Check signal ring position of service indicator (→ Page 187).
Fuel injection: Injector faulty u Replace (→ Page 158).
Engine: Overload u Contact Service.
100 | Troubleshooting | MS15034/00E 2018-08

Engine speed not steady
Speed transmitter faulty u Contact Service.
Charge-air temperature too high

Incorrect coolant concentration u Check (MTU test kit).
Intercooler dirty u Contact Service.
Engine room: Air-intake u Check fans and air supply/ventilation ducts.
temperature too high
Charge-air pressure too low

Intercooler dirty u Contact Service.
Exhaust turbocharger faulty u Contact Service.
Coolant leaks at intercooler

Intercooler leaking, major coolant u Contact Service.
discharge
Black exhaust gas

Engine: Overload u Contact Service.
Blue exhaust gas

Too much oil in engine u Drain engine oil (→ Page 190).
Oil separator or oil-preseparator u Replace.
of crankcase breather clogged
TIM-ID: 0000010520 - 005
Exhaust turbocharger, cylinder u Contact Service.

head, piston rings, cylinder liner
faulty
MS15034/00E 2018-08 | Troubleshooting | 101

White exhaust gas
Engine is not at operating u Run engine to reach operating temperature.
temperature
Intercooler leaking u Contact Service.
TIM-ID: 0000010520 - 005

7.2 Control cabinet of fuel treatment system – Troubleshooting
Water alarm
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 226).
exceeded 1.3 bar.
Replace filter element

The max. permissible differential 1. Replace coalescer filter element (→ Page 226).
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
open. Fuel will be led via the
bypass directly into the overflow
tank.
TIM-ID: 0000007734 - 009

7.3 Engine governor ADEC (ECU 7) fault messages for Series 4000
engines, marine application
The fault code numbers are generated by the engine governor and transmitted to the display below (if fitted).
The fault code (1) comprises 3 digits.

Fault messages may also be caused by faulty sensors/actuators. Contact Service to have sensors/actuators
tested and replaced as necessary if troubleshooting as described in the table (→ Page 104) proves unsuc-
cessful.
For explanations of alarm configuration parameters, refer to PR 2.8008.100.
Fault code list (→ Page 104).
TIM-ID: 0000016867 - 006

7.4 ADEC engine governor – Fault codes
29 – HI ETC Idle Speed too High
ZKP-Number: 1.8004.206

Idle speed of one of the u Contact Service.
secondary turbochargers is too
high.
38 – AL ETC Speed Deviation


Speeds of one of the secondary 1. Reduce power.
turbochargers deviates from 2. Contact Service.
primary turbocharger speed.
39 – AL ETC2 CutIn Failure


ETC2 could not be cut in. 1. Reduce power.
2. Contact Service.
81 – AL Rail Leakage

Pressure gradient in rail is too low u Contact Service.
during starting or too high during
stopping (HP system leaky or air
in the system)
102 – AL Cons. Counter Defect


Consumption meter faulty. u Contact Service.
TIM-ID: 0000018389 - 004
104 – AL Eng Hours Counter Defect


Hourmeter faulty. u Contact Service.

141 – AL Power too high

This alarm occurs if the average u Reduce power.
value of power over the last 24
hours exceeded the maximum
value specified in PR1.1088.001.
142 – AL MCR exceeded 1 hour


This alarm occurs if the MCR was u Reduce power.
exceeded for more than 1 hour
within the last 12 hours.
201 – SD T-Coolant

Coolant temperature sensor 1. Check sensor and cabling (B6), replace as necessary.
faulty; Short circuit or wire break 2. Error cleared after restarting the engine.
202 – SD T-Fuel

Coolant temperature sensor 1. Check sensor and cabling (B33), replace as necessary.
203 – SD T-Charge Air


Charge-air temperature sensor 1. Check sensor and cabling (B9), replace as necessary.
204 – SD Level Lube Oil

TIM-ID: 0000018389 - 004

lube oil level sensor faulty; Short u Check sensor and cabling, replace as necessary.
circuit or wire break

205 – SD T-Coolant Intercooler

Charge-air cooler coolant u Check sensor and cabling (B26), replace as necessary.
temperature sensor faulty; Short
206 – SD T-Exhaust A

Exhaust temperature sensor on A- u Check sensor and cabling (B4.21), replace as necessary.
side faulty; Short circuit or wire
break
207 – SD T-Exhaust B

Exhaust temperature sensor on B- u Check sensor and cabling (B4.22), replace as necessary.
break
208 – SD P-Charge Air


Charge-air pressure sensor faulty; 1. Check sensor and cabling (B10), replace as necessary.
Short circuit or wire break 2. Error cleared after restarting the engine.
211 – SD P-Lube Oil


Lube oil pressure sensor faulty; 1. Check sensor and cabling (B5), replace as necessary.
212 – SD P-Coolant
TIM-ID: 0000018389 - 004

Coolant pressure sensor faulty; 1. Check sensor and cabling (B16), replace as necessary.

213 – SD P-Coolant charge-air cooler

Charge-air cooler coolant 1. Check sensor and cabling (B43), replace as necessary.
pressure sensor faulty; Short 2. Error cleared after restarting the engine.
214 – SD P-CrankCase

Crankcase pressure sensor faulty; 1. Check sensor and cabling (B50), replace as necessary.
215 – SD P-HD

Rail pressure sensor faulty; high- 1. Check sensor and cabling (B48), replace as necessary.
pressure regulator emergency 2. Error cleared after restarting the engine.
mode; Short circuit or wire break
216 – SD T-Lube Oil


Lube oil temperature sensor 1. Check sensor and cabling (B7), replace as necessary.
219 – SD T-Intake Air


Intake air temperature sensor 1. Check sensor and cabling (B3), replace as necessary.
220 – SD Level Coolant Water

TIM-ID: 0000018389 - 004

Coolant level sensor faulty; Short 1. Check sensor and cabling (F33), replace as necessary.
circuit or wire break 2. Error cleared after restarting the engine.

221 – SD P-Diff-Lube Oil

Lube oil differential pressure 1. Check sensor and cabling (F25), replace as necessary.
sensor faulty; Short circuit or wire 2. Error cleared after restarting the engine.
break
222 – SD Level Leakage Fuel


Leak-off fuel level sensor faulty; 1. Check sensor and cabling (F46), replace as necessary.
223 – SD Level Coolant Intercooler


Coolant level sensor of charge-air 1. Check sensor and cabling (F57), replace as necessary.
cooler faulty; Short circuit or wire 2. Error cleared after restarting the engine.
break
227 – SD P-Lube Oil before Filter


Sensor for lube oil pressure 1. Check sensor and cabling (B5.3), replace as necessary.
before filter faulty; Short circuit or 2. Error cleared after restarting the engine.
wire break
228 – SD P-Fuel before Filter


Fuel pressure sensor faulty; Short 1. Check sensor and cabling (B5.3), replace as necessary.
229 – AL Stop Camshaft Sensor Defect

TIM-ID: 0000018389 - 004

Engine shutdown due to camshaft 1. Check connector and cabling to sensor B1, replace as necessary.
sensor fault (and a prior 2. Error cleared after restarting the engine.
crankshaft sensor fault in the
same operating cycle).

230 – SD Crankshaft Speed

Crankshaft sensor faulty; Short 1. Check sensor and cabling (B13), replace as necessary.
231 – SD Camshaft Speed


Camshaft sensor faulty; Short 1. Check sensor and cabling (B1), replace as necessary.
232 – SD Charger 1 Speed


Speed sensor of primary 1. Check sensor and cabling (B44.1), replace as necessary.
turbocharger faulty; Short circuit 2. Error cleared after restarting the engine.
or wire break
233 – SD Charger 2 Speed


Speed sensor of secondary 1. Check sensor and cabling (B44.2), replace as necessary.
turbocharger faulty; Short circuit 2. Error cleared after restarting the engine.
or wire break
239 – SD P-Diff Fuel


Fuel differential pressure sensor u Note further fault messages. Pressure sensor before or after filter
faulty; occurs only in combination is faulty.
with alarm "SD P-Fuel before
Filter" or "SD P-Fuel after Filter".
240 – SD P-Fuel
TIM-ID: 0000018389 - 004

Fuel pressure sensor faulty; Short 1. Check sensor and cabling (B34), replace as necessary.

241 – SD T-Circulating air

Recirculation temperature sensor 1. Check sensor and cabling (B49), replace as necessary.
242 – SD T-Coolant (R)


Redundant coolant temperature 1. Check sensor and cabling, replace as necessary.
break
244 – SD P-Lube Oil (R)


Redundant lube oil pressure 1. Check sensor and cabling, replace as necessary.
break
301 – AL Timing Cylinder A1


Time-of-flight measuring fault of u If alarm occurs frequently, replace solenoid valve of injector
injector in cylinder A1: Time-of
flight measured value extremely
low or extremely high.


TIM-ID: 0000018389 - 004












TIM-ID: 0000018389 - 004




311 – AL Timing Cylinder B1


injector B1: Time-of flight
measured value extremely low or
extremely high.


extremely high.


TIM-ID: 0000018389 - 004
injector B3: Time-of-flight
measurement value is extremely
small or extremely large.


extremely high.


extremely high.


extremely high.


extremely high.


TIM-ID: 0000018389 - 004
extremely high.


extremely high.


extremely high.
321 – AL Wiring Cylinder A1


Short-circuit in injector cabling to 1. Rectify injector solenoid valve short circuit (positive to negative)
cylinder A1. Result: Misfiring (e.g.by exchanging injectors).
2. Error cleared after restarting the engine.


cylinder A2. Result: Misfiring (e.g. by exchanging injectors).


TIM-ID: 0000018389 - 004












TIM-ID: 0000018389 - 004



331 – AL Wiring Cylinder B1

Cabling fault in injector cabling to 1. Rectify injector solenoid valve short circuit (positive to negative)
cylinder B1. Result: Misfiring (e.g. by exchanging injectors).








TIM-ID: 0000018389 - 004










341 – AL Open Load Cylinder A1


Disruption fault in injector cabling 1. Check continuity of injector cabling or exclude open load in
to cylinder A1. Result: Misfiring solenoid valve circuit (e.g. by injector replacement)
2. Error clearance: After each working cycle.
TIM-ID: 0000018389 - 004












Disruption fault in injector cabling 1. Check injector wiring for disruption or rule out any discontinuity in
to cylinder A7. Result: Misfiring the solenoid valve (e.g. by replacing the injector)
TIM-ID: 0000018389 - 004






351 – AL Open Load Cylinder B1


to cylinder B1. Result: Misfiring the solenoid valve (e.g. by replacing the injector)




TIM-ID: 0000018389 - 004












TIM-ID: 0000018389 - 004



361 – AL Power Stage Low

Internal electronic fault u Start ITS. If the ITS diagnosis result is "electronics OK", note
(electronics possibly faulty). If bit further fault messages (e.g. cabling faults).
"1.1020.021" (Power Stage
Failure: Stop Engine) is set,
engine will be shut down as
additional measure.
362 – AL Power Stage High


additional measure.
363 – AL Stop Power Stage


additional measure.
365 – AL Stop MV-Wiring Ground


Injector cabling fault. If bit u Check wiring, replace wiring harness as necessary.
additional measure. Possible
TIM-ID: 0000018389 - 004
causes:
1. Short circuit of positive
connection of one or more
injectors to ground
2. Short circuit of negative
connection of one or more
injectors to ground.

371 – AL Wiring TO 1

Short circuit or wire break on 1. Check charger valve/cabling, repair as necessary.
transistor output 1 (TO 1). 2. Replace engine governor

Short circuit or wire break on 1. Check air recirculation valve/cabling, repair as necessary.
transistor output 2 (TO 2). 2. Replace engine governor

Short circuit or wire break on u Check wiring of charger valve 2 (marine engine)
transistor output 3 (TO 3).

Short circuit or wire break on u Check wiring of charger valve 3 (marine engine)
transistor output 4 (TO 4).
390 – AL MCR exceeded


DBR/MCR feature: MCR 1. If the alarm occurs temporarily, no action required.
(maximum continuous rating) was 2. If the alarm is permanently active, contact Service.
exceeded.
396 – TD T-Coolant
TIM-ID: 0000018389 - 004

Maximum deviation of coolant 1. Check sensor and cabling, replace as necessary.
temperature values from sensors 2. Contact Service.

397 – TD P-Lube Oil

Maximum deviation of lube oil 1. Check sensor and cabling, replace as necessary.
pressure values from sensors 2. Contact Service.
417 – SD Level Water Fuel Prefilter


Water level sensor in fuel prefilter u Check sensor and cabling, replace as necessary.
faulty; Short circuit or wire break
419 – SD T-Coolant b.Engine


Coolant inlet temperature sensor u Check sensor and cabling (B3), replace as necessary.
444 – SD U-PDU

Injector power stage sensor u Replace ECU7.
defect; Internal fault in ECU7
445 – SD P-Ambient Air


Ambient air pressure sensor 1. Check pressure sensor and cabling, replace as necessary.
faulty. 2. Replace engine governor.
464 – SD P-AUX 1

TIM-ID: 0000018389 - 004
Analog input signal for Aux 1 u Check pressure sensor and cabling, replace as necessary.
pressure faulty; Short circuit or
wire break

468 – SD T-AUX 1

Analog input signal for Aux 1 1. Check signal transmitter and cabling, replace as necessary.
temperature faulty;. 2. Replace engine governor.
469 – SD AUX 1

Analog input signal for Aux 1 u Check signal transmitter and cabling, replace as necessary.
470 – SD T-ECU

Temperature sensor for ECU u Check sensor and cabling, replace as necessary.
471 – SD Coil Current


Control of HP fuel control block u Check sensor and cabling, replace as necessary.
473 – AL Wiring PWM_CM2


Cable break or short circuit on 1. Check cabling.
channel PWM_CM2. 2. Contact Service.
475 – AL CR Trigger Engine Stop


TIM-ID: 0000018389 - 004
Activated if the crash recorder 1. Determine cause of trigger/engine stop and rectify.
was triggered due to an engine 2. Contact Service.
stop.

476 – AL Crash Rec. Init. Error

Crash recorder initialization error. 1. Check setting with DiaSys.
2. Contact Service.
482 – SD T-Exhaust C

break
483 – SD T-Exhaust D

break


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


ETC3 could not be cut in. u Check control valve on ETC 3.
500 – AL Wiring POM Starter 1


TIM-ID: 0000018389 - 004
A wiring fault was detected in the u Check connection between POM and starter.
connection between starter 1 and
POM. This may be a missing
consumer, a wire break, or a short
circuit.

501 – AL Wiring POM Starter 2

A wiring fault was detected in the u Check connection between POM and starter.
connection between starter 2 and
POM. This may be a missing
consumer, a wire break, or a short
circuit.
502 – AL Open Load POM Alternator


Open load was detected at the u Check connection between POM and starter.
connection of the battery-
charging generator on the POM.
503 – AL Battery not Charging


The battery-charging generator u Check battery-charging generator and cabling.
does not charge the battery.
504 – AL CAN POM node Lost


POM missing on CAN bus. u Check connection and POM. If alarm occurs in combination with
alarm 508, the resistor in the POM cabling is missing.
506 – AL Low Starter Voltage


battery voltage is too low to u Check battery-charging generator and cabling.
accomplish a starting procedure.
507 – AL POM Error

TIM-ID: 0000018389 - 004

A general POM error occurred. u Replace POM.

508 – AL Wrong POM-ID

POM transmits an unexpected ID u Check POM wiring harness.
number. If alarm occurs in
combination with alarm 504, the
resistor in the POM cabling is
missing.
519 – Oillevel Calibration Error


Error when writing the calibration 1. Check sensor and cabling, replace as necessary.
value into the Flash or SD memory 2. Contact Service.
of the level sensor; associated PV:
AL Group 6 Mot Bit 11
525 – SD P-Lube Oil (R2)


Redundant lube oil pressure u Check sensor and cabling, replace as necessary.
sensor faulty; Short circuit or wire
break
526 – SD T-Coolant (R2)


Redundant coolant temperature u Check sensor and cabling, replace as necessary.
sensor faulty; Short circuit or wire
break
527 – TD EngineSpd. Sensor Deviation


Maximum deviation of speed 1. Check cabling of speed sensors. Observe additional messages.
TIM-ID: 0000018389 - 004
sensors 2. Contact Service.
528 – SD Engine Speed 3rd Sensor


Redundant crankshaft sensor u Check sensor and cabling, replace as necessary.

576 – AL ESCM Override

Violation of corrected MCR or u Reduce power.
DBR/MCR curve. Engine overload!
577 – SD T-Lube Oil Pan


Temperature sensor in oil pan u Check sensor and cabling, replace as necessary.
defective; Short circuit or wire
break
582 – AL Emergency Stop Failed


This alarm occurs if the engine u The delay between the emergency stop signal and this alarm signal
fails to come to a standstill within is set in parameter 1.1005.4.
a specified (by parametrization)
period of time after the
emergency stop signal was
output.
588 – SD P-Oil Refill Pump


Pressure sensor faulty; Short u Check sensor and cabling, replace as necessary.
596 – AL Develop PR Set


The parameter set used is a test u The alarm remains active until a series-production parameter set
parameter set. was installed.
TIM-ID: 0000018389 - 004
600 – SD T-Exhaust A+B


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

601 – SD ETC1+ETC2

SD ETC1 and ETC2 u Check sensor and cabling, replace as necessary.
625 – SD P-Fuel before Prefilter


Analog input signal for pressure 1. Check pressure sensor and cabling, replace as necessary.
before prefilter faulty; Short 2. Error cleared after restarting the engine.
TIM-ID: 0000018389 - 004

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

Shield A4 735233000100 2
Shield A5 735233000101 18
Shield A6 735233000102 4
Shield A7 735233000103 3
Shield A8 735233000104 4
Shield B2 735233000200 2
Shield B4 735233000202 1
Shield B6 735233000204 2
Shield E5 735233000500 4
Installing SOLAS shielding

1. Pinpoint installation location
(REFDM TARGET NOT FOUND).
2. Install suitable shielding.
3. Press shielding until locked.
TIM-ID: 0000068938 - 001
MS15034/00E 2018-08 | Task Description | 131

8.1.2 SOLAS shielding – Installation
Preconditions
☑ Engine is cooled down to ambient temperature.

Oil filter shield X00040625 5
Shield for switchable oil filter X00040625 4
Installing SOLAS shield

1. Pinpoint installation location.
2. Install suitable shielding.
TIM-ID: 0000068940 - 001
132 | SOLAS | MS15034/00E 2018-08

8.1.3 Installation locations for SOLAS shielding
General information
Primarily fit SOLAS shielding as per MTN 5233 (→ Page 131).
Shield unions with adhesive tape if SOLAS shielding as per MTN 5233 is not possible (→ Page 140).
When affixing adhesive connections ensure that escaping fluid can flow out without pressure (→ Page 140).
Fuel system, fuel lines with fuel pressures exceeding >1.8 bar
Item Type of shielding Installation location

1* Shield A8 After LP fuel pump
* This shield must be installed on the assembly line. This location is no longer accessible, or only with great
difficulty, following assembly of the air pipework and/or fuel filters.
TIM-ID: 0000068941 - 002
MS15034/00E 2018-08 | SOLAS | 133

1* Shield A8 Fuel filter head holder
difficulty, following assembly of the air pipework and/or fuel filters.

1 Shield E5 Fuel line on HP pump
2 Shield E5 Fuel line downstream of fuel filter head
TIM-ID: 0000068941 - 002

1 2 x shielding A8 Fuel line at fuel filter head holder
134 | SOLAS | MS15034/00E 2018-08

1* 2 x shielding B6 Fuel line at fuel filter head
difficulty, following assembly of the air pipework.
Lube oil system, oil lines with oil pressures exceeding 1.8 bar

TIM-ID: 0000068941 - 002
1 2 x shielding A5 Actuating cylinder air flap ETC A1
MS15034/00E 2018-08 | SOLAS | 135

1 2 x shielding A5 Actuating cylinder exhaust flap turbocharger A1
2 2 x shielding A5 Actuating cylinder air flap turbocharger A1
3 4 x shielding A5 4/2-way directional control valve

1 2 x shielding A5 Air recirculation valve
TIM-ID: 0000068941 - 002
2 2 x shielding A5 Oil drain into crankcase

1 x shielding A6
3 3 x shielding A6 Oil from main oil gallery at distrib-
utor piece
136 | SOLAS | MS15034/00E 2018-08

1 Shield A4 ETC oil supply
2 2 x shielding A5 ETC oil supply

1 Shield A4 ETC oil supply
TIM-ID: 0000068941 - 002
MS15034/00E 2018-08 | SOLAS | 137

1 Shield A6 Oil supply line to HP pump: To HP pump

1 Shield B4 Oil supply line to HP pump: On equipment carrier
TIM-ID: 0000068941 - 002
138 | SOLAS | MS15034/00E 2018-08

1 Shield B2 Oil line on equipment carrier
2 Shield B2 Oil line on pressure reducing valve

1 Cover Oil/easy-change fuel filter
TIM-ID: 0000068941 - 002
MS15034/00E 2018-08 | SOLAS | 139

8.1.4 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 (REFDM TARGET NOT FOUND).
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.
TIM-ID: 0000038330 - 002
Plug-in connections
Note: For installation positions of plug-in connections, see (REFDM TARGET NOT FOUND).
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.
140 | SOLAS | MS15034/00E 2018-08

8.2 Engine
8.2.1 Engine – Barring manually
Preconditions

Barring tool F6555766 1
Ratchet with extension F30006212 1
DANGER
Rotating and moving engine parts.
• Before barring the engine, make sure that there are no persons in the engine's danger zone.
• After finishing work on the engine, make sure that all safety devices are put back in place and all
tools are removed from the engine.
Engine – Barring manually

1. Release screws (1) and remove end cover (2)
from flywheel housing.
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MS15034/00E 2018-08 | Engine | 141

Note: Use barring device F6555766.
2. Engage barring device (2) in ring gear of fly-
wheel and install it on flywheel housing.
3. Fit ratchet (1) onto barring device (2).
Note: No resistance other than compression resist-
ance must be encountered.
4. Rotate crankshaft in engine direction of rota-
tion.
Result: If the resistance exceeds the normal com-
pression resistance, contact Service.
5. For removal, follow the reverse sequence of
work steps.
TIM-ID: 0000000917 - 014
142 | Engine | MS15034/00E 2018-08

8.2.2 Barring engine with starting system
Barring using the automation system
TIM-ID: 0000017532 - 004
MS15034/00E 2018-08 | Engine | 143

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 154).
2. Remove injector (→ Page 159).
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,
TIM-ID: 0000003304 - 006
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
144 | Cylinder Liner | MS15034/00E 2018-08

1. Compile endoscopic report using the table.
2. Use technical terms to describe the liner surface (→ Page 146).
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 159).
2. Install cylinder head cover (→ Page 154).
TIM-ID: 0000003304 - 006
MS15034/00E 2018-08 | Cylinder Liner | 145

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
TIM-ID: 0000000014 - 017
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
146 | Cylinder Liner | MS15034/00E 2018-08

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.
TIM-ID: 0000000014 - 017
MS15034/00E 2018-08 | Cylinder Liner | 147

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

Engine oil
Oil mist fine 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.
Replacing oil mist fine separator

1. Remove screws (1) and washer (2) and take
off together with plug (6).
2. Remove both retainers (3).
3. Replace oil mist fine separator (4).
4. Replace O-ring (5) as necessary.
5. Replace other oil mist fine separators in the
same way.
TIM-ID: 0000065663 - 003
148 | Crankcase Breather | MS15034/00E 2018-08

8.5 Valve Drive
8.5.1 Valve gear – Lubrication
Preconditions

Engine oil
Valve gear – Lubrication

1. Remove cylinder head covers (→ Page 153).
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 153).
TIM-ID: 0000000921 - 010
MS15034/00E 2018-08 | Valve Drive | 149

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

Feeler gauge Y20098771 1
Torque wrench, 60–320 Nm F30452768 1
Socket wrench, 24 mm F30039526 1
Engine oil
Preparatory steps
2. Install barring device (→ Page 141).
Note: The pointer (1) is in the lower opening of the
flywheel housing (arrow).
3. Use barring device to turn crankshaft in en-
gine direction of rotation until marking
OT/A1 on the rear side of the flywheel and
pointer (1) are aligned.
TIM-ID: 0000012225 - 006
150 | Valve Drive | MS15034/00E 2018-08

Note: Danger of interchanging: Additional marking
OT/A1 (1) on outer circumference, if applica-
ble.
4. Additional OT/A1 (1) marking on the outer
circumference of flywheel must not be used.
Diagram for 8V engines (two

crankshaft positions)
Checking valve clearance at two crankshaft positions

1. Check TDC position of piston in cylinder A1:
• The piston is in firing TDC when the rocker arms on cylinder A1 are unloaded.
• The piston is in overlap TDC when the rocker arms on cylinder A1 are loaded.
2. Check valve clearance setting with engine cold:
• Inlet (long rocker arm) = 0.2 ±0.05 mm
• Exhaust (short rocker arm) = 0.5 ±0.0 5mm
3. Check all valve clearances in two crankshaft positions (firing TDC and overlap TDC of cylinder A1) as per
diagram:
TIM-ID: 0000012225 - 006
1 Cylinder A1 is in firing TDC

2 Cylinder A1 is in overlap TDC
I Inlet valve
X Exhaust valve
4. Use feeler gauge to determine the distance between valve bridge and rocker arm.
5. Adjust valve clearance if the deviation from the set value exceeds 0.1 mm.
MS15034/00E 2018-08 | Valve Drive | 151

Adjusting valve clearance
1. Release locknut (1).
2. Insert feeler gauge (3) between valve bridge
and rocker arm.
Note: Replace or loosen stiff adjusting screws
and/or locknuts.
3. Using Allen key, set adjusting screw (2) so
that the specified valve clearance is provided.
Note: Feeler gauge must just pass through the gap.
4. Pull feeler 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.
Name Size Type Lubricant Value/Standard
Locknut Tightening torque 90 Nm + 9 Nm
6. Check valve clearance, adjust if necessary.
Final steps
1. Remove barring device (→ Page 141).
TIM-ID: 0000012225 - 006
152 | Valve Drive | MS15034/00E 2018-08

8.5.3 Cylinder head cover – Removal and installation
Preconditions

Gasket (→ Spare Parts Catalog)
Removing cylinder head cover

1. Clean very dirty cylinder head covers (3) prior
to removal.
2. Undo screws (1) and remove with wash-
ers (2).
3. Remove cylinder head cover (3) with gas-
ket (4) from cylinder head.
4. Remove other cylinder head covers in the
same way.
Installing cylinder head cover

1. Clean mating faces.
2. Check gasket (4) for damage, replace if necessary.
3. Place gasket (4) and cylinder head cover (3) onto cylinder head.
4. Install cylinder head cover (3) with screws (1) and washers (2).
5. Install other cylinder head covers in the same way.
TIM-ID: 0000000923 - 008
MS15034/00E 2018-08 | Valve Drive | 153

8.5.4 Cylinder head cover – Removal and installation
Preconditions

Torque wrench, 10–60 Nm F30510423
Ratchet bit F30027341
Assembly compound (Kluthe Hakuform 30-15) X00067260 1
Engine oil
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 (6) with assembly compound.
4. Insert O-ring (6) in groove on cylinder head cover (1).
5. Place cylinder head cover (7) on cylinder head.
6. Install cylinder head cover with screws (3, 4) and washers (2, 5).
7. Tighten screws (3), (4) to specified tightening torque using a torque wrench.
TIM-ID: 0000012309 - 017
Screw M10 Tightening torque (Engine oil) 42 Nm
154 | Valve Drive | MS15034/00E 2018-08

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.
MS15034/00E 2018-08 | Injection Pump / HP Pump | 155

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
156 | Injection Pump / HP Pump | MS15034/00E 2018-08

8.6.2 HP fuel pump – Relief bore check
DANGER
WARNING
HP fuel pump, checking relief

bore
1. Visually inspect relief bore (1) for fuel dis-
charge.
2. If fuel discharge is found or indicated, con-
tact Service.
TIM-ID: 0000012375 - 009
MS15034/00E 2018-08 | Injection Pump / HP Pump | 157

8.7 Injection Valve / Injector
8.7.1 Injector – Replacement
Injector (→ Spare Parts Catalog)
Replacing injector
u Remove injector and install new injector (→ Page 159).
TIM-ID: 0000000022 - 017
158 | Injection Valve / Injector | MS15034/00E 2018-08

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

Installation/removal jig F6789889 1
Milling cutter F30452739 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 - 031
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.
MS15034/00E 2018-08 | Injection Valve / Injector | 159

WARNING
Internal load and residual pressure in the HP fuel system. Parts may be expelled at high speed on re-
lease.
Fuel may spurt out.
Risk of injury by flying parts and sprayed fuel!
• Only use specified tools and devices.
• Always wear protective goggles / safety mask.
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.
Removing injector
1. Disconnect cable connector on injector.
Note: When the plug screw (1) is removed, fuel

emerges.
2. Place a suitable collecting vessel underneath.
3. Remove plug screw (1).
TIM-ID: 0000000925 - 031

Note: Observe system pressure.
4. Slowly loosen union on HP line (4).
5. Remove HP line (4).
Note: The fuel stored in the injector drains out
when the adapter (3) is unscrewed.
6. Unscrew adapter (3).
Note: Components are sensitive.
7. Protect contact surfaces of HP line (4) and
adapter (3) on cylinder head and the HP line
(4) itself against damage.
8. Unscrew screw (2).
9. Install installation/removal jig on cylinder

head.
10. Remove injector with installation/removal jig
and take off hold-down clamp.
11. Remove installation/removal jig.
Note: The sealing ring (4) for sealing the combus-

tion chamber must only be used once.
12. Remove sealing ring (4) from injector or use a
self-made wire hook or magnet to take it out
of the cylinder head and dispose properly.
Note: For new assembly:
13. Dispose of injector with O-rings in place.
Note: For repeated assembly:
14. Remove O-rings (3), O-ring (2) and damper
TIM-ID: 0000000925 - 031
ring (1) from injector.

15. Clean all mating and sealing surfaces.
16. 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).
• Use a multi-purpose grease without solids
content.
1. Install new sealing ring (1) with multi-purpose
grease and ensure that the installation posi-
tion is correct.
Note: If the milling cutter is pressed with excessive

force into the seat of the injector, this can
cause damage to the cylinder head.
2. Remove oil carbon from sealing face on cylin-
der head and protective sleeve by using the
milling cutter with little force.
Note: Remove seal plugs on HP line only before in-
stallation of the adapter.
3. Remove seal plug.
Note: The damper ring is already in place for new
assembly. Coat damper ring with assembly
compound.
4. Fit damper ring (1) on injector and coat with
assembly compound (Molykote P 37).
Note: The O-rings are already in place for new as-
sembly. Coat O-rings with assembly com-
pound.
5. Fit new O-rings (3) and (2) on injector and
coat with assembly compound (Kluthe Haku-
form 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 with hold-down clamp into cyl-
inder head, ensuring that the HP line connec-
tion is correctly aligned.
TIM-ID: 0000000925 - 031

8. Press in injector with installation/removal jig.
9. Remove installation/removal jig.
10. Coat screw mating face (2) and thread with

engine oil.
11. Fit hold-down clamp (1) in correct position, fit
screw (2) and tighten by hand.
Note: Make sure parts are perfectly clean.
12. Apply engine oil to thread, sealing taper and
thrust ring of adapter (3).
13. Coat O-ring on adapter (3) with assembly
compound (Kluthe Hakuform 30-15).
14. Install adapter (3).
15. Use torque wrench to tighten screw (2) to specified tightening torque.
Screw M12 Tightening torque (Engine oil) 100 Nm+10 Nm
16. Use torque wrench to tighten adapter (3) to specified tightening torque.
Adapter Tightening torque (Engine oil) 100 Nm+10 Nm
TIM-ID: 0000000925 - 031
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. Use torque wrench to tighten jacketed HP line (5) according to tightening sequence to specified tightening
torque. 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)
Union nut / thrust Tightening torque (Engine oil) 40 Nm +5 Nm
screw
22. Screw in plug screw (1) and use torque wrench to tighten to specified tightening torque.
Plug screw M10 Tightening torque (Engine oil) 15 Nm +3 Nm
TIM-ID: 0000000925 - 031

23. 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 - 031

8.8 Fuel Filter
8.8.1 Additional fuel filter – Overview
1 Storage tank 3 Passive fuel prefilter with 5 Additional fuel filter, switch-
2 Day tank water separator able
4 LP pump 6 Main engine filter, switcha-
ble
TIM-ID: 0000012629 - 005
166 | Fuel Filter | MS15034/00E 2018-08

8.8.2 Additional fuel filter – Replacement
Preconditions

Filter wrench F30379104 1
Diesel fuel
Easy-change filter (→ Spare Parts Catalog)
Synthetic ring (→ Spare Parts Catalog)
DANGER
WARNING
• Do not smoke.
WARNING
NOTICE
Severe material damage!
• For filter replacement with the engine running, operate the engine at low engine load.
• The filter which is to be replaced must be cut out for a brief period only.
Additional fuel filter – Replacement

1. Replace additional fuel filter with the engine at standstill (→ Page 168).
2. Replace additional fuel filter with the engine running (→ Page 168).
TIM-ID: 0000012645 - 005
MS15034/00E 2018-08 | Fuel Filter | 167

8.8.3 Fuel filter – Replacement
Preconditions

Diesel fuel
Easy-change filter (→ Spare Parts Catalog)
Synthetic ring (→ Spare Parts Catalog)
DANGER
WARNING
• Do not smoke.
WARNING
NOTICE
Replacing fuel filter with the en-

gine stopped
A Both filters cut in
B Left filter cut out
C Right filter cut out
1 Fuel filter
TIM-ID: 0000012704 - 004
168 | Fuel Filter | MS15034/00E 2018-08

1. Cut out the filter to be replaced.
2. Unscrew cut-out easy-change filter with oil filter wrench.
3. Clean sealing surface on filter head.
4. Check sealing ring of the new easy-change filter and moisten it with fuel.
5. Fit SOLAS shield (REFDM TARGET NOT FOUND).
6. Screw on easy-change filter and tighten by hand.
7. Set three-way cock to operating position (both filters cut in).
8. Replace other fuel filters in the same way.
9. Vent fuel system.
Replacing fuel filter with the en-

gine running
1. Cut out the filter to be replaced.
B Left-hand filter cut out
C Right-hand filter cut out
2. Unscrew cut-out easy-change filter with oil fil-
ter wrench.
3. Clean sealing surface on filter head.
4. Check sealing ring of the new easy-change fil-
ter and moisten it with fuel.
5. Fit SOLAS shield
6. Screw on easy-change filter (1) and tighten
by hand.
7. Set three-way cock to operating position
(both filters cut in).
8. Replace other fuel filters in the same way.
TIM-ID: 0000012704 - 004
MS15034/00E 2018-08 | Fuel Filter | 169

8.8.4 Fuel prefilter – Differential pressure gage check and adjustment
DANGER
WARNING
Adjusting differential pressure

gage
1. When putting the new filter element into op-
eration: Align adjustable pointer (2) with
pressure-indicating pointer (3) of pressure
gage (1).
2. Verify that differential pressure is within the
limit.
Fuel prefilter – Differential pressure check

1. With the engine running at full load or rated power, read off pressure at gage (1).
2. If differential pressure as indicated between position of adjustable pointer (2) and pressure-indicating point-
er (3) of pressure gage is ≥ 0.3 bar, flush filter element of the cut-in filter (→ Page 173).
TIM-ID: 0000004925 - 011
170 | Fuel Filter | MS15034/00E 2018-08

8.8.5 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 - 010
MS15034/00E 2018-08 | Fuel Filter | 171

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 170).
TIM-ID: 0000018510 - 010
172 | Fuel Filter | MS15034/00E 2018-08

8.8.6 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 - 012
MS15034/00E 2018-08 | Fuel Filter | 173

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 170).
TIM-ID: 0000012728 - 012
174 | Fuel Filter | MS15034/00E 2018-08

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

Ratchet adapter F30027340 1
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
Hot components/surfaces.
Risk of burns!
• Allow the engine to cool down to below 50 °C before beginning work.
TIM-ID: 0000012750 - 015
• Wear suitable protective equipment/thermal gloves.

• Avoid unprotected contact with hot surfaces.
NOTICE
MS15034/00E 2018-08 | Fuel Filter | 175

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 - 015
176 | Fuel Filter | MS15034/00E 2018-08

14. Close vent valve (1) as soon as fuel emerges
from vent pipe (4).
16. Set differential pressure gage (→ Page 170).
TIM-ID: 0000012750 - 015
MS15034/00E 2018-08 | Fuel Filter | 177

8.8.8 Fuel prefilter with water separator – O-ring replacement in rotary slide valve
Preconditions
☑ System is at atmospheric pressure.

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.
Fuel prefilter with water separa-

tor – O-ring replacement in rota-
ry slide valve
1. Open vent valves (1) carefully to make sure
that the system is not pressurized.
2. Open drain valves (6) and drain fuel.
3. Remove rotary slide valve retainer (4) with
handle (5).
4. Remove rotary slide valve (3) with O-rings (2).
5. Replace O-rings (2).
TIM-ID: 0000012751 - 006
6. For assembly, follow the reverse sequence of

working steps as described for disassembly.
178 | Fuel Filter | MS15034/00E 2018-08

8.9 Exhaust Turbocharger
8.9.1 Compressor wheel – Cleaning
Preconditions
☑ Engine is stopped and starting disabled

Torque wrench, 4-20 Nm F30044239 1
Cleaning agent 40377 1
Engine oil
Engine coolant
Sealing rings (→ Spare Parts Catalog) 5
Sealing rings (→ Spare Parts Catalog) 7
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
Inappropriate cleaning tool.
• Use appropriate cleaning tool.
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.
Preparatory steps
1. Drain engine coolant (→ Page 207).
2. Remove air filter (→ Page 186).
3. Seal openings with suitable covers.
TIM-ID: 0000018849 - 006
MS15034/00E 2018-08 | Exhaust Turbocharger | 179

4. Remove air pipework (1) from exhaust turbo-
charger to charge-air cooler.
5. Disconnect oil lines (2) from air flap actuator
cylinder.
6. Undo screws (3) and clamp (2).

7. Remove intake housing (1) with actuating cyl-
inder.
8. Remove coolant lines (1) on compressor cas-

ing. TIM-ID: 0000018849 - 006
180 | Exhaust Turbocharger | MS15034/00E 2018-08

9. Undo clamp (2).
10. Remove compressor casing (1).
Cleaning compressor wheel

Note: Do not use wire brushes, scrapers or similar
implements for cleaning!
1. Clean compressor casing with a soft brush.
2. Clean compressor wheel (2) and bearing
housing (1).
3. Thoroughly remove cleaning agent from all
parts.
4. Replace sealing rings between bearing hous-
ing/compressor casing and plug-in sleeves
as necessary.
Final steps
1. Reinstall compressor casing (1).
TIM-ID: 0000018849 - 006

2. Align clamp (2) and tighten to specified torque using a torque wrench.
Clamp Tightening torque (Engine oil) 5 Nm +1 Nm
3. Install coolant lines (1) on compressor cas-

ing.
4. Install intake housing (1) with actuating cylin-

der.
5. Align clamp (2) and tighten to specified torque using a torque wrench.
Clamp Tightening torque 15 Nm +2 Nm
TIM-ID: 0000018849 - 006
6. Tighten screws (3) on holder.
182 | Exhaust Turbocharger | MS15034/00E 2018-08

7. Install oil lines (2).
8. Install air pipework (1) from exhaust turbo-
charger to charge-air cooler.
9. Install air filter (→ Page 186).
10. Fill with engine coolant (→ Page 208).
TIM-ID: 0000018849 - 006

8.10 Charge-Air Cooling
8.10.1 Intercooler – Check water drain for coolant leakage and obstruction
DANGER
WARNING
WARNING
Checking intercooler water

drain for coolant leakage and
obstruction
1. With the engine running check the drain
bore(s) on the right and left of the engine for
emerging air (at driving end). If no air es-
capes:
2. Clean drain bore(s) and blow out with com-
pressed air.
3. More significant coolant leakage indicates a
leaking intercooler. Contact the Service.
Emergency measures prior to engine start with a leaking intercooler

1. Remove injectors (→ Page 159).
2. Bar engine manually (→ Page 141).
3. Crank engine on starting system to blow out cylinder chambers (→ Page 141).
4. Install injectors (→ Page 159).
TIM-ID: 0000013215 - 003
184 | Charge-Air Cooling | MS15034/00E 2018-08

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 186).
2. Reset signal ring of contamination indicator (→ Page 187).
TIM-ID: 0000005447 - 010
MS15034/00E 2018-08 | Air Filter | 185

8.11.2 Air filter – Removal and installation
Preconditions
Air filter – Removal and installa-

tion
1 Intake housing
2 Clamp
3 Air filter
1. Loosen clamp (2).

2. Remove air filter (3) and clamp (2) from flange of intake housing (1).
3. Verify that there are no objects in the flange of the intake housing (1) and clean it.
4. Place new air filter (3) with clamp (2) onto intake housing (1).
5. Tighten clamp (2).
TIM-ID: 0000013402 - 001
186 | Air Filter | MS15034/00E 2018-08

8.12 Air Intake
8.12.1 Contamination indicator – Signal ring position check
Preconditions
WARNING
The engine draws in large volumes of ambient air for combustion. This air intake results in a strong vac-
uum.
Risk of injury if body parts are drawn in! There is also a danger if opening of the entrance door
can be prevented!
• Only operate the engine with installed air filters.
• Never open air-carrying components during operation.
• Ensure that the engine room is well-ventilated.
Checking signal ring position

1. If the signal ring is completely visible in the
viewing window (2), replace air filter
(→ Page 185).
2. After installation of new filter, press reset
button (1).
Result: Engaged plunger with signal ring returns to
initial position.
TIM-ID: 0000005484 - 010
MS15034/00E 2018-08 | Air Intake | 187

8.13 Starting Equipment
8.13.1 Starter – Condition check
Preconditions
Starter – Condition check

1. Check securing screws of starter and nut on cable connection for secure seating and tighten if required.
2. Check cabling (→ Page 234).
TIM-ID: 0000000905 - 019
188 | Starting Equipment | MS15034/00E 2018-08

8.14 Lube Oil System, Lube Oil Circuit
8.14.1 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 190).
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 190).
5. Insert oil dipstick into guide tube up to the stop.
TIM-ID: 0000000931 - 017
MS15034/00E 2018-08 | Lube Oil System, Lube Oil Circuit | 189

8.14.2 Engine oil – Change
Preconditions
☑ Engine is at operating temperature.
☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.

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

1. Provide a suitable vessel in which to collect the engine oil.
2. Extract all oil from oil pan using the semirotary hand pump.
Draining residual oil at gearcase

1. Provide a suitable vessel in which to collect
the engine oil.
2. Remove drain plugs (1) and (2) and drain en-
gine oil:
• Approx. 12 liters at (1)
• Approx. 5 liters at (2)
TIM-ID: 0000014099 - 007
3. Install drain plug(s) with new sealing ring.
190 | Lube Oil System, Lube Oil Circuit | MS15034/00E 2018-08

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

1. Open cap (1) on filler neck.
2. Pour oil in at filler neck up to “max.” mark on
oil dipstick.
3. Close cap on filler neck.
4. Check engine oil level (→ Page 189).
5. Bar engine with starting system after engine
oil change (→ Page 143).
TIM-ID: 0000014099 - 007

8.14.3 Engine oil – Sample extraction and analysis
Preconditions

MTU test kit 5605892099/00 1
DANGER
WARNING
Oil is hot.
WARNING
Engine oil sample extraction

and analysis (engine with stand-
ard oil filter)
Note: Only take the engine oil sample by opening
an oil drain screw with the engine stationary.
1. With the engine shut down, open the screw,
e.g. at the oil filter.
2. Drain approx. 1 liter engine oil into a clean
container.
3. Seal oil drain screw again with a new sealing
ring.
4. Using the equipment and chemicals in the
MTU test kit, analyze the engine oil for:
• Dispersion capability (spot test)
TIM-ID: 0000014113 - 007
• Proportion of water
• Fuel dilution
192 | Lube Oil System, Lube Oil Circuit | MS15034/00E 2018-08

Engine oil, sample extraction
and analysis
1. With the engine running at operating temper-
ature, open screw on centrifugal oil filter car-
rier by 1 to 2 rotations.
2. Drain approx. 2 liters engine oil to flush out
the oil sludge.
container.
4. Close screw.
• Fuel dilution
Engine oil, sample extraction

and analysis (engine with
switchable oil filter)
1. With the engine running at operating temper-
ature, open screw on flange of centrifugal oil
filter by 1 to 2 rotations.
2. Drain approx. 2 liters engine oil to flush out
the oil sludge.
container.
4. Close screw.
• Fuel dilution
TIM-ID: 0000014113 - 007

8.15 Oil Filtration / Cooling
8.15.1 Engine oil filter – Replacement
Filter wrench F30379104
Engine oil
Oil filter (→ Spare Parts Catalog)
DANGER
WARNING
WARNING
Oil is hot.
NOTICE
Engine oil filter – Replacement

1. Stop engine (→ Page 92) and disable engine
start.
2. Unscrew engine oil filter using filter wrench.
3. Clean sealing surface on connecting piece.
4. Check condition of the new engine oil filter
sealing ring and coat it with engine oil.
TIM-ID: 0000014238 - 009
5. Fit SOLAS shield

6. Screw on engine oil filter and tighten by
hand.
7. Replace other engine oil filters in the same
way.
8. Crank engine on starting system after every
engine oil change and filter replacement
(→ Page 143).
194 | Oil Filtration / Cooling | MS15034/00E 2018-08

Engine oil filter with diverter
(option) – Oil filter replacement
with engine at standstill
start.
5. Fit SOLAS shield
hand.
way.
8. Crank engine on starting system after every
engine oil change and filter replacement
(→ Page 143).
Engine oil filter with diverter

(option) – Oil filter replacement
with engine running
1. To cut out the filter to be replaced, set the
three-way cock to the corresponding posi-
tion.
• Position A: Lower filters cut out
• Position B: Both filters cut in (normal oper-
ating position)
• Position C: Upper filters cut out

5. Fit SOLAS shield
hand.
TIM-ID: 0000014238 - 009

way.
MS15034/00E 2018-08 | Oil Filtration / Cooling | 195

8.15.2 Oil indicator filter – Cleaning and check
Preconditions

Cleaner (Snow-White 11-0) X00054118 1
Cleaner (Hakupur 50/136) X00056700 1
Engine oil
Strainer (→ Spare Parts Catalog)
Square-section ring (→ Spare Parts Catalog)
WARNING
Oil is hot.
WARNING
NOTICE
Inappropriate cleaning tool.
• Use appropriate cleaning tool.
Removing basket strainer – var-

iant A
1. Clean oil indicator filter before disassembling
it.
2. Remove screws (1).
3. Take off cover (2) and O-ring (3).
4. Remove spring (4) and strainer (6) from filter
TIM-ID: 0000036227 - 010
housing and allow oil to drip into container.

Cleaning strainer
1. Shake coarse contamination out of strainer (6).
2. Clean all metallic parts with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 50/136).
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 (6) with compressed air from outside to inside.
Checking strainer
Item Findings Task
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 (5) on strainer (6) with engine oil and install strainer (6).
2. Coat O-ring (3) with engine oil and install in filter housing.
3. Install spring (4).
4. Fill housing with new engine oil.
5. Install cover (2) and secure with screws (1) and washers.
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.
TIM-ID: 0000036227 - 010
Cleaning strainer
1. Shake coarse contamination out of strainer (5).
2. Clean all metallic parts with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 50/136).
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
Item Findings Task
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: 0000036227 - 010

8.15.3 Centrifugal oil filter – Cleaning and filter sleeve replacement
Preconditions

Cold cleaner (Hakutex 60) X00056750
Engine oil
Filter sleeve (→ Spare Parts Catalog)
WARNING
Oil is hot.
WARNING
TIM-ID: 0000014256 - 007

Centrifugal oil filter – Cleaning
and filter sleeve replacement
1. Remove clamp (14).
2. Loosen Tommy nut (2) and take off hood (1).
3. Carefully lift rotor (11), allow oil to drain and
remove from housing.
4. Holding the rotor (11) firmly, loosen rotor
cover nut (3).
5. Take off rotor cover (4).
6. Remove filter sleeve (6).
7. Measure layer thickness of oil residues on fil-
ter sleeve (6).
Result: If the oil residues exceed the maximum layer
thickness of 45 mm, shorten the mainte-
nance interval.
8. Disassemble rotor tube (7), conical disk (8)
and rotor base (10).
9. Wash rotor cover (4), rotor tube (7), conical
disk (8) and rotor base (10) with cold cleaner.
10. Blow out with compressed air.
11. Check sealing ring (9), fit new one as neces-
sary.
12. Assemble rotor tube (7), conical disk (8) and
rotor base (10) with sealing ring (9).
13. Insert new filter sleeve (6) in rotor tube (7)
with the smooth paper surface facing the out-
er wall.
14. Check sealing ring (5), fit new one as neces-
sary.
15. Mount rotor cover (4) with sealing ring (5).
16. Tighten rotor cover nut (3) to specified torque using a torque wrench.
Nut Tightening torque 80 Nm ± 12 Nm
17. Place rotor (11) in housing (12) and check for ease of movement.
18. Check sealing ring (13), fit new one as necessary.
19. Fit sealing ring (13) on housing (12).
20. Fit hood (1).
21. Tighten Tommy nut (2) by hand.
22. Install clamp (14) and tighten to specified torque using a torque wrench.
Clamp Tightening torque 20 Nm ± 3 Nm
23. Tighten cover nut (2) to specified torque using a torque wrench.
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Screw Tightening torque 7 Nm ± 1 Nm

Cleaning centrifugal oil filter
and replacing filter sleeve (oil
filters with diverter)
1. Undo screw (1) and remove.
2. Remove clamp (3) and take off hood (2).
3. Carefully remove rotor assembly (5) from
housing.
4. Hold rotor assembly (5) firmly in position with
filter wrench and undo knurled nut (7).
5. Take off rotor cap (8).
6. Take off filter sleeve (9), stiffener plate (10 )
and sealing ring (11).
7. Measure thickness of oil residue on filter
sleeve.
8. If maximum layer thickness of oil residues ex-
ceeds 30 mm, shorten maintenance interval.
9. Remove standpipe (12) from lower rotor sec-
tion (13).
10. Wash out hood (2), rotor cap (8), stiffener
plate (10), stand pipe (12), base (13) and noz-
zles (14) with cleaner and blow out with com-
pressed air. Do not use sharp-edged objects
for cleaning.
11. Check nozzles (14) for obstructions.
12. Press standpipe (12) onto rotor lower sec-
tion (13).
13. Insert new filter sleeve (9) with stiffener
plate (10) into rotor cap (8), ensuring that
smooth surface of filter sleeve (9) faces rotor
cap (8).
14. Check sealing ring (11), replace as necessa-
ry. Coat sealing ring with grease and insert in
groove of rotor cap (8).
15. Place rotor cap (8) onto standpipe (12).
16. Hold rotor assembly (5) firmly in position with
filter wrench and tighten knurled nut (7).
17. Lubricate bearings of rotor assembly (5), in-
sert into housing (6) and check for ease of
movement.
18. Check sealing ring (4), replace as necessary.
Fit sealing ring on housing (6).
19. Fit hood (2).
20. Tighten screw (1) by hand.
21. Install clamp (3) and tighten to specified torque using a torque wrench:
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Clamp Tightening torque 6 Nm + 1 Nm
22. Tighten screw (1) to specified torque using a torque wrench:

Screw Tightening torque 6 Nm + 1 Nm

8.16 Coolant Circuit, General, High-Temperature Circuit
8.16.1 Drain and vent points
Coolant line to carrier housing
1 Venting point
Coolant line to intercooler

Arrows Vent points
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202 | Coolant Circuit, General, High-Temperature Circuit | MS15034/00E 2018-08

Coolant line to crankcase breather
1 Venting point
Coolant line to raw water cooler

1 Distribution cross
2 Venting point
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MS15034/00E 2018-08 | Coolant Circuit, General, High-Temperature Circuit | 203

Coolant drain point, driving end
1 Drain points
Coolant drain point, free end

1 Drain point
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8.16.2 Engine coolant level – Check
Preconditions
WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.
Checking engine coolant level at filler neck:

1. Turn breather valve on coolant expansion tank (for engines with remote heat exchanger: the expansion tank
is part of the remote cooling system) counterclockwise up to the first stop and allow pressure to escape.
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 in the filler neck).
Checking engine coolant level at

external cooler:
1. Check coolant level (coolant must be visible
at marker plate).
2. Top up with treated coolant as necessary
(→ Page 208).
3. Check and clean breather valve.
4. Set breather valve onto filler neck and close
it.
Checking engine coolant level by means of level sensor:

1. Switch on engine control system and check readings on the display.
2. Top up with treated coolant as necessary (→ Page 208).
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8.16.3 Engine coolant – Change
Coolant
Engine coolant change

1. Drain engine coolant (→ Page 207).
2. Fill with engine coolant (→ Page 208).
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8.16.4 Engine coolant – Draining
Preconditions
WARNING
Preparatory steps
1. Provide an appropriate container to drain the coolant into.
2. Switch off preheating unit.
Engine coolant – Draining

1. Turn breather valve on expansion tank (for
engines with remote heat exchanger: the ex-
pansion tank is part of the remote cooling
system) counterclockwise up to the first stop
and allow pressure to escape.
2. Continue to turn breather valve counterclock-
wise and remove.
3. Draw off precipitated corrosion inhibitor oil
from the expansion tank through filler neck.
4. Open vent valves at the following points:
• On carrier housing and near the crankcase
breather (1)
• On seawater cooler (2) (with remote heat
exchanger, the seawater cooler is not en-
gine-mounted)
5. Open drain screws and drain engine coolant
at the following drain points:
• Elbow of HT coolant pump (3)
• Crankcase, left and right side (4)
Final steps
1. Close all open drain and vent points.
2. Set breather valve onto filler neck and close it.
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8.16.5 Engine coolant, filling
Preconditions

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.
Preparatory steps
1. Turn valve cover (1) on expansion tank (for
engines with remote heat exchanger: the ex-
pansion tank is part of the remote cooling
system) counterclockwise up to the first stop
and allow pressure to escape.
2. Continue to turn valve cover counterclock-
wise and remove.
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Filling with coolant through fill-
er neck
1. Open vent points on exhaust turbocharger,
charge-air cooler, at the crankcase ventila-
tion and on plate-core heat exchanger (ar-
rows).
2. Fill coolant through the filler neck of the ex-
pansion tank (for engines with remote heat
exchanger: the expansion tank is part of the
remote cooling system) until the coolant level
at the top edge of the filler neck remains con-
stant.
3. When coolant emerges from the vent points,
close vent points one by one, proceeding
from the lowest point upwards.
4. Check proper condition of valve cover and
clean sealing faces if required.
5. Set valve cover onto filler neck and turn until
the first stop.
7. After 10 seconds of running the engine with-
out load, shut down the engine (→ Page 92).
8. Turn valve cover counterclockwise and re-
move.
9. Check coolant level (→ Page 205) and top up
coolant as required:
a) Repeat the steps from "Start engine"
(→ Step 6) until coolant is no longer
needed to be topped up.
b) Check proper condition of valve cover
and clean sealing faces if required.
c) Place valve cover on filler neck and
close.
Final steps
1. Start the engine and run it without load for some minutes.
2. Check coolant level (→ Page 205) and top up coolant as required.
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8.16.6 HT coolant pump – Relief bore check
DANGER
WARNING
HT coolant pump – Relief bore

check
1. Check relief bore for oil and coolant dis-
charge.
2. Stop engine (→ Operating Instructions for
Electronic System) and disable engine start.
3. Clean relief bore with a wire if dirty.
• Admissible engine coolant discharge: up to
10 drops per hour;
• Admissible oil discharge: up to 5 drops per
hour.
4. Contact Service if discharge exceeds the
specified limits.
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8.16.7 Engine coolant – Sample extraction and analysis
Preconditions

MTU test kit F6798833 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.
container.
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4. Tighten shut-off cock (arrow) with torque wrench to the specified tightening torque.
Spindle 11a/f Tightening torque 12 Nm
5. Using the equipment and chemicals of the MTU test kit, examine engine coolant for:
• antifreeze concentration
• concentration of corrosion protection oil
• pH value
6. For engine coolant change intervals, see (→ MTU Fluids and Lubricants Specifications).

8.16.8 Engine coolant filter – Replacement
Preconditions

Engine oil
Engine coolant filter (→ Spare Parts Catalog)
WARNING
Engine coolant filter – Replace-

ment
1. Remove locking device (1).
2. Close shut-off cock (3).
3. Remove engine coolant filter (2) with filter
wrench.
5. Coat seal on new engine coolant filter (2)
with engine oil.
6. Screw on engine coolant filter (2) and tighten
hand-tight.
7. Open shut-off cock (3).
8. Install locking device (1).
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8.16.9 Preheater – Function and leak-tightness check
Preconditions
☑ Preheater is switched on.
WARNING
Coolant is hot and highly pressurized.
Risk of injury! Risk of scalding!
• Allow engine to cool down.
Checking operation
Note: The coolant temperature must correlate to the control range of the thermostat when the preheater is ready
for operation.
1. Check coolant preheating temperature.
2. Set the thermostat accordingly if the temperatures are not in the control range.
Checking for leaks

1. Check leak-tightness at coolant inlet and outlet.
2. Tighten any leaking unions.
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8.16.10 Preheating unit
HotstartPreheating unit
1 Plastic cap (drain) 4 Shut-off valve 7 Thermostat

2 On/Off switch 5 Continuous flow heater 8 Circulating pump
3 Plastic cap (inlet) 6 Vent valve
Number of Rated voltage / frequency Heating output kW
cylinders
8V 230 V / 50 Hz 9
400 V / 50 Hz 9
230 V / 60 Hz 9
440 V / 60 Hz 9
Function
The preheating unit heats up the engine coolant. The circulating pump (8) ensures the circulation of the pre-
heated coolant through the engine.
The flow heater (5) incorporates a heating element. When the coolant temperature has reached the value of
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the thermostat setting (7), the thermostat switches off the preheating unit via contactors.
In the event of excessive coolant temperature, the temperature limiter of the thermostat (7) opens the con-
trol loop. The preheating unit is switched off.
The system is reset manually after the fault has been eliminated.

HilzingerPreheating unit
1 On/Off switch
Number of Rated voltage / frequency Heating output kW
cylinders
8V 230 V / 50 Hz 4.5
400 V / 50 Hz 4.5
230 V / 60 Hz 4.5
440 V / 60 Hz 4.5
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1 Flange (supply and return) 3 Non-return flap 5 Thermostat
2 Junction box 4 Continuous flow heater 6 Circulating pump
Function
The preheating unit heats up the engine coolant. The circulating pump (6) ensures the circulation of the pre-
heated coolant through the engine.
The flow heater (4) incorporates a heating element. A non-return flap (3) prevents coolant from flowing
through the preheating unit when the engine is running.
When the coolant temperature has reached the value of the thermostat setting, the thermostat (5) switches
off the preheating unit via contactors.
In the event of excessive coolant temperature, the temperature limiter in the thermostat (5) opens the con-
trol loop. The preheating unit is switched off.
The system is reset manually after the fault has been eliminated.
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8.16.11 Preheater – Overhaul
Preconditions
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
Overhauling preheater
1. Disconnect power supply to heating element.
2. Close shut-off valve in coolant line before and after preheater.
3. Drain coolant at drain valve into a clean container.
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. Remove heating element.
8. Clean heating element and tank.
9. Remove pump from volute (if applicable) and check for residues in impeller and lines.
10. Install heating element.
11. Connect heating element to power supply.
12. Connect hoses and open shut-off valves.
13. Check preheater for leakage and correct operation (→ Page 213).
14. Check coolant level (→ Page 205).
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8.17 Raw Water Pump with Connections
8.17.1 Raw water pump – Relief bore check
DANGER
WARNING
Raw water pump – Relief bore

check
1. Check relief bore for oil and coolant dis-
charge.
start.
3. Clean the relief bore with a wire if it is conta-
minated.
• Admissible engine coolant discharge: up to
10 drops per hour
• Admissible oil discharge: up to 5 drops per
hour
4. If discharge exceeds the specified limits, con-
tact Service.
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218 | Raw Water Pump with Connections | MS15034/00E 2018-08

8.18 Battery-Charging Generator
8.18.1 Battery-charging generator drive – Coupling condition check
Preconditions

Endoscope Y20097353 1
Battery-charging generator drive, coupling condition check

1. Install barring tool (→ Page 141).
2. Guide endoscope optics between guard
plate (1) and battery-charging generator car-
rier (2) (arrow).
Note: Seek the assistance of a second person
3. Bar engine slowly by hand.
4. Examine the resilient coupling over the entire
circumference for plastic deformation and
cracks.
5. If there is serious deformation or crack for-
mation, contact Service.
6. Remove barring gear (→ Page 141).
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MS15034/00E 2018-08 | Battery-Charging Generator | 219

8.19 Engine Mounting / Support
8.19.1 Engine mounting – Checking resilient element
NOTICE
Contamination of engine mounts made of natural rubber with fuel or oil.
Engine mounts swell. Risk of shorter service life or destruction of the mounts!
• Cover engine mounts when working with fuel or oil.
• Remove contaminations on the rubber mounts immediately with a dry cloth and degrease them.
Engine mounting – Check

Item Findings Action
Visually inspect resilient elements. • Damage Replace (contact Service).
• Brittleness
• Deformation
• Crack formation
• Swelling
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220 | Engine Mounting / Support | MS15034/00E 2018-08

8.20 Auxiliary PTO
8.20.1 Bilge pump – Relief bore check
DANGER
WARNING
Bilge pump – Relief bore check

1. Check relief bores for oil and water dis-
charge.
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.
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MS15034/00E 2018-08 | Auxiliary PTO | 221

8.21 Fuel Supply System
8.21.1 Water drain valve – Check
Water drain valve – Check

1. Open water drain valve.
2. Check water outlet for obstructions.
3. Close water drain valve.
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222 | Fuel Supply System | MS15034/00E 2018-08

8.21.2 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.
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MS15034/00E 2018-08 | Fuel Supply System | 223

8.21.3 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.
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8.21.4 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 90).
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).
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8.21.5 Coalescer filter element ‒ Replacement
Preconditions
☑ System is stopped and starting disabled.

Ratchet adapter F30027340 1
Fuel
Engine oil
Coalescer filter element (→ Spare Parts Catalog)
Gasket (→ Spare Parts Catalog)
WARNING
• Do not smoke.
NOTICE
Contamination of components.
• Check components for special cleanliness.
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.
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).
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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.
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8.22 Wiring (General) for Engine/Gearbox/Unit
8.22.1 Engine wiring harness and mounts – Overview
Designation Terminal assignment
Sensors B1 Camshaft speed
B3 Intake air temperature
B4.21 Exhaust gas temperature, A-side
B4.22 Exhaust temperature, B-side
B5.1 Lube oil pressure after filter
B5.3 Lube oil pressure before filter
B5.8 Lube oil pressure before ETC, A-side (optional)
B6 Coolant temperature
B7 Lube oil temperature
B9 Charge-air temperature
B10 Charge-air pressure
B13 Crankshaft speed
B16 Coolant pressure
B33 Fuel temperature
B34.1 Fuel pressure after filter
B34.2 Fuel pressure before filter
B34.3 Fuel pressure before external filter
B44.1 Exhaust turbocharger A speed
B44.2 Exhaust turbocharger B speed
B48 HP fuel
B49 Charge air before recirculation
B50 Crankcase pressure
B54 Replenishment pump pressure
Level monitor F33 Coolant level
XF33 Coolant level adaption
XXF33 Coolant level, hull-mounted cooling system
F46 Leak fuel level
Pump M8 Fuel pump
Limit switch S37.1 Start interlock A
S37.2 Start interlock B
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228 | Wiring (General) for Engine/Gearbox/Unit | MS15034/00E 2018-08

Designation Terminal assignment
Adaption X1 ECU
X2 Governor ECU-7
X3 ECU Power
X4 Governor ECU-7
X37 Start interlock turning
X52 EIM engine box
XB19 Starting air pressure
XD1 Dialog
XG03 Battery-charging generator
XY1 Starting system
Valves Y26 Charge-air recirculation
Y27 Exhaust turbocharger
Injectors Y39A1 to Y39AX Engine side A
Y39B1 to Y39BX Engine side B
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MS15034/00E 2018-08 | Wiring (General) for Engine/Gearbox/Unit | 229

Engine wiring harness for sensors
X2 Engine governor B16 Coolant pressure M8 Fuel pump

B1 Camshaft speed B33 Fuel temperature F46 Leak fuel level
B3 Intake air temperature B34.1 Fuel pressure after filter S37.1 Start interlock limit switch A
B4.21 Exhaust gas temperature, A- B34.2 Fuel pressure before filter S37.2 Start interlock limit switch B
side B34.3 Fuel pressure before exter- X37 Start interlock turning
B4.22 Exhaust temperature, B-side nal filter Y26 Charge-air recirculation
B5.1 Lube oil pressure after filter B44.1 Exhaust turbocharger A Y27 Turbocharger valve
B5.3 Lube oil pressure before fil- speed XG03 Battery-charging generator
ter B44.2 Exhaust turbocharger B XF33 Coolant level
B6 Coolant temperature speed XXF33 Coolant level
B7 Lube oil temperature B48 HP fuel
B9 Charge-air temperature B49 Charge air before recircula-
B10 Charge-air pressure tion
B13 Crankshaft speed B50 Crankcase pressure
B54 Refill pump pressure
F33 Coolant level
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Engine wiring harness for injectors
80 Injector wiring harness

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Engine wiring harness for EIM
1 XD1 4 X52 7 XB19

2 X1 5 XY1 8 X37
3 X3 6 X11
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Engine wiring harness for electric starter
1 EIM terminals 2 Fuse FM1 3 Starter connecting termi-

nals
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8.22.2 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.
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8.23 Accessories for (Electronic) Engine Governor / Control System
8.23.1 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.
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MS15034/00E 2018-08 | Accessories for (Electronic) Engine Governor / Control System | 235
8.23.2 Engine Control Unit ECU 7 – Checking plug connections
Preconditions
Check plug connections on ECU

7
1. Check all connectors on ECU for firm seating.
Ensure that the clips (1) are engaged.
2. Check screws (2) of cable clamps on ECU for
firm seating. Ensure that cable clamps are
not faulty.
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236 | Accessories for (Electronic) Engine Governor / Control System | MS15034/00E 2018-08
8.23.3 Engine Monitoring Unit EMU 7 – Plug connection check
Preconditions
Checking EMU plug connections

1. Check both connectors on EMU (2) for firm
seating. Make sure that frames (3) are engag-
ed.
2. Check screws (1) of cable clamps on EMU (2)
for firm seating. Make sure that cable clamps
are not defective.
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8.23.4 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.
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8.23.5 Engine governor ECU 7 – Removal and installation
Preconditions
☑ Engine electronics is powered off.
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 (3).
3. Undo clips (2) on connectors.
4. Remove all male 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.
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8.23.6 Engine Interface Module EIM 2 – Removal and installation
Preconditions
Removing Engine Interface Mod-

ule from engine
1. Note or mark assignment of cables and con-
nectors.
2. Unscrew all screws (1).
4. Disconnect all connectors.
5. Unscrew power and starter cable.
7. EIM 2.
Installing Engine Interface Module on 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 2 still does not have appropriate FSW and parameter/descriptor module (the diagnostic lamp
(DILA) indicates flashing code 4 when the power supply is connected, (→ Page 241)).
2. The FSW and the parameter/descriptor module must first be downloaded from the central database (CDB)
based on the relevant engine number using the DiaSys ® software tool, and then loaded in the EIM 2.
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8.23.7 Engine Interface Module EIM 2 – Diagnostic features
Diagnostic lamp (DILA)
A diagnostic lamp (LED, blue) is integrated in the housing of the Engine Interface Module (EIM 2).
It indicates the operating status of the EIM 2.
Functions of diagnostic lamp DILA
DILA glows Engine Interface Module (EIM 2) is OK.
DILA dark EIM 2 supply voltage missing or diagnostic lamp activation is faulty.
DILA flashes Hardware or software fault in the Engine Interface Module
The diagnostic lamp (DILA) signals the following states:
1 Time in seconds 4 Application loader active 7 No firmware

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

A second indicator is the fuse lamp.
TIM-ID: 0000038009 - 005
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 2 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: 0000038009 - 005
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 2.
TIM-ID: 0000038009 - 005
8.23.8 EMU 7 – Removal and installation
Preconditions
☑ Engine electronics is powered off.
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 ECU with EMU from

engine
1. Note or mark assignment of cables and
plugs.
2. Remove all screws (2).
4. Remove all male connectors.
6. Remove ECU (5) with EMU (4).
Removing EMU
1. Unscrew screws on base of EMU (4).
2. Remove EMU (4) from ECU (5).
Installing EMU
1. Place EMU (4) on ECU (5).
2. Screw in and tighten screws on base of EMU (4).
Installing ECU with EMU 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: 0000016799 - 008
8.23.9 CDC parameters – Reset
Preconditions
Note: Failure to reset drift compensation (CDC parameters) will void the emissions certification.
Resetting CDC parameters with DiaSys®

u (→ Dialog system DiaSys® E531920/..).
Resetting CDC parameters without DiaSys®

u If no DiaSys® is available, contact Service.
TIM-ID: 0000044684 - 001
9 Appendix A
9.1 List of abbreviations
Abbrevia- Meaning Explanation
tion
ADEC Advanced Diesel Engine Control Engine Control Unit
AL Alarm Alarm (general)
ANSI American National Standards Institute Association of American standardization organiza-
tions
ATL Abgasturbulader Exhaust turbocharger
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 Con-
trol Unit
CPP Controllable Pitch Propeller
DILA Diagnostic lamp On EIM
DIN Deutsches Institut für Normung e. V. German National Standards Institute, 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
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
EIL Engine Ident Label Electronic nameplate which identifies the engine
EMU Engine Monitoring Unit
EPA Environmental Protection Agency US regulatory body which implements federal laws
on environmental protection and develops standards
to ensure compliance with these laws
ETK Spare parts catalog
FPP Fixed Pitch Propeller
GCU Gear Control Unit
GMU Gear Monitoring Unit
TIM-ID: 0000002050 - 007
HAT Harbor Acceptance Test

HI High Range violation alarm (1st upper limit)
HIHI High High Range violation alarm (2nd upper limit)
HT High Temperature
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
246 | Appendix A | MS15034/00E 2018-08

Abbrevia- Meaning Explanation
tion
IIG Initial Injector Equalization Entering of injector code with DiaSys in engine gover-
nor
IMO International Maritime Organization
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 Range violation alarm (1st lower limit value)
LOLO Low Low Range violation alarm (2nd lower 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
OT Oberer Totpunkt Top Dead Center
P-xyz Pressure-xyz Pressure measuring point xyz
PAN Panel Control panel
PCU Propeller Control Unit Propeller controller
PIM Peripheral Interface Module
RCS Remote Control System
RL Redundancy Lost Alarm: Redundant CAN bus failure
SAE Society of Automotive Engineers U.S. standardization organization
SAT Sea Acceptance Test
SD Sensor Defect Alarm: Sensor failure
SDAF Shut Down Air Flap(s) Emergency air-shutoff flap(s)
SILA Fuse lamp on EIM
SOLAS International Convention for the Safety
of Life at Sea
SS Safety System Safety system alarm
TIM-ID: 0000002050 - 007
SSK Schnellschlussklappe(n) Emergency air-shutoff flap(s)

T-xyz Temperature-xyz Temperature measuring point xyz
TD Transmitter Deviation Alarm: Deviation in transmitter values
UT Unterer Totpunkt Bottom Dead Center
VS Voith Schneider Voith-Schneider drive
WJ Water jet Water jet drive
WZK Werkzeugkatalog Tool catalog
ZKP Zugehörigkeit-Kategorie-Parameter Assignment category parameter; number scheme for
signals from the ADEC engine governor
MS15034/00E 2018-08 | Appendix A | 247

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
248 | Appendix A | MS15034/00E 2018-08

10 Appendix B
10.1 Special Tools
Barring tool
Part No.: F6555766
Qty.: 1
Used in: 8.2.1 Engine – Barring manually (→ Page 141)
Qty.: 1
Used in: 8.3.1 Cylinder liner – Endoscopic examination
(→ Page 144)
Endoscope
Part No.: Y20097353
Qty.: 1
(→ Page 144)
Qty.: 1
Used in: 8.18.1 Battery-charging generator drive – Coupling condi-
tion check (→ Page 219)
Feeler gauge
Part No.: Y20098771
Qty.: 1
Used in: 8.5.2 Valve clearance – Check and adjustment
(→ Page 150)
DCL-ID: 0000051756 - 001
MS15034/00E 2018-08 | Appendix B | 249

Filter wrench
Part No.: F30379104
Qty.: 1
Used in: 8.8.2 Additional fuel filter – Replacement (→ Page 167)
Qty.: 1
Used in: 8.8.3 Fuel filter – Replacement (→ Page 168)
Qty.:
Used in: 8.15.1 Engine oil filter – Replacement (→ Page 194)
Qty.: 1
Used in: 8.16.8 Engine coolant filter – Replacement (→ Page 212)
Fuel suction device

Part No.: F30378207
Qty.: 1
Used in: 8.6.1 HP fuel pump – Filling with engine oil (→ Page 155)
High-pressure cleaner
Part No.:
Qty.: 1
Used in: 5.15 Plant – Cleaning (→ Page 95)
Installation/removal jig
Part No.: F6789889
Qty.: 1
Used in: 8.7.2 Injector – Removal and installation (jacketed fuel
system) (→ Page 159) DCL-ID: 0000051756 - 001
250 | Special Tools | MS15034/00E 2018-08

Milling cutter
Part No.: F30452739
Qty.: 1
system) (→ Page 159)
MTU test kit

Part No.: 5605892099/00
Qty.: 1
Used in: 8.14.3 Engine oil – Sample extraction and analysis
(→ Page 192)
MTU test kit

Part No.: F6798833
Qty.: 1
Used in: 8.16.7 Engine coolant – Sample extraction and analysis
(→ Page 211)
Ratchet adapter
Part No.: F30027340
Qty.: 1
Used in: 8.8.7 Fuel prefilter with water separator – Filter element
replacement (→ Page 175)
Qty.: 1
DCL-ID: 0000051756 - 001
Used in: 8.21.5 Coalescer filter element ‒ Replacement

(→ Page 226)
MS15034/00E 2018-08 | Special Tools | 251

Ratchet bit
Part No.: F30027341
Qty.:
Used in: 8.5.4 Cylinder head cover – Removal and installation
(→ Page 154)
Qty.: 1
Used in: 8.14.2 Engine oil – Change (→ Page 190)
Ratchet bit
Part No.: F30027340
Qty.: 1
Qty.: 1
Used in: 8.15.3 Centrifugal oil filter – Cleaning and filter sleeve re-
placement (→ Page 199)
Ratchet bit
Part No.: F30027342
Qty.: 1
Ratchet with extension

Part No.: F30006212
Qty.: 1
Used in: 8.2.1 Engine – Barring manually (→ Page 141)
Qty.: 1
DCL-ID: 0000051756 - 001
(→ Page 144)

Socket wrench, 24 mm
Part No.: F30039526
Qty.: 1
(→ Page 150)
Torque wrench, 10–60 Nm

Part No.: F30510423
Qty.:
Used in: 8.5.4 Cylinder head cover – Removal and installation
(→ Page 154)

Part No.: F30452769
Qty.: 1
Used in: 8.6.1 HP fuel pump – Filling with engine oil (→ Page 155)
Qty.: 1
Qty.: 1
Used in: 8.8.7 Fuel prefilter with water separator – Filter element
replacement (→ Page 175)

Part No.: F30026582
Qty.: 1
DCL-ID: 0000051756 - 001

Torque wrench, 4-20 Nm
Part No.: F30044239
Qty.: 1
Used in: 8.9.1 Compressor wheel – Cleaning (→ Page 179)

Part No.: F30027337
Qty.: 1
Used in: 8.14.2 Engine oil – Change (→ Page 190)

Part No.: F30044239
Qty.: 1

Part No.: F30452768
Qty.: 1
(→ Page 150)
Qty.: 1
DCL-ID: 0000051756 - 001


Part No.: F30043446
Qty.: 1
Used in: 8.21.5 Coalescer filter element ‒ Replacement
(→ Page 226)
DCL-ID: 0000051756 - 001

10.2 Index
A D
Additional fuel filter Diagnostic lamp (DILA)
– Overview 166 – EIM 2 241
– Replacement 167 Diagnostics
ADEC (ECU 7) – EIM 2 241
– Fault messages 104 Differential pressure gage
Adhesive tape for SOLAS shielding – Adjustment
– Application 140 – Fuel prefilter 170
After shutdown 94 – Alarm function check 223
Air filter – Check
– Replacement 185 – Fuel prefilter 170
Air filter – Removal and installation 186 Drain and vent points 202
Drift compensation
B – Reset 245
Battery-charging generator drive
– Check 219 E
Bilge pump ECU 7
– Relief bore check 221 – Installation 239
– Removal 239
C EMU 7
Cabling – Installation 244
– Check – Removal 244
– On engine 234 Endoscopic inspection
CDC parameters – Cylinder liner
– Reset 245 – Instructions and comments 146
Centrifugal oil filter Engine
– Cleaning 199 – Barring
Checks – Manually 141
– Prior to start-up 86 – With starting system 143
Coalescer filter element – Emergency stop 93
– Replacement 226 – Start 83
Compressor wheel – Stopping 92
– Cleaning 179 Engine cabling
Contact persons 248 – Check 234
Contamination indicator Engine Control Unit ECU 7
– Signal ring position check 187 – Checking plug connections 236
Controls 79 Engine coolant
Coolant – Change 206
– Change 206 – filling 208
Coupling – Filter replacement 212
– Check 219 – Sample analysis 211
Crankcase breather – Sample extraction 211
– Oil mist fine separator Engine coolant level
DCL-ID: 0000051756 - 001
– Replacement 148 – Check 205

Cylinder Engine coolant – Draining 207
– Designation 52 Engine data
Cylinder head cover – 8V4000M53, EPA Tier 2, EU Stage IIIA, IMO Tier II
– Installation 153, 154 67
– Removal 153, 154 – 8V4000M63, EPA Tier 2, EU Stage IIIA, IMO Tier II
Cylinder liner 72
– Endoscopic examination 144 ENGINE DATA 8V4000M53R (provisional) 63
– Endoscopic inspection Engine driving end
– Instructions and comments on endoscopic and visu- – Definition 52
al examination 146 Engine free end
– Definition 52
256 | Index | MS15034/00E 2018-08

Engine governor ADEC (ECU 7) H
– Fault messages 104 Hotline 248
Engine governor ECU 7 HP pump
– Installation 239 – Filling with engine oil 155
– Removal 239 – Relief bore check 157
Engine Monitoring Unit EMU 7 HT coolant pump
– Plug connection check 237 – Check
Engine mounting – Relief bore 210
– Check 220
Engine oil I
– Change 190 Injector
– Sample extraction and analysis 192 – Installation 159
Engine oil filter – Removal 159
– Replacement 194 – Replacement 158
Engine oil level Intercooler
– Check 189 – Check water drain for coolant leakage and obstruction
Engine overview 21 184
Engine sides Interface module EIM
– Designation 52 – Check 238
Engine wiring harness Interface module EIM 2
– Overview 228 – Removal and installation 240
F L
Fault messages Lifting requirements 19
– Engine governor ADEC (ECU 7) 104 Limit switch for start interlock
Filter – Check 235
– Engine coolant List of abbreviations 246
– Replacement 212
Filter sleeve M
– Replacement 199 Main engine dimensions
Firing order 77 – With engine-mounted heat exchanger 78
Fuel – With separate heat exchanger 78
– Treatment system Maintenance Schedule
– Switching on 90 – Maintenance task reference table [QL1] 96, 98
– Troubleshooting 103 MTU contact persons 248
– treatment system
– Shutdown 91 O
Fuel filter Oil indicator filter
– Replacement 168 – Check 196
Fuel prefilter – Cleaning 196
– Adjustment Operational checks 84
– Differential pressure gage 170
– Check P
– Differential pressure gage 170 Plant
Fuel prefilter with water separator – Cleaning 95
– Draining 171 Plug connections
– Filter element – Check 238
DCL-ID: 0000051756 - 001
– Flushing 173 Preheater

– Replacement 175 – Overhaul 217
– Replacement – Function and leak-tightness
– O-ring in rotary slide valve 178 – check 213
Fuel treatment system Preheating unit 214
– Initial start-up 87 Product description 25
– Shutdown 91 Pump capacity
– Switching on 90 – Check 225
Fuse lamp (SILA) Putting the engine into operation after extended out-of-
– EIM 2 241 service periods (>3 months) 80
Putting the engine into operation after scheduled out-of-
service-period 81
MS15034/00E 2018-08 | Index | 257

R
Raw water pump
– Relief bore check 218
S
Safety regulations
– Assembly work 11
– Auxiliary materials 15
– Environmental protection 15
– Fire prevention 15
– Fluids and lubricants 15
– Important provisions 5, 7
– Initial start-up 9
– Maintenance work 11
– Operation 9
– Organizational requirements 8
– Personnel requirements 8
– Repair work 11
Safety requirements
– Warning notices, standards 17
Sensors and actuators – Overview 53
Service partners 248
SOLAS shielding
– Adhesive tape application 140
– Installation 132
– As per MTN 5233 131
– Installation locations 133
Spare parts service 248
Starter
– Condition check 188
T
Tasks after extended out-of-service periods (>3 weeks) 85
Tightening specifications
– Nuts 39
– Screws and bolts 39
– Screws, nuts and bolts 39
transport 18
Transportation
– Lifting requirements 19
Troubleshooting 100
– Fuel treatment system 103
V
Valve clearance
– Adjustment 150
– Check 150
DCL-ID: 0000051756 - 001
Valve gear
– Lubrication 149
W
Warning notices, standards 17
Water drain valve
– Check 222
Water level probe (3-in-1 rod electrode)
– Check 224
258 | Index | MS15034/00E 2018-08

Operating Instructions: Diesel Engine 8V4000Mx3x

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Operating Instructions

© 2018 Copyright MTU Friedrichshafen GmbH

scheduled out-of-service-period 81 8.4.1 Crankcase breather – Oil mist fine separator

MS15034/00E 2018-08 | Table of Contents | 3

8.16 Coolant Circuit, General, High-Temperature 9 Appendix A

4 | Table of Contents | MS15034/00E 2018-08

Emission specifications and emission label

Emission certification applicable to engines with EPA Nonroad Tier 4 emission

MS15034/00E 2018-08 | Safety | 5

TIM-ID: 0000040530 - 013

6 | Safety | MS15034/00E 2018-08

MS15034/00E 2018-08 | Safety | 7

Clothing and personal protective equipment

TIM-ID: 0000040531 - 012

8 | Safety | MS15034/00E 2018-08

Safety regulations during operation

Malfunctions and emergency stop

MS15034/00E 2018-08 | Safety | 9

Operation of electrical equipment

TIM-ID: 0000040533 - 020

10 | Safety | MS15034/00E 2018-08

Safety regulations when performing assembly, maintenance, and repair work

Setting down, lifting and climbing

MS15034/00E 2018-08 | Safety | 11

Removing, installing and cleanliness

Safety regulations after performing assembly, maintenance, and repair work

12 | Safety | MS15034/00E 2018-08

Hydraulic installation and removal

Working with batteries

Working on electrical and electronic assemblies

MS15034/00E 2018-08 | Safety | 13

Working with laser equipment

Measuring component dimensions

TIM-ID: 0000040535 - 021

14 | Safety | MS15034/00E 2018-08

Environmental protection and disposal

Fluids and lubricants/auxiliary materials (process materials)

MS15034/00E 2018-08 | Safety | 15

Acids/alkalines/reducing agents (e.g. AdBlue®, DEF)

16 | Safety | MS15034/00E 2018-08

MS15034/00E 2018-08 | Safety | 17

Attach the engine at the lifting eyes provided only.

Setting the engine down after transport

18 | Transport | MS15034/00E 2018-08

Lifting requirements for installed heat exchanger

1 Maximum permissible diag- 2 Center of gravity

MS15034/00E 2018-08 | Transport | 19

1 Maximum permissible diag- 2 Center of gravity

Take note of the engine center of gravity

20 | Transport | MS15034/00E 2018-08

1 Centrifugal oil filter 5 Fuel filter 9 Bilge pump (option)

MS15034/00E 2018-08 | General Information | 21

1 Exhaust outlet 6 Engine mounting 11 Compressor housing

TIM-ID: 0000018215 - 003

22 | General Information | MS15034/00E 2018-08

1 Raw-water outlet 6 Cylinder head 11 Raw water pump

MS15034/00E 2018-08 | General Information | 23

1 Exhaust outlet 6 Oil filler neck 11 Charge-air cooler

Engine model designation

24 | General Information | MS15034/00E 2018-08

• Centrifugal lube oil filter

Intermittent oil priming for on-board power generating engines (M23-M43)

MS15034/00E 2018-08 | General Information | 25