Operating Instructions

Diesel Engine
20 V 4000 M93
20 V 4000 M93L

MS150048/03E

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 Printed in Germany
© 2012 Copyright MTU Friedrichshafen GmbH
This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior
written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, micro‐
filming and storage or processing on electronic systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage
during operation.
Subject to alterations and amendments.

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 Table of Contents
1 Safety 4.5 Starting the engine 53
4.6 Fuel treatment system – Switching on 54
1.1 General conditions 5 4.7 Starting the engine 55
1.2 Personnel and organizational requirements 6 4.8 Engine emergency stop at BlueLine
1.3 Transport 7 automation system (control stand) 56
1.4 Crankshaft transport locking device 8 4.9 Operational checks 57
1.5 Safety regulations for startup and operation 11 4.10 Coupling – Engaging from LOP 58
1.6 Explosion hazard when removing 4.11 Coupling – Disengaging from LOP 59
inspection port cover on engine 12 4.12 Waterjet – Flushing from LOP (optional) 60
1.7 Safety regulations for maintenance and 4.13 Stopping the engine from LOP 61
repair work 13 4.14 Stopping the engine at the BlueLine
1.8 Auxiliary materials, fluids and lubricants, automation system (control stand) 62
fire prevention and environmental 4.15 Emergency stop from LOP 63
protection 16 4.16 After stopping the engine 64
1.9 Conventions for safety instructions in the 4.17 Fuel treatment system – Shutdown 65
text 18 4.18 Plant cleaning 66

2 General Information 5 Maintenance

2.1 Engine side and cylinder designations 19 5.1 Maintenance schedule task reference table
2.2 Product description 20 [QL1] 67
2.3 Engine overview 29
2.4 Sensors, actuators and injectors –
Overview 30
6 Troubleshooting
6.1 Fuel treatment system – Troubleshooting 68
3 Technical Data 6.2 Troubleshooting 69
3.1 20V 4000 M93 engine data: IMO, engine-
mounted heat exchanger, intercooler made
of copper-based alloy 35 7 Task Description
3.2 20V 4000 M93 engine data: EPA 2, engine-
7.1 Engine 72
mounted heat exchanger 38
7.1.1 Engine – Barring manually 72
3.3 20V 4000 M93L engine data: IMO, engine- 7.1.2 Engine – Barring with starting system 73
mounted heat exchanger, intercooler made
of copper-based alloy 41 7.2 Cylinder Liner 74
3.4 20V 4000 M93L engine data: EPA 2, 7.2.1 Cylinder liner – Endoscopic examination 74
engine-mounted heat exchanger 44 7.2.2 Cylinder liner – Instructions and comments on
3.5 Firing order 47 endoscopic and visual examination 76
DCL-ID: 0000015617 - 001

7.3 Valve Drive 78

7.3.1 Valve gear – Lubrication 78
7.3.2 Valve clearance – Check and adjustment 79
4 Operation
7.3.3 Cylinder head cover – Removal and
4.1 Controls 48 installation 83
4.2 Tasks after extended out-of-service periods
7.4 Injection Valve / Injector 84
(>3 weeks) 49 7.4.1 Injector – Replacement 84
4.3 Checks prior to start-up 50 7.4.2 Injector – Removal and installation 85
4.4 Fuel treatment system – Putting into
operation 51 7.5 Fuel Filter 90
7.5.1 Fuel filter – Replacement 90

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 7.5.2 Fuel prefilter – Differential pressure gauge
check and adjustment 92 7.16 Battery-Charging Generator 132
7.5.3 Fuel prefilter – Draining 93 7.16.1 Battery-charging generator drive – Coupling
7.5.4 Fuel prefilter ‒ Flushing 94 condition check 132
7.5.5 Fuel prefilter – Filter element replacement 96
7.17 Engine Mounting / Support 133
7.6 Charge-Air Cooling 98 7.17.1 Engine mounts – Checking securing screws
7.6.1 Compressor wheel – Cleaning 98 for firm seating 133
7.6.2 Intercooler – Check water drain for coolant 7.17.2 Engine mounts – Resilient element check 134
discharge and obstruction 100
7.18 Drive Systems, Driving End and Free End
7.7 Air Filter 101 (Coupling) 136
7.7.1 Air filter – Replacement 101 7.18.1 Coupling – Condition check 136
7.7.2 Air filter – Removal and installation 102
7.19 Fuel Supply System 137
7.8 Air Intake 103 7.19.1 Water drain valve – Check 137
7.8.1 Contamination indicator – Signal ring position 7.19.2 Differential pressure gauge – Check 138
check (optional) 103 7.19.3 Water level probe (3-in-1 rod electrode) –
7.8.2 Air flap – Check for ease of movement 104 Check 139
7.19.4 Pump capacity – Check 140
7.9 Exhaust Flap with Actuator 105 7.19.5 Coalescer filter element – Replacement 141
7.9.1 Exhaust flap – Check for easy movement 105
7.20 Wiring (General) for Engine/Gearbox/Unit 143
7.10 Starting Equipment 106 7.20.1 Engine wiring – Check 143
7.10.1 Starter – Condition check 106
7.21 Accessories for (Electronic) Engine
7.11 Lube Oil System, Lube Oil Circuit 107 Governor / Control System 144
7.11.1 Engine oil level – Check 107 7.21.1 CDC parameters – Reset with DiaSys® 144
7.11.2 Engine oil – Change 108 7.21.2 Engine governor and connectors – Cleaning 145
7.11.3 Engine oil – Sample extraction and analysis 110 7.21.3 EMU and connectors – Cleaning 146
7.21.4 Engine Monitoring Unit EMU 7 – Plug
7.12 Oil Filtration / Cooling 111 connection check 147
7.12.1 Engine oil filter – Replacement 111
7.21.5 Engine governor – Checking plug-in
7.12.2 Automatic oil filter – Oil filter candle
connections 148
replacement 113
7.21.6 ECU 7 engine governor – Removal and
7.12.3 Oil indicator filter – Check 116
installation 149
7.12.4 Centrifugal oil filter – Cleaning and filter
sleeve replacement 118 7.22 Emergency Instrumentation (Local
Operating Panel) 150
7.13 Coolant Circuit, General, High-
7.22.1 LOP and connectors – Cleaning 150
Temperature Circuit 120
7.13.1 Ventilation points 120
7.13.2 Engine coolant – Level check 121
7.13.3 Engine coolant – Change 122
7.13.4 Engine coolant draining 123 8 Appendix A
7.13.5 Engine coolant – Filling 124
7.13.6 Engine coolant pump – Relief bore check 127 8.1 Abbreviations 151
7.13.7 Engine coolant – Sample extraction and 8.2 MTU contact persons/service partners 153
analysis 128
DCL-ID: 0000015617 - 001

7.13.8 Coolant filter – Replacement 129

7.14 Low-Temperature Circuit 130 9 Appendix B

7.14.1 Charge-air coolant – Draining 130
9.1 Special Tools 154
7.15 Raw Water Pump with Connections 131 9.2 Index 161
7.15.1 Raw water pump – Relief bore check 131

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 1 Safety
1.1 General conditions

General
In addition to the instructions in this publication, the applicable country-specific legislation and other com‐
pulsory regulations regarding accident prevention and environmental protection must be observed. This
state-of-the-art engine has been designed to meet all applicable laws and regulations. The engine may
nevertheless present a risk of injury or damage in the following cases:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Modifications or conversions
• Noncompliance with the Safety Instructions

Correct use
The engine is intended solely for use in accordance with contractual agreements and the purpose envis‐
aged for it on delivery. Any other use is considered improper use. The engine manufacturer accepts no
liability whatsoever for resultant damage or injury in such case. The responsibility is borne by the user
alone.
Correct use also includes observation of and compliance with the maintenance specifications.

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

Spare parts
Only genuine MTU spare parts must be used to replace components or assemblies. MTU accepts no
liability whatsoever for damage or injury resulting from the use of other spare parts and the warranty shall
be voided in such case.

Reworking components
Repair or engine overhaul must be carried out in workshops authorized by MTU.
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 1.2 Personnel and organizational requirements

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

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

Working clothes and protective equipment

Wear proper protective clothing for all work.
Use the necessary protective equipment for the given work to be done.

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 1.3 Transport

Transport

Lift the engine only with the lifting eyes provided.

The lifting eyes are designed for engine transport only, not for the transport of propulsion units (engine
and gearbox).
Use only the transport and lifting equipment approved by MTU.
The engine must only be transported in installation position, max. permissible diagonal pull 10°.
Take note of the engine center of gravity.
In the case of special packaging with aluminum foil, suspend the engine on the lifting eyes of the trans‐
port pallet or transport with equipment for heavy loads (forklift truck).
Prior to transporting the engine, it is imperative to install transportation locking devices for crankshaft and
engine mounts.
Secure the engine against tilting during transportation. The engine must be especially secured against
slipping 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.
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 1.4 Crankshaft transport locking device

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Torque wrench, 10-60 Nm F30510423 1
Torque wrench, 60-320 Nm F30047446 1
Engine oil

Transport locking device

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

For installation and removal of the transport locking device, follow the instructions
below:
1. The transport locking device must remain installed as long as possible during engine installation in order
to avoid damage.
2. Prior to every engine transport, the transport locking device must be reinstalled on both sides according
to the instructions.
3. If the engine is to be moved together with the generator, the transport locking device for the generator
must also be installed.
4. Always use the screws supplied with or installed in the transport locking device to secure it on the en‐
gine.
5. Starting or barring the engine is allowed only with the transport locking device removed. If the generator
is already mounted on the engine, ensure that the transport locking device of the generator is also re‐
moved.
6. Attach these instructions, clearly visible, to the engine.

Removing guard plates and engine

mounting brackets (if applicable)
on driving end (KS)
1. Remove screws (4) om both sides and take
off with washers (3), guard plates (1) and
engine mounting brackets (2).
2. Store the removed parts of the transport
locking device carefully for possible reuse.
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 Fitting the transport locking device
on driving end (KS)

Note: Attach plates (2) only to the upper part of the openings.
1. Secure the two plates (2) with screws (6) and washers (5) at the bores on both sides of the flywheel
housing and tighten to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw M16 Tightening torque (Engine oil) 250 Nm +25 Nm
2. Screw nut (3) onto screws (4) up to the end of the thread.
3. The long end of retainers (1) must face downwards. Push retainers (1) with the round front face through
the plate openings (2).
Note: The retainers (1) must lock the flywheel only, not the ring gear.
4. Install screws (4) into the bores of retainers (1) until the retainers (1) are locked in position.
5. Tighten screws (4) alternately with torque wrench to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw M10 Tightening torque (Engine oil) 30 Nm +3 Nm
6. Screw on nuts (3) of both screws (4) at plates (2) and secure.

Removing the transport locking

device from driving end (KS)
1. Release the locknuts (3) on both sides of
the flywheel housing, remove screws (4)
and take off the two locks (1).
2. Unscrew screws (6) and remove together
with washers (5) and plates (2).
3. Store the removed parts of the transport
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locking device together with this documen‐

tation carefully for possible reuse.

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 Installing guard plates and engine
mounting brackets (if applicable)
on driving end (KS)
Note: Always use the screws supplied with the or
removed from the guard plates and engine
mounting brackets to secure them on the
engine.
1. Install engine mounting brackets (2) on both
sides with guard plates (1) washers (3), and
screws (4).
2. Tighten screws (4).

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 1.5 Safety regulations for startup and operation

Safety precautions when putting the equipment into operation

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

Safety regulations for equipment operation

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

Engine operation
The following conditions must be fulfilled before starting the engine:
• Wear ear protectors.
• Ensure that the engine room is well ventilated.
• Do not inhale engine exhaust gases.
• Ensure that the exhaust system is free of leaks and that the gases are discharged to atmosphere.
• Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binding
agent.
• Protect battery terminals, battery-charger terminals and cables against accidental contact.
• When the engine is running, never release coolant, oil, fuel, compressed-air or hydraulic lines.

Operation of electrical equipment

When operating electrical equipment, certain components of this equipment are live.
Observe the safety instructions for these devices.
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 1.6 Explosion hazard when removing inspection port cover on
engine

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

Safety instructions
u Before starting maintenance work, allow the engine to cool down for at least 10 min. (danger of explosion
due to oil vapors).

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 1.7 Safety regulations for maintenance and repair work

Safety regulations for maintenance and repair work

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

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 Welding work
Never carry out welding work on the assembly, system, or engine-mounted units. Cover the engine when
welding in its vicinity.
Do not use the assembly or system as ground terminal.
Do not route the welding lead over or near the wiring harnesses of MTU systems. The welding current
may otherwise induce an interference voltage in the wiring harnesses which could conceivably damage
the electrical system.
Remove parts (e.g. exhaust pipes) which are to be welded from the engine beforehand.

Hydraulic installation and removal

Check the function and safe operating condition of tools and fixtures to be used. Use only the specified
devices for hydraulic removal/installation procedures.
Observe the max. permissible push-on pressure specified for the equipment.
Do not attempt to bend or apply force to lines.
Before starting work, pay attention to the following:
• Vent the hydraulic installation/removal tool, the pumps and the lines at the relevant points for the
equipment to be used (e.g. open vent plugs, pump until bubble-free air emerges, close vent plugs).
• For hydraulic installation, screw on the tool with the piston retracted.
• For hydraulic removal, screw on the tool with the piston extended.
For a hydraulic installation/removal tool with central expansion pressure supply, screw spindle into shaft
end until correct sealing is established.
During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of the
component to be installed/removed.

Working on electrical/electronic assemblies

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

Working with laser equipment

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

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 For conducting light-beam procedures and measurement work, only the following laser devices must be
used:
• Laser devices of classes 1, 2 or 3A.
• Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700
nm), a maximum output of 5 mW, and in which the beam axis and surface are designed to prevent
any risk to the eyes.
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 1.8 Auxiliary materials, fluids and lubricants, fire prevention and
environmental protection

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

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

Environmental protection and disposal

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

Auxiliary materials, fluids and lubricants

Use only fluids and lubricants that have been tested and approved by MTU.
The Fluids and Lubricants Specifications will be amended or supplemented as necessary. Before using
them, make sure you have the latest version. The latest version is also available at: http://www.mtu-on‐
line.com/mtu/mtu-valuecare/mtu-valueservice-Technische-Dokumentation.
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Keep fluids and lubricants in suitable, properly designated containers. When using fluids, lubricants and
other chemical substances, follow the safety instructions that apply to the product. Take special care
when using hot, chilled or caustic materials. When using flammable materials, avoid all sparks and do
not smoke.

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

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 Lead
• When working with lead or lead-containing compounds, avoid direct contact to the skin and do not
inhale lead vapors.
• Adopt suitable measures to avoid the formation of lead dust.
• Switch on extraction system.
• Wash hands after contact with lead or lead-containing substances.

Compressed air
Observe special safety precautions when working with compressed air:
• Pay special attention to the pressure level in the compressed air network and pressure vessel.
• Assemblies and equipment to be connected must either be designed for this pressure, or, if the per‐
mitted pressure for the connecting elements is lower than the pressure required, a pressure reducing
valve and safety valve (set to permitted pressure) must form an intermediate connection.
• Hose couplings and connections must be securely attached.
• Wear goggles when blowing off components or blowing away chips.
• Provide the snout of the air nozzle with a protective disk (e.g. rubber disk).
• First shut off compressed air lines before compressed air equipment is disconnected from the supply
line, or before equipment or tool is to be replaced.
• Unauthorized use of compressed air, e.g. forcing flammable liquids (danger class AI, AII and B) out of
containers, results in a risk of explosion.
• Forcing compressed air into thin-walled containers (e.g. containers made of tin, plastic and glass) for
drying purposes or to check for leaks, results in a risk of bursting.
• Carry out leak test in accordance with the specifications.

Paints and lacquers

• When carrying out painting work outside the spray stands provided with fume extraction systems, en‐
sure that the area is well ventilated. Make sure that neighboring work areas are not impaired.
• No open flames.
• No smoking.
• Observe fire prevention regulations.
• Always wear a mask providing protection against paint and solvent vapors.

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

Acids and alkaline solutions

• When working with acids and alkaline solutions, wear protective goggles or face mask, gloves and
protective clothing.
• If such solutions are spilled onto clothing, remove the affected clothing immediately.
• Rinse injured parts of the body thoroughly with clean water.
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• Rinse eyes immediately with eyedrops or clean tap water.

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 1.9 Conventions for safety instructions in the text

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

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

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

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

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

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

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 2 General Information
2.1 Engine side and cylinder designations

Engine sides are always designated as viewed from the driving end (KS).
The cylinders of the left engine side are designated "A" and those of the right side "B" (as per DIN ISO
1204). The cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end.
Other components are numbered in the same way, i.e. starting with No. 1 on driving end.

1 Left engine side 3 Right engine side

2 KGS = Free end 4 KS = Driving end
TIM-ID: 0000002185 - 010

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 2.2 Product description

Description of the engine

Engine
The engine is a liquid-cooled four-stroke cycle diesel engine, rotating counterclockwise (seen from driv‐
ing end), with direct injection, sequential exhaust turbocharging and charge-air cooling.
The engine is monitored by an engine control and monitoring system (ADEC).
The monitoring in the engine room is carried out by the engine control and monitoring unit (LOP).

Fuel 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 timing
• Injection amount
• Injection pressure

Exhaust system
The exhaust system is equipped with triple-walled, water-cooled exhaust lines.
The triple-walled design permits
• low surface temperature,
• reduced amount of heat to be dissipated by the coolant,
• absolute gas-tightness.

Turbocharging
Sequential turbocharging with internal, engine-coolant-controlled charge-air cooling. The right-hand ex‐
haust turbocharger is cut-in and cut-out on 12V and 16V engines with electronically-controlled, hydrauli‐
cally-actuated flaps. ETC B1 A2 and B2 on 20V engines.

Cooling system
Engine cooling as split-circuit cooling system with plate-core heat exchanger.
Heating of the charge air in idle and low-load operation prevents white smoke formation.
Seawater only flows through engine coolant and fuel heat exchanger as well as the raw water pump.

Service block
The service components are mounted at the auxiliary PTO end.
The layout permits easy access for maintenance.
TIM-ID: 0000010057 - 001

Service-components:
• Raw water pump, coolant pump
• Fuel duplex filter, switchable
• Automatic oil filter
• Centrifugal lube oil filter
• Coolant expansion tank (20V 4000 M03 only, not installed on engine).

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

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 Electronic engine governor (ECU)
Functions:
• Engine speed control with fuel and speed limitation dependent on engine status and operating condi‐
tions;
• Control of sequential turbocharging, cylinder bank cut-out and air recirculation function.
• Data processing logistics for analog and binary signals;
• Interface for data transfer to CAN field bus for remote control and ship-side monitoring;
• RS 232 Interface for connection of MTU dialog unit.

Electronic engine monitoring unit (EMU), optional

Functions:
• Data processing logistics for analog and binary signals;
• Interface for data transfer to CAN field bus for remote control and ship-side monitoring;

Electronic gear control unit (GCU), ship-side wall mounting

Functions:
• Date processing logistics for gear coupling control;
• Input/output signals as well as data transfer to CAN field bus for remote control and ship-side monitor‐
ing.

Monitoring in engine room

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

SOLAS – Fire protection specifications

Fuel system, fuel lines with fuel pressures exceeding 1.8 bar
All lines with SOLAS-compliant covers for pipe connections, according to MTU standard MTN5233, are
shown.

1 Fuel line to fuel filter head

TIM-ID: 0000010057 - 001

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 1 Fuel line from fuel filter head

1 Fuel line to HP pump

Lube oil system, oil lines with oil pressures exceeding 1.8 bar
All lines with SOLAS-compliant covers for pipe connections, according to MTU standard MTN5233, are
shown. TIM-ID: 0000010057 - 001

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 1 Parting line ETC oil supply free end

1 Parting line ETC oil supply driving

end

1 Oil line to equipment carrier

TIM-ID: 0000010057 - 001

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 1 Oil supply to HP pump

1 Oil supply to flap control free end

1 ETC oil supply on main oil gallery

TIM-ID: 0000010057 - 001

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 1 Switching cylinder air flap A2

1 Oil line connection

2 Switching cylinder exhaust flap tur‐
bocharger A2
3 T piece flap control

1 Connection oil line to turbocharger

B1
2 Switching cylinder exhaust flap tur‐
bocharger B1
3 T piece flap control turbocharger B1
TIM-ID: 0000010057 - 001

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 1 Switching cylinder air flap turbo‐
charger B1

1 Connection oil line to turbocharger

B2
2 Switching cylinder exhaust flap tur‐
bocharger B2
3 Switching cylinder air flap turbo‐
charger B2
4 T piece flap control turbocharger B2

1 Flap control distributor

TIM-ID: 0000010057 - 001

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

Plug-in pipe connection

Design precludes lateral spray as the point of separation is shielded by the sleeve (4).
Only seepage along the pipeline is possible whereby the pressure is greatly reduced by a faulty O-ring
(3).
TIM-ID: 0000010057 - 001

The connection is confirmed as compliant with SOLAS by DNV and GL.

Plugs and sensors

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

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 HP connections

1 Jacket tube 8 Thrust ring 15 Union nut

2 HP line 9 Union nut 16 Thrust ring
3 O-ring 10 Union nut 17 HP line outer pipe
4 Union nut 11 Connecting piece 18 HP line inner
5 Recess for O-ring 12 Circlip 19 Ball retaining area
6 Thrust ring 13 Thrust ring 20 Leak fuel connection
7 Leakage-overflow bore 14 Shims
The HP fuel line is sealed by the thrust ring (8).
In case of leakage around the thrust ring (8) or the HP line (5) fuel escapes into the cavity chamber.
Leak fuel is allowed to escape without pressure via the leakage overflow bore (7). The cavity chamber is
sealed by the O-rings (3).
This prevents leakage egress.
The connection is confirmed as compliant with SOLAS by DNV and GL.
TIM-ID: 0000010057 - 001

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 2.3 Engine overview

1 Oil cooler 6 Charge-air pipework 11 Automatic oil filter

2 Crankcase breather 7 Cylinder head 12 HP fuel pump
3 Air filter 8 Oil filler neck 13 Fuel filter
4 Exhaust turbocharger 9 Engine mounting 14 Centrifugal oil filter(s)
5 Intercooler 10 Oil pan 15 Coolant cooler

Engine model designation

Key to the engine model designations 20V 4000 Mxyz
20 Number of cylinders
V Cylinder arrangement: V engine
4000 Series
M Application
X Application segment
y Design index
TIM-ID: 0000009992 - 002

z R (reduced power/speed)
L (enhanced power/speed)

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 2.4 Sensors, actuators and injectors – Overview

Top view 20V 4000 M

1 B4.A1 (exhaust temper‐ 10 B4.A10 (exhaust tem‐ 19 B4.B7 (exhaust temper‐

ature cyl. A1) perature cyl. A10) ature cyl. B7)
2 B4.A2 (exhaust temper‐ 11 B5.2 (lube oil pressure 20 B4.B6 (exhaust temper‐
ature cyl. A2) after filter) ature cyl. B6)
3 B4.A3 (exhaust temper‐ 12 B34.2 (fuel pressure be‐ 21 B4.B5 (exhaust temper‐
ature cyl. A3) fore filter) ature cyl. B5)
4 B4.A4 (exhaust temper‐ 13 B34.1 (fuel pressure af‐ 22 B4.B4 (exhaust temper‐
ature cyl. A4) ter filter) ature cyl. B4)
5 B4.A5 (exhaust temper‐ 14 B5.3 (lube oil pressure 23 B4.B3 (exhaust temper‐
ature cyl. A5) before filter) ature cyl. B3)
6 B4.A6 (exhaust temper‐ 15 B48 (fuel pressure in 24 B4.B2 (exhaust temper‐
ature cyl. A6) common rail) ature cyl. B2)
7 B4.A7 (exhaust temper‐ 16 B4.B10 (exhaust tem‐ 25 B4.B1 (exhaust temper‐
ature cyl. A7) perature cyl. B10) ature cyl. B1)
8 B4.A8 (exhaust temper‐ 17 B4.B9 (exhaust temper‐
ature cyl. A8) ature cyl. B9)
TIM-ID: 0000034733 - 001

9 B4.A9 (exhaust temper‐ 18 B4.B8 (exhaust temper‐

ature cyl. A9) ature cyl. B8)

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 20V 4000 M left side

1 B7 (lube oil tempera‐ 8 B10 (charge-air pres‐ 15 B57.7 (main bearing

ture) sure) temperature)
2 B50 (crankcase pres‐ 9 B57.1 (main bearing 16 B57.8 (main bearing
sure) temperature) temperature)
3 B44.3 (turbocharger C 10 B57.2 (main bearing 17 B57.9 (main bearing
speed) temperature) temperature)
4 B4.23 (temperature, tur‐ 11 B57.3 (main bearing 18 B57.10 (main bearing
bocharger C) temperature) temperature)
5 B4.21 (temperature, tur‐ 12 B57.4 (main bearing 19 B57.11 (main bearing
bocharger A) temperature) temperature)
6 B3 (intake air tempera‐ 13 B57.5 (main bearing 20 B5.1 (lube-oil pressure
ture) temperature) after filter)
7 B44.1 (turbocharger A 14 B57.6 (main bearing
speed) temperature)
TIM-ID: 0000034733 - 001

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 20V 4000 M free end

1 B6 (coolant tempera‐ 3 B33 (fuel temperature) 5 B54 (oil refill pump

ture) 4 B1 (camshaft speed) pressure)
2 F46 (leak fuel level) 6 B6.2 (coolant tempera‐
ture)

TIM-ID: 0000034733 - 001

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 20V 4000 M right side

1 B44.2 (turbocharger B 7 B21 (raw water pres‐ 13 B77.B5 (spray oil temp.
speed) sure) conrod bearing)
2 B4.22 (temperature, tur‐ 8 B77.B10 (spray oil temp. 14 B77.B4 (spray oil temp.
bocharger B) conrod bearing) conrod bearing)
3 B49 (charge-air temper‐ 9 B77.B9 (spray oil temp. 15 B77.B3 (spray oil temp.
ature, recirculation conrod bearing) conrod bearing)
valve) 10 B77.B8 (spray oil temp. 16 B77.B2 (spray oil temp.
4 B4.24 (temperature, tur‐ conrod bearing) conrod bearing)
bocharger D) 11 B77.B7 (spray oil temp. 17 B77.B1 (spray oil temp.
5 B44.4 (turbocharger D conrod bearing) conrod bearing)
speed) 12 B77.B6 (spray oil temp.
6 B16 (coolant pressure) conrod bearing)
TIM-ID: 0000034733 - 001

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 20 V 4000 M driving end

1 B13.2 (crankshaft 3 S37.2 (safety switch)

speed) 4 S37.1 (safety switch)
2 B13 (crankshaft speed)

TIM-ID: 0000034733 - 001

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 3 Technical Data
3.1 20V 4000 M93 engine data: IMO, engine-mounted heat
exchanger, intercooler made of copper-based alloy

EXPLANATION
Abbr. Meaning
DL Reference value: Continuous power (CP)
BL Reference value: Fuel stop power (FSP)
A Design value
G Guaranteed value
R Benchmark
L Limit value up to which the engine can be operated without change, e.g. of power setting.
N Not yet defined value
- Not applicable
X Applicable

REFERENCE CONDITIONS
Engine model 20V 4000
M93
Application group 1DS
Intake air temperature °C 25
Raw water inlet temperature °C 25
Barometric pressure mbar 1000
Site altitude above sea level m 100

POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)
Number of cylinders 20
Rated engine speed A rpm 2100
Fuel stop power, ISO 3046 A kW 3900

GENERAL CONDITIONS (for maximum power)

Number of cylinders 20
Intake depression (new filter) A mbar 15
TIM-ID: 0000010820 - 002

Intake depression, max. L mbar 30

MODEL-RELATED DATA (basic design)

Number of cylinders 20
Cylinder arrangement: V angle Degrees 90
Bore mm 170
Stroke mm 190

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

RAW WATER CIRCUIT (open circuit)

Number of cylinders 20
Raw water pump: Inlet pressure, min. L bar -0.2
Raw water pump: Inlet pressure, max. L bar 0.5
Pressure loss in off-engine raw water system, max. L bar 0.7

LUBE OIL SYSTEM

Number of cylinders 20
Lube oil operating temperature before engine, from R °C 72*
Lube oil operating temperature before engine, to R °C 80*
Lube oil operating pressure before engine, from R bar 6
Lube oil operating pressure before engine, to R bar 8
Lube oil operating pressure (low idle) (measuring point: before engine) R bar 2.0

FUEL SYSTEM
Number of cylinders 20
Fuel pressure at engine inlet connection, min. (during engine start) L bar -0.1
Fuel pressure at engine inlet connection, min. (during engine operation) L bar -0.3
Fuel pressure at engine inlet connection, max. (during engine start) L bar 1.5
Fuel supply rate, max. R liters/min 30

GENERAL OPERATING DATA

Number of cylinders 20
Firing speed, from R rpm 80
Firing speed, to R rpm 120

STARTING (electric)
Number of cylinders 20
Rated starter voltage (standard design) R V= 24
TIM-ID: 0000010820 - 002

STARTING (with pneumatic/hydraulic starter)

Number of cylinders 20
Starting-air pressure before starter motor, min. R bar 8
Starting-air pressure before starter motor, max. R bar 10

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 INCLINATIONS, STANDARD OIL SYSTEM (Reference: Waterline)
Number of cylinders 20
Longitudinal inclination, continuous max., driving end down (Option: max. L Degrees 15
operating inclinations)
Longitudinal inclination, temporary max., driving end down (Option: max. L Degrees 22.5
operating inclinations)
Longitudinal inclination, continuous max., driving end up (Option: max. op‐ L Degrees 10
erating inclinations)
Longitudinal inclination, temporary max., driving end up (Option: max. oper‐ L Degrees NN
ating inclinations)
Transverse inclination, continuous max. (Option: max. operating inclina‐ L Degrees 22.5
tions)
Transverse inclination, temporary max. (Option: max. operating inclinations) L Degrees --

CAPACITIES
Number of cylinders 20
Engine coolant, engine side (with cooling system) R Liters 440
Engine oil on initial filling (standard oil system) (Option: max. operating incli‐ R Liters 365
nations)
Oil change quantity, max. (standard oil system) (Option: max. operating in‐ R Liters 320
clinations)
Oil pan capacity at dipstick mark “min.” (standard oil system) (Option: max. L Liters 255
operating inclinations)
Oil pan capacity at dipstick mark “max.” (standard oil system) (Option: max. L Liters 300
operating inclinations)

WEIGHTS / MAIN DIMENSIONS

Number of cylinders 20
Dry engine weight (with standard accessories, without coupling) R kg 12080

NOISE
Number of cylinders 20
Exhaust noise, unsilenced - BL (free-field sound-pressure level Lp, 1m dis‐ R dB(A) 117
tance, ISO 6798, +3dB(A) tolerance)
Engine surface noise with attenuated intake noise (filter) - BL (free-field R dB(A) 106
sound-pressure level Lp, 1m distance, ISO 6798+2dB(A) tolerance)
TIM-ID: 0000010820 - 002

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

EXPLANATION
Abbr. Meaning
DL Reference value: Continuous power (CP)
BL Reference value: Fuel stop power (FSP)
A Design value
G Guaranteed value
R Benchmark
L Limit value up to which the engine can be operated without change, e.g. of power setting.
N Not yet defined value
- Not applicable
X Applicable

REFERENCE CONDITIONS
Engine model 20V 4000
M93
Application group 1DS
Intake air temperature °C 25
Raw water inlet temperature °C 25
Barometric pressure mbar 1000
Site altitude above sea level m 100

POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)
Number of cylinders 20
Rated engine speed A rpm 2100
Fuel stop power, ISO 3046 A kW 3900

GENERAL CONDITIONS (for maximum power)

Number of cylinders 20
Intake depression (new filter) A mbar 15
Intake depression, max. L mbar 30

MODEL-RELATED DATA (basic design)

TIM-ID: 0000010857 - 002

Number of cylinders 20
Cylinder arrangement: V angle Degrees 90
Bore mm 170
Stroke mm 190
Cylinder displacement Liters 4.31
Total displacement Liters 86.2

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

RAW WATER CIRCUIT (open circuit)

Number of cylinders 20
Raw water pump: Inlet pressure, min. L bar -0.2
Raw water pump: Inlet pressure, max. L bar 0.5
Pressure loss in off-engine raw water system, max. L bar 0.7

LUBE OIL SYSTEM

Number of cylinders 20
Lube oil operating temperature before engine, from R °C 72*
Lube oil operating temperature before engine, to R °C 80*
Lube oil operating pressure before engine, from R bar 6
Lube oil operating pressure before engine, to R bar 8
Lube oil operating pressure (low idle) (measuring point: before engine) R bar 2.0

FUEL SYSTEM
Number of cylinders 20
Fuel pressure at engine inlet connection, min. (during engine start) L bar -0.1
Fuel pressure at engine inlet connection, min. (during engine operation) L bar -0.3
Fuel pressure at engine inlet connection, max. (during engine start) L bar 1.5
Fuel supply rate, max. R liters/min 30

GENERAL OPERATING DATA

Number of cylinders 20
Firing speed, from R rpm 80
Firing speed, to R rpm 120

STARTING (electric)
Number of cylinders 20
Rated starter voltage (standard design) R V= 24

STARTING (with pneumatic/hydraulic starter)

TIM-ID: 0000010857 - 002

Number of cylinders 20
Starting-air pressure before starter motor, min. R bar 8
Starting-air pressure before starter motor, max. R bar 10

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 INCLINATIONS, STANDARD OIL SYSTEM (Reference: Waterline)
Number of cylinders 20
Longitudinal inclination, continuous max., driving end down (Option: max. L Degrees 15
operating inclinations)
Longitudinal inclination, temporary max., driving end down (Option: max. L Degrees 22.5
operating inclinations)
Longitudinal inclination, continuous max., driving end up (Option: max. op‐ L Degrees 10
erating inclinations)
Longitudinal inclination, temporary max., driving end up (Option: max. oper‐ L Degrees NN
ating inclinations)
Transverse inclination, continuous max. (Option: max. operating inclina‐ L Degrees 22.5
tions)
Transverse inclination, temporary max. (Option: max. operating inclinations) L Degrees --

CAPACITIES
Number of cylinders 20
Engine coolant, engine side (with cooling system) R Liters 440
Engine oil on initial filling (standard oil system) (Option: max. operating incli‐ R Liters 365
nations)
Oil change quantity, max. (standard oil system) (Option: max. operating in‐ R Liters 320
clinations)
Oil pan capacity at dipstick mark “min.” (standard oil system) (Option: max. L Liters 255
operating inclinations)
Oil pan capacity at dipstick mark “max.” (standard oil system) (Option: max. L Liters 300
operating inclinations)

WEIGHTS / MAIN DIMENSIONS

Number of cylinders 20
Dry engine weight (with standard accessories, without coupling) R kg 12080

NOISE
Number of cylinders 20
Exhaust noise, unsilenced - BL (free-field sound-pressure level Lp, 1m dis‐ R dB(A) 117
tance, ISO 6798, +3dB(A) tolerance)
Engine surface noise with attenuated intake noise (filter) - BL (free-field R dB(A) 106
sound-pressure level Lp, 1m distance, ISO 6798+2dB(A) tolerance)
TIM-ID: 0000010857 - 002

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

EXPLANATION
Abbr. Meaning
DL Reference value: Continuous power (CP)
BL Reference value: Fuel stop power (FSP)
A Design value
G Guaranteed value
R Benchmark
L Limit value up to which the engine can be operated without change, e.g. of power setting.
N Not yet defined value
- Not applicable
X Applicable

REFERENCE CONDITIONS
Engine model 20V 4000
M93L
Application group 1DS
Intake air temperature °C 25
Raw water inlet temperature °C 25
Barometric pressure mbar 1000
Site altitude above sea level m 100

POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)
Number of cylinders 20
Rated engine speed A rpm 2100
Fuel stop power, ISO 3046 A kW 4300

GENERAL CONDITIONS (for maximum power)

Number of cylinders 20
Intake depression (new filter) A mbar 15
Intake depression, max. L mbar 30

MODEL-RELATED DATA (basic design)

TIM-ID: 0000010893 - 002

Number of cylinders 20
Cylinder arrangement: V angle Degrees 90
Bore mm 170
Stroke mm 190
Cylinder displacement Liters 4.31
Total displacement Liters 86.2

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

RAW WATER CIRCUIT (open circuit)

Number of cylinders 20
Raw water pump: Inlet pressure, min. L bar -0.2
Raw water pump: Inlet pressure, max. L bar 0.5
Pressure loss in off-engine raw water system, max. L bar 0.7

LUBE OIL SYSTEM

Number of cylinders 20
Lube oil operating temperature before engine, from R °C 72*
Lube oil operating temperature before engine, to R °C 80*
Lube oil operating pressure before engine, from R bar 6
Lube oil operating pressure before engine, to R bar 8
Lube oil operating pressure (low idle) (measuring point: before engine) R bar 2.0

FUEL SYSTEM
Number of cylinders 20
Fuel pressure at engine inlet connection, min. (during engine start) L bar -0.1
Fuel pressure at engine inlet connection, min. (during engine operation) L bar -0.3
Fuel pressure at engine inlet connection, max. (during engine start) L bar 1.5
Fuel supply rate, max. R liters/min 30

GENERAL OPERATING DATA

Number of cylinders 20
Firing speed, from R rpm 80
Firing speed, to R rpm 120

STARTING (electric)
Number of cylinders 20
Rated starter voltage (standard design) R V= 24

STARTING (with pneumatic/hydraulic starter)

TIM-ID: 0000010893 - 002

Number of cylinders 20
Starting-air pressure before starter motor, min. R bar 8
Starting-air pressure before starter motor, max. R bar 10

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 INCLINATIONS, STANDARD OIL SYSTEM (Reference: Waterline)
Number of cylinders 20
Longitudinal inclination, continuous max., driving end down (Option: max. L Degrees 15
operating inclinations)
Longitudinal inclination, temporary max., driving end down (Option: max. L Degrees 22.5
operating inclinations)
Longitudinal inclination, continuous max., driving end up (Option: max. op‐ L Degrees 10
erating inclinations)
Longitudinal inclination, temporary max., driving end up (Option: max. oper‐ L Degrees NN
ating inclinations)
Transverse inclination, continuous max. (Option: max. operating inclina‐ L Degrees 22.5
tions)

CAPACITIES
Number of cylinders 20
Engine coolant, engine side (with cooling system) R Liters 440
Engine oil on initial filling (standard oil system) (Option: max. operating incli‐ R Liters 365
nations)
Oil change quantity, max. (standard oil system) (Option: max. operating in‐ R Liters 320
clinations)
Oil pan capacity at dipstick mark “min.” (standard oil system) (Option: max. L Liters 255
operating inclinations)
Oil pan capacity at dipstick mark “max.” (standard oil system) (Option: max. L Liters 300
operating inclinations)

WEIGHTS / MAIN DIMENSIONS

Number of cylinders 20
Dry engine weight (with standard accessories, without coupling) R kg 12080

NOISE
Number of cylinders 20
Exhaust noise, unsilenced - BL (free-field sound-pressure level Lp, 1m dis‐ R dB(A) 118
tance, ISO 6798, +3dB(A) tolerance)
Engine surface noise with attenuated intake noise (filter) - BL (free-field R dB(A) 107
sound-pressure level Lp, 1m distance, ISO 6798+2dB(A) tolerance)
TIM-ID: 0000010893 - 002

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

EXPLANATION
Abbr. Meaning
DL Reference value: Continuous power (CP)
BL Reference value: Fuel stop power (FSP)
A Design value
G Guaranteed value
R Benchmark
L Limit value up to which the engine can be operated without change, e.g. of power setting.
N Not yet defined value
- Not applicable
X Applicable

REFERENCE CONDITIONS
Engine model 20V 4000
M93L
Application group 1DS
Intake air temperature °C 25
Raw water inlet temperature °C 25
Barometric pressure mbar 1000
Site altitude above sea level m 100

POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)
Number of cylinders 20
Rated engine speed A rpm 2100
Fuel stop power, ISO 3046 A kW 4300

GENERAL CONDITIONS (for maximum power)

Number of cylinders 20
Intake depression (new filter) A mbar 15
Intake depression, max. L mbar 30

MODEL-RELATED DATA (basic design)

TIM-ID: 0000010629 - 002

Number of cylinders 20
Cylinder arrangement: V angle Degrees 90
Bore mm 170
Stroke mm 190
Cylinder displacement Liters 4.31
Total displacement Liters 86.2

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

RAW WATER CIRCUIT (open circuit)

Number of cylinders 20
Raw water pump: Inlet pressure, min. L bar -0.2
Raw water pump: Inlet pressure, max. L bar 0.5
Pressure loss in off-engine raw water system, max. L bar 0.7

LUBE OIL SYSTEM

Number of cylinders 20
Lube oil operating temperature before engine, from R °C 75**
Lube oil operating temperature before engine, to R °C 80**
Lube oil operating pressure before engine, from R bar 6
Lube oil operating pressure before engine, to R bar 8
Lube oil operating pressure (low idle) (measuring point: before engine) R bar 2.0

FUEL SYSTEM
Number of cylinders 20
Fuel pressure at engine inlet connection, min. (during engine start) L bar -0.1
Fuel pressure at engine inlet connection, min. (during engine operation) L bar -0.3
Fuel pressure at engine inlet connection, max. (during engine start) L bar 1.5
Fuel supply rate, max. R liters/min 30

GENERAL OPERATING DATA

Number of cylinders 20
Firing speed, from R rpm 80
Firing speed, to R rpm 120

STARTING (electric)
Number of cylinders 20
Rated starter voltage (standard design) R V= 24

STARTING (with pneumatic/hydraulic starter)

TIM-ID: 0000010629 - 002

Number of cylinders 20
Starting-air pressure before starter motor, min. R bar 8
Starting-air pressure before starter motor, max. R bar 10

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 INCLINATIONS, STANDARD OIL SYSTEM (Reference: Waterline)
Number of cylinders 20
Longitudinal inclination, continuous max., driving end down (Option: max. L Degrees 15
operating inclinations)
Longitudinal inclination, temporary max., driving end down (Option: max. L Degrees 22.5
operating inclinations)
Longitudinal inclination, continuous max., driving end up (Option: max. op‐ L Degrees 10
erating inclinations)
Longitudinal inclination, temporary max., driving end up (Option: max. oper‐ L Degrees NN
ating inclinations)
Transverse inclination, continuous max. (Option: max. operating inclina‐ L Degrees 22.5
tions)

CAPACITIES
Number of cylinders 20
Engine coolant, engine side (with cooling system) R Liters 440
Engine oil on initial filling (standard oil system) (Option: max. operating incli‐ R Liters 365
nations)
Oil change quantity, max. (standard oil system) (Option: max. operating in‐ R Liters 320
clinations)
Oil pan capacity at dipstick mark “min.” (standard oil system) (Option: max. L Liters 255
operating inclinations)
Oil pan capacity at dipstick mark “max.” (standard oil system) (Option: max. L Liters 300
operating inclinations)

WEIGHTS / MAIN DIMENSIONS

Number of cylinders 20
Dry engine weight (with standard accessories, without coupling) R kg 12080

NOISE
Number of cylinders 20
Exhaust noise, unsilenced - BL (free-field sound-pressure level Lp, 1m dis‐ R dB(A) 118
tance, ISO 6798, +3dB(A) tolerance)
Engine surface noise with attenuated intake noise (filter) - BL (free-field R dB(A) 107
sound-pressure level Lp, 1m distance, ISO 6798+2dB(A) tolerance)
TIM-ID: 0000010629 - 002

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 3.5 Firing order

Firing order
Num‐ Firing order
ber of
cylin‐
ders
8V A1-B4-A4-A2-B3-A3-B2-B1
12V 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
20 V A1-B5-A8-B7-A5-B2-A7-B10-A2-B3-A10-B6-A3-B4-A6-B9-A4-B1-A9-B8
TIM-ID: 0000002796 - 003

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 4 Operation
4.1 Controls

Automation system controls

Refer to automation system operating instructions

TIM-ID: 0000016959 - 003

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

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

Note: Operate fuel treatment system for at least 5 minutes.
1. Start up fuel treatment system (→ Page 51).
2. Shut down fuel treatment system (→ Page 65).
TIM-ID: 0000007730 - 005

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 4.3 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 54).
5. Check direction of rotation of pump.
6. Vent bypass and fuel lines of the system.
a) Open ball valve for pressure tank.
b) Open ball valve for overflow tank.
c) Close ball valve at the inlet to the fuel treatment system.
Result: Bypass line is vented via the overflow tank.
d) Open ball valve at the inlet to the fuel treatment system.
7. Check the fuel treatment system for leaks.
Result: The fuel treatment system is ready for operation.

TIM-ID: 0000007736 - 005

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 4.4 Fuel treatment system – Putting into operation

Overview of fuel treatment system

1 Pressure-free overflow
2 Bypass 1
3 Bypass 2
4 Safety valve, 3 bar
5 Ball valve, inlet
6 Pressure gage
7 Ventilation, sample extraction
8 Differential pressure gage
9 Ball valve, outlet
10 Check valve 700 mbar
11 Check valve 5 mbar
12 Return to overflow container
13 Engine
14 Overflow container
15 Water separator filter
16 Ball valve, drain
17 Automatic water drain
18 Water level electrode
19 Ball valve, sample extraction, inlet
20 Switchgear cabinet
21 Pump
22 Coarse filter
23 Fuel supply from tank
24 Tank

Switching on fuel treatment system

1. Switch on fuel treatment system (→ Page 54).
2. Check differential pressure at differential pressure gage (8). Differential pressure in a new system:
0.1 bar to 0.3 bar.
Result: If no differential pressure is measured, the coalescer filter element is probably being bypassed.
1. Remove coalescer filter element (→ Page 141).
2. Check sealing surfaces on coalescer filter element and in the pressure tank.

Initial operation: HAT

1. Replace fuel filter on engine (→ Page 90).
Note: Determine the suction pressure upstream of the engine-mounted fuel delivery pump.
2. Install pressure gage in fuel supply line from Yard fuel system to engine.
3. Switch on fuel treatment system and operate it for some minutes (→ Page 54).
Result: The fuel is drawn from tank (24), cleaned by the water separator filter (15) and then routed via overflow
tank (14) back to tank (24). Water that collects in the tank is separated.
TIM-ID: 0000015773 - 005

4. Start engine (→ Page 53).

5. Run engine at idling speed.
6. Check suction pressure (see technical data of the engine) at the engine-mounted fuel delivery pump.
Note: If the suction pressure is within the permissible limits and engine operation is satisfactory.
7. Increase engine speed to 1000 rpm and monitor suction pressure.
8. Check suction pressure at the engine-mounted fuel delivery pump.
Result: If the values are within the limits specified by the manufacturer, the system is ready to start filter replace‐
ment simulation with the engine running as part of the Harbor Acceptance Tests.

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 Simulation of filter replacement with the engine running: HAT
1. Switch on fuel treatment system (→ Page 54).
2. Start engine (→ Page 53).
3. Run engine at idling speed.
4. Close ball valve (5) at inlet to fuel treatment system.
Result: The pressure upstream of the fuel treatment system increases until the overflow valve at the pump 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.
Note: If the suction pressure is within the permissible limits and engine operation is satisfactory.
7. Increase engine speed to 1000 rpm and monitor suction pressure.
Result: If all engine operating values are within the specified limits, open ball valve (5) at inlet to fuel treatment
system.

Simulation of power failure (emergency): HAT

1. Switch on fuel treatment system (→ Page 54).
2. Start engine (→ Page 53).
3. Run engine at idling speed.
4. Switch off pump (21) on switchgear cabinet (20).
Result: The engine-mounted fuel delivery pump draws fuel via bypass (2) directly from tank (24).
5. Check suction pressure at the engine-mounted fuel delivery pump.
Note: If the suction pressure is within the permissible limits and engine operation is satisfactory.
6. Increase engine speed to 1000 rpm and monitor suction pressure.
Result: If the suction pressure is within the specified limits, simulation was successful.

Simulation of power failure (emergency): SAT

1. Switch on fuel treatment system (→ Page 54).
2. Start engine (→ Page 53).
3. Run engine at idling speed.
4. Switch off pump (21) at switchgear cabinet (20).
Result: The engine-mounted fuel delivery pump draws fuel via bypass (2) directly from tank (24).
5. Check suction pressure at the engine-mounted fuel delivery pump.
Note: If the suction pressure is within the permissible limits and engine operation is satisfactory.
6. Operate engine at full load and monitor suction pressure.
Result: If the suction pressure is within the specified limits, simulation was successful. TIM-ID: 0000015773 - 005

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 4.5 Starting the engine

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

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

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

The engine can be started from the following points

Item Action
Control stand (→ Operating instructions for electronic system)
Local Operating Panel LOP (→ Operating instructions for electronic system)
Local Operation Station (→ Operating instructions for electronic system)
LOS
CCU (→ Operating instructions for electronic system)
TIM-ID: 0000002240 - 003

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 4.6 Fuel treatment system – Switching on

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

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

Switching on fuel treatment system

1. Carry out checks prior to start-up (→ Page 50).
2. Switch on master switch on switch cabinet.
Result: Signal lamp “Control voltage present” lights up.
3. Switch on switch for pump.
Result: Signal lamp “Pump running” lights up.

TIM-ID: 0000007731 - 005

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 4.7 Starting the engine

BlueLine automation system

Starting the engine at LOS or at LOP 8 (with display)

(→ BlueLine Operating Instructions)

Starting the engine at LOP 6 (without display)

(→ BlueLine Operating Instructions)

Starting the engine at control stand

(→ BlueLine Operating Instructions)

BlueVision automation system

Starting the engine at LOP 8 (without oil priming pump option)

(→ BlueVision ECS-5 Operating Instructions )

Starting the engine at LOP 8 (with oil priming pump option)

(→ BlueVision ECS-5 Operating Instructions )
TIM-ID: 0000017526 - 001

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

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

Engine emergency stop at BlueLine automation system

Item Measure
Engine Emergency shutdown at automation system BlueLine (→ Operating In‐
structions for BlueLine).

TIM-ID: 0000002704 - 004

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 4.9 Operational checks

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

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

Operational checks
Item Action
Engine oil Check engine oil level (→ Page 107).
Engine under load, Visually inspect engine for leaks and general condition;
engine at nominal speed Check speed, pressures and temperatures;
Check engine and external lines for leaks;
Check for abnormal running noises and vibration;
Check exhaust color (→ Page 69).
Air filter Check signal ring position of service indicator (→ Page 103);
Replace air filter (→ Page 101) if the signal ring is completely visible in the
service indicator observation window.
Intercooler Check condensate drain(s) for water discharge and obstruction
(→ Page 100).
Exhaust gas system Check condensate drain for obstructions.
Fuel prefilter(s) Drain water and contamination from fuel prefilter (if fitted) (→ Page 93).
Check pointer position of differential pressure gage at fuel prefilter (if ap‐
plicable).
HT coolant pump Check relief bore for oil and coolant discharge and contamination
(→ Page 127).
Raw water pump Check relief bore for oil and water discharge and contamination
(→ Page 131).
TIM-ID: 0000010131 - 005

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 4.10 Coupling – Engaging from LOP

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

DANGER
Vessel is sailing blind.
In Local Operation mode, the propulsion plant is controlled from the engine room.
Risk of accidents!
• Only execute vessel movements on the instructions of a person who has visual contact with the
area outside the vessel.

Engaging coupling without reversing gearbox (CPP, WJ, VS)

Item Measure
LOP Press COUPLING IN illuminated pushbutton (→ Page 48).
• COUPLING IN button flashes.
• Coupling is engaged.
• After receiving the feedback signal from coupling, the COUPLING IN
button is illuminated brightly.

Engaging coupling in ahead direction with reversing gearbox (FPP, WJ)

Item Measure
LOP Press COUPLING AHEAD illuminated pushbutton (→ Page 48).
• COUPLING AHEAD button flashes.
• Gearbox is engaged in AHEAD direction.
• After receiving the feedback signal from coupling, the COUPLING
AHEAD button is illuminated brightly.

Engaging coupling in astern direction with reversing gearbox (FPP)

Item Measure
LOP Press COUPLING ASTERN illuminated pushbutton (→ Page 48).
• COUPLING ASTERN button flashes.
• Gearbox is engaged astern.
• After receiving the feedback signal from coupling, the COUPLING AS‐
TERN button is illuminated brightly.
TIM-ID: 0000002700 - 004

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 4.11 Coupling – Disengaging from LOP

Preconditions
☑ LOCAL OPERATION illuminated pushbutton lights up brightly (local operating mode is active).
☑ Engine speed in disengagement window.

Disengaging coupling without reversing gearbox (CPP, WJ, VS)

Item Measure
LOP Press COUPLING OUT illuminated pushbutton (→ Page 48).
• COUPLING OUT button flashes.
• Coupling is disengaged.
• After receiving the feedback signal from coupling, the COUPLING OUT
button is illuminated brightly.

Disengaging coupling with reversing gearbox (FPP, WJ)

Item Measure
LOP Press COUPLING NEUTRAL illuminated pushbutton (→ Page 48).
• COUPLING NEUTRAL button flashes.
• Gearbox is disengaged (neutral position).
• After receiving the feedback signal from coupling, the COUPLING
NEUTRAL button is illuminated brightly.
TIM-ID: 0000002810 - 004

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 4.12 Waterjet – Flushing from LOP (optional)

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

CAUTION
Waterjet flushing puts excessive strain on the bearings.
Bearing damage!
• Do not flush waterjet for too long.
• Follow instructions of the waterjet manufacturer.

Flushing with reversing gearbox and flushing mode

Item Measure
LOP Press FLUSH illuminated pushbutton and keep pressed (→ Page 48).
• FLUSH pushbutton flashes.
• Gearbox is engaged astern.
• After receiving the feedback signal from coupling, the FLUSH pushbut‐
ton is illuminated brightly.
LOP Release FLUSH illuminated pushbutton.
• FLUSH pushbutton flashes.
• Gearbox is disengaged (neutral position).
• Illumination of FLUSH pushbutton is switched off as soon as the feed‐
back signal from coupling is received.

TIM-ID: 0000002330 - 005

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 4.13 Stopping the engine from LOP

Preconditions
☑ Engine is running in local mode.

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

Stopping the engine from LOP

Item Measure
LOP Disengage gearbox (→ Page 48).
LOP Operate engine at idle speed (→ Page 48).
Temperature indications Wait until engine temperatures do not fall any further.
LOP Press STOP illuminated pushbutton (→ Page 48).
• STOP button is illuminated.
• Engine at a standstill.
TIM-ID: 0000002300 - 004

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

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

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

Item Measure
Engine Stop the engine at the BlueLine automation system (control stand)
(→ BlueLine Operating Instructions).

TIM-ID: 0000002702 - 004

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 4.15 Emergency stop from LOP

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

Emergency stop from LOP

Item Measure
LOP Open cap of illuminated EMERGENCY STOP pushbutton (→ Page 48).
LOP Press EMERGENCY STOP illuminated pushbutton.
• Engine is stopped by disconnecting the power supply to the ECU.
• On engines with emergency-air shutoff flaps: flaps close;
• EMERGENCY STOP illuminated pushbutton flashes. Horn, flashing
lamp etc. are tripped.

After emergency stop from LOP

Item Measure
LOP Press ALARM ACKNOWLEDGE illuminated pushbutton (→ Page 48).
• Audible and visual signalization stops.
LOP Press ALARM ACKNOWLEDGE button again.
• Power supply to ECU is provided;
• Alarm has been acknowledged.
Engine On engines with emergency-air shutoff flaps: open flaps.
• Engine is ready for starting.
TIM-ID: 0000002314 - 003

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 4.16 After stopping the engine

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

After stopping the engine

Item Action
Coolant circuit Drain coolant (→ Page 123) if:
• freezing temperatures are expected and the engine is to remain out of
service for an extended period, but engine coolant has no antifreeze
additive;
• the engine room is not heated;
• the coolant is not kept at a suitable temperature;
• the antifreeze concentration is insufficient for the engine-room tempera‐
ture;
• antifreeze concentration is 50 % and engine-room temperature is below
-40 °C.
Raw water Drain
• If freezing temperatures are to be expected and the engine is to remain
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's air and exhaust sides.
Engine Out-of-service-period > 1 month
• Preserve engine (→ MTU Fluids and Lubricants Specifications
A001061/.. )

TIM-ID: 0000002324 - 007

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 4.17 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

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 4.18 Plant cleaning

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

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Steam jet cleaner - 1
Cleaner (Hakupur 312) 30390 1

WARNING
Compressed air
Risk of injury!
• Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

WARNING
Water jet.
Risk of injury and scalding!
• Do not direct water jet at persons.
• Wear protective clothing, gloves, and goggles / safety mask.

CAUTION
Excessive reaction time of cleaning agents on components.
Damage to component!
• Observe manufacturer's instructions.
• Wear protective clothing, gloves, and goggles / safety mask.

NOTICE
Dry with compressed air.
Damage to component!
• Never aim compressed air directly at electronic components.

Plant cleaning
1. Carry out plant cleaning only in areas where an appropriate oil separator is provided (environmental pro‐
tection).
2. Prior to putting the cleaning unit into operation, read the Operating Instructions of the water/steam jet unit
carefully and observe the safety precautions.
3. During external cleaning of the plant with water/steam-jet units, the pressure of the high-pressure jet
(cleaning jet) must not exceed 50 bar. A minimum distance between spray nozzle and plant of 1 m must
be observed. The temperature of the cleaning medium must not exceed 80 °C.
TIM-ID: 0000010171 - 024

4. For external cleaning with high-pressure jet, use a flat-mouth nozzle only.
5. Carry out external cleaning as follows:
a) Seal all openings in a suitable fashion.
b) Remove coarse dirt.
c) Spray on cleaner sparingly and leave it for 1 to 5 minutes.
d) Use the high-pressure jet to remove the loosened dirt.
Note: Never aim compressed air directly at electronic components.
e) Dry engine.

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 5 Maintenance
5.1 Maintenance schedule task reference table [QL1]
The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The
Maintenance Schedule is a stand-alone publication.
The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance
Schedule.
Task Maintenance tasks
W0500 Check engine oil level (→ Page 107)
W0501 Visually inspect engine for leaks and general condition (→ Page 57)
W0502 Check intercooler drain (if applicable) (→ Page 100)
W0503 Check maintenance indicator of air filter (→ Page 103)
W0504 Check telltale bores of HP fuel pump (→ Page 57)
W0505 Check relief bores of coolant pump(s) (→ Page 127)
W0506 Check engine for abnormal running noises, exhaust color (→ Page 57)
and vibrations
W0507 Drain water and dirt from fuel prefilter (if applicable) (→ Page 57)
W0508 Check reading on differential pressure gage of fuel prefilter (if (→ Page 57)
applicable)
W1001 Replace fuel filter or fuel filter element (→ Page 90)
W1005 Replace air filter (→ Page 101)
W1006 Replace fuel injectors (→ Page 84)
W1008 Replace engine oil filter at each oil change or when the time (→ Page 111)
limit (years) is reached, at the latest
W1009 Check layer thickness of oil residues, clean and replace filter (→ Page 118)
sleeve (if applicable) at each oil change, at the latest
W1011 Perform endoscopic inspection of combustion chambers (→ Page 74)
W1016 Generator: Check condition of coupling (→ Page 132)
W1036 Replace coolant filter (→ Page 129)
W1047 Check and clean oil indicator filter (→ Page 116)
W1076 Exhaust turbocharger: Clean compressor wheel (→ Page 98)
W1207 Check and adjust valve clearance. ATTENTION! First adjust‐ (→ Page 79)
ment after 1,000 operating hours!
W1244 Check operation of rod electrode (if applicable) (→ Page 139)
TIM-ID: 0000035260 - 001

W1245 Differential-pressure gage, check alarm function (if applica‐ (→ Page 138)
ble)
W1246 Check pump performance (if applicable) (→ Page 140)
W1463 Check general condition of engine mounting (visual inspec‐ (→ Page 133)
tion)
W1713 Injector: Reset drift correction (CDC) parameters (→ Page 144)
Table 1: Maintenance schedule task reference table [QL1]

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 6 Troubleshooting
6.1 Fuel treatment system – Troubleshooting

Illuminated pushbutton “Water alarm” is lit.

Cause Corrective action
When the maximum water level 1. Press illuminated pushbutton “Water alarm” to acknowledge.
is reached, the water level elec‐ 2. In addition to the automatic water drain function, water can also
trode opens the water drain be drained manually. To do so, press the illuminated pushbutton
valve and water is discharged. If “Water drain” to open the drain valve.
the opening period of the valve
exceeds a preset limit (4 mi‐
nutes), the pump will switch off
and an alarm is initiated.

Signal lamp “Pump fault” is lit.

Cause Corrective action
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-run‐
ning, the motor protection relay
triggers and the pump is switch‐
ed off.

Signal lamp “Warning filter” is lit.

Cause Corrective action
The differential pressure exceed‐ u Replace coalescer filter element (→ Page 141).
ed 1.3 bar.

Illuminated pushbutton “Replace filter element” is lit.

Cause Corrective action
The max. permissible differential 1. Replace coalescer filter element (→ Page 141).
pressure of 1.5 bar was exceed‐ 2. Press illuminated pushbutton “Replace filter element” to ac‐
ed. If the coalescer filter element knowledge.
is not replaced, pressure will in‐
crease further and the safety
TIM-ID: 0000007734 - 006

valve will open. Fuel will be led

via the bypass directly into the
overflow tank.

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 6.2 Troubleshooting

Engine does not turn when starter is actuated

Component Probable cause Task
Battery Low or defective Charge or replace (see manufacturer's
documentation).
Cable connections defective Check whether cable connections are
properly secured (see manufacturer's
documentation).
Starter Engine wiring or starter defective Check whether cable connections are
properly secured, contact Service.
Engine wiring Defective Check (→ Page 143).
LOP Seating of assemblies or connectors Inspect visually.
possibly loose
ECU Plug-in connections possibly loose Check plug connections (→ Page 148).
Engine Running gear blocked (engine cannot Contact Service.
be barred manually)

Engine turns on starting but does not fire

Component Probable cause Task
Starter Poor rotation by starter: Battery low or Charge or replace battery (see manu‐
defective facturer's documentation).
Engine wiring Defective Check (→ Page 143).
ECU Defective Contact Service.

Engine fires unevenly

Component Probable cause Task
Fuel injection equip‐ Injector defective Replace (→ Page 84).
ment
Engine wiring Defective Check (→ Page 143).
ECU Defective Contact Service.

Engine does not reach rated speed

Component Probable cause Task
Fuel supply Easy-change fuel filter clogged Replace (→ Page 90).
Air supply Air filter clogged Check signal ring position of service in‐
dicator (→ Page 103).
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Fuel injection equip‐ Injector defective Replace (→ Page 84).

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

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 Engine speed not steady
Component Probable cause Task
Fuel injection equip‐ Injector defective Replace (→ Page 84).
ment
Speed sensor Defective Contact Service.
ECU Defective Contact Service.

Charge-air temperature too high

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

Charge-air pressure too low

Component Probable cause Task
Air supply Air filter clogged Check signal ring position of service in‐
dicator (→ Page 103).
Intercooler Contaminated Contact Service.
Exhaust turbocharger Defective Contact Service.

Coolant leaks on intercooler

Component Probable cause Task
Intercooler Leaking, major coolant discharge Contact Service.

Exhaust gas black

Component Probable cause Task
Air supply Air filter clogged Check signal ring position of service in‐
dicator (→ Page 103).
Fuel injection equip‐ Injector defective Replace (→ Page 84).
ment
Engine Overload Contact Service.

Exhaust gas blue

Component Probable cause Task
Engine oil Too much oil in engine Drain engine oil (→ Page 108).
TIM-ID: 0000010521 - 001

Oil separator or oil preseparator of Replace.

crankcase breather clogged
Exhaust turbocharg‐ Defective Contact Service.
er, cylinder head, pis‐
ton rings, cylinder lin‐
er

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 Exhaust gas white
Component Probable cause Task
Engine Not at operating temperature Run engine to reach operating temper‐
ature.
Intercooler Leaking Contact Service.
TIM-ID: 0000010521 - 001

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 7 Task Description
7.1 Engine
7.1.1 Engine – Barring manually

Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Barring device F6555766 1
Ratchet head with extension F30006212 1

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

Engine – Barring manually

1. Remove guard plate.
Result: Safety switch preventing engine starting ac‐
tivated.
2. Engage barring device (2) in ring gear (3)
and install on flywheel housing.
3. Apply ratchet (1) to barring device (2).
4. Rotate crankshaft in engine direction of ro‐
tation. Apart from the normal compression
resistance, there should be no resistance.
5. For barring device removal, follow reverse
sequence of working steps.

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 7.1.2 Engine – Barring with starting system

Barring using the automation system

Refer to automation system operating instructions
TIM-ID: 0000017532 - 003

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 7.2 Cylinder Liner
7.2.1 Cylinder liner – Endoscopic examination

Preconditions
☑ Engine is stopped and starting disabled

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Rigid endoscope Y20097353 1

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

Positioning crankshaft at BDC

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

Endoscopic examination of cylinder liner

Findings Action
• Thin carbon coating on circumference of carbon scraper ring No action required
• Slight localized additive deposits at top edge
• Localized smooth areas on bottom edge
• Carbon deposits on circumference in clearance between top piston
ring and bottom edge of carbon scraper ring
• First signs of marks left by top piston ring
• Bright mark on entire circumference
• Consistent honing pattern without objections
• First signs of marks left by lower cooling bores
• Running pattern seems darker
• Dark areas with even or varying degrees of discoloration Further endoscopic examina‐
• Beginning and end of the discoloration are not sharply defined and tion required as part of main‐
do not cover the entire stroke area tenance work
• Dark areas in the upper section of the cooling bore, remaining cir‐
cumference without objections
• Piston rings without objections
• On the entire circumference, apart from light areas of discoloration Cylinder liner must be re‐
(that do not impair operation) clearly darker stripes that start at the placed; Service must be con‐
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top piston ring tacted

• Heat discoloration in the direction of stroke and honing pattern dam‐
age
• Heat discoloration of piston rings
1. Compile endoscopy report using the table.
2. Use technical terms for description of the liner surface (→ Page 76).
3. Depending on findings:
• do not take any action or
• carry out a further endoscopic examination as part of maintenance work or
• contact Service; cylinder liner must be replaced.

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 Final steps
1. Install injector (→ Page 85).
2. Install cylinder head cover (→ Page 83).
TIM-ID: 0000000015 - 013

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 7.2.2 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 exami‐
nation report.
Findings Measure
Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing prod‐
ucts, particles, broken-off burrs). Removed cylinders clearly show such 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 hone pattern in the direction of stroke.
Findings not critical.
Scored area These areas consist of scores of different length and depth next to one anoth‐
er. In most cases, they are found at the 6-o'clock and 12-o'clock positions (in‐
let/exhaust) along the transverse engine axis.
Findings not critical.
Smoothened area Smoothened areas are on the running surface but almost the whole honing
pattern is still visible. Smoothened areas appear brighter and more brilliant
than the surrounding running surface.
Findings not critical.
Bright area Bright areas are on the running surface and show local removal of the honing
pattern. Grooves from honing process are not visible any more.
Discoloration This is caused by oxidation (surface discoloration through oil or fuel) and tem‐
perature differences around the liner. It appears rather darker within the honed
structure in contrast to the bright metallic running surface. The honing pattern
is undisturbed. Discolorations extend in stroke direction and may be interrupt‐
ed.
Findings not critical.
Corrosion fields / spots Corrosion fields / spots result from water (condensed water) with the valves in
the 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 step towards heat discoloration. They are visible as a clear
discoloration from TDC to BDC in the running surface and the start of localized
damage to the honing pattern.
TIM-ID: 0000000014 - 013

Cylinder liners with a large number of black lines around the running surface
have limited service life and should be replaced.

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 Findings Measure
Burn mark This is caused by a malfunction in the liner / ring tribosystem. Usually they run
over the whole ring-travel area (TDC/BDC), starting at the first TDC-ring and
becoming more visible from the second TDC-ring 2 onwards and less pro‐
nounced from TDC-ring 1. The honing pattern is usually no longer visible and
displays a clearly defined (straight) edge to the undisturbed surface. The dam‐
aged surface is usually discolored. The circumferential length varies.
Liners with burn marks, or heat discoloration, starting in TDC ring 1 have to be
replaced.
Seizure marks, scuff‐ Irregular circumference lengths and depths. Can be caused either by the pis‐
ing ton skirt or the piston crown. Material deposits on the liner (smear), heavy dis‐
coloration. Severe, visible scoring.
Replace liner.

Evaluation of findings and further measures

The findings in the start phase of oxidation discoloration and heat discoloration 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 fur‐
ther operation of the engine.
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 7.3 Valve Drive
7.3.1 Valve gear – Lubrication

Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Engine oil

Valve gear – Lubrication

1. Remove cylinder head covers (→ Page 83).
2. Fill oil chambers of valve bridges with oil.
3. Fill oil chambers of rocker arms and adjust‐
ing screws with oil.
4. Install cylinder head covers (→ Page 83).

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 7.3.2 Valve clearance – Check and adjustment

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

Special tools, Material, Spare parts

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

Preparatory steps
1. Remove cylinder head cover (→ Page 83).
2. Install barring device (→ Page 72).
3. The TDC marking (1) (if fitted) on the fly‐
wheel must not be used for reference.
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 4. Rotate crankshaft with barring device in di‐
rection of engine rotation until TDC-A1
marking and pointer are aligned.

Diagram for 8V engines (two

crankshaft positions)
1 Cylinder A1 is in firing TDC
2 Cylinder A1 is in overlap TDC
I Inlet valve
X Exhaust valve

Diagram for 12V engines (two

crankshaft positions)
1 Cylinder A1 is in firing TDC
2 Cylinder A1 is in overlap TDC
I Inlet valve
X Exhaust valve
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 Diagram for 16V engines (two
crankshaft positions)
1 Cylinder A1 is in firing TDC
2 Cylinder A1 is in overlap TDC
I Inlet valve
X Exhaust valve

Diagram for 20V engines (two

crankshaft positions)
1 Cylinder A1 is in firing TDC
2 Cylinder A1 is in overlap TDC
I Inlet valve
X Exhaust valve

Checking valve clearance at two crankshaft positions

1. Check TDC position of piston in cylinder A1:
• If the rocker arms are unloaded on cylinder A1, the piston is in firing TDC.
• If the rocker arms are under load on cylinder A1, the piston is in overlap TDC.
2. Check valve clearance adjustment with cold engine:
• Inlet (long rocker arm) = 0.2 mm
• Exhaust (short rocker arm) = 0.5 mm
3. Check all valve clearances in two crankshaft positions (firing TDC and overlap TDC of cylinder A1) as
per diagram.
TIM-ID: 0000000922 - 008

4. Use feeler gauge to determine the distance between valve bridge and rocker arm.
5. If the deviation from the set value exceeds 0.1 mm, adjust valve clearance.

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 Adjusting valve clearance
1. Release locknut (1).
2. Insert feeler gauge between valve bridge
and rocker arm.
3. Use Allen key to set adjusting screw (2) so
that the specified valve clearance is estab‐
lished.
4. Feeler gauge must just pass through the
gap.

5. Tighten locknut (1) with torque wrench to the specified tightening torque, holding the adjusting screw (2)
to prevent it from turning.
Name Size Type Lubricant Value/Standard
Locknut M16 x 1.5 Tightening torque (Engine oil) 90 Nm +9 Nm
6. Replace or rectify adjusting screws and/or locknuts which do not move freely.
7. Check valve clearance.

Final steps
1. Remove barring device (→ Page 72).
2. Install cylinder head cover (→ Page 83).

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 7.3.3 Cylinder head cover – Removal and installation

Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Grease (Kluthe Hakuform 30-10/Emulgier) X00058061
O-ring (→ Spare Parts Catalog)

Removing cylinder head cover

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

Installing cylinder head cover

1. Clean mounting surface.
2. Check O-ring (4) for damage, replace if necessary.
3. Coat O-ring (4) with grease.
4. Position O-ring (4) in groove of cylinder head cover (3).
5. Fit cylinder head cover (3) on cylinder head (5).
6. Install cylinder head cover (3) with screws (1) and washers (2).
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 7.4 Injection Valve / Injector
7.4.1 Injector – Replacement

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Injector (→ Spare Parts Catalog)

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

TIM-ID: 0000000022 - 013

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 7.4.2 Injector – Removal and installation

Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

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

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

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

Removing injector
1. Disconnect cable connector on injector.
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 2. Remove HP fuel line (4).
3. Remove return line (5).
Note: The injector accumulator will be emptied
when removing the adapter.
4. Remove adapter (3).
5. Remove screw (2) and take off hold-down
clamp (1).

6. Install installation/removal tool on cylinder

head.
7. Remove injector with installation/removal
tool.
8. Remove installation/removal tool.

9. Remove sealing ring (4) from injector or use

a self-made hook to take it out of the cylin‐
der head.
10. Remove O-rings (3), O-ring (2) and damper
ring (1) from injector.
11. Clean all mating and sealing surfaces.
12. Cover all connections and bores, or seal
with suitable plugs.
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 Installing injector
1. Remove plug before installing the injector.
(Do not remove the plug from the HP line
before installing the adapter.)
2. Coat injector with assembly paste at the
seat of the nozzle clamping nut.
3. Fit new sealing ring (4) (included in the
scope of supply of the injector) with grease
on injector, observe installation position of
sealing ring (4).

4. Fit new O-rings (3) (included in the scope of

supply of the injector), O-ring (2) and damp‐
ing ring (1) onto the injector and coat with
grease.

5. Clean sealing face on cylinder head and

protective sleeve with milling cutter.
6. Insert injector into cylinder head, ensuring
that the HP line adapter is correctly aligned.
7. Use installation/removal tool to press in in‐
jector.
8. Remove installation/removal tool.
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 9. Coat screw head mating face (2) and
thread with engine oil.

10. Fit hold-down clamp (1) in the correct position and use torque wrench to tighten screw (2) to the specified
initial tightening torque.
Name Size Type Lubricant Value/Standard
Screw M12 Preload torque (Engine oil) 5 Nm to 10 Nm
Note: Ensure special cleanness.
11. Coat thread and sealing cone of adapter (3) with engine oil.
12. Install adapter (3) and use torque wrench to tighten to the specified initial tightening torque.
Name Size Type Lubricant Value/Standard
Adapter Preload torque (Engine oil) 5 Nm to 10 Nm
13. Tighten screw (2) with torque wrench to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw M12 Tightening torque 100 Nm + 10 Nm
14. Tighten adapter (3) with torque wrench to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Adapter Tightening torque 100 Nm + 10 Nm
15. Install return line (7).
Note: Ensure special cleanness.
16. Coat thread and sealing cone of HP line (5) with engine oil.
Note: Two HP line versions (single- and double-walled) with different torques as described below.
17. Mount single-walled HP line (5) and use torque wrench to tighten to the specified torque. Tightening se‐
TIM-ID: 0000035394 - 001

quence:
1 Rail (6)
2 Adapter (4)
Name Size Type Lubricant Value/Standard
Union nut / thrust Tightening torque 30 Nm + 5 Nm
screw

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 18. Mount double-walled HP line (5) and use torque wrench to tighten to the specified torque. Tightening
sequence:
1 Adapter (4)
2 Rail (6)
Name Size Type Lubricant Value/Standard
Union nut / thrust Tightening torque 40 Nm + 5 Nm
screw
19. Fit cable connector onto injector.
Note: If the CDC parameters are not reset, the
exhaust emissions certification of the en‐
gine will become null and void.
20. Reset CDC parameters (→ Page 144).

Final steps
1. Install cylinder head cover (→ Page 83).
2. Open fuel supply to engine.
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 7.5 Fuel Filter
7.5.1 Fuel filter – Replacement

Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Oil filter wrench F30379104 1
Diesel fuel
Easy-change filter (→ Spare Parts Catalog)
Synthetic ring (→ Spare Parts Catalog)

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

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

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

CAUTION
Damage to component.
Serious damage to plant!
• For filter replacement with the engine running, operate the engine at low engine load.
• The filter which is to be exchanged must be cut out for a brief period only. TIM-ID: 0000012705 - 001

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 Fuel filter replacement with the
engine stopped
A Both filters operating
B Left filter cut out
C Right filter cut out
1 Fuel vent
2 Fuel filter

1. Cut out the filter to be replaced.

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

Fuel filter replacement with the

engine running
1. Cut out the filter to be replaced.
2. Remove cut-out easy-change filter using
the oil filter wrench.
3. Clean the sealing face of the filter head.
4. Check sealing ring of the new easy-change
filter and coat it with fuel.
5. Install SOLAS shielding (→ Page 20).
6. Install and tighten easy-change filter by
hand.
7. Set three-way cock to operating position
(both filters cut in).
8. Replace further fuel filters in the same way.
TIM-ID: 0000012705 - 001

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 7.5.2 Fuel prefilter – Differential pressure gauge check and adjustment

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

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

Adjusting differential pressure

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

Checking differential pressure of fuel prefilter

1. With the engine running at full load or rated power, read off pressure at gauge (1).
2. If differential pressure as indicated between position of adjustable pointer (2) and pressure-indicating
pointer (3) of pressure gauge is ≥ 0.3 bar, flush filter element of the cut-in filter (→ Page 94).

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 7.5.3 Fuel prefilter – Draining

Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Diesel fuel
Gasket (→ Spare Parts Catalog)

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

Fuel prefilter – Draining

1. Cut out filter to be drained.
I Left filter cut in
II Right filter cut in

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

drained.
3. Unlock drain valve (6) by pressing toggle
and open it.
4. Drain water and contaminants from filter un‐
til pure fuel emerges.
5. Close drain valve (6).
6. Remove screws for cover and take off cov‐
er (2).
TIM-ID: 0000004929 - 003

7. Fill filter housing with clean fuel.

8. Place new gasket in cover (2).
9. Fit cover with gasket and secure it with
screws.
10. Cut in the cut-out filter again.
11. Close threaded vent plug (5) when fuel
emerges.

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 7.5.4 Fuel prefilter ‒ Flushing

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Fuel
Gasket (→ Spare Parts Catalog)

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

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

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

Fuel prefilter ‒ Flushing

1. Cut out clogged filter.
I Left filter cut in
II Right filter cut in

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 2. Open threaded vent plug (5) of filter to be
flushed.
3. Unlock drain valve (6) by pressing valve
toggle, open it and drain fuel.
Result: Fuel flows from filtered side back to the un‐
filtered side, flushing the filter deposits
downwards out of the filter.
4. Close threaded vent plug (5) and drain
valve (6).

Fuel prefilter – Topping up with fuel

1. Stop engine (→ Page 61) and disable engine start.
2. Remove screws for cover and take off cover (2).
3. Fill filter housing with clean fuel.
4. Place new gasket in cover (2).
5. Fit cover with gasket and secure it with screws.
6. Check differential pressure (→ Page 92).
Result: If flushing did not lead to an improvement of the differential pressure, replace filter element of fuel prefil‐
ter (→ Page 96).
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 7.5.5 Fuel prefilter – Filter element replacement

Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Diesel fuel
Filter element (→ Spare Parts Catalog)
Gasket (→ Spare Parts Catalog)

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

Replacing filter element

1. Cut out filter to be drained.
I Left filter cut in
II Right filter cut in

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 2. Open threaded vent plug (5) of contaminat‐
ed filter.
3. Unlock drain valve (6) by pressing toggle
and open it.
4. Drain water and dirt from filter.
5. Close drain valve (6).
6. Remove screws securing the cover and
take off cover (2).
7. Remove spring housing (4) and filter ele‐
ment (3).
8. Insert new filter element (3) and spring
housing (4).
9. Fill filter housing with clean fuel.
10. Place new gasket in cover (2).
11. Fit cover with gasket and secure it with
screws.
12. Cut in the cut-out filter again.
13. Close threaded vent plug (5) when fuel
emerges.
14. Adjust the differential pressure gauge
(→ Page 92).
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 7.6 Charge-Air Cooling
7.6.1 Compressor wheel – Cleaning

Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Cold cleaner X00056750 1

WARNING
Compressed air
Risk of injury!
• Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

WARNING
Chemical substances.
Risk of irritation and chemical burns!
• Always obey manufacturer's instructions for use!

CAUTION
Incorrect installation of components and lines.
Damage to component!
• Ensure that components/lines are installed so that they are never under tension or strain.
• Ensure correct installation position of components.

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

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

Compressor wheel – Cleaning

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Note: Do not use wire brush, scraper or similar tools for cleaning!
1. Clean compressor housing with paint brush or smooth brush.
2. Clean compressor wheel and bearing housing with cold cleaner.
3. Thoroughly blow out all parts with compressed air to remove cold cleaner.

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 Final steps
1. Install air intake.
2. Install exhaust flap with actuators.
3. Install exhaust system after exhaust turbocharger.
4. Install air filter.(→ Page 102)
5. Fill with engine coolant.(→ Page 124)
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 7.6.2 Intercooler – Check water drain for coolant discharge and obstruction

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

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

WARNING
Compressed air
Risk of injury!
• Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

Checking intercooler water drain

for coolant discharge 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
emerges:
2. Clean drain bore(s) and blow out with com‐
pressed air.
3. Significant coolant discharge indicates a
leaking intercooler. Contact Service.

Emergency measures prior to engine start with a leaking intercooler

1. Remove injectors (→ Page 85).
2. Bar engine manually (→ Page 72).
3. Bar engine with starting system to blow out cylinder chambers (→ Page 72).
4. Install injectors (→ Page 85).
TIM-ID: 0000013246 - 007

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 7.7 Air Filter
7.7.1 Air filter – Replacement

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Air filter (→ Spare Parts Catalog)

Replacing the air filter

1. Remove old air filter and install new air filter (→ Page 102).
2. Reset signal ring of contamination indicator (→ Page 103).
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 7.7.2 Air filter – Removal and installation

Preconditions
☑ Engine is stopped and starting disabled.

Removing and installing air filter

1. Release clamp (2).
2. Remove air filter (3) and clamp (2) from
connecting flange of intake housing (1).
3. Verify that there are no objects in the con‐
necting flange of the intake housing (1) and
clean it.
4. Place new air filter (3) with clamp (2) onto
intake housing (1).
5. Tighten clamp (2).

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 7.8 Air Intake
7.8.1 Contamination indicator – Signal ring position check (optional)

Preconditions
☑ Engine is stopped and starting disabled.

Checking signal ring position

1. If the signal ring is completely visible in the
observation window (2), replace air filter
(→ Page 101).
2. After installation of new filter, press reset
button (1).
Result: Engaged piston with signal ring moves back
to initial position.
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 7.8.2 Air flap – Check for ease of movement

Preconditions
☑ Engine is stopped and starting disabled.

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

Checking air flap for ease of

movement
1. Open air flap by moving the lever in the di‐
rection of the arrow.
2. Release lever.
Result: The air flap returns to the original position.
3. Contact Service if the air flap does not fully
return to the original position.

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 7.9 Exhaust Flap with Actuator
7.9.1 Exhaust flap – Check for easy movement

Preconditions
☑ Engine is stopped and starting disabled.

Checking exhaust flap for easy

movement
1. Actuate control linkage and actuating cylin‐
der several times by hand to check for easy
movement.
2. If it does not move freely, contact Service.
TIM-ID: 0000005827 - 003

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 7.10 Starting Equipment
7.10.1 Starter – Condition check

Preconditions
☑ Engine is stopped and starting disabled.

Checking starter condition

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

TIM-ID: 0000000905 - 017

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 7.11 Lube Oil System, Lube Oil Circuit
7.11.1 Engine oil level – Check

Preconditions
☑ Engine shut down and starting disabled.

Checking oil level prior to engine

start
1. Withdraw oil dipstick from guide tube and
wipe it.
2. Insert oil dipstick into guide tube up to stop,
withdraw after approx. 10 seconds and
check oil level.
Note: After extended standstill, the oil level may
exceed the mark (1) by up to 2 cm. This
can be caused by oil flowing from e.g. oil fil‐
ter or heat exchanger back to the oil pan.
3. The oil level must reach mark (1) or exceed
mark (1) by up to 2 cm.
4. Top up with oil to mark (1) as necessary
(→ Page 108).
5. Insert oil dipstick into guide tube up to the
stop.

Checking oil level after the engine is stopped

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

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

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Torque wrench F30027337 1
Ratchet adapter F30027341 1
Engine oil
Sealing ring (→ Spare Parts Catalog)

WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Wear protective clothing, gloves, and goggles / safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.

Oil change without semirotary hand pump: Draining oil at drain plug(s) on oil pan
1. Provide a suitable container in which to collect the oil.
2. Remove drain plug(s) and drain oil.
3. Install drain plug(s) with new sealing ring.

Oil change using semirotary hand pump: Oil extraction

1. Provide a suitable container in which to collect the oil.
2. Extract all oil from oil pan using the semirotary hand pump.

Draining residual oil at the

equipment carrier
1. Provide a suitable container in which to col‐
lect the oil.
2. Remove drain plugs (1) and (2) and drain
oil:
• Approx. 12 liters at (1)
• Approx. 5 liters at (2)
3. Check oil indicator filter (→ Page 116).
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4. Install drain plug(s) with new sealing ring.

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 5. Tighten drain plugs (1) and (2) with torque wrench to the specified torque:
Name Size Type Lubricant Value/Standard
Tightening torque 100 Nm+10Nm

Filling new oil

1. Open cover of filler neck.
2. Pour oil in at filler neck up to "max." mark at
oil dipstick.
3. Close cover of filler neck.
4. Check engine oil level (→ Page 107).
5. After oil change, bar engine with starting
system (→ Page 73).
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 7.11.3 Engine oil – Sample extraction and analysis

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

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
MTU test kit 5605892099/00 1

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

WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Wear protective clothing, gloves, and goggles / safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.

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

Engine oil sample extraction and

analysis
1. With the engine running at operating tem‐
perature, open screw on automatic oil filter
by 1 to 2 turns.
2. Drain approx. 2 liters engine oil to flush out
the oil sludge.
3. Drain approx. 1 liter engine oil into a clean
container.
4. Close screw.
5. Using the equipment and chemicals of the
MTU test kit, check engine oil for:
• Dispersing capacity (spot test);
• Water content;
TIM-ID: 0000014114 - 003

• Dilution by fuel.

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 7.12 Oil Filtration / Cooling
7.12.1 Engine oil filter – Replacement

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Filter wrench F30379104
Engine oil
Oil filter (→ Spare Parts Catalog)

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

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

WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Wear protective clothing, gloves, and goggles / safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.

CAUTION
Damage to component.
Serious damage to plant!
• For filter replacement with the engine running, operate the engine at low engine load.
• The filter which is to be exchanged must be cut out for a brief period only.

Replacing engine oil filter

1. Stop engine (→ Page 61) and disable en‐
gine start.
2. Unscrew oil filter using filter wrench.
3. Clean sealing surface on connecting piece.
4. Check condition of new oil filter sealing ring
and moisten it with oil.
TIM-ID: 0000014238 - 003

5. Screw on and tighten new oil filter by hand.

6. Replace other oil filters in the same way.
7. Turn engine with starting system after every
oil change and filter replacement
(→ Page 73).
8. Check oil level (→ Page 107).

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 Oil filter with diverter (option): Oil
filter replacement with the engine
stopped
1. Stop engine (→ Page 61) and disable en‐
gine start.
2. Unscrew oil filter using oil filter wrench.
3. Clean sealing surface on connecting piece.
4. Check condition of new oil filter sealing ring
and moisten it with oil.
5. Fit SOLAS shield (→ Page 20).
6. Screw on and tighten new oil filter by hand.
7. Replace other oil filters in the same way.
8. Turn engine with starting system after every
oil change and filter replacement
(→ Page 73).
9. Check oil level (→ Page 107).

Oil filter with diverter (option): Oil

filter replacement with the 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 op‐
erating position)
• Position C: Upper filters cut out.

2. Unscrew oil filter using oil filter wrench.

3. Clean sealing surface on connecting piece.
4. Check condition of new oil filter sealing ring
and moisten it with oil.
5. Fit SOLAS shield (→ Page 20).
6. Screw on and tighten new oil filter by hand.
7. Replace other oil filters in the same way.
8. Check oil level (→ Page 107).
TIM-ID: 0000014238 - 003

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 7.12.2 Automatic oil filter – Oil filter candle replacement

Preconditions
☑ Engine shut down and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 1
Engine oil
O-ring (→ Spare Parts Catalog)
Oil filter candles (→ Spare Parts Catalog)

WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Wear protective clothing, gloves, and goggles / safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.

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

Removing oil filter candles

1. Remove nuts (2) from oil filter cover (1).
2. Remove oil filter cover.
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 3. Withdraw filter insert (1).
4. Remove O-ring.

5. Remove screw (2).

6. Withdraw plastic spinner (1) with spring.
7. Unscrew nut (3).
8. Take off spring washer and washer.
9. Remove screw (4).
10. Remove flushing arm (5) from screen
plate (6).

11. Turn filter element through 180° and use

appropriate tool to push out filter can‐
dles (1).
12. Turn filter element through 180° and insert
new filter candles (1) with chamfer facing
downwards.
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 Installing oil filter candles
1. For installation follow reverse sequence of working steps.
2. Additionally, the following instructions are to be observed:
• Replace all sealing elements with new parts
• Coat O-rings with grease
• Insert O-rings in grooves
• Pay attention to installation position of fillister-head screw to elongated hole in shaft
TIM-ID: 0000029294 - 003

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 7.12.3 Oil indicator filter – Check

Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Strainer (→ Spare Parts Catalog)
Square-section ring (→ Spare Parts Catalog)
O-ring (→ Spare Parts Catalog)

WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Wear protective clothing, gloves, and goggles / safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.

WARNING
Compressed air
Risk of injury!
• Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

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

Removing strainer
1. Clean oil indicator filter before disassem‐
bling it.
2. Remove screws (1).
3. Take off cover (2) with O–ring (3).
4. Take strainer (5) from filter housing. TIM-ID: 0000006402 - 001

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 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

Cleaning strainer
1. Wash strainer (5) with cleaner.
2. Remove stubborn deposits with soft brush.
3. Blow out strainer (5) with compressed air from inside.

Installing strainer
1. Coat square-section ring (4) on strainer (5) with engine oil and install strainer (5).
2. Coat O–ring (3) with engine oil and fit in filter housing.
3. Fit cover (2) and secure with screws (1) and washers.
TIM-ID: 0000006402 - 001

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 7.12.4 Centrifugal oil filter – Cleaning and filter sleeve replacement

Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

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

WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Wear protective clothing, gloves, and goggles / safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.

WARNING
Compressed air
Risk of injury!
• Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

TIM-ID: 0000000934 - 008

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 Centrifugal oil filter cleaning and
filter sleeve replacement
1. Remove clamp (14).
2. Release cover screw (2) and take off cov‐
er (1).
3. Carefully lift rotor (11), allow oil to drain and
remove from housing.
4. Holding the rotor (11) firmly, release rotor
cover nut (3).
5. Take off rotor cover (4).
6. Remove filter sleeve (6).
7. Measure thickness of oil residues on filter
sleeve (6).
8. If maximum layer thickness of oil residues
exceeds 45 mm, shorten maintenance in‐
terval.
9. Disassemble rotor tube (7), conical disk (8)
and rotor base (10).
10. Wash rotor cover (4), rotor tube (7), conical
disk (8) and rotor base (10) with cold clean‐
er.
11. Blow out with compressed air.
12. Check sealing ring (9), fit new one if neces‐
sary.
13. Assemble rotor tube (7), conical disk (8)
and rotor base (10) with sealing ring (9).
14. Insert new filter sleeve (6) in rotor tube (7)
with the smooth paper surface facing the
outer wall.
15. Check sealing ring (5), fit new one if neces‐
sary.
16. Mount rotor cover (4) with sealing ring (5).
17. Tighten rotor cover nut (3) with torque wrench to the specified torque.
Name Size Type Lubricant Value/Standard
Nut Tightening torque 35 Nm to 45 Nm
18. Place rotor (11) in housing (12) and check for ease of movement.
19. Check sealing ring (13), fit new one if necessary.
20. Fit sealing ring (13) on housing (12).
21. Fit cover (1).
22. Fit cover screw (2) by hand.
23. Install clamp (14) and tighten with torque wrench to the specified torque.
Name Size Type Lubricant Value/Standard
Clamp Tightening torque 8 Nm to 10 Nm
TIM-ID: 0000000934 - 008

24. Tighten cover nut (2) with torque wrench to the specified torque.
Name Size Type Lubricant Value/Standard
Screw Tightening torque 5 Nm to 7 Nm

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 7.13 Coolant Circuit, General, High-Temperature Circuit
7.13.1 Ventilation points

Coolant lines on exhaust turbocharger

1 Ventilation point

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 7.13.2 Engine coolant – Level check

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

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

Checking engine coolant level at filler neck:

1. Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to
escape.
2. Continue to turn breather valve counterclockwise and remove.
3. Check engine coolant level (coolant must be visible at the bottom edge of the filler neck's cast eye).

Checking engine coolant level at

remote cooler:
1. Check engine coolant level (coolant must
be visible at marker plate).
2. Top up engine coolant if necessary
(→ Page 124).
3. Check and clean breather valve.
4. Place breather valve on filler neck and
close.

Checking engine coolant level via level sensor:

1. Switch on engine control system and check readings on the display.
2. Top up engine coolant if necessary (→ Page 124).
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 7.13.3 Engine coolant – Change

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Coolant

Engine coolant – Change

1. Drain engine coolant (→ Page 123).
2. Fill with engine coolant (→ Page 124).

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 7.13.4 Engine coolant draining

Preconditions
☑ Engine is stopped and starting disabled.

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

Preparatory steps
1. Provide an appropriate container to drain the coolant into.
2. Switch off preheating unit.

Engine coolant draining

1. Turn breather valve of filler neck on expan‐
sion tank counterclockwise to first stop and
allow pressure to escape.
2. Continue to turn breather valve counter‐
clockwise and remove.
3. Draw off precipitated corrosion inhibitor oil
from the expansion tank through filler neck.
4. Open drain valves and drain plugs and
drain coolant at the following points:
• Preheating unit
• Elbow of HT coolant pump (2)
• Crankcase, left and right side (3)
• T piece (5) on engine driving end;
• Intercooler
• Carrier housing (1)

Final steps
1. Seal all open drain points
2. Place breather valve onto filler neck and close it.
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 7.13.5 Engine coolant – Filling

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

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Engine coolant

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

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

Preparatory steps
1. Turn breather valve of coolant expansion
tank counterclockwise to first stop and allow
pressure to escape.
2. Continue to turn breather valve counter‐
clockwise and remove.
3. Release the coolant line union on both tur‐
bochargers (→ Page 120).
4. Release the coolant line union at the cool‐
ant distributor (→ Page 120).

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 Filling with coolant using a pump
1. Connect appropriate pump with hose to fill‐
ing connection (arrow) on A side or B side.
Alternatively:

2. Connect a suitable pump with a hose to

drain valve (arrowed).
3. Pump coolant into engine at 0.5 bar mini‐
mum until coolant emerges from the loos‐
ened unions at the coolant distributor.
4. Tighten the union for coolant line at the
coolant distributor (→ Page 120).
5. Fill expansion tank until overflow edge is
reached.
6. Check proper condition of breather valve
and clean sealing faces if required.
7. Place breather valve on filler neck and
close.
8. Continue filling process until coolant emerg‐
es from the loosened unions at the two tur‐
bochargers.
9. Tighten the coolant line union on both tur‐
bochargers (→ Page 120).
10. Start engine (→ Page 53).
11. After the engine has run at idling speed for
10 seconds, stop engine (→ Page 61).
12. Turn breather valve of coolant expansion
tank counterclockwise to first stop and allow
pressure to escape.
13. Continue to turn breather valve counter‐
clockwise and remove.
14. Check coolant level (→ Page 121) and top
up engine coolant as required:
a) Fill in coolant in expansion tank until the
TIM-ID: 0000006727 - 004

coolant level at top edge of filler neck

remains constant.
b) Place breather valve on filler neck and
close.
c) Repeat the steps from "Start engine"
(→ Step 10) until coolant no longer
needs to be topped up.
d) Disconnect pump and hose.

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 Filling with coolant through filler neck
1. Alternatively: Fill coolant through filler neck on expansion tank until coolant emerges from the loosened
unions at the coolant distribution.
2. Tighten the union for coolant line at the coolant distributor (→ Page 120).
3. Continue to fill until coolant level remains constant at top edge of filler neck.
4. Tighten the coolant line union on both turbochargers (→ Page 120).
5. Check proper condition of breather valve and clean sealing faces if required.
6. Set breather valve onto filler neck and turn until the first stop to close.
7. Start engine (→ Page 53).
8. After the engine has run at idling speed for 10 seconds, stop engine (→ Page 61).
9. Turn breather valve counterclockwise and remove.
10. Check coolant level (→ Page 121) and top up engine coolant as required:
a) Repeat the steps from "Start engine" (→ Step 7) until coolant no longer needs to be topped up.
b) Check proper condition of breather valve and clean sealing faces if required.
c) Place breather valve on filler neck and close.

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 7.13.6 Engine coolant pump – Relief bore check

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

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

Engine coolant pump – Relief bore

check
1. Check relief bore for oil and coolant dis‐
charge.
2. Shut down engine (→ Page 53) and disable
engine start, observe general safety instruc‐
tions “Maintenance and Repair”.
3. Clean the relief bore with a wire if it is dirty.
• Permissible coolant discharge: up to 10
drops per hour;
• Permissible oil discharge: up to 5 drops
per hour.
4. If discharge exceeds the specified limits:
Contact Service.
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 7.13.7 Engine coolant – Sample extraction and analysis

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

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
MTU test kit 5605892099/00 1

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

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

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

Engine coolant – Sample extraction

and analysis
1. With the engine running, open drain valve
(1).
2. Rinse extraction point by draining approx. 1
liter of engine coolant.
3. Drain approx. 1 liter of engine coolant into a
clean container.
4. Close drain valve (1).
5. Use the equipment and chemicals of the
MTU test kit to check the engine coolant
for:
• Antifreeze concentration
• Corrosion inhibitor concentration
• pH value
6. Engine coolant change intervals (→ MTU
TIM-ID: 0000014608 - 004

Fluids and Lubricants Specifications).

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 7.13.8 Coolant filter – Replacement

Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Filter wrench F30379104 1
Engine oil
Coolant filter (→ Spare Parts Catalog)

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.

Coolant filter – Replacement

1. Close shut-off cocks (1).
2. Remove coolant filter (2) with filter wrench.
3. Clean sealing surface on connecting piece.
4. Coat seal on new coolant filter with engine
oil.
5. Screw on coolant filter and tighten hand-
tight.
6. Open shut-off cocks (1).
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 7.14 Low-Temperature Circuit
7.14.1 Charge-air coolant – Draining

Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Sealing ring (→ Spare Parts Catalog)

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.

Charge-air coolant – Draining

1. Provide an appropriate container to drain
the coolant into.
2. Turn breather valve of filler neck on coolant
expansion tank counterclockwise to first
stop and allow pressure to escape.
3. Continue to turn breather valve counter‐
clockwise and remove.
4. Draw off separated corrosion inhibitor oil in
expansion tank through the filler neck.
5. Open drain valves and/or drain plugs and
drain coolant at the following points:
• at the LT coolant pump
• at the LT thermostat housing.

6. Draining of residual coolant:

• at the intercooler
7. Close all drain valves and screw in drain
plugs with new sealing rings.
8. Place breather valve on filler neck and
close.
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 7.15 Raw Water Pump with Connections
7.15.1 Raw water pump – Relief bore check

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

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

Raw water pump – Relief bore

check
1. Check relief bore for oil and raw water dis‐
charge.
2. Shut down engine (→ Page 53) and disable
engine start, observe general safety instruc‐
tions “Maintenance and Repair”.
3. Clean the relief bore with a wire if it is dirty.
• Permissible raw water discharge: up to
10 drops per hour;
• Permissible oil discharge: up to 5 drops
per hour.
4. If discharge exceeds the specified limits:
Contact Service.
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 7.16 Battery-Charging Generator
7.16.1 Battery-charging generator drive – Coupling condition check

Preconditions
☑ Engine shut down and starting disabled.

Checking condition of battery-

charging generator drive coupling
1. Remove protective cover.
2. Check resilient coupling for cracks and de‐
formation (arrow).
3. Contact Service in case of severe deforma‐
tion or cracking.
4. Install protective cover.

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 7.17 Engine Mounting / Support
7.17.1 Engine mounts – Checking securing screws for firm seating

Preconditions
☑ Engine is stopped and starting disabled.

Engine mounts – Checking securing screws for firm seating

1. Check securing screws for firm seating.
2. Tighten loose threaded connections.
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 7.17.2 Engine mounts – Resilient element check

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

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Feeler gauge Y20010128 1
Calipers Y20001743 1
Box wrench F30379609 1
Engine oil

Engine mounts – Checking the

condition of resilient elements
1. Wipe rubber surface with dry cloth, do not
use organic detergents.
2. Check resilient elements for crack formation
and deformation by visual inspection.
3. Have cracked mounts replaced, contact
Service.

Engine mounts – Measuring adjustment dimension

1. Measure dimension (a) with Vernier caliper.
Note: On new blocked mounts, the adjustment dimension is approx. 28 mm.
2. If the measured value of dimension a = 20 mm is lower than the specified value, the resilient element
must be replaced, contact Service.
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 Engine mounts – Checking buffer
clearance
1. Take off protective cap (2).
2. Check marking (1):
• With marking 30: a = 3 mm +0,3 mm.
• With marking 40: a = 4 mm +0,3 mm.
3. Check dimension (a) with feeler gauge on
measuring groove (4).
4. If dimension (a) deviates from the above
specifications, adjust buffer clearance.

Engine mounts – Buffer clearance adjustment

1. Undo nut (3).
2. Adjust buffer clearance by turning the central buffer (1).
3. Coat mating face of nut (3) and thread of central buffer (1) with a little engine oil. Engine oil must not get
in contact with the rubber elements of the resilient mount.
4. Tighten nut (3) to the specified tightening torque securing the central buffer (1) to prevent it turning.
Name Size Type Lubricant Value/Standard
Nut M27 x 2 Tightening torque (Engine oil) 580 Nm +50 Nm
5. Fit protective cap (2).
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 7.18 Drive Systems, Driving End and Free End (Coupling)
7.18.1 Coupling – Condition check

Preconditions
☑ Engine is stopped and starting disabled.

Coupling condition check

1. Remove perforated plate(s).
2. Wipe rubber element with dry cloth, do not use organic detergents.
3. Check condition of coupling through assembly hole(s) using an inspection lamp. Hair cracks in the rubber
elements are permissible.
4. If a considerable number of deeper cracks or places with broken-off rubber are found, contact Service.
5. Install perforated plate(s).

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 7.19 Fuel Supply System
7.19.1 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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 7.19.2 Differential pressure gauge – Check

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

Checking differential pressure gauge

1. Switch on fuel treatment system (→ Page 54).
2. Set the alarm points at the differential pressure gauge to zero.
Result: Alarm is initiated with preset delay.
3. Reset the alarm points at the differential pressure gauge to the specified values.

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

Preconditions
☑ System is put out of operation and emptied.

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

Checking water level probe (3-in-1 rod electrode)

1. Disconnect connector from water level probe.
2. Unscrew water level probe.
3. Disconnect connector from water level probe.
4. Immerse water level probe into a tank filled with water until water level reaches the thread.
5. Switch system on.
Result: Water drain valve opens.
6. Leave water level probe in tank.
Result: Alarm must be triggered with the preset delay.
7. Switch off the system.
8. Disconnect connector from water level probe.
9. Remove water level probe from tank.
10. Screw in water level probe.
11. Connect connector for water level probe.
12. Fill and vent the system then put it into operation.
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 7.19.4 Pump capacity – Check

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

Pump capacity – Check

1. Install suitable pressure gauge in the intake connection of the pump.
2. Check pump pressure.
a) Switch on fuel treatment system (→ Page 54).
Note: The pressure limiting valve at the pump might respond and open. Audible noise is caused by overflowing
fuel and can be disregarded.
b) Close ball valve at the outlet of the fuel treatment system.
c) Check pressure at the pressure gauge in the inlet to the fuel treatment system and note down.
3. Checking pump pressure with reduced 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
If the measured value (reduced suction condition) is 10% lower than the measured value (normal con‐
dition), the wear limit is reached. Repair pump (contact Service).

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 7.19.5 Coalescer filter element – Replacement

Preconditions
☑ System is switched off and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Torque wrench, 6-50 Nm F30027336 1
Ratchet adapter F30027339 1
Diesel fuel
Engine oil
Coalescer filter element (→ Spare Parts Catalog)
Gasket (→ Spare Parts Catalog)

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

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

CAUTION
Incorrect installation of components and lines.
Damage to component!
• Ensure that components/lines are installed so that they are never under tension or strain.
• Ensure correct installation position of components.

Coalescer filter element –

Replacement
1. Close ball valve at the inlet and outlet of the
fuel treatment system.
2. Open drain valve.
3. Drain fuel.
4. Close drain valve.
5. Remove nut (9) with washer (2).
6. Remove screws (1).
7. Remove cover with gasket (10).
TIM-ID: 0000007735 - 007

8. Remove nut (3), washer (8) and end

plate (7).
9. Remove coalescer filter element (4).
10. Catch fuel as it runs out.
11. Clean housing with a non-linting cloth, rinse
with fuel if required.
12. Check housing for corrosion.
13. Clean housing sealing surfaces.
14. Install coalescer filter element.
15. Install end plate (7), washer (8) and nut (3).

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 16. Tighten nut (3) to specified tightening torque using a torque wrench.
Name Size Type Lubricant Value/Standard
Nut M16 Tightening torque (Engine oil) 30 Nm +3 Nm
17. Fit gasket (10).
18. Install cover.
19. Install screw (1), washer (2) and nut (9).
20. Tighten nut (9).
21. Open ball valve at the inlet and outlet of the fuel treatment system.
Result: The fuel treatment system is ready for operation.

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

Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Isopropyl alcohol X00058037 1

Engine wiring – Check

1. Check securing screws of cable clamps on engine and tighten loose threaded connections.
2. Ensure that cables are fixed in their clamps and cannot swing freely.
3. Check that cable ties are firm, tighten loose cable ties.
4. Replace faulty cable ties.
5. Visually inspect the following electrical line components for damage:
• connector housings;
• contacts;
• sockets;
• cables and terminals;
• plug-in contacts.
6. (→ Contact Service) if cable conductors are damaged.
Note: Close male connectors that are not plugged in with the protective cap supplied.
7. Clean dirty connector housings, sockets and contacts with isopropyl alcohol.
8. Ensure that all sensor connectors are securely engaged.
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 7.21 Accessories for (Electronic) Engine Governor / Control
System
7.21.1 CDC parameters – Reset with DiaSys®

Preconditions
☑ Engine is stopped and starting disabled.

Resetting CDC parameters (DiaSys® is available)

Note: The CDC parameters must be reset, otherwise the emission certification of the engine is no longer appli‐
cable.
u Reset the CDC parameters with DiaSys® (→ Manufacturer's documentation).

Resetting CDC parameters (DiaSys® is not available)

Note: The CDC parameters must be reset, otherwise the emission certification of the engine is no longer appli‐
cable.
u Contact Service.

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 7.21.2 Engine governor and connectors – Cleaning

Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Isopropyl alcohol X00058037 1

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

Engine governor and connectors – Cleaning

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

Cleaning severely contaminated connectors on the engine governor

Note: Seal unused connectors with the supplied protective cap.
1. Release the latch and pull off connectors.
2. Clean connector housings, connector socket housings and all contacts with isopropyl alcohol.
3. When connectors, sockets and all contacts are dry: Fit connectors and lock them.
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 7.21.3 EMU and connectors – Cleaning

Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Isopropyl alcohol

EMU and connectors – Cleaning

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

Cleaning severely contaminated EMU connectors

1. Release latches of connectors and withdraw connectors.
2. Clean connector housings, connector socket housings and all contacts with isopropyl alcohol.
3. When connectors, sockets and all contacts are dry: Fit connectors and secure latches.

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 7.21.4 Engine Monitoring Unit EMU 7 – Plug connection check

Preconditions
☑ Engine is stopped and starting disabled.

Checking EMU plug connections

1. Check both connectors on EMU (2) for firm
seating. Ensure that clips (3) are engaged.
2. Check screws (1) of cable clamps on EMU
(2) for firm seating. Ensure that cable
clamps are not faulty.
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 7.21.5 Engine governor – Checking plug-in connections

Preconditions
☑ Engine is stopped and starting disabled.

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

Checking plug-in connections on engine governor

1. Check all plug-in connections for secure seating.
2. Latch connectors if loose.

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 7.21.6 ECU 7 engine governor – Removal and installation

Preconditions
☑ Engine is stopped and starting disabled.

CAUTION
Wrong engine governor installed.
Engine damage!
• When reassembling an engine, make sure that the governor with the data record for the given
engine is installed.

Removing engine governor from

engine
1. Note or mark assignment of cables and
connectors.
2. Remove all screws (2).
3. Undo latches (3) of the connectors.
4. Remove all connectors.
5. Remove screws (1).
6. Take off engine governor.

Installing engine governor on engine

1. Install in reverse order. In doing so, ensure correct assignment of connectors and sockets.
2. Check rubber mount before installation.
Result: If the rubber mount is porous or defective, replace it.
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 7.22 Emergency Instrumentation (Local Operating Panel)
7.22.1 LOP and connectors – Cleaning

Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Isopropyl alcohol X00058037 1

Cleaning LOP
1. Wipe LCD display with dry cloth, without applying excessive pressure.
2. Remove dirt from keys using isopropyl alcohol.
3. Remove heavy soiling from housing surface with isopropyl alcohol.

Cleaning connectors on LOP

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

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 8 Appendix A
8.1 Abbreviations

Abbrevia‐ Meaning Explanation

tion
ADEC Advanced Diesel Engine Control Engine governor
AL Alarm Alarm (general)
ANSI American National Standards Institute Association of American standardization organiza‐
tions
ETC Exhaust turbocharger
BR Series
BV Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU Publica‐
tion No. A01061/..
CAN Controller Area Network Data bus system, bus standard
CPP Controllable Pitch Propeller Controllable pitch propeller
DIN Deutsches Institut für Normung e. V. 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
EMU Engine Monitoring Unit Engine monitoring unit
SPC Spare Parts Catalog
FPP Fixed Pitch Propeller Fixed pitch propeller
GCU Gear Control Unit Gear control unit
GMU Gear Monitoring Unit Gear monitoring unit
HAT Harbour Acceptance Test
HI High Alarm: Measured value exceeds 1st maximum limit
HIHI High High Alarm: Measured value exceeds 2nd maximum lim‐
it value
HT High Temperature High temperature
TIM-ID: 0000002050 - 003

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
IMO International Maritime Organization International maritime organisation
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

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 Abbrevia‐ Meaning Explanation
tion
KS Driving end Engine driving end in accordance with DIN ISO
1204
LCD Liquid Crystal Display, Liquid Crystal Liquid-crystal display
Device
LCU Local Control Unit Local control unit (LOP subassembly)
LED Light Emitting Diode Light emitting diode
LMU Local Monitoring Unit Local monitoring unit (LOP subassembly)
LO Low Alarm: Measured value lower than 1st minimum
limit value
LOLO Low Low Alarm: Measured value lower than 2nd minimum
limit value
LOP Local Operating Panel Control console, control panel
LOS Local Operating Station Local operating station
MCS Monitoring and Control System Monitoring and Control System
MG Message Message
MPU Microprocessor Unit, Microprocessing Microprocessor (unit)
Unit
OT Oberer Totpunkt
P-xyz Pressure-xyz Pressure measuring point xyz
PAN Panel Control panel
PCU Propeller Control Unit Propeller control unit
PIM Peripheral Interface Module Peripheral interface module
RCS Remote Control System 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 Flaps Emergency-air shutoff flap(s)
SOLAS International Convention for the Safe‐ International Convention for the Safety of Life at
ty of Life at Sea Sea
SS Safety System Safety system alarm
SSK Emergency-air shutoff flap(s)
T-xyz Temperature-xyz Temperature measuring point xyz
TD Transmitter Deviation Alarm: Sensor comparison fault
TIM-ID: 0000002050 - 003

UT Unterer Totpunkt
VS Voith Schneider Voith Schneider drive
WJ Water Jet Water jet drive
TC Tool Catalog
ZKP Zugehörigkeit-Kategorie-Parameter Assignment category parameter, number scheme
for signals from the ADEC engine governor

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 8.2 MTU contact persons/service partners

Our worldwide sales network with its subsidiaries, sales offices, representatives and customer service
centers ensures fast and direct support on site and 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 the outstanding flexibility of our service staff, we are always ready to assist you
– either during operation, for preventive maintenance, corrective work in case of malfunction or changed
operating conditions, or for spare parts supply.
Your contact at Headquarters: [email protected]

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: [email protected]
Phone: +49 7541 908555
Fax: +49 7541 908121
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 9 Appendix B
9.1 Special Tools
Barring device
Part No.: F6555766
Qty.: 1
Used in: 7.1.1 Engine – Barring manually (→ Page 72)

Box wrench
Part No.: F30379609
Qty.: 1
Used in: 7.17.2 Engine mounts – Resilient element check (→
Page 134)

Box wrench socket, 24 mm

Part No.: F30039526
Qty.: 1
Used in: 7.3.2 Valve clearance – Check and adjustment (→ Page
79)

DCL-ID: 0000015617 - 001

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 Calipers
Part No.: Y20001743
Qty.: 1
Used in: 7.17.2 Engine mounts – Resilient element check (→
Page 134)

Feeler gauge
Part No.: Y20098771
Qty.: 1
Used in: 7.3.2 Valve clearance – Check and adjustment (→ Page
79)

Feeler gauge
Part No.: Y20010128
Qty.: 1
Used in: 7.17.2 Engine mounts – Resilient element check (→
Page 134)

Filter wrench
Part No.: F30379104
Qty.:
Used in: 7.12.1 Engine oil filter – Replacement (→ Page 111)
Qty.: 1
Used in: 7.13.8 Coolant filter – Replacement (→ Page 129)
DCL-ID: 0000015617 - 001

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 Installation/removal tool
Part No.: F6789889
Qty.: 1
Used in: 7.4.2 Injector – Removal and installation (→ Page 85)

Milling cutter
Part No.: F30452739
Qty.: 1
Used in: 7.4.2 Injector – Removal and installation (→ Page 85)

MTU test kit

Part No.: 5605892099/00
Qty.: 1
Used in: 7.11.3 Engine oil – Sample extraction and analysis (→
Page 110)
Qty.: 1
Used in: 7.13.7 Engine coolant – Sample extraction and analysis
(→ Page 128)

Oil filter wrench

Part No.: F30379104
Qty.: 1
Used in: 7.5.1 Fuel filter – Replacement (→ Page 90)
DCL-ID: 0000015617 - 001

156 | Appendix B | MS150048/03E 2012-07

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 Ratchet adapter
Part No.: F30027341
Qty.: 1
Used in: 7.3.2 Valve clearance – Check and adjustment (→ Page
79)
Qty.: 1
Used in: 7.11.2 Engine oil – Change (→ Page 108)

Ratchet adapter
Part No.: F30027339
Qty.: 1
Used in: 7.19.5 Coalescer filter element – Replacement (→ Page
141)

Ratchet head with extension

Part No.: F30006212
Qty.: 1
Used in: 7.1.1 Engine – Barring manually (→ Page 72)

Rigid endoscope
Part No.: Y20097353
Qty.: 1
Used in: 7.2.1 Cylinder liner – Endoscopic examination (→ Page
74)
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 Steam jet cleaner
Part No.: -
Qty.: 1
Used in: 4.18 Plant cleaning (→ Page 66)

Torque wrench
Part No.: F30027337
Qty.: 1
Used in: 7.11.2 Engine oil – Change (→ Page 108)

Torque wrench, 0.5-5 Nm

Part No.: 0015384230
Qty.: 1
Used in: 7.4.2 Injector – Removal and installation (→ Page 85)

Torque wrench, 10-60 Nm

Part No.: F30510423
Qty.: 1
Used in: 1.4 Crankshaft transport locking device (→ Page 8)

Torque wrench, 10-60 Nm

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Part No.: F30452769

Qty.: 1
Used in: 7.4.2 Injector – Removal and installation (→ Page 85)

158 | Appendix B | MS150048/03E 2012-07

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 Torque wrench, 6-50 Nm
Part No.: F30027336
Qty.: 1
Used in: 7.19.5 Coalescer filter element – Replacement (→ Page
141)

Torque wrench, 6-50 Nm

Part No.: F30027336
Qty.: 1
Used in: 7.12.4 Centrifugal oil filter – Cleaning and filter sleeve
replacement (→ Page 118)

Torque wrench, 60-320 Nm

Part No.: F30047446
Qty.: 1
Used in: 1.4 Crankshaft transport locking device (→ Page 8)

Torque wrench, 60-320 Nm

Part No.: F30452768
Qty.: 1
Used in: 7.3.2 Valve clearance – Check and adjustment (→ Page
79)
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 Torque wrench, 60-320 Nm
Part No.: F30452768
Qty.: 1
Used in: 7.4.2 Injector – Removal and installation (→ Page 85)

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160 | Appendix B | MS150048/03E 2012-07

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 9.2 Index
20V 4000 M93 engine data: EPA 2, engine-mounted Cylinder liner
heat exchanger 38 – Endoscopic examination 74
20V 4000 M93 engine data: IMO, engine-mounted heat – Instructions and comments on endoscopic and visual
exchanger, intercooler made of copper-based alloy 35 examination 76
20V 4000 M93L engine data: EPA 2, engine-mounted
heat exchanger 44 D
20V 4000 M93L engine data: IMO, engine-mounted heat Differential pressure gauge
exchanger, intercooler made of copper-based alloy 41 – Check 138
Disengaging
A – from LOP 59
Abbreviations 151
Actuators E
– Overview 30 ECU 7 engine governor
After stopping the engine 64 – Removal and installation 149
Air filter Emergency stop
– Removal and installation 102 – From LOP 63
– Replacement 101 EMU 7
Air flap – Check for ease of movement 104 – Plug connection check 147
Automatic oil filter EMU and connectors – Cleaning 146
– Filter candles Engine
– Replacement 113 – Barring with starting system 73
Auxiliary materials 16 – Overview 29
– Start 53
B – Stopping
Battery-charging generator drive – At the BlueLine automation system (control stand)
– Coupling condition check 132 62
– From LOP 61
C – Wiring check 143
CDC parameters Engine coolant
– Reset 144 – Change 122
Centrifugal oil filter – Filling 124
– Cleaning and filter sleeve replacement 118 – Level check 121
Charge-air coolant – Draining 130 – Sample extraction and analysis 128
Checks Engine coolant draining 123
– Prior to start-up 50 Engine coolant pump – Relief bore check 127
Coalescer filter element Engine emergency stop
– Replacement 141 – At BlueLine automation system (control stand) 56
Compressor wheel Engine governor
– Cleaning 98 – Checking plug-in connections 148
Connectors – Cleaning 145
– Cleaning 145 Engine Monitoring Unit EMU 7
Contact persons 153 – Plug connection check 147
Contamination indicator Engine mounts
– Signal ring position check 103 – Resilient element check 134
Controls 48 Engine mounts
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Coolant filter – Checking securing screws for firm seating 133

– Replacement 129 Engine oil
Coupling – Centrifugal oil filter – Cleaning and filter sleeve re‐
– Condition check 136 placement 118
– From LOP 58 Engine oil filter
Crankshaft transport locking device – Replacement 111
– Removal/installation 8 Engine oil level
Cylinder – Check 107
– Designation 19 Engine oil – Change 108
Cylinder head cover Engine oil – Sample extraction and analysis 110
– Removal and installation 83

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 Engine side L
– Designation 19 LOP
Engine wiring – Cleaning 150
– Check 143 – Connector cleaning 150
Engine – barring manually 72
Environmental protection 16 M
Exhaust flap Maintenance work
– Check for easy movement 105 – Safety regulations 13
MTU contact persons 153
F
Filter O
– Automatic oil filter Oil indicator filter – Check 116
– Filter candles - Replacement 113 Operation
– Coalescer Element – Safety regulations 11
– Replacement 141 Operational checks 57
Fire prevention 16 Overview
Firing order 47 – Engine 29
Fluids and lubricants 16
Fuel P
– prefilter Personnel and organizational requirements 6
– Flushing 94 Plant
– Treatment system – Cleaning 66
– Troubleshooting 68 Product description 20
– treatment system Pump capacity
– Shutdown 65 – Check 140
– Switching on 54
Fuel filter – Replacement 90 R
Fuel prefilter Raw water pump – Relief bore check 131
– Differential pressure gauge Repair work
– Check and adjustment 92 – Safety regulations 13
– Draining 93
– Filter element S
– Replacement 96 Safety instructions 18
– Flushing 94 Safety regulations 11, 13
– From LOP (option) 60 Sensors
Fuel treatment system – Overview 30
– Putting into operation 51 Service partners 153
– Shutdown 65 Spare parts service 153
– Switching on 54 Starter
– Condition check 106
G Starting the engine 55
General conditions 5 Startup
– Safety regulations 11
H
Hotline 153 T
Tasks
I – After extended out-of-service periods 49
Injector Tasks after extended out-of-service periods (>3 weeks)
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– Removal and installation 85 49

– Replacement 84 Transport 7
Injectors Troubleshooting 69
– Overview 30 – Fuel treatment system 68
Inspection port cover
– Explosion hazard 12 V
Intercooler Valve clearance
– Check water drain for coolant discharge and obstruc‐ – Adjustment 79
tion 100 – Check 79
Valve gear
– Lubrication 78

162 | Appendix B | MS150048/03E 2012-07

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 Ventilation points 120

W
Water drain valve
– Check 137
Water level probe (3-in-1 rod electrode)
– Check 139
Waterjet
– Flushing
– From LOP (option) 60
Wiring - engine
– Check 143
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