manual operacion motor

8/18/2019 manual operacion motor

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Technical Publication

Diesel Engine8V 4000 M60/M60R

12V 4000 M60/M60R

16V 4000 M60/M60R

Operating instructionsM015411/00E

DaimlerChrysler Off-Highway


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1

2

3

4

5

6

7

Safety

Safety, accident prevention andenvironmental protection instructions

Product Summary

Engine layout, technical data

Operation

Task descriptions

Maintenance and Servicing

Maintenance schedule

Troubleshooting

Malfunctions, causes, measures

Task Description

Inspection and maintenance tasks

Annex Abbreviations

Index


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Wichtig - Important - Importante

Bitte die Karte „Inbetriebnahmemeldung“ abtrennen und ausgefüllt an MTU Friedrichshafen GmbHzurücksenden.

Die Informationen der Inbetriebnahmemeldung sind Grundlage für den vertraglich vereinbarten Logistik-Support(Gewährleistung, Ersatzteile etc.)

Please complete and return the „Commissioning Note“ card below to MTU Friedrichshafen GmbH.

The Commissioning Note information serves as a basis for the contractually agreed logistic support (warranty, spareparts, etc.).

Veuillez séparer la carte “Signalisation de mise en service” et la renvoyer à la MTU Friedrichshafen.

Les informations concernant la signalisation de mise en service constituent la base pour l’assistance en exploitationcontractuelle (garantie, rechanges, etc.).

Rogamos separen la tarjeta «Aviso de puesta en servicio» y la devuelvan rellenada a MTU FriedrichshafenGmbH.

Las informaciones respecto al aviso de puesta en servicio constituyen la base para H el soporte logistíco contractual(garantía, piezas de repuesto, etc.).

Staccare «Avviso di messa in servizio» e risperdirlo debitamente compilato alla MTU Friedrichshafen GmbH.

Le informazioni ivi registrate sono la base per il supporto logitico contrattuale (garanzia, ricambi, ecc.).

Postcard

MTU Friedrichshafen GmbH

Abteilung SCSD

88040 Friedrichshafen

GERMANY


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Amendment Service !

Amendments to this publication will be sent to you in the form of Amendment Sets as and when they are issuedprovided that you complete and return the receipt section on the reverse of this page.

This also applies when this manual is used within the MTU group of companies.

Postcard

MTU Friedrichshafen GmbH

Abteilung SCT

88040 Friedrichshafen

GERMANY


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M015411/00E

O p e r a t

i n g i n s t r u c t i o n s

8V 4000 M60/M60R12V 4000 M60/M60R16V 4000 M60/M60R

No. Date Name

Amendment filed 1.

2.

3.4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

Please use block capitals! 15.

16.

Receipt Amendment No. 1.

2.

3.

4.

Publication No.: 5.

M015411/00E 6.

7.

8.

Name…………….……………………………………..…….. 9.

Company…………….……………………………………….. 10.

Department…………….…………………………………….. 11.

Fax……………………… Telephone………..………….. 12.Street…………………….….……………………………….. 13.

P.O.Box…………………….……………………………….. 14.

(ZIP) City………………..….……………………………….. 15.

Country…………….…………………………………….….. 16.


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Safety 1 - 1

Safety, Accident Prevention and Environmental Protection Instructions

These instructions must be read and followed by every person involved in operation,maintenance or transportation of the machinery plant.

General

In addition to the instructions in this publication, the applicable country-specific legislation and other compulsoryregulations regarding accident prevention must be observed.

This engine is a state-of-the art product and conforms with all applicable specifications and regulations.Nevertheless, persons and property may be at risk in the event of:

Incorrect use

Operation, maintenance and repair by unqualified personnel

Modifications or Conversions

Non-compliance with the Safety Instructions

Correct use

The engine is intended exclusively for the application specified in the contract or defined at the time of delivery. Anyother use is considered improper use. The manufacturer will accept no liability for any resultant damage. Theresponsibility is borne by the user alone.

Correct use also includes observation of and compliance with the maintenance specifications.

Personnel requirements

Work on the engine must only be carried out by properly qualified and instructed personnel.

The specified legal minimum age must be observed.

Responsibilities of the operating, maintenance and repair personnel must be specified.

Modifications or conversions

Modifications made by the customer to the engine may affect safety.

MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications orconversions.

Organizational measures

This publication must be issued to all personnel involved in operation, maintenance, repair or transportation.

It must be kept at hand near the engine and accessible at any time to all personnel involved in operation,maintenance, repair or transportation.

The personnel must be instructed on engine operation and repair by means of this publication, and in particular the

safety instructions must be explained.

This is especially important for personnel who work on the engine only on an occasional basis. Such personnelmust be given instructions repeatedly.

Spare parts

Only genuine MTU spare parts must be used to replace components or assemblies. In the event of any damagecaused by the use of other spare parts, no liability nor warranty claims vis-à-vis the engine manufacturer will beaccepted.

Working clothes and protective equipment

Wear proper work clothing for all work.

Depending on the kind of work, use additional protective equipment, e.g. protective goggles, gloves, helmet, apron.

Work clothing must be tight fitting so that it does not catch on rotating or projecting components.

Do not wear jewelry (e.g. rings, chains etc.).

M015411/00E 02-04 © MTU


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1 - 2 Safety

Transportation

Lift the engine only with the lifting eyes provided.

Use only the transport and lifting equipment approved by MTU.

Take note of the engine center of gravity.

Transport the engine only in the installation position.

In the case of special packaging with aluminum foil, suspend the engine on the lifting eyes of the transport pallet ortransport with equipment for heavy loads (forklift truck).

Prior to transporting the engine, it is imperative to install transportation locking devices for crankshaft and enginemounts.

Secure the engine against tilting during transportation. The engine must be especially secured against slipping ortilting when going up or down inclines and ramps.

Setting the engine down after transportation

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.

Working with laser equipment

When working with laser equipment, always wear special laser-protection goggles.

Laser equipment can generate extremely intensive, concentrated radiation by the effect of stimulated emission inthe range of visible light or in the infrared or ultraviolet spectral range. The photochemical, thermal andoptomechanical effects of the laser can cause damage. The main danger is irreparable damage to the eyes.

Laser equipment must be fitted with the protective devices necessary for safe operation according to type andapplication.

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), amaximum output of 5 mW, and in which the beam axis and surface are designed to prevent any risk to the eyes.

Engine operation

When the engine is running, always wear ear protectors.

Ensure that the engine room is well ventilated.

Mop up any leaked or spilt fluids and lubricants immediately or soak up with a suitable bonding agent.

Exhaust gases from combustion engines are poisonous. Inhalation of poisonous exhaust gases is a health hazard.The exhaust pipework must be free of leaks and discharge the gases to atmosphere.

During engine operation, do not touch battery terminals, generator terminals or cables.

Inadequate protection of electrical components can lead to electric shocks and serious injuries.

When the engine is running, never release coolant, oil, fuel, compressed-air or hydraulic lines.

M015411/00E 02-04 © MTU


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1 - 4 Safety

Welding work

Never carry out welding work on the engine or engine-mounted units.

Never use the engine as a ground connection. (This prevents the welding current passing through the engine andcausing scoring or burning at bearings, sliding surfaces and tooth flanks, which can lead to pitting or other materialdamage).

Never position the welding power supply cable adjacent to, or crossing MTU plant wiring harnesses. (The weldingcurrent could be induced in the cable harnesses and could possibly damage the electrical plant).

The welding unit ground connection must not be more than 60 cm from the weld point.

If components (e.g. exhaust manifold) are to be welded, they must be removed from the engine.

It is not necessary to remove the connector and the connections when carrying out welding operation on MTUelectronics if the master switch for power supply is switched from "ON" to "OFF" and the wire is disconnected fromthe negative and positive poles on the battery.

Hydraulic installation and removal

Only the hydraulic installation and removal equipment specified in the work schedule and in the assembly

instructions must be used.The max. permissible push-on pressure specified for the equipment must not be exceeded.

The H.P. lines for hydraulic installation and removal are tested with 3800 bar.

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 system to beused (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 achieved.During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of thecomponent to be installed/removed. As long as the system is under pressure, there is the risk that the componentto be installed/removed may be suddenly released from the pressure connection.

Before use, the tools must be checked at regular intervals (crack test).

Working on electrical assemblies

Switch off all live appliances before carrying out any work on electrical assemblies.

Gases released from the battery are explosive. Avoid sparks and naked flames. Do not allow battery acids to comein contact with skin or clothing. Wear protective goggles. Do not place tools on the battery. Before connecting thecable to the battery, check battery polarity. Battery pole reversal may lead to injury through the sudden discharge of

acid or bursting of the battery body.Do not damage wiring during removal work and when reinstalling wiring and ensure that during operation it is notdamaged by contact with sharp objects, by rubbing against other component or by a hot surface.

Do not secure wiring to fluid-carrying lines.

On completion of the maintenance and repair work, any cables which have become loose must be correctlyconnected and secured.

Always tighten connectors with connector pliers.

If wires are installed beside mechanical components and there is a risk of chafing, use cable clamps to properlysupport the wires.

For this purpose, no cable binders must be used as, during maintenance and / or repair work, the binders can be

removed but not installed a second time.

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Safety 1 - 5

Operation of electrical equipment

When operating electrical equipment, certain components of this equipment are live.

Noncompliance with the warning instructions given for this equipment may result in serious injury or damage toproperty.

Fire preventionRectify any fuel or oil leaks immediately; even splashes of oil or fuel on hot components can cause fires - thereforealways keep the engine in a clean condition. Do not leave cloths soaked with fluids and lubricants lying around onthe engine. Do not store combustible fluids near the engine.

Do not weld pipes and components carrying oil or fuel. Before welding, clean with an inflammable fluid.

When starting the engine with a foreign power source, connect the ground lead last and remove it first. To avoidsparks in the vicinity of the battery, connect the ground lead from the foreign power source to the ground lead ofthe engine or to the ground terminal of the starter.

Always keep suitable fire-fighting 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 aredrowned.

At all workplaces with a sound pressure level over 85 dB(A), always wear ear protectors (protective wadding, plugsor capsules).

Environmental protection

Dispose of used fluids, lubricants and filters in accordance with local regulations.

Manipulation of the injection control system can influence the engine performance and exhaust emissions. As aresult, compliance with environmental regulations may no longer be guaranteed.

Only fuels of the specified quality required to achieve emission limits must be used.

In Germany, the VAwS (= regulations governing the use of materials that may affect water quality) is applicable,which means work must only be carried out by authorized specialist companies (MTU is such a company).

Auxiliary materials

Use only fluids and lubricants that have been tested and approved by MTU.

Fluids and lubricants must be kept in suitable, properly designated containers. When using fluids, lubricants andother chemical substances, follow the safety instructions applicable to the product. Take care when handling hot,chilled or caustic materials. When using inflammable materials, avoid sparks and do not smoke.

Lead

When working with lead or lead-containing pastes, avoid direct contact to the skin and do not inhale lead vapors.

Adopt suitable measures to avoid the formation of lead dust!Switch on fume extraction system.

After coming into contact with lead or lead-containing materials, wash hands!

Acids and alkaline solutions

When working with acids and alkalis, wear protective goggles or face mask, gloves and protective clothing.

Immediately remove clothing wetted by acids and alkalis!

Rinse injuries with plenty of water!

Rinse eyes immediately with eyedrops or clean tap water.

M015411/00E 02-04 © MTU


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1 - 6 Safety

Painting

When painting in other than spray booths equipped with extractors, ensure good ventilation. Make sure thatadjacent work areas are not affected.

It is absolutely necessary to wear masks providing protection against paint and solvent fumes.

Observe fire prevention regulations!

No smoking.

No naked flame!

Liquid oxygen

Liquid oxygen is highly inflammable.

Liquid oxygen should only be stored in small quantities and in regulation containers (without fixed seals)! Do notbring liquid oxygen in contact with the body (hands), as this causes frostbite and possibly the loss of tissue.

No smoking, no naked flame (risk of explosion)! Excessive oxygen in the air leads to explosive combustion.

Do not store combustible substances (e.g. oils and greases) within 5 m of the working area!

Under no circumstances should clothing be oily or greasy.

Do not allow vapors to penetrate clothing! Oxygen enrichment in fabric can cause working clothes to ignitesuddenly!

After working with liquid oxygen, do not smoke until clothing is free of vapors!

Avoid all knocks and jars to the containers, fixtures or workpieces.

Liquid nitrogen

Store liquid nitrogen only in small quantities and always in regulation containers without fixed covers.

Do not bring liquid nitrogen in contact with the body (eyes, hands), as this causes frostbite and numbing.

Wear protective clothing (including gloves and closed shoes) and protective goggles!

Ensure the room is well ventilated (88% contamination of breathing with nitrogen will result in suffocation).

Avoid all knocks and jars to the containers, fixtures or workpieces.

Compressed air

Compressed air is air compressed at excess pressure and is stored in tanks from which it can be extracted.

The pressure at which the air is kept can be read off at pressure gauges which must be connected to thecompressed air tanks and the compressed air lines.

When working with compressed air, safety precautions must be constantly observed:

Pay special attention to the pressure level in the compressed air network and pressure vessel!

Connecting devices and equipment must either be designed for this pressure or, if the permitted pressure for

the connecting elements is lower than the pressure required, a pressure reducing valve and safety valve (set topermitted pressure) must form an intermediate connection. Hose coupling and connections must be securelyattached!

Always wear protective goggles when blowing off tools or extracting chips!

The snout of the air nozzle is provided with a protective disc (e.g. rubber disc), which prevents air-borneparticles being reflected and thereby prevents injury to eyes.

First shut off compressed air lines before compressed air equipment is disconnected from the supply line orbefore equipment or tool is to be replaced!

Unauthorized use of compressed air, e.g. forcing flammable liquids (danger class AI, AII and B) out ofcontainers, results in a risk of explosion!

Forcing compressed air into thin-walled containers (e.g. containers made of tin, plastic and glass) for dryingpurposes or to check for leaks, results in a risk of explosion!

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Safety 1 - 7

Do not blow dirty clothing with compressed air when being worn on the body.Even compressed air at low pressure penetrates clothing and, if the jet is directed at the back, the air can enterthe anal cavity and fatally rupture the intestines!

Used oil

Used oil may contain health-threatening combustion residues.

Rub barrier cream into hands!

Wash hands after contact with used oil.

Warning signs

Before putting the engine into service and before working on the engine, read and follow all warning signs. Do notpaint on warning signs. Replace illegible signs.

Warning notices

This Publication contains especially emphasized safety instructions in accordance with the American standard ANSI Z535, which begin with one of the following signal words according to the degree of danger:

DANGER

In event of immediate danger.Consequences: Death or serious injury

WARNING

In event of dangerous situations.Consequences: Death or serious injury.

CAUTION

In event of dangerous situations.Consequences: Slight injury or material damage

In these cases, take special care.

Read and become acquainted with all cautions and symbols before operating or repairing this product.

Pass on all safety instructions to your operating, maintenance, repair and transport personnel!

M015411/00E 02-04 © MTU


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1 - 8 Safety

M015411/00E 02-04 © MTU


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Product Summary 2 - 1

Engine layout

Illustration is applicable to 8V 4000 M engines

010 Crankcase and externally mounted components 140 Exhaust system

020 Gear train 170 Starting system

030 Running gear 180 Lube oil system

040 Cylinder head 200 Cooling system

050 Valve gear 210 Power supply, engine side070 Fuel system (high pressure) 230 Mounting / support

080 Fuel system (low pressure) 250 PTO systems, driving end and free end

100 Exhaust turbocharger 500 Monitoring, control and regulation system

110 Intercooler

120 Air intake / air supply

Engine model designation

Key to the engine model designations 8V 4000 M4xy to M9xy

8 = Number of cylinders

V = Cylinder configuration: V engine

4000 = Series

M4 to M9 = Application segment

x = Design index

y = Additional engine features

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2 - 2 Product Summary

Engine layout

Illustration is applicable to 12/16V 4000 M engines analoguously

010 Crankcase and externally mounted components 120 Air intake / air supply

020 Gear train 140 Exhaust system

030 Running gear 170 Starting system

040 Cylinder head 180 Lube oil system

050 Valve gear 200 Cooling system070 Fuel system (high pressure) 210 Power supply, engine side

080 Fuel system (low pressure) 230 Mounting / support

100

110

Exhaust turbocharger

Intercooler

250

500

PTO systems, driving end and free end

Monitoring, control and regulation system

Engine model designation

Key to the engine model designations 12/16V 4000 M4xy to M9xy

12/16 = Number of cylinders

V = Cylinder configuration: V engine

4000 = Series

M4 to M9 = Application segment

x = Design index

y = Additional engine features

M015411/00E 02-04 © MTU


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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.

The numbering of engine components is also from the driving end, starting with No. 1.

Illustration is applicable to 8/12/16V 4000 M engines analogously

Applicable designations and abbreviations

Driving end = KS

Free end = KGS

Left side

Right side

Main engine dimensionsIllustration is applicable to 8/12/16V 4000 M engines analogously

Engine model Overalllength (A)

Overallwidth (B)

Overallheight (C)

8V 4000M60/M60R

approx.2340 mm

approx.1380 mm

approx.1750 mm

12V 4000M60/M60R

approx.3220 mm

approx.1520 mm

approx.1835 mm

16V 4000M60/M60R

approx.3690 mm

approx.1520 mm

approx.1835 mm

Engine weight

Engine model Engine dry weight

8V 4000 M60/M60R approx. 4740 kg12V 4000 M60/M60R approx. 6540 kg

16V 4000 M60/M60R approx. 7690 kg

M015411/00E 02-04 © MTU


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Engine transportation

8/12/16V 4000 M60/M60R

Use only the transport and lifting equipment approvedby MTU.

The engine must only be transported in installationposition, max. permissible diagonal pull 10°.

Lift the engine only with the lifting eyes provided.

M015411/00E 02-04 © MTU


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Basic Data8V 4000 M60, M60R Application: Vessels with unrestricted continuous operation

Engine Power Rating 880 kW [1200 mHP] at 1800 rpm (8V 4000 M60)

700 kW [ 950 mHP] at 1600 rpm (8V 4000 M60R)(Continuous Power ICFN)

The engine power represents the net brake power according toISO 3046 at the PTO flange.

To calculate the available power at the gearbox output flange, agearbox efficiency of 0.97 must be taken into account.

Application MTU application group 1A:

vessels with unrestricted continuous operation

(e.g. work boats, ferries, fishing vessels)

Reference Conditions Intake air temperature Raw water temperature

Barometric pressure

Intake air depression

Exhaust back pressure

45 °C

32 °C

1000 mbar

25 mbar

30 mbar

Basic Design 8 cylinders 90° V cylinder arrangement

Four-stroke diesel

Liquid cooling

Direct fuel injection

Sequential exhaust turbocharging and charge-air cooling

Wet, replaceable cylinder liners Piston cooling

2 inlet, 2 exhaust valves per cylinder

Triple-walled, liquid-cooled exhaust lines

Cylinder cutout system

Electronically controlled common rail fuel injection system

Electronic engine management

Bore

Stroke

Cylinder displacement

Total displacement

Compression ratio

Direction of rotation

(facing driving end)

Firing order

Final compression pressure at

120 rpm

Firing speed at 40°C engine coolant

temperature

Flywheel housing

Cold start capability: air temperature

(w/o start assistance, w/o coolant

preheating)

165 mm

190 mm

4.06 lit.

32.5 lit.

15.5 : 1

CCW

A1-B4-A4-A2-B3-A3-

B2-B1

22 to 24 bar

approx. 80 - 120 rpm

SAE 00

+ 10 °C

M015411/00E 02-04 © MTU


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Technical Data8V 4000 M60, M60R Application: Vessels with unrestricted continuous operation

M60 M60R

Engine Rated Power (Continuous Power ICFN) kW 880 700Speed rpm 1800 1600Mean piston speed m/sec 11.4 10.1Mean effective pressure (M.E.P.) bar 18.0 16.1

Consumption

Specific fuel consumption (tolerance to ISO 3046)(IMO 2000 NOx exhaust emission certified)(with / without engine-mounted recooling equipment)

at rated power g/kWh 211 / 209 211 / 209optimum value in performance map g/kWh 210 / 208 208 / 206

Lube oil consumption (after 100 hrs operation), average / max. 0.3 / 0.5 % of fuel consumption

Oil and Coolant CapacityEngine lube oil (standard oil system)

Total initial filling lit. 145 145Oil dipstick mark, min. / max. lit. 85 / 115 85 / 115Oil change quantity lit. 120 120

Coolantwith engine-mounted recooling equipment lit. 210 210- without engine-mounted recooling equipment lit. 150 150

Heat Dissipation

Heat dissipated by engine coolant kW 900 680Radiation and convection heat, engine kW 30 30

Cooling System with engine-mounted recooling equipmentRaw-water pump flow rate, approx. min. / max. m³/h 65 / 70 53 / 63Raw water pump inlet pressure, min. / max. permissible bar -0.2 / +0.5 -0.2 / +0.5

Pressure loss in off-engine raw water system, max. permissible. bar 0.7 1.3- without engine-mounted recooling equipmentCoolant temperature at engine outlet °C 92 92Recooling equipment: coolant flow rate m³/h 25 22Pressure loss in off-engine coolant system, max. permissible bar 0.5 0.5

Fuel SystemFuel pressure at supply connection on engine, max. bar -0.3 / +1.5 -0.3 / +1.5Fuel flow rate to engine, max. lit./min 14.2 13.3Fuel return flow from engine, max. lit./min 10 10Fuel pressure at return connection on engine, max. permissible. bar 0.5 0.5

Combustion Air System Combustion-air flow rate m³/sec 1.35 1.04Intake air depression, design / max. permissible mbar 25 / 35 25 / 35

Exhaust SystemExhaust gas flow rate m³/sec 2.6 2.0Exhaust gas temperature after turbocharger °C 340 350Exhaust back pressure, design / max. permissible mbar 30 / 50 30 / 50

Starting System - Electric Starting

Voltage / Power V / kW 24 / 1 x 7.5 24 / 1 x 7.5- Pneumatic Starting (compressed air starter motor)

Starting air pressure, min. / max. permissible bar 16 / 30 16 / 30 Air consumption per starting attempt (at atmospheric press.) mN³ 0.69 0.69Starting attempt duration, approx. (engine preheated) sec 3 3

Inclinations (temporary / permanent, relative to water line)Longitudinal (driving end down) ° / 15 / 15

Longitudinal (driving end up)

° / 10 / 10Transverse right ° / 22.5 / 22.5

Transverse left ° / 22.5 / 22.5

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M60 M60R

Lube Oil System Lube oil operating temperature before engine (from / to) °C 85 / 90 85 / 90Lube oil operating pressure, low idle (meas. point: before engine) bar 2.0 2.0Lube oil operating pressure before engine (from / to) bar 5.3 /5.8 5.3 /5.8

Charge Air Charge-air pressure before cylinder bar ABS 3.2 2.8

Acoustics (approximate value)Engine surface noise (free-field sound pressure level, 1mdistance)

db(A) 103 112

Exhaust noise, unsilenced (free-field sound pressure level, 1mdistance)

db(A) 101 108

M015411/00E 02-04 © MTU


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Basic Data12V 4000 M60, M60R Application: vessels with unrestricted continuous operation


1050 kW [1425 mHP] at 1600 rpm (12V 4000 M60R)(Continuous Power ICFN)







Barometric pressure



45 °C

32 °C

1000 mbar

25 mbar

30 mbar


Four-stroke diesel

Liquid cooling









Bore

Stroke


Total displacement

Compression ratio



Firing order


120 rpm


temperature

Flywheel housing



preheating)

165 mm

190 mm

4.06 lit.

48.7 lit.

15.5 : 1

CCW

A1-B2-A5-B4-A3-B1-

A6-B5-A2-B3-A4-B6

22 to 24 bar


SAE 00

+ 10 °C

M015411/00E 02-04 © MTU


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Technical Data12V 4000 M60, M60R Application: vessels with unrestricted continuous operation

M60 M60R


Consumption







Heat Dissipation

Heat dissipated by engine coolant kW 1100 870Radiation and convection heat, engine kW 35 35

Cooling System with engine-mounted recooling equipmentRaw-water pump flow rate, approx. min. / max. m³/h 80 / 88 61 / 79Raw water pump inlet pressure, min. / max. permissible bar -0.2 / +0.5 -0.2 / +0.5Pressure loss in off-engine raw water system, max. permissible. bar

- without engine-mounted recooling equipmentCoolant temperature at engine outlet °C 92 92Recooling equipment: coolant flow rate m³/h 34 29Pressure loss in off-engine coolant system, max. permissible bar 0.4 0.4

Fuel SystemFuel pressure at supply connection on engine, max. bar -0.3 / +1.5 -0.3 / +1.5Fuel flow rate to engine, max. lit./min 17.8 16.6Fuel return flow from engine, max. lit./min 12 12Fuel pressure at return connection on engine, max. permissible. bar 0.5 0.5


Exhaust System

Exhaust gas flow rate m³/sec 4.3 3.3Exhaust gas temperature after turbocharger °C 430 490Exhaust back pressure, design / max. permissible mbar 30 / 50 30 / 50




Inclinations (temporary / permanent, relative to water line)Longitudinal (driving end down) ° / 15 / 15

Longitudinal (driving end up)

° / 10 / 10Transverse right ° / 22.5 / 22.5


M015411/00E 02-04 © MTU


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M60 M60R

Lube Oil System Lube oil operating temperature before engine (from / to) °C 85 / 90 85 / 90Lube oil operating pressure, low idle (meas. point: before engine) bar 2.0 2.0Lube oil operating pressure before engine (from / to) bar 5.3 /5.8 5.3 /5.8



db(A) 103 102


db(A) 108 106

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Basic Data16V 4000 M60, M60R Application: vessels with unrestricted continuous operation


1400 kW [1900 mHP] at 1600 rpm (16V 4000 M60R)(Continuous Power ICFN)







Barometric pressure



45 °C

32 °C

1000 mbar

25 mbar

30 mbar


Four-stroke diesel

Liquid cooling









Bore

Stroke


Total displacement

Compression ratio



Firing order


120 rpm


temperature

Flywheel housing



preheating))

165 mm

190 mm

4.06 lit.

65.0 lit.

15.5 : 1

CCW

A1-A7-B4-B6-A4-B8-A2-A8-

B3-B5-A3-A5-B2-A6-B1-B7

22 to 24 bar


SAE 00

+ 10 °C

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Technical Data16V 4000 M60, M60R Application: vessels with unrestricted continuous operation

M60 M60R


Consumption







Heat DissipationHeat dissipated by engine coolant kW 1470 1155Radiation and convection heat, engine kW 40 40

Cooling System with engine-mounted recooling equipmentRaw-water pump flow rate, approx. min. / max. m³/h 103 / 117 87 / 105Raw water pump inlet pressure, min. / max. permissible bar -0.2 / +0.5 -0.2 / +0.5Pressure loss in off-engine raw water system, max. permissible. bar 1.7 1.3

- without engine-mounted recooling equipmentCoolant temperature at engine outlet °C 92 92Recooling equipment: coolant flow rate m³/h 36 31Pressure loss in off-engine coolant system, max. permissible bar 0.5 0.5

Fuel SystemFuel pressure at supply connection on engine, max. bar -0.3 / +1.5 -0.3 / +1.5Fuel flow rate to engine, max. lit./min 21.6 20Fuel return flow from engine, max. lit./min 13.7 13.7Fuel pressure at return connection on engine, max. permissible. bar 0.5 0.5


Exhaust SystemExhaust gas flow rate m³/sec 5.6 4.4Exhaust gas temperature after turbocharger °C 445 470Exhaust back pressure, design / max. permissible mbar 30 / 50 30 / 50




Inclinations (temporary / permanent, relative to water line)Longitudinal (driving end down) ° / 12.5 / 12.5

Longitudinal (driving end up) ° / 10 / 10Transverse right ° / 22.5 / 22.5


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M60 M60R

Lube Oil System Lube oil operating temperature before engine (from / to) °C 85 / 90 85 / 90Lube oil operating pressure, low idle (meas. point: before engine) bar 2.0 2.0Lube oil operating pressure before engine (from / to) bar 5.3 / 5.8 5.3 / 5.8



db(A) 107 105


db(A) 109 108

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Table of Contents 3 – I

3 Operation

3.1 LOP controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 1

3.2 Putting the engine into operation after extended out-of-service periods (>3 months) . . . 3 – 3

3.3 Putting the engine into operation after scheduled out-of-service-period . . . . . . . . . . . . . 3 – 4

3.4 Starting the engine from LOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 4

3.5 Operational checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 5

3.6 Stopping the engine from LOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 6

3.7 Emergency stop from LOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 6

3.8 After stopping the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 7

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3 – II Table of Contents

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Operation 3 – 1

3.1 LOP controls

LOP controls

Item Color Inscription Meaning / Function

1 White F1

2 White F2

3 White F3

4 White F4

5 White F5

Function keys for operating the screen. Functions changeand are indicated on the display.

6 White ALARM ACKN. Pressing the button the first time stops alarm signalization.

Pressing the button a second time acknowledges an activealarm.

LED (spot) lights up when an alarm is active.

7 White DIMMER ↑ Holding down the button increases LCD backgroundillumination.

8 White DIMMER ↓ Holding down the button decreases LCD backgroundillumination.

9 White LAMP TEST Pressing the button initiates lamp test.

10 Red OVERSPEED TEST Pressing the button initiates overspeed test.

LED (spot) lights up as soon long as the overspeed test isrunning.

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3 – 2 Operation

Item Color Inscription Meaning / Function

11 Green FPP: Pressing the button engages “Ahead”.

CPP, WJ, VS: Pressing the button engages clutch.

LED (spot) lights up when GCU acknowledgement received.

12 Green FPP, CPP, WJ, VS: Pressing the button disengages clutch.


13 Green

(Depending on type of gearbox and propulsionsystem)

FPP: Pressing the button engages “Astern”.

CPP, VS: No function assigned.

WJ: Holding down the button provides flushing of water jetintake channel.


14 White INCREASE ENGINESPEED

Engine speed is increased as long as the button is held down.

15 White DECREASE ENGINESPEED

Engine speed is decreased as long as the button is helddown.

16 Green READY FOROPERATION

Pressing the switch causes changeover between “Not readyfor operation” and “Ready for operation” status.

LED (spot) lights up at "Ready for operation" switch position.

17 Green LOCAL MODE Pressing the switch activates changeover between local andremote control mode.

LED (spot) lights up when local mode is active.

18 White START Pressing the button initiates automatic engine startingprocedure.

LED (spot) lights up as long as the starting procedure isrunning.

19 White STOP Pressing the button initiates automatic engine stoppingprocedure.

LED (spot) lights up as long as the STOP signal is present(also if transmitted from RCS).

20 Red EMERG. STOP Pressing the button initiates immediate emergency stop.

LED (spot) flashes once the emergency stop has beentripped and until the alarm has been acknowledged.

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Operation 3 – 3

3.2 Putting the engine into operation after extended

out-of-service periods (>3 months)

Preconditions• Engine is stopped and starting disabled.• MTU Fluids and Lubricants Specification (A001061/..) is available.

Putting the engine into operation after extended out-of-service-periods (>3 months)

Item Task

Engine Depreserve (→ MTU Fluids and Lubricants Specification A001061/..).

Lube oil system Check oil level (→ Page 6 – 34), preheat engine oil, if required.

Fuel prefilter Prime (→ Page 6 – 26).

Fuel prefilter, pressure gauge Align adjustable pointer with pressure indicator (→ Page 6 – 26).

Fuel system Vent (→ Page 6 – 19).

Raw-water pump (if locatedabove waterline)

Prime (approx. 3 to 4 liters).

Cooling system If engine is out of service for more than one year, change coolant(→ Page 6 – 41).

Cooling system Check coolant level (→ Page 6 – 39).

Cooling system Preheat coolant with preheating unit.

ECU Check plug-in connections (→ Page 6 – 56).

Engine control system Switch main switch to ON.

Press READY FOR OPERATION button (→ Page 3 – 1).

LOP Press LAMP TEST button (→ Page 3 – 1).

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3 – 4 Operation

3.3 Putting the engine into operation after scheduled

out-of-service-period

Preconditions• Engine is stopped and starting disabled.

Putting the engine into operation

Item Task

Lube oil system Check oil level (→ Page 6 – 34), preheat engine oil, if required.

Cooling system Check coolant level (→ Page 6 – 39).

Cooling system Preheat coolant with preheating unit.

Fuel prefilter Drain (→ Page 6 – 23);

Check if suction-side pressure indicated at the fuel prefilter pressure gauge iswithin the limit (→ Page 6 – 24).

Engine control system Switch main switch to ON.

Press READY FOR OPERATION button (→ Page 3 – 1).

LOP Press LAMP TEST button (→ Page 3 – 1).

3.4 Starting the engine from LOP

DANGER

Unguarded rotating and moving engine components.

Risk of serious injury — danger to life!• Before barring or starting the engine, ensure that nobody is in the danger zone.

WARNING

Engine noise above 85 dB (A).

Risk of damage to hearing!• Wear ear protectors.

Barring the engine (out-of-service period > 1 month)

Item Task

Engine Bar with starting system (→ Page 6 – 1).

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Operation 3 – 5

Starting the engine from LOP

Item Task

Engine Make sure that engine is in unloaded condition.

Control system Switch ON.

LOP:• LOCAL MODE button is illuminated brightly (local operating mode is

active) (→ Page 3 – 1);• CLUTCH NEUTRAL button is illuminated brightly (gearbox is disengaged)

(→ Page 3 – 1).

LOP Press READY FOR OPERATION button briefly (→ Page 3 – 1).

• READY FOR OPERATION button is illuminated brightly.

LOP Press START button briefly (→ Page 3 – 1).

• START button of the engine concerned is illuminated brightly, if all start

conditions are fulfilled;• Automatic starting procedure is performed, if all starting conditions arefulfilled;

• Tachometer indicates increasing crankshaft speed;• After the starting procedure is completed, engine is running at idle speed

and START button is reset to basic illumination.

3.5 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 Task

Control and display panels Check indicated operating parameters (speed, temperatures, pressures).

Engine under load

Engine at nominal speed

Check all pipework for leaks, rectify any leaks with the engine stopped.

Check for abnormal running noises and vibrations.

Exhaust system Check exhaust color (→ Page 5 – 1).

Intercooler Check drain line for water discharge and obstruction (→ Page 6 – 28).

Air filter Check signal ring position of service indicator (→ Page 6 – 30);

Replace air filter (→ Page 6 – 29), if the signal ring is completely visible inthe service indicator control window.

Compressed-air system (if installed)

Check operating pressure at pressure gauge.

Always fill compressed-air tank to maximum pressure.

Drain condensate from compressed-air tank, pressure drop must not exceed1 bar.

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3 – 6 Operation

3.6 Stopping the engine from LOP

Preconditions• Engine is running in local mode.

CAUTION

Never stop the engine when it is running at full load, this can lead to overheating and wear of engine components.

Risk of overheating, damage to components!• Before stopping the engine, disengage gearbox / transmission and run the engine at idle

speed until operating temperatures decrease and stable values are indicated.

Stopping the engine from LOP

Item Task

LOP Disengage clutch (→ Page 3 – 1).

LOP Operate engine at idle speed (→ Page 3 – 1).

Temperature readings Wait until engine temperatures do not sink any further.

LOP Press STOP button (→ Page 3 – 1).

• STOP button is illuminated;• Engine is stopped.

3.7 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 Task

LOP Open cap of EMERG. STOP button (→ Page 3 – 1).

LOP Press EMERG. STOP button.

• Engine is stopped by switching power supply to ECU off;• Engines with emergency air-shut-off flaps: Flaps close;

• EMERG. STOP button flashes, horn, flash lamp etc. are activated.

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Operation 3 – 7

After emergency stop from LOP

Item Task

LOP Press ALARM ACKN. button (→ Page 3 – 1).

• Audible and visual alarms stop.

LOP Press ALARM ACKN. button again.

• Power supply to ECU is provided.• Alarm is acknowledged.

Engine Engines with emergency air-shut-off flaps: Flaps open.

• Engine is ready for operation.

3.8 After stopping the engine

Preconditions• MTU Fluids and Lubricants Specification (A001061/..) is available.

After stopping the engine

Item Task

Cooling system Drain coolant (→ Page 6 – 40) if:• freezing temperatures are expected and the engine is to remain out of

service for an extended period and engine coolant has no antifreezeadditive;

• the engine room is not heated;

• the coolant is not maintained at a suitable temperature;• the antifreeze concentration is insufficient for the engine-room

temperature;• antifreeze concentration is 50 % and engine-room temperature is below

-40 C.

Raw water Drain• if freezing temperatures are expected and the engine is to remain out

of service for an extended period.

Engine control system Switch OFF.

Air intake and exhaust system If the engine is to remain out of service for more than 1 week, seal the engine’sair and exhaust sides. If the engine is to remain out of service for more than

1 month, carry out preservation (→ MTU Fluids and Lubricants Specification A001061/..).

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4 Maintenance

4.1 Maintenance and servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 1

4.2 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 1

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Maintenance 4 – 1

4.1 Maintenance and servicing

Low operating and maintenance costs as well as operational reliability and availability depend onmaintenance and servicing being carried out in compliance with our specifications and instructions.The overall system, of which the engine is an integral part, must be maintained in such a way as

to ensure trouble-free engine operation. For this purpose, ensure:• that sufficient fuel is available;• that the combustion air is dry and clean;• that only dry and clean compressed air is used;• that raw water is clean and filtered.

Your service partner will always be at your disposal to help or assist you if required.

Preventive maintenance instructions

• Special care should be taken to keep the machinery plant in a clean and serviceable condition at alltimes to facilitate detection of possible leaks and prevent subsequent damage.

• Protect rubber and synthetic parts from oil and fuel, never treat with organic detergents, only wipe with dry cloth.• Always replace all seals and gaskets.

Maintenance systemThe maintenance concept is based on a preventive approach.

Preventive maintenance permits advance operational planning and increases availability. The maintenanceschedule refers to the specified load profile. The time intervals according to which the maintenance operationsare to be performed and the relevant inspection and maintenance tasks are based on operational experienceand are therefore to be considered as approximate values. Particular operating conditions may require themaintenance schedule to be altered. Remanufactured parts are offered for components to be replaced.

Note:

Maintenance intervals for oil and coolant are specified in the, (→ MTU Fluids and Lubricants SpecificationPublication No. A001061/..). Use only fluids and lubricants which are approved by MTU. The followingmaintenance operations must be performed on direct responsibility of the user / customer:

Fuel prefilter:

• Maintenance depends on fuel quality (purity).• The fuel prefilter must be replaced after 2 years at the latest (→ Page 6 – 26).

Battery:• Maintenance intervals of batteries depend on their operating and ambient conditions. The

information of the battery manufacturer is binding.

Out-of-service periods

If the engine is to remain out of service for more than one month, carry out engine preservation in accordancewith the (→ MTU Fluids and Lubricants Specification Publication No. A001061/..).

4.2 Maintenance schedule

Application group

1A: Vessels with unrestricted continuous operation

Load profile: V 4000 M60R (1600 rpm)

Load (%), referring to fuel stop power 100 90


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4 – 2 Maintenance

MTU maintenance levels

Maintenance level Operating hours Time limit Scope of maintenance

W2 500 6 months W2

W3 1000 1 year W2, W3

W4 with nominalspeed = 1600 rpm

5000 2 years W2, W3, W4

W4 with nominalspeed = 1800 rpm

4000 2 years W2, W3, W4

The maintenance operations must be carried out in the following cases:• when the number of operating hours as per MTU maintenance level (W) is reached;• when the time limit specified by MTU is reached.

Maintenance task schedule

W Item Task

W2 Fuel prefilter Flush (→ Page 6 – 24).

W2 Air system Check air intake for leaks.

W2 Air-flow control flap Check for ease of movement (→ Page 6 – 30).

W2 Exhaust-flow control flap Check for ease of movement (→ Page 6 – 31).

W2 Engine oil Take sample and analyze (→ Page 6 – 32).

W2 Engine oil Change (→ Page 6 – 33)

• with oil category 1 and centrifugal oil filter(s) every 2nd W2maintenance level = 500 operating hours;

• with oil category 2 and centrifugal oil filter(s) every 4th W2maintenance level = 1000 operating hours.

W2 Engine oil f il ter Replace, accomplish when changing the oil. (→ Page 6 – 35).

W2 Centrifugal oil filter(s) Clean and replace sleeve, accomplish when changing the oil(→ Page 6 – 37).

W2 LOP Carry out test procedures (→ Page 6 – 62).

W3 Valve gear Check valve clearances (→ Page 6 – 6).

W3 Fuel filter Replace (→

Page 6 – 21).

W3 Fuel prefilter Replace filter element (→ Page 6 – 26).

W3 Engine coolant Take sample and analyze (→ Page 6 – 43).

W3 HT coolant pump Check relief bore for oil and coolant discharge and obstructions(→ Page 6 – 43).

W3 Raw-water pump Check relief bore for oil and water discharge and obstructions(→ Page 6 – 45).

W3 Torsionally resilientcoupling

Check condition (visual inspection).

W3 Battery Check (see manufacturer’s information).

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Maintenance 4 – 3

W Item Task

W3 Bilge pump Check r elief bore for oil and water discharge and obstructions(→ Page 6 – 50).

W4 Crankcase breather Replace oil separator (only 8V) (→ Page 6 – 3).

W4 Crankcase breather Replace oil-separator filter elements, check / replace membrane.(→ Page 6 – 4).

W4 HP pump Check relief bore for oil and fuel discharge and obstructions(→ Page 6 – 12).

W4 Injectors Replace (→ Page 6 – 13).

W4 Air filter Replace (→ Page 6 – 29).

W4 Star ter Check condition (visual inspection).

W4 Generator drive Check condition of coupling (→

Page 6 – 46).W4 Engine mounts Check tightness of securing screws (→ Page 6 – 47).

W4 Engine mounts Check condition of resilient mounts (→ Page 6 – 47).

W4 Engine mounts Check buffer clearance (→ Page 6 – 47).

W4 Engine wiring Check (→ Page 6 – 51).

W4 LOP Check (visual inspection) (→ Page 6 – 59).

W4 LOP and connectors Clean (→ Page 6 – 59).

W4 ECU Check (visual inspection) (→ Page 6 – 56).

W4 ECU Clean (→ Page 6 – 55).

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5 Troubleshooting

5.1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 1

5.2 LOP alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 4

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Troubleshooting 5 – 1

5.1 Troubleshooting

Engine does not turn when starter is actuated

Component Probable Cause Task

Low or defective Charge or replace (see manufacturer’sdocumentation).

Batter y

Cable connections defective Check if cable connections areproperly secured (see manufacturer’sdocumentation).

Starter Engine wiring or starter defective Check if cable connections are properlysecured, contact Service.

Engine wiring Defective Check (→ Page 6 – 51).

LOP Loose seating of assemblies or

connectors

Visual inspection (→ Page 6 – 59).

ECU Loose plug-in connections Check plug-in connections (→ Page 6 – 56).

Engine Running gear blocked (enginecannot be barred manually)

Contact Service.

Engine turns but does not fire


Starter Poor rotation by starter: Batterylow or defective

Charge or replace battery (seemanufacturer’s documentation).


Fuel system Not vented Vent (→ Page 6 – 19).

ECU Defective Contact Service.

Engine fires unevenly


Fuel injection equipment Injector defective Replace (→ Page 6 – 13).




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5 – 2 Troubleshooting

Engine does not reach full-load speed


Shut of f Open shut-off valve before fuel prefilter

completely.

Fuel prefilter clogged Replace (→ Page 6 – 26).

Fuel supply

Fuel f ilter clogged Replace (→ Page 6 – 21).

Air supply Air filter clogged Check signal ring position of serviceindicator (→ Page 6 – 30).



Overloaded Contact Service.

Vessel too heavy Check vessel’s loading condition, reduceload if necessary.

Vessel’s trim position Trim vessel.

Vessel

Marine growths on hull, propeller shaft, propeller, rudder

Clean.

Rudder Rudder position Align rudder.

Propeller After propeller replacement:Propeller is too big.

Replace.

Engine speed not steady



Speed sensor Defective Contact Service.



Charge-air temperature too high


Cooling system Incorrect coolant concentration Check (MTU test kit).

Intercooler Contaminated Contact Service.

Engine room Air-intake temperature too high Check fans and air supply / ventilation ducts.

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Charge air pressure too low


Air supply Air filter clogged Check signal ring position of service

indicator (→ Page 6 – 30).

Intercooler Contaminated Contact Service.

Exhaust turbocharger Defective Contact Service.

Coolant leaks on intercooler


Intercooler Leaking, major coolantdischarge

Contact Service.

Exhaust gas black


Air supply Air filter clogged Check signal ring position of serviceindicator (→ Page 6 – 30).


Vessel Overloaded Contact Service.

Exhaust gas blue


Too much oil in engine Drain engine oil (→ Page 6 – 33).Lube oil system

Oil separator or oil-preseparator of crankcase breather clogged

Replace (→ Page 6 – 4).

Exhaust turbocharger, cylinder head, piston rings, cylinder liner

Defective Contact Service.

Exhaust gas white


Motor Not at operating temperature Run engine to reach operating temperature.

Fuel system Water in fuel Check fuel system at fuel prefilter.

Drain fuel prefilter (→ Page 6 – 23).

Intercooler Leaking Contact Service.

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5.2 LOP alarms

LOP

At the LOP, alarm texts and measuring-point messages are indicated on the DIS. Explanation of the

displayed texts can be gathered by pressing the help key on the touch screen. Alarms can also be causedby defective sensors / actuators. If troubleshooting in accordance with the following table is not successful,contact Service to have the sensors / actuators checked and, if required, replaced.

Display text Meaning Corrective measures

AL T-ExhaustMonitoring Fail

Exhaust temperature monitoringfailure

Contact Service:• Have EMU replaced.

AL RCS SpeedDemand Defect

No speed demand signal 1. Check remote control system2. Check LOP visually (→ Page 6 – 59);3. Perform LOP test procedures (→ Page 6 – 62);

4. Check ECU plug-in connections (→ Page 6 – 56);5. Check engine wiring (→ Page 6 – 51).

AL Battery Charger Fail

No battery charging 1. Check power circuit breakers and fuses;2. Check transistor controllers.

AL Press MonitoringFail (EMU)

EMU pressure monitoring failure Contact Service:• Have EMU replaced.

AL ECU Defect ECU 4 is defective 1. Check LOP visually (→ Page 6 – 59);2. Perform LOP test procedures (→ Page 6 – 62);3. Check ECU plug-in connections (→ Page 6 – 56);4. Check engine wiring (→ Page 6 – 51);5. Contact Service:

• Have ECU checked and replaced, if required.

AL Power Amplifier 1 Fail

Power amplifier cylinder side Afailure

1. Check LOP visually (→ Page 6 – 59);2. Perform LOP test procedures (→ Page 6 – 62);3. Check ECU plug-in connections (→ Page 6 – 56);4. Check engine wiring (→ Page 6 – 51);5. Contact Service:


AL Power Amplifier 2 Fail

Power amplifier cylinder side Bfailure



AL Gear Control Fail(GCU)

GCU failure Contact Service:• Have GCU solenoid valve checked and replaced,

if required;• Have GCU wiring checked and replaced, if

required.

AL Gear Oil Filter Clogged

Gear-Oil Filter Clogged Clean gear-oil filter and replace, if required (seegearbox documentation).

AL Override Activated

Engine safety system not active Status message:• Overr ide activated.

AL Power FailControl

Power failure of control system Check power circuit breakers and fuses.

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AL Power FailMonitoring

Power failure Check power circuit breakers and fuses.

AL Transistor Output1/2 Fail

One of the ECU 4 transistor outputs (TAA1 or TAA2) isdefective

Contact Service:• Have ECU checked and replaced, if required.

AL Transistor Output3/4 Fail

One of the ECU 4 transistor outputs (TAA3 or TAA4) isdefective

Contact Service:• Have ECU checked and replaced, if required.

AL Water in FuelPrefilter

Water in fuel prefilter Drain (→ Page 6 – 23).

DL 211+A001-A001 Display panel DIS not detectedon def ault bus

1. Check LOP visually (→ Page 6 – 59);2. Perf orm LOP test procedures (→ Page 6 – 62);3. Check ECU plug-in connections (→ Page 6 – 56);

4. Check engine wiring (→ Page 6 – 51);5. Contact Service:

• Have DIS checked and replaced, if required.

DL 211+A001-A010 LCU of LOP 1 (PIM No.21.X+A001-A010) not detectedon default bus


• Have MPU 23 of PIM No. 21.X+A001-A010checked and replaced, if required.

DL 211+A001-A020 LMU of LOP 1 (PIM No.21.X+A001-A020) not detectedon default bus

1. Check LOP visually (→ Page 6 – 59);2. Perf orm LOP test procedures (→ Page 6 – 62);3. Check ECU plug-in connections (→ Page 6 – 56);4. Check engine wiring (→ Page 6 – 51);5. Contact Service:


DL 211+A002-A030 GCU 1 (PIM No.21.X+A002-A030) not detectedon default bus


• Have GCU/GMU checked and replaced, if required.

DL 211+A002-A040 GCU 1 (PIM No.21.X+A002-A040) not detectedon default bus



DL 211+A003-ECU ECU 4 not detected on defaultbus



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DL 211+A004-EMU EMU 1 not detected on defaultbus

1. Check LOP visually (→ Page 6 – 59);2. Perfor m LOP test procedures (→ Page 6 – 62);3. Check ECU plug-in connections (→ Page 6 – 56);

4. Check engine wiring (→ Page 6 – 51);5. Contact Service:

• Have EMU checked and replaced, if required.

DL 211+A300-A500 RCS with PIM No.21.X+A300-A500 not detectedon default bus


• Have RCS checked and replaced, if required.

DL 211+A300-A501 PCU (PIM No. 21.X+A300- A501) not detected on defaultbus


• Have PCU checked and replaced, if required.

HI P-Oil Filter Difference

Excessive oil-pressuredifference between oil-filter inlet and outlet

Replace engine oil filter (→ Page 6 – 35).

MG Disengage Error Message from RCS Contact Service:• Have GCU solenoid valve checked and replaced,


required.

MG Eng SpeedHigh/Low (Clutch)

Message from RCS Reduce speed.

MG Engage Error Message from RCS Contact Service:• Have GCU solenoid valve checked and replaced,


required.

MG Check StartInterlocks

Start conditions not fulfilled Check start conditions and fulfill if necessary.

RL 211+A001-A001 DIS not detected on redundant

bus

1. Check LOP visually (→ Page 6 – 59);

2. Perform LOP test procedures (→

Page 6 – 62);3. Contact Service:• Have DIS checked and replaced, if required.

RL 211+A001-A010 LCU of LOP 1 (PIM No.21.X+A001-A010) not detectedon redundant bus

1. Check LOP visually (→ Page 6 – 59);2. Perform LOP test procedures (→ Page 6 – 62);3. Contact Service:


RL 211+A001-A020 LMU of LOP 1 (PIM No.21.X+A001-A020) not detectedon redundant bus


• Have MPU 23 of PIM No. 21.X+A001-A020

checked and replaced, if required.

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RL 211+A002-A030 GCU 1 (PIM No.21.X+A002-A030) not detectedon redundant bus

1. Check LOP visually (→ Page 6 – 59);2. Perfor m LOP test procedures (→ Page 6 – 62);3. Contact Service:


RL 211+A002-A040 GCU 1 (PIM No.21.X+A002-A040) not detectedon redundant bus



RL 211+A003-ECU ECU 4 not detected onredundant bus

1. Check LOP visually (→ Page 6 – 59);2. Perform LOP test procedures (→ Page 6 – 62);3. Check ECU plug-in connections (→ Page 6 – 56);4. Contact Service:


RL 211+A004-EMU EMU 1 not detected onredundant bus


• Have EMU checked and replaced, if required.

RL 211+A300-A500 RCS with PIM No.21.X+A300-A500 not detectedon redundant bus


• Have RCS checked and replaced, if required.

RL 211+A300-A501 PCU (PIM No. 21.X+A300- A501) not detected on redundant

bus

1. Check LOP visually (→ Page 6 – 59);2. Perform LOP test procedures (→ Page 6 – 62);

3. Contact Service:• Have PCU checked and replaced, if required.

SS Safety SystemFail (EMU)

Safety system has detectedEMU f ailure

Contact Service.

SS Power Reduction Active

Safety system has requestedpower reduction

1. Determine cause of automatic power reduction;2. Note further alarms / indications on display;3. Contact Service.

SS Emergency Stop Safety system has tripped anemergency stop

1. Determine cause of shutdown and rectify;2. Note further alarms / indications on display.

SS Emergency StopExt.

Safety system has executed anexternally tripped emergencystop

1. Determine cause of shutdown and rectify;2. Note further alarms / indications on display.

SS P-Gear Lube Oil(GCU)

Safety system detects thatcontrol-oil pressure in gearboxis too low

Check gearbox lube-oil level and top up, if required (seegearbox documentation).

SS P-Gear Lube Oil(GMU)

Safety system detects thatlube-oil pressure in gearbox istoo low

Check gearbox lube-oil level and top up, if required (seegearbox documentation).

SS P-Gear ControlOil (GCU)


Check gearbox control-oil level and top up, if required(see gearbox documentation).

SS P-Gear ControlOil (GMU)


Check gearbox control-oil level and top up, if required(see gearbox documentation).

M015411/00E 02-04 © MTU


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SS P-Coolant Safety system detects thatcoolant pressure is too low

Check coolant level and top up, if required(→ Page 6 – 42) .

SS P-Lube Oil (ECU) Safety system detects thatengine-oil pressure is too low

1. Check engine-oil level and top up, if required(→ Page 6 – 34);

2. Contact Service.

SS P-Lube Oil (EMU) Safety system detects thatengine-oil pressure is too low

1. Check engine-oil level and top up, if required(→ Page 6 – 34);

2. Contact Service.

SS Security ChannelDef EMU

Fault message from safetysystem

Contact Service:• Have EMU checked and replaced, if required.

SS SDAF Closed Safety system reports closedemergency air-shuttoff flaps

Open air-shutoff flaps (→ Page 6 – 30).

SS SecurityShutdown

Safety system has tripped ashutdown

Determine cause of shutdown and rectify.

SS T-Coolant (ECU) Safety system detects excessivecoolant temperature

Reduce power.

SS T-Coolant (EMU) Safety system detects excessivecoolant temperature

Reduce power.

SS T-Lube Oil Safety system detects excessivelube-oil temperature

Reduce power.

Stop Activated(EMU)

GMU has tripped automatic stopcommand due to limit value

violation

1. Determine cause of shutdown and rectify;2. Note further alarms indications on display.

TD P-Lube Oil Different measurement valuestransmitted by the two sensorsfor lube-oil pressure

1. Check LOP visually (→ Page 6 – 59);2. Perform LOP test procedures (→ Page 6 – 62);3. Check ECU plug-in connections (→ Page 6 – 56);4. Check engine wiring (→ Page 6 – 51).5. Contact Service:

• Have sensors checked and replaced, if required.

TD T-Coolant Different measurement valuestransmitted by the two sensorsfor coolant temperature

1. Check LOP visually (→ Page 6 – 59);2. Perform LOP test procedures (→ Page 6 – 62);3. Check ECU plug-in connections (→ Page 6 – 56);4. Check engine wiring (→ Page 6 – 51).5. Contact Service

• Have sensors checked and replaced, if required.

Tr olling Active RCS measuring point Status message (signal lamp ’Trolling Active’ is ON).

Cylinder Cutout Measuring point "Cylinder Cutout"

Status message of ’Cylinder cutout / half of cylindersrunning’ mode in idle operation.

M015411/00E 02-04 © MTU


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6 Task Description

6.1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 1

6.1.1 Engine – barring manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 16.1.2 Engine – barring with starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 1

6.2 Crankcase Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 3

6.2.1 Crankcase breather (8V) – oil separator replacement . . . . . . . . . . . . . . . . . . . . . . . 6 – 3

6.2.2 Crankcase breather – replacing filter element of oil separator, checking and replacingdiaphragm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 4

6.3 Valve Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 6

6.3.1 Valve gear lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 6

6.3.2 Valve clearance check and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 6

6.3.3 Cylinder-head cover removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 10

6.4 Injection Pump / HP Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 12

6.4.1 HP pump – relief bore check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 12

6.5 Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 13

6.5.1 Injector replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 13

6.5.2 Injector removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 13

6.6 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 19

6.6.1 Fuel system venting and filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 19

6.7 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 21

6.7.1 Fuel filter replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 21

6.7.2 Fuel prefilter – differential pressure check and adjustment of gauge . . . . . . . . . . . . 6 – 226.7.3 Fuel prefilter – draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 23

6.7.4 Fuel prefilter – flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 24

6.7.5 Fuel prefilter – filter element replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 26

6.8 Charge-Air Cooling, General, Left Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 28

6.8.1 Intercooler – checking condensate drain line for coolant discharge andobstruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 28

6.9 Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 29

6.9.1 Air f ilter replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 2 9

6.9.2 Air filter removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 29

6.10 Air Intake with Air-Control Flaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 30

6.10.1 Service indicator – signal ring position check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 30

6.10.2 Air-flow control flap – check for ease of movement . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 30

6.11 Exhaust-Flow Control Flap with Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 31

6.11.1 Exhaust-flow control flap – check for ease of movement . . . . . . . . . . . . . . . . . . . . . 6 – 31

6.12 Lube Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 �

manual operacion motor

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