Operating Instructions: Diesel Engine 8 V 4000 M40A 8 V 4000 M40B Application Group 3B

Operating Instructions
Diesel engine
8 V 4000 M40A
8 V 4000 M40B
Application group 3B
MS15021/01E
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.
Table of Contents
1 Safety 4.6 Fuel treatment system – Putting into
operation 60
1.1 General conditions 5 4.7 Engine – Starting 62
1.2 Personnel and organizational requirements 6 4.8 Fuel treatment system – Switching on 63
1.3 Transportation 7 4.9 Operational checks 64
1.4 Crankshaft transport locking device 8 4.10 Stopping the engine at the LOP 65
1.5 Safety regulations for startup and operation 11 4.11 Emergency stop from LOP 66
1.6 Explosion hazard when removing 4.12 After stopping the engine 67
inspection port cover on engine 12 4.13 Fuel treatment system – Shutdown 68
1.7 Safety regulations for maintenance and 4.14 Plant – Cleaning 69
repair work 13
1.8 Auxiliary materials, fire prevention and
environmental protection 16
1.9 Conventions for safety instructions in the 5 Maintenance
text 19
5.1 Maintenance task reference table [QL1] 70
2 General Information
6 Troubleshooting
2.1 Engine side and cylinder designations 20
6.1 Fuel treatment system – Troubleshooting 71
2.2 Product description 21
6.2 Troubleshooting 72
2.3 Engine – Overview 28
6.3 LOP fault messages 75
2.4 Sensors, actuators and injectors –
Overview 29
7 Task Description
3 Technical Data 7.1 Engine 80
7.1.1 Engine – Barring manually 80
3.1 8 V 4000 M40A engine data 34 7.1.2 Engine cranking on starter 81
3.2 8 V 4000 M40A engine data 37
3.3 8 V 4000 M40A engine data 40 7.2 Cylinder Liner 82
3.4 8 V 4000 M40B engine data 43 7.2.1 Cylinder liner – Endoscopic examination 82
3.5 8 V 4000 M40B engine data 46 7.2.2 Cylinder liner – Instructions and comments on
3.6 8 V 4000 M40B engine data 49 endoscopic and visual examination 84
3.7 Firing order 52 7.3 Crankcase Breather 86
3.8 Engine – Main dimensions 53 7.3.1 Crankcase breather – Oil separator
replacement, diaphragm check and
replacement 86
7.3.2 Crankcase breather – oil separator
4 Operation replacement 88
4.1 LOP – Controls 54
DCL-ID: 0000015771 - 001
7.4 Valve Drive 89

4.2 Engine – Preparations for putting into 7.4.1 Valve gear - Lubrication 89
operation after extended out-of-service 7.4.2 Valve clearance – Check and adjustment 90
periods (>3 months) 56 7.4.3 Cylinder head cover – Removal and
4.3 Putting the engine into operation after installation 95
scheduled out-of-service-period 57
4.4 Tasks after extended out-of-service periods 7.5 Injection Pump / HP Pump 96
7.5.1 HP pump – Relief bore check 96
(>3 weeks) 58
4.5 Checks prior to start-up 59 7.6 Injection Valve / Injector 97
7.6.1 Injector – Replacement 97
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7.6.2 Injector – Removal and installation 98
7.18 Battery-Charging Generator 138
7.7 Fuel System 103 7.18.1 Battery-charging generator drive – Coupling
7.7.1 Fuel system – Venting and filling 103 condition check 138
7.8 Fuel Filter 105 7.19 Engine Mounting / Support 139

7.8.1 Fuel filter – Replacement 105 7.19.1 Engine mounts – Checking securing screws
7.8.2 Fuel prefilter – Differential pressure gauge for firm seating 139
check and adjustment 107 7.19.2 Engine mounts – Resilient element check 140
7.8.3 Fuel prefilter – Draining 108
7.8.4 Fuel prefilter ‒ Flushing 109 7.20 Auxiliary PTO 142
7.8.5 Fuel prefilter – Filter element replacement 111 7.20.1 Bilge pump – Relief bore check 142
7.9 Charge-Air Cooling 113 7.21 Fuel Supply System 143

7.9.1 Intercooler – checking condensate drain line 7.21.1 Water drain valve – Check 143
for coolant discharge and obstruction 113 7.21.2 Differential pressure gauge – Check 144
7.21.3 Water level probe (3-in-1 rod electrode) –
7.10 Air Filter 114 Check 145
7.10.1 Air filter – Replacement 114 7.21.4 Pump capacity – Check 146
7.10.2 Air filter – Removal and installation 115 7.21.5 Coalescer filter element – Replacement 147
7.11 Air Intake 116 7.22 Wiring (General) for Engine/Gearbox/Unit 149
7.11.1 Contamination indicator – Signal ring position 7.22.1 Engine wiring – Check 149
check 116
7.11.2 Air flap – Check for ease of movement 117 7.23 Accessories for (Electronic) Engine
Governor / Control System 150
7.12 Exhaust Flap with Actuator 118 7.23.1 Engine governor and connectors – Cleaning 150
7.12.1 Exhaust flap – Check for easy movement 118 7.23.2 Engine monitoring unit and connectors –
Cleaning 151
7.13 Starting Equipment 119 7.23.3 Start interlock limit switch – Check 152
7.13.1 Starter – Condition check 119 7.23.4 Checking engine control unit plug connections 153
7.23.5 Engine monitoring unit – Plug connection
7.14 Lube Oil System, Lube Oil Circuit 120
check 154
7.14.1 Engine oil level – Check 120
7.23.6 Engine control unit – Removal and installation 155
7.14.2 Engine oil – Change 121
7.14.3 Engine oil – Sample extraction and analysis 123 7.24 Emergency Instrumentation (Local
7.15 Oil Filtration / Cooling 124 Operating Panel) 157
7.24.1 LOP – Visual inspection 157
7.15.1 Engine oil filter - Replacement 124
7.24.2 LOP – Test procedures 160
7.15.2 Centrifugal oil filter – Cleaning and filter
sleeve replacement 126
7.16 Coolant Circuit, General, High-

Temperature Circuit 128 8 Appendix A
7.16.1 Venting points 128
7.16.2 Engine coolant – Level check 129 8.1 Abbreviations 162
7.16.3 Engine coolant – Change 130 8.2 MTU contacts/service partners 164
7.16.4 Engine coolant – Draining 131
7.16.5 Engine coolant – Filling 132
DCL-ID: 0000015771 - 001
7.16.6 Engine coolant pump – Relief bore check 135

7.16.7 Engine coolant – Sample extraction and 9 Appendix B
analysis 136
9.1 Special Tools 165
7.17 Raw Water Pump with Connections 137 9.2 Index 169
7.17.1 Raw water pump – Relief bore check 137
4 | Table of Contents | MS15021/01E 2012-02

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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MS15021/01E 2012-02 | Safety | 5

1.2 Personnel and organizational requirements
Personnel requirements
Work on the engine must only be carried out by appropriately qualified and instructed personnel.
Observe the minimum legal age.
Responsibilities of the operating, maintenance and repair personnel must be specified by the operating
company.
Organizational measures
This publication must be issued to all personnel involved in operation, maintenance, repair or transporta‐
tion.
Keep it handy in the vicinity of the engine such that it is accessible to operating, maintenance, repair and
transport personnel at all times.
Use the manual as a basis for instructing personnel on engine operation and repair. In particular, person‐
nel must have read and understood the safety-relevant instructions.
This is especially important for personnel who work on the engine only on an occasional basis. These
persons shall receive repeated instruction.
Use the Spare Parts Catalog to identify spare parts during maintenance and repair work.
Working clothes and protective equipment

Wear proper protective clothing for all work.
Depending on the kind of work, use the necessary personal protective equipment.
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1.3 Transportation
Transportation
Only use the lifting eyes provided to lift the engine.

The lifting eyes are designed for engine transport only, not for the transport of gensets (engine and alter‐
nator).
Only use transport and lifting devices approved by MTU.
The engine must only be transported in installation position, max. permissible diagonal pull 10°.
Take the center of gravity of the engine into account.
If the engine is supplied with special aluminum foil packing, lift the engine at the lifting eyes of the bear‐
ing pedestal or use a means of transportation which is appropriate for the given weight (forklift truck).
Install the crankshaft locking device and the locking screws for the engine mounts prior to engine trans‐
portation.
Secure the engine against tilting during transportation. In particular when going down inclines or ramps,
the engine must be secured against moving and tilting.
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Setting down the engine following transportation

Set the engine down on a firm, level surface only.
Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate.
Never set an engine down on the oil pan unless expressly authorized to do so by MTU on a case-to-case
basis .
MS15021/01E 2012-02 | Safety | 7

1.4 Crankshaft transport locking device
Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Torque wrench, 10-60 Nm F30510423 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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8 | Safety | MS15021/01E 2012-02

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.
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.
MS15021/01E 2012-02 | Safety | 9

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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10 | Safety | MS15021/01E 2012-02

1.5 Safety regulations for startup and operation
Safety requirements for initial operation

Prior to initial operation of the unit, install the assembly or unit according to the specifications 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 nobody is in the danger area of moving machine parts.
Immediately after putting the device or plant into operation, make sure that all control and display instru‐
ments as well as the signaling and alarm systems work properly.
Safety requirements for operators

The procedures for cases of emergency must be practiced regularly.
The operator must be familiar with the control and display elements.
The operator must be familiar with the consequences of any operations performed.
During operation, the display instruments and monitoring units must be permanently observed with 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 protection.
• 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 spilt 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 electrical equipment is in operation, certain components of these appliances are electrically 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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12 | Safety | MS15021/01E 2012-02

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.
MS15021/01E 2012-02 | Safety | 13

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.
14 | Safety | MS15021/01E 2012-02

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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MS15021/01E 2012-02 | Safety | 15

1.8 Auxiliary materials, 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 around on the engine. Do not store combustible fluids near the engine.
Do not weld pipes and components carrying oil or fuel. Before welding, clean with a non-combustible
fluid.
When starting the engine with a foreign 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 foreign power source to
the ground lead of the 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.
SOLAS classification
On engines/plants with SOLAS classification, operational checks must include the following tasks:
• Check all covers (fitted in accordance with SOLAS requirements) on lube oil and fuel pipe connections
(>1.8 bar) for damage, replace as necessary. (→ Page 21)
Noise
Noise can lead to an increased risk of accident if acoustic signals, warning shouts or noises indicating
danger are drowned.
At all workplaces with a sound pressure level over 85 dB(A), always wear ear protectors (protective wad‐
ding, plugs or capsules).
Environmental protection
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 could involve the termination of the operating license by the emission authorities. MTU does not ac‐
cept 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 reliability and performance of MTU engines and must be complied with over the entire life cycle of the
engine.
Only fuels of the specified quality required to achieve emission limits must be used.
In Germany, the VAwS (=regulations governing the use of plants that may affect water quality) is applica‐
ble, which means work must only be carried out by authorized specialist companies (MTU is an author‐
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ized specialist company).

Dispose of used fluids, lubricants and filters in accordance with local regulations.
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, lubri‐
cants and other 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.
16 | Safety | MS15021/01E 2012-02

Lead
• When working with lead or lead-containing pastes, avoid direct contact with 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.
Painting
• When painting in other than spray booths equipped with extractors, ensure good ventilation. Make
sure that adjacent work areas are not affected.
• No naked flames!
• No smoking.
• Observe fire prevention regulations!
• It is absolutely necessary to wear masks providing protection against paint and solvent fumes.
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 numb‐
ing.
• Wear protective clothing, gloves, closed shoes and protective goggles!
• Ensure the room is well ventilated. 88% contamination of breathing air with nitrogen will result in suffo‐
cation.
• 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 extract‐
ed.
The pressure at which the air is kept can be read off at pressure gauges which must be connected to the
compressed 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 pres‐
sure 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 coupling and
connections must be securely attached!
• Always wear protective goggles when blowing off tools or extracting chips!
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• The snout of the air nozzle is provided with a protective disc (e.g. rubber disc), which prevents air-
borne particles being reflected and thereby prevents injury to eyes.
• 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. sheet metal, plastic, glass) for drying purpos‐
es or to check for leaks will result in a risk of bursting!
• Do not blow dirty clothing with compressed air when being worn on the body.
MS15021/01E 2012-02 | Safety | 17

Used oil
Used oil may contain health-threatening combustion residues.
Rub barrier cream into hands! Wash hands after contact with used oil.
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18 | Safety | MS15021/01E 2012-02

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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MS15021/01E 2012-02 | Safety | 19

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 KGS = Free end 3 KS = Driving end

2 Right engine side 4 Left engine side
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20 | General Information | MS15021/01E 2012-02

2.2 Product description
Description of the engine
Engine
The engine is a liquid-cooled four-stroke diesel engine, rotating counterclockwise (seen from driving
end), with direct injection, sequential turbocharging and charge air cooling.
The engine is monitored by an engine control and monitoring system (MDEC).
Monitoring in the engine room is facilitated with the local engine control and monitoring unit (LOP).
Fuel system
Electronically controlled common rail injection system with high-pressure pump, pressure accumulator
(rail) and single injectors.
The electronic control unit controls
• Injection start
• Injection quantity
• Injection pressure
Exhaust system
The exhaust system is equipped with triple-walled, water-cooled exhaust lines.
The triple-walled design permits
• low surface temperature,
• reduced amount of heat to be dissipated by the coolant,
• absolute gas-tightness.
Turbocharging
Sequential turbocharging with internal, engine-coolant-controlled charge-air cooling. The right-hand ex‐
haust turbocharger is cut-in and cut-out with electronically controlled, hydraulically actuated flaps.
Cooling system
Engine cooling as split-circuit cooling system with plate-core heat exchanger.
Heating of the charge air in idle and low-load operation prevents white smoke formation.
Seawater only circulates in the engine coolant cooler and seawater pump.
Service block
The service components are mounted at the auxiliary PTO end.
The layout permits easy access for maintenance.
Service components:
TIM-ID: 0000002179 - 003
• Raw water pump, coolant pump

• Fuel duplex filter, switchable
• Lube oil multiple filter, switchable
• Centrifugal lube oil filter
• Coolant expansion tank
Electronic system
Electronic control and monitoring system with integrated security and test system with interfaces to re‐
mote control system (RCS) and to remote control system (MCS).
MS15021/01E 2012-02 | General Information | 21

Electronic engine control unit (ECU)
Functions:
• Engine speed control with fuel and speed limitation dependent on engine status and operating condi‐
tions;
• Control of sequential turbocharging;
• 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:
• Data 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/gearbox control;
• Flashing light and horn for combined alarm in engine room;
• Interface to CAN field bus for connected, communicating monitoring system components.
TIM-ID: 0000002179 - 003

SOLAS – Fire safety requirements
Fuel system, fuel lines with fuel pressure >1.8 bar
1 Return line 3 Non-return valve 5 Fuel line on HP fuel

2 Fuel line on fuel delivery 4 Sealing cone pump
pump 6 Fuel line on vent line
All lines with SOLAS-compliant covers for pipe connections, according to MTU standard MTN5233, are
shown.
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Lube oil system, oil lines with oil pressure >1.8 bar
1 Seal, oil line to ETC 6 Oil line on distributor 11 Oil line, actuating cylinder
2 Oil line, ETC 7 Connection, oil line on to control block
3 Connection, oil line to dis‐ control block 12 Oil line, actuating cylinder
tributor 8 Oil line on control block to control block
4 Oil line, ETC 9 Oil lines on T-piece 13 Connection, oil line to ac‐
5 Oil line, lube oil pump 10 Oil line, valve housing tuating cylinder
All lines with SOLAS-compliant covers for pipe connections, according to MTU standard MTN5233, are
shown.
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Special connections
In case of leakage, the following connection types are spray-protected even without a cover and have
been confirmed compliant with SOLAS by GL and DNV.
Plug-in pipe connection

The sleeve (3) covers the joint to prevent lateral spray.
Only leak-off along the line is possible, the pressure is decreased significantly if an O-ring (3) defect oc‐
curs.
The connection is confirmed as compliant with SOLAS by DNV and GL.
Plugs and sensors

Screw-in plugs (4) are sealed toward the outside either with a copper sealing ring (1), according to DIN,
or an O-ring (ISO).
In case of a loose thread or a defective sealing ring (1), the fluid first has to pass the thread.
The pressure is so greatly reduced by this and the faulty sealing ring (1) that any leakage is not under
pressure.
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HP connections
1 Jacket pipe 8 Leakage overflow bore 15 Snap ring

2 HP line 9 Thrust ring 16 Thrust ring
3 O-ring 10 Union nut 17 Compensating washers
4 Union nut 11 Internal pipe of HP line 18 Leak fuel connection
5 Recess for O-ring 12 External pipe of HP line 19 Union nut
6 Thrust ring 13 Union nut 20 Thrust ring
7 Ball-type seal area 14 Connecting piece
The HP fuel line is sealed by the thrust ring (9).
If leakage in the area of the thrust ring (9) or the HP line (2) occurs, the emerging fuel is routed to the
leakage chamber.
The leak fuel is drained off without pressure via the leakage overflow bore (8). The leakage chamber is
sealed toward the outside by the O-rings (3).
This prevents leaking fuel from escaping.
The connection is confirmed as compliant with SOLAS by DNV and GL.
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Shielding of fuel filter and lube oil filter
Shielding with synthetic ring – Shielding by overhang design
The synthetic ring (1) or the overhang (2) prevents lateral spray.
The fluid is diverted to the catch basin whereby the pressure is significantly reduced.
TIM-ID: 0000002179 - 003

2.3 Engine – Overview
1 Exhaust pipework 15 Fuel system (high pres‐ 24 Engine coolant pump

2 Air recirculation valve sure) 25 Charge-air line
3 Exhaust turbocharger 16 Fuel system (low pres‐ 26 Mounting/support
4 Air intake/air supply sure) 27 Starting equipment
5 Oil separator 17 Inspection port cover 28 Flywheel housing
6 Intake elbow 18 Crankcase 29 Running gear
7 Exhaust pipework 19 Running gear 30 Drive systems, driving
8 Oil heat exchanger 20 Valve gear end and free end (cou‐
9 Coolant expansion tank 21 Electric power supply, en‐ pling)*
10 Engine governor gine-related* 31 Cylinder head
11 Seawater cooler 22 Drive systems, driving 32 Intercooler
12 Thermostat housing end and free end (cou‐ 33 Auxiliary systems / ac‐
13 Coolant line pling)* cessory equipment*
14 Valve gear 23 Equipment carrier * not shown
Engine model designation

Key to the engine model designation 8 V 4000 Mxyz
TIM-ID: 0000002083 - 004
8 Number of cylinders
V Cylinder arrangement: V engine
4000 Series
M Application
x Application segment (4, 5, 6, 7, 9)
y Design index (0,1, 2,...)
z Additional features

2.4 Sensors, actuators and injectors – Overview
1 Injector Y39.1 (cylinder 6 B6.2 (coolant tempera‐ 11 Injector Y39.11 (cylinder

A1) ture) B1)
2 Injector Y39.2 (cylinder 7 B06 (coolant tempera‐ 12 B44.2 (turbocharger
A2) ture) speed, B-side)
3 Injector Y39.3 (cylinder 8 Injector Y39.14 (cylinder 13 B44.1 (turbocharger
A3) B4) speed, A-side)
4 Injector Y39.4 (cylinder 9 Injector Y39.13 (cylinder
A4) B3)
5 F25 (lube-oil pressure dif‐ 10 Injector Y39.12 (cylinder
ferential at filter) B2)
The injectors are underneath the cylinder head covers of the cylinder. Injector replacement and necessa‐
ry activities (→ Page 97).
TIM-ID: 0000008381 - 002

1 B10 (charge-air pressure) 5 B05 (lube oil pressure) 9 B4.2 (exhaust tempera‐
2 B09 (charge-air tempera‐ 6 B50 (crankcase pressure) ture, cylinder A2)
ture) 7 B4.4 (exhaust tempera‐ 10 B4.1 (exhaust tempera‐
3 F46 (leak-off fuel level) ture, cylinder A4) ture, cylinder A1)
4 B07 (lube oil tempera‐ 8 B4.3 (exhaust tempera‐
ture) ture, cylinder A3)
TIM-ID: 0000008381 - 002

1 B5.2 (lube-oil pressure) 4 B33 (fuel temperature in
2 B01 (camshaft speed) common rail)
3 Sensor B34 (fuel pres‐ 5 B48 (fuel pressure in
sure after filter) common rail)
TIM-ID: 0000008381 - 002

1 B4.11 (exhaust tempera‐ 3 B4.13 (exhaust tempera‐ 5 B16 (coolant pressure)
ture, cylinder B1) ture, cylinder B3) 6 F33 (coolant level)
2 B4.12 (exhaust tempera‐ 4 B4.14 (exhaust tempera‐
ture, cylinder B2) ture, cylinder B4)
TIM-ID: 0000008381 - 002

1 B4.21 (exhaust bulk tem‐ 3 B4.22 (exhaust bulk tem‐
perature, A side) perature, B side)
2 B49 (T-charge air, air re‐ 4 B13 (crankshaft speed)
circulation valve) 5 B13.2 (crankshaft speed)
TIM-ID: 0000008381 - 002

3 Technical Data
3.1 8 V 4000 M40A engine data
Explanation:
Abbrevia‐ Meaning
tion
DL Ref. value: Continuous power
BL Ref. value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power set‐
ting)
N Not yet defined value
- Not applicable
X Applicable
REFERENCE CONDITIONS
Engine model 8V4000M
40A
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 8
Rated engine speed A rpm 1500
Continuous power ISO 3046 (10% overload capability, design power DIN A kW 880
6280, ISO 8528)
GENERAL CONDITIONS (for maximum power)

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Intake depression (new filter) A mbar 25

Intake depression, max. L mbar 35
MODEL RELATED DATA (basic design)

Cylinder arrangement: V angle Degrees 90
(°)
Bore mm 165
34 | Technical Data | MS15021/01E 2012-02

Stroke mm 190
Cylinder displacement Liters 4.06
Total displacement Liters 32.5
Number of inlet valves per cylinder 2
Number of exhaust valves per cylinder 2
RAW WATER CIRCUIT (open circuit)

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 0.8
LUBE OIL SYSTEM

Lube oil operating temperature before engine, from R °C 85
Lube oil operating temperature before engine, to R °C 90
Lube oil operating pressure before engine, from R bar 4.8
Lube oil operating pressure before engine, to R bar 5.3
Lube oil operating pressure (low idle) (meas. point: before engine) R bar 2.0
FUEL SYSTEM
Fuel pressure at supply connection to engine, min. (when engine is starting) L bar -0.1
Fuel pressure at supply connection to engine, min. (when engine is run‐ L bar -0.3
ning)
Fuel pressure at supply connection to engine, max. (when engine is start‐ L bar 1.5
ing)
Fuel supply flow, max. R Liters/min 13.8
GENERAL OPERATING DATA

Firing speed, from R rpm 80
Firing speed, to R rpm 120
STARTER (electric)
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Rated starter voltage (standard design) R V= 24
STARTING (with compressed air/hydraulic starter)

Starting-air pressure before starter motor, min. R bar 16
Starting-air pressure before starter motor, max. R bar 30
MS15021/01E 2012-02 | Technical Data | 35

CAPACITIES
Engine coolant, engine side (with cooling system) R Liters 210
Engine oil on initial filling (standard oil system) (option: max. operating incli‐ R Liters 145
nations)
Oil change quantity, max. (standard oil system) (option: max. operating in‐ R Liters 120
clinations)
Oil pan capacity, dipstick mark "min." (standard oil system) (option: max. L Liters 110
operating inclinations)
Oil pan capacity at dipstick mark "max." (standard oil system) (option: max. L Liters 140
WEIGHTS / MAIN DIMENSIONS

Engine dry weight (with attached standard accessories, without coupling) R kg 4630
ACOUSTICS
Exhaust noise, unsilenced - BL (free-field sound pressure level Lp, 1m dis‐ R dB(A) 112
tance, ISO 6798, +3dB(A) tolerance)
Engine surface noise with attenuated intake noise (filter) - BL (free-field R dB(A) 105
sound power level Lp, 1 m distance, ISO 6798, +2dB(A) tolerance)
TIM-ID: 0000011024 - 002

Explanation:
Abbrevia‐ Meaning
tion
A Design value
G Guaranteed value
R Guideline value
ting)
- Not applicable
X Applicable
40A
6280, ISO 8528)

TIM-ID: 0000010960 - 002

(°)
Bore mm 165
Stroke mm 190

LUBE OIL SYSTEM

FUEL SYSTEM
ning)
ing)

STARTER (electric)

TIM-ID: 0000010960 - 002
CAPACITIES
nations)
clinations)


ACOUSTICS
TIM-ID: 0000010960 - 002

Explanation:
Abbrevia‐ Meaning
tion
A Design value
G Guaranteed value
R Guideline value
ting)
- Not applicable
X Applicable
40A
6280, ISO 8528)

TIM-ID: 0000010950 - 002

(°)
Bore mm 165
Stroke mm 190

LUBE OIL SYSTEM

FUEL SYSTEM
ning)
ing)

STARTER (electric)

TIM-ID: 0000010950 - 002
CAPACITIES
nations)
clinations)


ACOUSTICS
TIM-ID: 0000010950 - 002

3.4 8 V 4000 M40B engine data
Explanation:
Abbrevia‐ Meaning
tion
A Design value
G Guaranteed value
R Guideline value
ting)
- Not applicable
X Applicable
40B
6280, ISO 8528)

TIM-ID: 0000010850 - 002

(°)
Bore mm 165
Stroke mm 190

RAW WATER CIRCUIT (open circuit)

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 1.3
LUBE OIL SYSTEM

FUEL SYSTEM
ning)
ing)

STARTER (electric)
TIM-ID: 0000010850 - 002


CAPACITIES
Engine coolant, engine side (with cooling system) R Liters 210
nations)
clinations)

ACOUSTICS
TIM-ID: 0000010850 - 002

Explanation:
Abbrevia‐ Meaning
tion
A Design value
G Guaranteed value
R Guideline value
ting)
- Not applicable
X Applicable
40B
6280, ISO 8528)

TIM-ID: 0000010885 - 002

(°)
Bore mm 165
Stroke mm 190

LUBE OIL SYSTEM

FUEL SYSTEM
ning)
ing)

STARTER (electric)

TIM-ID: 0000010885 - 002
CAPACITIES
nations)
clinations)


ACOUSTICS
TIM-ID: 0000010885 - 002

Explanation:
Abbrevia‐ Meaning
tion
A Design value
G Guaranteed value
R Guideline value
ting)
- Not applicable
X Applicable
40B
6280, ISO 8528)

TIM-ID: 0000010809 - 002

(°)
Bore mm 165
Stroke mm 190

LUBE OIL SYSTEM

FUEL SYSTEM
ning)
ing)

STARTER (electric)

TIM-ID: 0000010809 - 002
CAPACITIES
nations)
clinations)

Oil pan capacity, dipstick mark "min". (standard oil system) (option: max. L Liters 110

ACOUSTICS
TIM-ID: 0000010809 - 002

3.7 Firing order
Firing order
Number of cylin‐ Firing order
ders
8V A1-B4-A4-A2-B3-A3-B2-B1
12V A1-B2-A5-B4-A3-B1-A6-B5-A2-B3-A4-B6
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: 0000002794 - 004

3.8 Engine – Main dimensions
Engine – Main dimensions
Engine model Length (A) Width (B) Height (C)

8 V 4000 M40/50 A/B approx. 2340 mm approx. 1380 mm approx. 1990 mm
TIM-ID: 0000002147 - 002

4 Operation
4.1 LOP – Controls
LOP – Controls
Item Color Inscription Meaning / Function

1 White F1 Function keys for operating the screen.
2 White F2 Functions vary and are displayed on the LCD screen.
3 White F3
4 White F4
TIM-ID: 0000008856 - 004
5 White F5
6 White ALARM AC‐ Pressing the key the first time stops alarm signalization.
KNOWLEDGE
Pressing the key a second time acknowledges an active
alarm.
LED (spot) lights up when an alarm is active.
7 White DIMMER ↑ Holding down the key increases LCD background illumina‐
tion.
54 | Operation | MS15021/01E 2012-02

Item Color Inscription Meaning / Function
8 White DIMMER ↓ Holding down the key decreases LCD background illumina‐
tion.
9 White LAMP TEST Pressing the key initiates lamp test.
10 Red TEST OVER‐ Pressing the key initiates overspeed test.
SPEED
LED (spot) lights up as long as the overspeed test is run‐
ning.
11 Green (none) (none)
14 White ENGINE SPEED Engine speed is increased as long as the key is held down.
INCREASE
15 White ENGINE SPEED Engine speed is decreased as long as the key is held down.
DECREASE
16 Green READY FOR OP‐ Pressing the key causes changeover between “Not ready
ERATION for operation” and “Ready for operation” status.
LED (spot) lights up at "Ready for operation" switch posi‐
tion.
17 Green LOCAL OPERA‐ Pressing the key switches between local operation and re‐
TION mote control.
LED (spot) lights up when local mode is active.
18 White START Pressing the key initiates automatic engine starting proce‐
dure.
LED (spot) lights up as long as the starting procedure is
running.
19 White STOP Pressing the key initiates automatic engine stopping proce‐
dure.
Spot LED lit when stop signal is applied (also from remote
control system).
20 Red EMERGENCY Pressing the key initiates an immediate emergency engine
STOP stop.
LED (spot) flashes once the emergency stop has been trip‐
ped and until the alarm has been acknowledged.
TIM-ID: 0000008856 - 004
MS15021/01E 2012-02 | Operation | 55

4.2 Engine – Preparations for putting into operation after
extended out-of-service periods (>3 months)
Preconditions
☑ Engine is stopped and starting disabled.
☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.
Putting into operation after extended out-of-service periods (>3 months)

Item Measure
Engine Depreserve (→ MTU Fluids and Lubricants Specifications A001061/..).
Lube oil system Check engine oil level (→ Page 120);
preheat engine oil, if required.
Bar engine with starting system.
Fuel prefilter Fill with fuel (→ Page 111).
Fuel prefilter, pressure Align adjustable pointer with position of pressure indicator (→ Page 107).
gauge
Fuel system Vent (→ Page 103).
Raw water pump (if raw Fill with water (approx. 3 – 4 liters).
water pump lies above the
water line)
Coolant circuit If engine is out of service for more than one year, change engine coolant
(→ Page 130).
Coolant circuit Check coolant level (→ Page 129).
Coolant circuit Heat engine coolant with coolant preheating unit.
ECU Check plug-in connections (→ Page 153).
Engine control system Switch master switch to ON;
Press READY FOR OPERATION button (→ Page 54).
LOP Press LAMP TEST illuminated button (→ Page 54).
TIM-ID: 0000002208 - 004
56 | Operation | MS15021/01E 2012-02

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

Item Action
Lube oil system Check engine oil level (→ Page 120);
, preheat engine oil, if required.
Coolant circuit Check coolant level (→ Page 129).
Coolant circuit Heat engine coolant with coolant preheating unit.
Fuel prefilter Drain water (→ Page 108);
Check if suction-side pressure indicated at the fuel prefilter is within the
limit (→ Page 107).
Engine control system Switch master switch to ON;
Press illuminated pushbutton READY FOR OPERATION (→ Page 54).
LOP Press illuminated pushbutton LAMP TEST (→ Page 54).
TIM-ID: 0000002686 - 004
MS15021/01E 2012-02 | Operation | 57

4.4 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 60).
2. Shut down fuel treatment system (→ Page 68).
TIM-ID: 0000007730 - 005
58 | Operation | MS15021/01E 2012-02

4.5 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 63).
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
MS15021/01E 2012-02 | Operation | 59

4.6 Fuel treatment system – Putting into operation
Fuel treatment system – Overview

2. Check the differential pressure at differential pressure gauge (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 147).
2. Check sealing faces on coalescer filter element and in the pressure tank.
Initial operation: HAT

1. Replace fuel filter on engine (→ Page 105).
Note: Determine the suction pressure upstream of the engine-mounted fuel delivery pump.
2. Install a pressure gauge in the fuel supply line from the shipyard-side fuel system to the engine.
3. Switch on fuel treatment system and operate it for some minutes (→ Page 63).
Result: Fuel is sucked from the tank, dirt particles and water are filtered and separated, then the fuel is delivered
via the overflow tank back to the tank. Water which has settled in the tank is separated.
TIM-ID: 0000007738 - 005
4. Start engine (→ Page 62).

5. Run engine at idling speed.
6. Check suction pressure (see technical data of the engine) at the engine-mounted fuel delivery pump.
Note: If the suction pressure is within the 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.
60 | Operation | MS15021/01E 2012-02

Simulation of filter replacement with the engine running: HAT
4. Close ball cock (5) at the inlet to the 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 cock (19).
Result: Fuel emerges. If no fuel emerges:
• Open ball cock (5) at the inlet to the fuel treatment system.
• No function of bypasses (2) and (3); carry out functional test of bypasses (2) and (3).
6. Check suction pressure (see technical data of the engine) at the fuel delivery pump.
Result: If all engine operating values are within the specified limits, open ball cock (5) at the inlet to the fuel treat‐
ment4 system.
Simulation of power failure (emergency): HAT

4. Switch off pump (21) on switch cabinet.
Result: The engine-mounted fuel delivery pump sucks fuel via bypass (2) directly from the tank.
Note: If the suction pressure is within the permissible limits and engine operation is satisfactory.
Result: If the suction pressure is within the specified limits, simulation was successful.
Simulation of power failure (emergency): SAT

4. Switch off pump (21) on switch cabinet.
Result: The engine-mounted fuel delivery pump sucks fuel via bypass (2) directly from the tank.
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: 0000007738 - 005
MS15021/01E 2012-02 | Operation | 61

4.7 Engine – Starting
Preconditions
☑ External start interlock is not activated.
☑ Emergency-air shutoff flaps (if fitted) must be opened.
DANGER
Unguarded rotating and moving engine components.
• 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.
Barring the engine (out-of-service period > 1 month)

Item Measure
Engine Bar with starting system (→ Page 81).
Starting the engine from LOP

Item Measure
Engine Start in unloaded condition.
System Switch on.
LOP:
• LOCAL OPERATION button is illuminated brightly (local operating
mode is active) (→ Page 54).
LOP Press illuminated pushbutton READY FOR OPERATION briefly
(→ Page 54).
• Illuminated pushbutton READY FOR OPERATION lights up brightly.
LOP Press illuminated pushbutton START briefly (→ Page 54).
• Illuminated pushbutton START of the relevant engine lights up brightly;
• Automatic starting sequence is performed;
• Engine speed display instrument indicates increasing speed;
• After completion of the starting sequence, the engine runs at idle speed
and the illuminated pushbutton START changes to basic brightness.
TIM-ID: 0000002237 - 002
62 | Operation | MS15021/01E 2012-02

4.8 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 59).
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
MS15021/01E 2012-02 | Operation | 63

4.9 Operational checks
DANGER
• Take special care when working on a running engine.
WARNING
Operational checks
Item Task
Engine under load Check engione and pipework for leaks, rectify any leaks with the engine
stopped.
Engine at nominal speed
Check for abnormal running noises and vibrations.
HP pump Inspect relief bore for oil and coolant discharge and for dirt. (→ Page 96).
Fuel prefilter Check if suction-side pressure indicated at the fuel prefilter pressure
gauge is within the limit. (→ Page 107).
Drain water and contaminants (→ Page 108).
Exhaust system Check exhaust color (→ Page 72).
Intercooler Check condensate drain(s) for water discharge and obstruction
(→ Page 113).
Air filter Check signal ring position of service indicator (→ Page 116);
Replace air filter (→ Page 114), if the signal ring is completely visible in the
service indicator control window.
HT cooling pump Check relief bore for oil and coolant discharge and dirt (→ Page 135).
Bilge pump Check relief bore for oil and water discharge and dirt (→ Page 142).
TIM-ID: 0000002270 - 001
64 | Operation | MS15021/01E 2012-02

4.10 Stopping the engine at the 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 stopping the engine, operate it at idle speed until operating temperatures decrease and
stable values are indicated.
Stopping the engine at the LOP

Item Action
LOP Operate engine at idle speed (→ Page 54).
Temperature readings Wait until engine is at operating temperature.
LOP Press STOP pushbutton (→ Page 54).
• STOP pushbutton is illuminated;
• engine is stopped.
TIM-ID: 0000002293 - 004
MS15021/01E 2012-02 | Operation | 65

4.11 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 EMERGENCY STOP button (→ Page 54).
LOP Press EMERGENCY STOP button.
• Engine is stopped by switching off power supply to ECU;
• Engine control is deactivated;
• Engines with emergency air-shut-off flaps: Flaps close;
• EMERGENCY STOP button flashes.signalization by horn, flash lamp
etc. is released.
After emergency stop from LOP

Item Task
LOP Press ALARM ACKNOWLEDGE button (→ Page 54).
• Audible and visual signalization stops.
LOP Press ALARM ACKNOWLEDGE 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.
TIM-ID: 0000002309 - 003
66 | Operation | MS15021/01E 2012-02

4.12 After stopping the engine
Preconditions
After stopping the engine

Item Action
Coolant circuit Drain coolant (→ Page 131) 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
MS15021/01E 2012-02 | Operation | 67

4.13 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
68 | Operation | MS15021/01E 2012-02

4.14 Plant – Cleaning
Preconditions
☑ Operating voltage is not applied.

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.
Note: There is a risk of damaging sensors with compressed air.
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. For external cleaning with high-pressure jet, use a flat-mouth nozzle only.
4. Carry out external cleaning as follows:
a) Remove coarse dirt.
b) Spray on cleaner sparingly and leave it for 1 to 5 minutes.
c) Use the high-pressure jet to remove the loosened dirt.
d) During external cleaning of the plant with water/steam-jet units, the pressure of the high-pressure jet
TIM-ID: 0000010171 - 021
(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.
MS15021/01E 2012-02 | Operation | 69

5 Maintenance
5.1 Maintenance 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 120)
W0501 Visually inspect engine for leaks and general condition (→ Page 64)
W0502 Check intercooler drain (if fitted) (→ Page 113)
W0503 Check signal ring position of service indicator on air filter (→ Page 64)
W0504 Check HP fuel pump weep holes (→ Page 64)
W0505 Check relief bores of coolant pump(s) (→ Page 64)
W0506 Check engine for abnormal running noises, exhaust color (→ Page 64)
and vibrations
W0507 Drain water and contaminants from fuel prefilter (if fitted) (→ Page 64)
W0508 Check reading on differential pressure gauge of fuel prefilter (→ Page 64)
(if fitted)
W1001 Replace fuel filter or fuel filter element (→ Page 105)
W1002 Check valve clearance (→ Page 90)
W1005 Replace air filter (→ Page 114)
W1006 Replace fuel injectors (→ Page 97)
W1008 Replace engine oil filter at each oil change or when the time (→ Page 124)
limit (years) is reached, at the latest
W1009 Check layer thickness of oil residue, clean and replace filter (→ Page 126)
sleeve (if fitted) at each engine oil change, at the latest
W1011 Perform endoscopic inspection of combustion chambers (→ Page 82)
W1046 Crankcase breather: Replace filter or filter element (→ Page 86)
W1244 Check operation of rod electrode (if fitted) (→ Page 145)
W1245 Differential-pressure gauge, check alarm function (if fitted) (→ Page 144)
W1246 Check pump capacity (if fitted) (→ Page 146)
W1463 Check general condition of the engine mounting (visual in‐ (→ Page 140)
spection)
TIM-ID: 0000035707 - 001
Table 1: Maintenance task reference table [QL1]
70 | Maintenance | MS15021/01E 2012-02

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.

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.

The differential pressure exceed‐ u Replace coalescer filter element (→ Page 147).
ed 1.3 bar.
Illuminated pushbutton “Replace filter element” is lit.

The max. permissible differential 1. Replace coalescer filter element (→ Page 147).
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 - 005
valve will open. Fuel will be led

via the bypass directly into the
overflow tank.
MS15021/01E 2012-02 | Troubleshooting | 71

6.2 Troubleshooting
Engine does not turn when starter is actuated

Component Cause Measure
Battery Discharged or faulty Charge or replace (see manufacturer's
documentation).
Cable connections faulty Check if cable connections are proper‐
ly secured (see manufacturer's docu‐
mentation).
Starter Engine cabling or starter faulty Check if cable connections are proper‐
ly secured, contact Service.
Engine wiring Faulty Check (→ Page 149).
LOP Seating of assemblies or plug connec‐ Perform visual inspection
tors possibly loose (→ Page 157).
ECU Seating of plug connections possibly Check plug connections (→ Page 153).
loose
Engine Running gear blocked (engine cannot Contact Service.
be barred manually)
Engine turns but does not fire

Starter Poor rotation by starter: Battery dis‐ Charge or replace battery (see manu‐
charged or faulty facturer's documentation).
Fuel system Air in fuel system Vent fuel system (→ Page 103).
ECU Faulty Contact Service.
Engine fires unevenly

Fuel injection equip‐ Injector faulty Replace (→ Page 97).
ment
Engine does not reach rated speed

TIM-ID: 0000002550 - 002
Fuel supply Fuel prefilter clogged Replace (→ Page 111).

Easy-change fuel filter clogged Replace (→ Page 105).
Air supply Air filter clogged Check signal ring position of contami‐
nation indicator (→ Page 116).
ment
Engine Overloaded Contact Service.
72 | Troubleshooting | MS15021/01E 2012-02

Engine speed not steady
ment
Speed sensor Faulty Contact Service.
Charge-air temperature too high

Engine coolant Engine coolant treatment incorrect 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

Intercooler Contaminated Contact Service.
Exhaust turbocharger Faulty Contact Service.
Coolant leaks at intercooler

Intercooler Leaking, major coolant discharge Contact Service.
Black exhaust gas

ment
Engine Overloaded Contact Service.
Blue exhaust gas

TIM-ID: 0000002550 - 002
Engine oil Too much oil in engine Drain engine oil (→ Page 121).
Oil separator or oil preseparator of Replace.
crankcase breather clogged
Exhaust turbocharg‐ Faulty Contact Service.
er, cylinder head, pis‐
ton rings, cylinder lin‐
er

White exhaust gas
Engine Not at operating temperature Run engine to reach operating temper‐
ature.
Fuel system Water in fuel Check fuel system at fuel prefilter
Drain fuel prefilter (→ Page 108).
Intercooler Leaking Contact Service.
TIM-ID: 0000002550 - 002

6.3 LOP fault messages
Fault messages and measuring points (status reports) are displayed as text messages on the LOP dis‐
play (DIS). Explanation of the displayed texts can be gathered by pressing the help button on the
touchscreen. Fault messages can also be caused by faulty sensors/actuators. Contact Service to have
sensors/actuators checked and replaced as necessary if the troubleshooting measures listed in the table
below prove unsuccessful.
LOP
Display text Meaning Measure
AL Exhaust Monitor‐ Exhaust temperature monitoring failure Contact Service.
ing Fail • Have EMU replaced.
AL RCS Speed De‐ No speed demand signal 1. Check speed demand source sys‐
mand Defect tem (e. g. from automatic onboard
network);
2. Check LOP visually (→ Page 157);
3. Perform LOP test procedures
(→ Page 160);
4. Check ECU plug-in connections
(→ Page 153);
5. Check engine wiring (→ Page 149).
AL Shutdown Expect‐ Yellow alarm occurred; Red alarm with 1. Start other genset
ed engine shutdown will probably follow
as preventive measure.
2. Determine cause of yellow alarm
and rectify.
AL Battery Charge Battery not being charged 1. Check power circuit breakers and
Fault fuses;
2. Check transistorized regulator.
AL Press. Monitoring EMU pressure monitoring failure Contact Service.
Fail (EMU) • Have EMU replaced.
AL ECU Defective ECU 4 is defective 1. Check LOP visually (→ Page 157);
(→ Page 160);
(→ Page 153);
4. Check engine wiring (→ Page 149);
5. Contact Service.
• Have ECU checked and re‐
placed, if required.
AL Power Amplifier 1 Power amplifier cylinder bank A failure 1. Check LOP visually (→ Page 157);
Failure 2. Perform LOP test procedures
(→ Page 160);
TIM-ID: 0000008900 - 002

(→ Page 153);
5. Contact Service.

AL Power Amplifier 2 Power amplifier cylinder bank B fault 1. Check LOP visually (→ Page 157);
Failure 2. Perform LOP test procedures
(→ Page 160);
(→ Page 153);
5. Contact Service.
AL Override Activat‐ Safety system overridden Status message:
ed • Override activated.
AL Power Failure Power failure of control system Check power circuit breakers and
Control fuses.
AL Power Failure Power failure Check power circuit breakers and
Monitoring fuses.
AL Transistor Output One of the ECU 4 transistor outputs Contact Service.
1/2 Fail (TAA1 or TAA2) defective • Have ECU checked and replaced, if
required.
AL Transistor Output One of the ECU 4 transistor outputs Contact Service.
3/4 Fail (TAA3 or TAA4) defective • Have ECU checked and replaced, if
required.
AL Water in Fuel Pre‐ Water in fuel prefilter Drain fuel prefilter (→ Page 108).
filter
DL 211+A001-A001 DIS not recognized on default bus 1. Check LOP visually (→ Page 157);
(→ Page 160);
(→ Page 153);
5. Contact Service.
• Have DIS checked and re‐
DL 211+A001-A010 LCU of LOP 1 (PIM No. 21.X+A001- 1. Check LOP visually (→ Page 157);
A010) not recognized on default bus 2. Perform LOP test procedures
(→ Page 160);
(→ Page 153);
5. Contact Service.
• Have MPU 23 of PIM No. 21.X
+A001-A010 checked and re‐
DL 211+A001-A020 LMU of LOP 1 (PIM No. 21.X+A001- 1. Check LOP visually (→ Page 157);
TIM-ID: 0000008900 - 002
A020) not recognized on default bus 2. Perform LOP test procedures

(→ Page 160);
(→ Page 153);
5. Contact Service.

DL 211+A003-ECU ECU 4 not recognized on default bus 1. Check LOP visually (→ Page 157);
(→ Page 160);
(→ Page 153);
5. Contact Service.
DL 211+A004-EMU EMU 1 not recognized on default bus 1. Check LOP visually (→ Page 157);
(→ Page 160);
(→ Page 153);
5. Contact Service.
• Have EMU checked and re‐
HI P-Oil Filter Diff. Oil pressure difference between oil Replace engine oil filter (→ Page 124).
pressure upstream of filter and oil
pressure downstream of filter too high
MG Start condition Conditions for starting not met Check start conditions and fulfill if nec‐
check essary.
RL 211+A001-A001 DIS not recognized on redundant bus 1. Check LOP visually (→ Page 157);
(→ Page 160);
3. Contact Service.
• Have DIS checked and re‐
RL 211+A001-A010 LCU of LOP 1 (PIM No. 21.X+A001- 1. Check LOP visually (→ Page 157);
A010) not recognized on redundant 2. Perform LOP test procedures
bus (→ Page 160);
3. Contact Service.
RL 211+A001-A020 LMU of LOP 1 (PIM No. 21.X+A001- 1. Check LOP visually (→ Page 157);
A020) not recognized on redundant 2. Perform LOP test procedures
bus (→ Page 160);
3. Contact Service.
RL 211+A003-ECU ECU 4 not recognized on redundant 1. Check LOP visually (→ Page 157);
TIM-ID: 0000008900 - 002
bus 2. Perform LOP test procedures

(→ Page 160);
(→ Page 153);
4. Contact Service.

RL 211+A004-EMU EMU 1 not recognized on redundant 1. Check LOP visually (→ Page 157);
bus 2. Perform LOP test procedures
(→ Page 160);
3. Contact Service.
• Have EMU checked and re‐
SS Safety System Safety system has determined fault on contact Service.
Failure (EMU) Engine Monitoring Unit
SS Power Reduction Safety system has requested power 1. Determine cause for automatic
Active reduction power reduction;
2. Observe further display messages/
alarms;
3. Contact Service.
SS Emergency Stop Safety system has triggered emergen‐ 1. Determine cause for shutoff and
cy stop rectify;
alarms.
SS Emergency Stop Safety system has carried out an ex‐ 1. Determine cause for shutoff and
External ternally triggered emergency stop rectify;
alarms.
SS P-Coolant Safety system detects that coolant Check coolant level and top up if re‐
pressure is too low quired (→ Page 129).
SS P-Lube Oil (ECU) Safety system detects that engine oil 1. Check lube oil level and top up if
pressure is too low required (→ Page 120) .
2. Contact Service.
SS P-Lube Oil (EMU) Safety system detects that engine-oil 1. Check lube oil level and top up if
pressure is too low required (→ Page 120) .
2. Contact Service.
SS Security Channel Safety system fault message Contact Service.
Def EMU • Have EMU checked and replaced, if
required.
SS SDAF closed Safety system reports closed emer‐ Open emergency-air shutoff flaps
gency-air shutoff flaps (→ Page 117).
SS Security Shut‐ Safety system has caused emergency Determine cause for shutoff and recti‐
down stop fy.
SS T-Coolant (ECU) Safety system has determined that the Reduce power.
coolant temperature is too high
SS T-Coolant (EMU) Safety system has determined that the Reduce power.
engine coolant temperature is too high
SS T-Lube Oil Safety system has determined that the Reduce power.
lube oil temperature is too high
TIM-ID: 0000008900 - 002
Stop Activated (EMU) EMU has triggered automatic stop 1. Determine cause for shutoff and
command due to limit value violation rectify
2. Observe further alarms / indica‐
tions on display.

TD P-Lube Oil Different measurement values trans‐ 1. Check LOP visually (→ Page 157);
mitted by the two sensors for lube oil 2. Perform LOP test procedures
pressure (→ Page 160);
(→ Page 153);
5. Contact Service.
• Have sensors checked and re‐
TD T-Coolant The two coolant temperature sensors 1. Check LOP visually (→ Page 157);
provide different values 2. Perform LOP test procedures
(→ Page 160);
(→ Page 153);
5. Contact Service.
• Have sensors checked and re‐
Cylinder cutout Measuring point "Cylinder cutout ac‐ Status report for "cylinder cutout/num‐
tive" ber of cylinders halved" during idling
TIM-ID: 0000008900 - 002

7 Task Description
7.1 Engine
7.1.1 Engine – Barring manually
Preconditions

Barring device F6555766 1
Ratchet with extension F30006212 1
DANGER
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.
2. Engage barring device (2) with ring gear (3)
and install on flywheel housing.
3. Place ratchet (1) onto barring device (2).
4. Rotate crankshaft in engine direction of ro‐
tation. Apart from the normal compression
resistance, there should be no further re‐
sistance.
5. For barring device removal, follow reverse
sequence of working steps.
TIM-ID: 0000000917 - 007
80 | Task Description | MS15021/01E 2012-02

7.1.2 Engine cranking on starter

Connector pliers 0135315483 1
DANGER
• before barring or starting the engine, ensure that nobody is in the danger zone.
• After working on the engine, check that all protective devices have been reinstalled and all tools
removed from the engine.
Engine cranking on starter

1. Disengage the bayonet union nut (4) of
connector X4 with connector pliers (2) and
withdraw connector (3) from Engine Control
Unit.
2. Bar engine in unloaded condition: Press
START button.
3. Let the crankshaft rotate until oil pressure is
indicated.
4. Engine start is automatically interrupted
when max. admissible starting period has
expired. Re-start engine after approx. 20
seconds if necessary.
5. Plug connector X4 (3) and use connector
pliers (2) to secure the bayonet union
nut (4) by turning it clockwise until it latches
into place.
TIM-ID: 0000031172 - 005
MS15021/01E 2012-02 | Task Description | 81

7.2 Cylinder Liner
7.2.1 Cylinder liner – Endoscopic examination
Preconditions
☑ Engine is stopped and starting disabled

Rigid endoscope Y20097353 1
Preparatory steps
1. Remove cylinder head cover (→ Page 95).
2. Remove injector (→ Page 98).
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‐
TIM-ID: 0000000015 - 013
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 84).
3. Depending on findings:
• do not take any action or
• carry out a further endoscopic examination as part of maintenance work or
• contact Service; cylinder liner must be replaced.

Final steps
1. Install injector (→ Page 98).
2. Install cylinder head cover (→ Page 95).
TIM-ID: 0000000015 - 013

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.
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.
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.
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.
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.

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.
TIM-ID: 0000000014 - 013

7.3 Crankcase Breather
7.3.1 Crankcase breather – Oil separator replacement, diaphragm check and
replacement
Preconditions
☑ Engine shut down and starting disabled.

Ratchet adapter F30027340 1
Engine oil
Filter element (→ Spare Parts Catalog)
Diaphragm (→ Spare Parts Catalog)
Gasket (→ Spare Parts Catalog)
WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Avoid contact with skin.
• Do not inhale oil vapor.
Replacing filter element on

crankcase breather (variant A)
1. Release clamps (1).
2. Slide rubber sleeve (2) over pipe (3).
3. Release band clamp (4) with lever (6).
4. Remove cover (7).
5. Replace filter element (5).
6. Fit cover (7).
7. Tension band clamp (4) with lever (6).
8. Replace further oil filter elements in the
same way.
TIM-ID: 0000003534 - 004

Crankcase breather – replacing
filter element (variant B)
1. Remove cover (2) with O-ring (3).
2. Remove filter element (1) from housing (4).
3. Insert new filter element in housing (4).
4. Install cover (2) with new O-ring.
5. Use torque wrench to tighten the screws of cover (2) to the specified torque.
Screw Tightening torque (Engine oil) 6 Nm +2 Nm
6. Replace further oil separator elements in the same way.
Checking diaphragm (variant B)

1. Remove cover (4).
2. Remove spring (5), gasket (2) and dia‐
phragm (3).
3. Check diaphragm (3) for damage, fit new
diaphragm if used one is damaged.
4. Install diaphragm (3) on housing (1).
5. Install new gasket (2) and spring (5) togeth‐
er with cover (4).
6. Use torque wrench to tighten the screws of cover (4) to the specified torque.
Screw Tightening torque (Engine oil) 6 Nm +2 Nm
TIM-ID: 0000003534 - 004
7. Check diaphragms in further oil separators in the same way.

7.3.2 Crankcase breather – oil separator replacement
Preconditions

Ethanol, denatured
Oil separator (→ Spare Parts Catalog)
Crankcase breather – oil separator

replacement
1. Loosen clamps (1), push rubber sleeves (2)
over tubes (3).
2. Remove screws (4), take off oil separator,
clamps (7), washers (5) and spacer sleeves
(6).
3. Loosen clamp (8), remove guide sleeve (9)
from oil separator by turning it.
4. Coat O-ring in the new oil separator with

denatured ethanol.
5. Press guide sleeve into new oil separator to
stop, tighten clamp.
6. Insert guide sleeve into rubber sleeve.
7. Mount oil separator, clamp, washer, spacer
sleeve and hex screw on holder, tighten on‐
ly lightly.
8. Align oil separator, push remaining rubber
sleeves over the respective union and tight‐
en all clamps.
9. Replace further oil separators in the same
way.
TIM-ID: 0000003495 - 001

7.4 Valve Drive
7.4.1 Valve gear - Lubrication
Preconditions

Engine oil
Lubricating valve gear (valve

bridge with guide)
1. Remove cylinder head covers (→ Page 95).
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 95).
Lubricating valve gear (flying valve

bridge)
1. Remove cylinder head covers (→ Page 95).
2. Fill oil chambers of rocker arms and adjust‐
ing screws with oil.
3. Install cylinder head covers (→ Page 95).
TIM-ID: 0000004338 - 003

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

Feeler gauge Y20010128 1
Torque wrench 10-60 Nm F30510423 1
Torque wrench 60-320 Nm F30047446 1
Ring socket wrench F30039518 1
Preparatory steps
2. Install barring device (→ Page 80).
3. Rotate crankshaft with barring device in en‐
gine direction of rotation until "OT-A1" mark
and pointer are aligned.
TIM-ID: 0000004352 - 004

Checking valve bridge balance
Fig. Component
X Valve bridge with guide
Y Flying valve bridge
Note: Not applicable for engines with flying valve

bridge.
1. Prior to adjusting valve clearance, check
valve bridge balance on all valve bridges.
2. Use feeler gauge to determine distance be‐
tween valve bridge and rocker arm.
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3. Insert feeler gauge with determined value
between valve bridge and valve-stem end
(A).
4. At the opposite valve-stem end (B), a feeler
gauge thicker by 0.05 mm should not fit,
otherwise adjust valve bridge balance.
Adjusting valve bridge balance

Note: Not applicable for engines with flying valve
bridge.
1. Hold valve bridge (1) firmly in position with
open-end wrench and release locknut (2).
2. Use feeler gauge to determine distance be‐

tween valve bridge and rocker arm.
3. Place one feeler gauge (of the determined
value) each between valve bridge and the
two valve-stem ends (A) and (B).
4. Turn adjusting screw such that both feeler
gauges can just be pulled through.
5. Hold adjusting screw securely in position
with Allen key and fit locknut by hand on
valve bridge.
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6. Replace or rectify adjusting screws which

do not move freely.

7. Tighten locknut (2) to 35 Nm +5 Nm, hold‐
ing valve bridge (1) in position with open-
end wrench.
8. Recheck valve bridge balance.
Checking valve clearance at two crankshaft positions
Item Explanation
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1 Cylinder A1 is in firing TDC

2 Cylinder A1 is in overlap TDC
I Inlet valve
X Exhaust valve

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 with cold engine:
• Inlet valves (long rocker arm) = 0.2 mm
• Exhaust valves (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.
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.
Adjusting valve clearance

1. Release locknut (1).
2. Insert feeler gauge between valve bridge
and rocker arm.
3. Turn adjusting screw (2) with Allen key until
appropriate valve clearance is set.
4. Feeler gauge must just pass through the
gap.
5. Tighten locknut (1) to 90 +9 Nm, holding
adjusting screw (2) firmly.
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 80).
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7.4.3 Cylinder head cover – Removal and installation
Preconditions

Removing cylinder head cover

1. Clean cylinder head covers prior to removal
if they are heavily soiled.
2. Remove screws.
3. Remove cylinder head cover with gasket
from cylinder head.
Installing cylinder head cover

1. Clean mating face.
2. Check condition of gasket, replace if necessary.
3. Place gasket and cylinder head cover on cylinder head.
4. Install cylinder head cover.
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7.5 Injection Pump / HP Pump
7.5.1 HP pump – Relief bore check
DANGER
WARNING
HP pump – Relief bore check

1. Check relief bore for oil and fuel discharge
by visual inspection.
2. If relief bore is contaminated, stop the en‐
gine, disable engine start, and clean relief
bore.
3. Note the following in case of fluid dis‐
charge:
• Heavy discharge means continuous dis‐
charge of fluids (leakage). Contact Serv‐
ice.
• Minor discharge of fluids up to 10 drops
per day is normal (moistening) and not
considered a leakage.
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7.6 Injection Valve / Injector
7.6.1 Injector – Replacement

Injector (→ Spare Parts Catalog)
Replacing injector
u Remove injector and install new injector (→ Page 98).
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7.6.2 Injector – Removal and installation
Preconditions

Installation and removal device for injector F6790161 1
Milling cutter F30452739 1
Slotted nut screwdriver F30452578 1
Torque wrench, 0.5-5 Nm 0015384230 1
Assembly paste (Optimoly Paste White T) 40477 1
Grease (Kluthe Hakuform 30-10/Emulgier) X00058060 1
Engine oil
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Do not smoke.
CAUTION
Removal of all injectors.
• Ensure that the high-pressure fuel accumulator is secured on the engine through two HP lines.
CAUTION
Cable damage during operation.
Fire hazard!
• Twist cables when installing.
• Ensure that cables do not touch components.
Preparatory steps
1. Shut off fuel supply to engine.
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Removing injector
Note: Always replace the first and last injectors of
one engine side first. Replace the inner in‐
jectors only after the installation of the outer
injectors on this engine side is completed.
1. Undo cable terminal screws (arrow) on in‐
jector and remove cable terminals.
2. Remove screw (2) and take off hold-down

clamp (1).
3. Remove high-pressure fuel line (5).
4. Install installation/removal device on cylin‐

der head.
5. Remove injector with installation/removal
device.
6. Remove installation/removal device.
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7. Remove sealing ring (1) from injector or use
a self-made wire hook to remove it from the
cylinder head.
8. Remove O-rings (2) from injector.
9. Cover all connections and bores, or seal
with suitable plugs.
Installing injector
1. Remove all plugs before installing.
2. Coat nozzle retaining nut area of injector
with assembly paste.
3. Fit new O-rings on injector and coat with
grease.
4. Fit new sealing ring on injector with grease
ensuring correct installation position of seal‐
ing ring.
5. Clean sealing surface on cylinder head and

protective sleeve with milling cutter.
6. Insert injector into cylinder head ensuring
that the HP line connection is aligned cor‐
rectly.
7. Press in injector with installation/removal
device.
8. Remove installation/removal device.
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9. Use slotted screwdriver to check thrust ring
at both line ends for secure seating.
10. Tighten loose thrust ring to the specified tightening torque.

Thrust ring Tightening torque 5 Nm to 10 Nm
11. Coat screw head mating face (2) and
thread with engine oil.
12. Place hold-down clamp (1) in correct installation position. Tighten screw (2) with torque wrench to the
specified initial tightening torque.
Screw M12 Preload torque (Engine oil) 5 Nm to 10 Nm
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13. Fit O-rings (4) and (6) on high-pressure fuel line (5) and coat with grease.
14. Tighten high-pressure fuel line (5) to the specified initial tightening torque.
HP line Preload torque (Engine oil) 5 Nm to 10 Nm
15. Tighten screw (2) to specified torque using a torque wrench.
Screw M12 Tightening torque 100 Nm + 10 Nm

16. Tighten union nut of connecting piece (limiting valve) to specified torque using a torque wrench.
Union nut Tightening torque 140 Nm + 10 Nm
17. Tighten union nut of connecting piece (injector) to specified torque using a torque wrench.
Union nut Tightening torque 120 Nm +10 Nm
18. Twist cable several times.
19. Insert cable terminals (arrows) underneath screws on injector and tighten screws to specified torque us‐
ing a torque wrench.
Screw Tightening torque 1.5 Nm
Final steps
2. Open up fuel supply to engine.
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7.7 Fuel System
7.7.1 Fuel system – Venting and filling
Preconditions

Filling device B80144852 1
Diesel fuel
WARNING
• Do not smoke.
Venting and filling LP fuel system

1. Connect filling device to connection (2).
2. Open vent plugs (6) on filter (5).
3. Use hand pump to fill fuel system, providing
pressure of min. 0.5 bar / max. 2.0 bar, until
fuel emerges without bubbles at vent plugs
(6).
4. Close vent plugs (6).
5. Remove filling device and seal connection
(2).
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Venting and filling HP fuel system
1. Connect filling device to connection (3).
2. Remove flushing line (4) from HP pump (1).
3. Connect return hose of filling device to HP pump (1).
4. Unscrew vent line (8) from connection (7).
5. Seal connection (7) with sealing cone.
Note: During filling, the opening of the valves in the HP pump must be audible (whistling noise). To open the
valves, minimum pressure of 9 bar must be provided.
6. Fill fuel system with hand pump, providing 9 bar minimum pressure.
7. If no whistling sound is audible, pump must be operated faster.
8. Filling is completed if:
• Whistling noise is no more audible during pumping;
• Bubble-free fuel emerges from the return hose of the filling device.
9. Disconnect return hose from filling device at HP pump (1).
10. Connect flushing line (4) to HP pump.
11. Remove sealing cone from connection (7).
12. Connect vent line (8) at connection (7).
13. Remove filling device from connection (3) and seal.
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7.8 Fuel Filter
7.8.1 Fuel filter – Replacement
Preconditions

Oil filter wrench F30379104 1
Diesel fuel
Easy-change filter (→ Spare Parts Catalog)
Plastic ring (→ Spare Parts Catalog)
DANGER
WARNING
• Do not smoke.
WARNING
CAUTION
Damage to component.
Serious damage to plant!
• For filter replacement with the engine running, operate the engine at low engine load.
• The filter which is to be exchanged must be cut out for a brief period only.
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Replacing fuel filter with the engine
stopped
1. Cut out the filter to be replaced.
A Both filters cut in (operating position)
B Left filter cut out
C Right filter cut out
2. Unscrew cut-out easy-change filter with oil
filter wrench.
3. Clean sealing face on filter head.
4. Check sealing ring on new easy-change fil‐
ter and moisten with fuel.
5. Fit SOLAS shield (→ Page 21).
6. Screw on easy-change filter and tighten by
hand.
7. Set three-way cock to operating position for
both filters (normal position).
8. Replace other fuel filters in the same way.
9. Vent fuel system (→ Page 103).
Replacing fuel filter with the engine

running
1. Cut out the filter to be replaced.
2. Open threaded vent plugs at filter head of
cut-out filter and ensure that fuel filter is not
under pressure.
3. Close threaded vent plugs.
4. Unscrew cut-out easy-change filter with oil
filter wrench.
5. Clean sealing face on filter head.
6. Check sealing ring on new easy-change fil‐
ter and moisten with fuel.
8. Screw on easy-change filter and tighten by
hand.
9. Set three-way cock to operating position for
both filters (normal position).
10. Replace other fuel filters in the same way. TIM-ID: 0000004911 - 005

7.8.2 Fuel prefilter – Differential pressure gauge check and adjustment
DANGER
WARNING
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 109).
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7.8.3 Fuel prefilter – Draining
Preconditions

Diesel fuel
WARNING
• 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).
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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.

7.8.4 Fuel prefilter ‒ Flushing

Fuel
DANGER
WARNING
• Do not smoke.
WARNING
Fuel prefilter ‒ Flushing

1. Cut out clogged filter.
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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 65) and disable engine start.
2. Remove screws for cover and take off cover (2).
5. Fit cover with gasket and secure it with screws.
6. Check differential pressure (→ Page 107).
Result: If flushing did not lead to an improvement of the differential pressure, replace filter element of fuel prefil‐
ter (→ Page 111).
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7.8.5 Fuel prefilter – Filter element replacement
Preconditions

Diesel fuel
Filter element (→ Spare Parts Catalog)
WARNING
• Do not smoke.
Replacing filter element

1. Cut out filter to be drained.
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2. Open threaded vent plug (5) of contaminat‐
ed filter.
3. Unlock drain valve (6) by pressing toggle
and open it.
4. Drain water and dirt from filter.
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).
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 107).
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7.9 Charge-Air Cooling
7.9.1 Intercooler – checking condensate drain line for coolant discharge and
obstruction
DANGER
WARNING
WARNING
Compressed air
Risk of injury!
Intercooler - checking condensate

drain line for coolant discharge and
obstruction
1. With the engine running, verify that air
emerges from the condensate drain line at
driving end, left and right engine side. If no
air emerges:
2. Remove condensate drain line(s) and blow
out with compressed air.
3. Replace obstructed drain line(s) by new
one.
4. Install drain line(s).
5. If a large amount of coolant is continuously
discharged, the intercooler is leaking. Con‐
tact Service.
Emergency measures prior to engine start with a leaking intercooler

1. Remove injectors (→ Page 98).
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2. Bar engine manually (→ Page 80).

3. Bar engine with starting system to blow out combustion chambers (→ Page 81).
4. Install injectors (→ Page 98).

7.10 Air Filter
7.10.1 Air filter – Replacement

Air filter (→ Spare Parts Catalog)
Replacing the air filter

1. Remove old air filter and install new air filter (→ Page 115).
2. Reset signal ring of contamination indicator (→ Page 116).
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7.10.2 Air filter – Removal and installation
Preconditions
Air filter – Removal and installation

1. Release clamp (2).
2. Remove air filter (3) and clamp (2) from
flange of intake housing (1).
3. Verify that there are no objects in the flange
of the intake housing (1) and clean it.
4. Place new air filter (3) with clamp (2) onto
intake housing (1).
5. Tighten clamp (2).
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7.11 Air Intake
7.11.1 Contamination indicator – Signal ring position check
Preconditions
Checking signal ring position

1. If the signal ring is completely visible in the
control window (2), replace air filter
(→ Page 114).
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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7.11.2 Air flap – Check for ease of movement
Preconditions
Checking air flap for easy

movement
1. Actuate lever several times to check ease
of movement.
Result: The spring must push back the air flap.
2. If spring does not return air flap to initial po‐
sition, contact Service.
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7.12 Exhaust Flap with Actuator
7.12.1 Exhaust flap – Check for easy movement
Preconditions
Checking exhaust flap for easy

movement
1. Actuate control linkage several times by
hand to check for ease of movement.
2. Contact Service if the control linkage is
sluggish.
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7.13 Starting Equipment
7.13.1 Starter – Condition check
Preconditions
Starter – Condition check

1. Check securing screws of starter for secure seating and tighten if required.
2. Check wiring (→ Page 149).
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7.14 Lube Oil System, Lube Oil Circuit
7.14.1 Engine oil level – Check
Preconditions
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 121).
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 121).
5. Insert oil dipstick into guide tube up to the stop.
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7.14.2 Engine oil – Change
Preconditions
☑ Engine is at operating temperature.
☑ MTU fluids and lubricants specifications (A001061/..) are available.

Engine oil
Sealing ring (→ Spare Parts Catalog)
WARNING
Hot oil.
Version without semirotary hand pump: Drain the engine oil through the drain plug(s)
on the oil pan.
1. Provide a suitable container in which to collect the engine oil.
2. Remove drain plug(s) and drain engine oil.
3. Install drain plug(s) with new sealing ring.
Version with semirotary hand pump: Extracting the engine oil

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

equipment carrier (only with
unscheduled engine oil change)
1. Provide a suitable container in which to col‐
lect the engine oil.
2. Remove drain plug (1) and drain engine oil
from engine oil heat exchanger and from
TIM-ID: 0000000930 - 007
engine oil filter.

3. Remove drain plugs (2) and (3) and drain
engine oil.
4. Replace engine oil filter (→ Page 124).
5. Install drain plug(s) with new sealing ring.

6. Tighten drain plugs (2) and (3) with torque wrench to specified tightening torque.
Screw M26 x 1.5 Tightening torque (Engine oil) 100 Nm +10 Nm
Filling with new engine oil

1. Open cover on filler neck.
2. Pour engine oil through the filler neck up to
the "max." mark on the oil dipstick.
3. Close cover on filler neck.
4. Check engine oil level (→ Page 120).
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7.14.3 Engine oil – Sample extraction and analysis
Preconditions

MTU test kit 5605892099/00 1
DANGER
WARNING
Hot oil.
WARNING
Engine oil sample extraction and

analysis
1. With the engine running at operating tem‐
perature, open screw on flange of centrifu‐
gal oil filter by 1 to 2 rotations.
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, examine oil for:
• Dispersing capacity (spot test);
• Water content;
TIM-ID: 0000000956 - 003
• Fuel dilution.

7.15 Oil Filtration / Cooling
7.15.1 Engine oil filter - Replacement

Oil filter wrench F30379104 1
Engine oil
Oil filter (→ Spare Parts Catalog)
DANGER
WARNING
WARNING
Hot oil.
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.
Oil filter replacement with the

engine stopped
1. Stop engine (→ Page 65) and disable en‐
gine start.
2. Unscrew oil filter with oil filter wrench.
3. Clean sealing face on connecting piece.
4. Check condition of the new sealing ring and
TIM-ID: 0000006397 - 004
coat it with oil.

6. Screw on and tighten new engine oil filter
by hand.
7. Replace other oil filters in the same way.
8. After each oil change and filter replace‐
ment, bar engine with starting system
(→ Page 81).
9. Check oil level (→ Page 120).

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 po‐
sition)
• Position C: Upper filters cut out.
2. Unscrew oil filter with oil filter wrench.

3. Clean sealing face on connecting piece.
4. Check condition of the new sealing ring and
coat it with oil.
6. Screw on and tighten new engine oil filter
by hand.
7. Replace other oil filters in the same way.
8. Check oil level (→ Page 120).
TIM-ID: 0000006397 - 004

7.15.2 Centrifugal oil filter – Cleaning and filter sleeve replacement
Preconditions

Filter wrench F30379104 1
Cold cleaner (Hakutex 60) 50602 1
Grease (Kluthe Hakuform 30-10/emulsifier) X00029933 1
Filter sleeve (→ Spare Parts Catalog)
WARNING
Hot oil.
WARNING
Compressed air
Risk of injury!
TIM-ID: 0000000958 - 003

Cleaning centrifugal oil filter and
replacing filter sleeve
1. Undo screw (1) and remove.
2. Remove clamp (3) and take off hood (2).
3. Carefully remove rotor (5) from housing.
4. Hold rotor assembly (5) firmly in position
with filter wrench and undo knurled nut (7).
5. Take off rotor cap (8).
6. Remove filter sleeve (9), stiffener plate (10)
and sealing ring (11).
7. Measure thickness of oil residues on filter
sleeve.
8. If maximum layer thickness of oil residues
exceeds 30 mm, shorten maintenance in‐
terval.
9. Remove standpipe (12) from lower rotor
section (13).
10. Wash hood (2), rotor cap (8), stiffener
plate, (10) standpipe (12), rotor lower sec‐
tion (13) and nozzles (14) with cold cleaner
and blow out with compressed air. Do not
use sharp objects for cleaning.
11. Check nozzles (14) for obstructions.
12. Press standpipe (12) onto rotor lower sec‐
tion (13).
13. Insert new filter sleeve (9) with stiffener
plate (10) into rotor cap (8), ensuring that
smooth surface of filter sleeve (9) faces ro‐
tor cap (8).
14. Check sealing ring (11), replace if necessa‐
ry. Coat sealing ring with grease and insert
in groove of rotor cap (8).
15. Place rotor cap (8) onto standpipe (12).
16. Hold rotor assembly (5) firmly in position
with filter wrench and tighten knurled
nut (7).
17. Lubricate bearings of rotor (5) with oil, in‐
sert into housing (6) and check for ease of
movement.
18. Check sealing ring (4), replace if necessary.
Fit sealing ring on housing (6).
19. Fit hood (2).
20. Tighten screw (1) by hand.
21. Install clamp (3) and tighten to specified torque using a torque wrench.
TIM-ID: 0000000958 - 003
Clamp Tightening torque 6 Nm + 1 Nm

22. Tighten screw (1) to specified torque using a torque wrench.
Screw Tightening torque 6 Nm + 1 Nm

7.16 Coolant Circuit, General, High-Temperature Circuit
7.16.1 Venting points
Coolant lines on ETC

1 Venting point
Vent line – Cross-distributionn expansion tank

1 Venting point
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7.16.2 Engine coolant – Level check
Preconditions
WARNING
Coolant is hot and under pressure.
• Let the engine cool down.
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 coolant level (coolant must be visible at the lower edge of the cast-in eye).
Checking engine coolant level at

remote cooler:
1. Check coolant level (coolant must be visible
at marking plate).
2. Top up coolant if necessary (→ Page 132).
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 coolant if necessary (→ Page 132).
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7.16.3 Engine coolant – Change

Engine coolant
Changing engine coolant

1. Drain engine coolant (→ Page 131).
2. Fill with engine coolant (→ Page 132).
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7.16.4 Engine coolant – Draining
Preconditions
WARNING
Preparatory steps
1. Provide a suitable receptacle to catch the coolant.
2. Switch off preheating unit.
Draining engine coolant

1. Turn breather valve on coolant expansion
tank counterclockwise to first stop and allow
pressure to escape.
2. Continue to turn breather valve counter‐
clockwise and remove.
3. Draw off separated corrosion inhibitor oil in
expansion tank through the filler neck.
4. Open drain valves and/or drain plugs and
drain coolant at the following points:
• At the preheating unit;
• HT coolant pump elbow;
• On crankcase, left and right side.
5. Additional drain points on 12/16V 4000 M

engines:
• T adapter (3) on engine driving end;
• Intercooler (2), left and right side;
• Carrier-housing cover (1), left and right
side.
6. Close all open drain points.
close.
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7.16.5 Engine coolant – Filling
Preconditions

Engine coolant
WARNING
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
pressure to escape.
3. Release the coolant line union on both tur‐
bochargers (→ Page 128).
4. Release the coolant line union at the cool‐
ant distributor (→ Page 128).
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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 128).
5. Fill expansion tank until overflow edge is
reached.
6. Check proper condition of breather valve
and clean sealing faces if required.
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 128).
11. After the engine has run at idling speed for
10 seconds, stop engine (→ Page 65).
12. Turn breather valve of coolant expansion
pressure to escape.
14. Check coolant level (→ Page 129) 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 9) until coolant no longer needs
to be topped up.
d) Disconnect pump and hose.

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 128).
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 128).
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.
8. After the engine has run at idling speed for 10 seconds, stop engine (→ Page 65).
9. Turn breather valve counterclockwise and remove.
10. Check coolant level (→ Page 129) 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.
TIM-ID: 0000006727 - 004

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

check
1. Check relief bore for oil and coolant dis‐
charge.
gine start, observe general safety instruc‐
tions for 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.
TIM-ID: 0000000961 - 008

7.16.7 Engine coolant – Sample extraction and analysis
Preconditions

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

and analysis
1. With the engine running, open drain valve
(1).
2. Flush sample-extraction point by draining
approx. 1 liter coolant.
3. Drain approx. 1 liter coolant into a clean
container.
5. Using the equipment and chemicals of the
MTU test kit, check the coolant for:
• Antifreeze concentration
• Corrosion inhibitor concentration
• pH value.
6. For engine coolant change intervals, refer
to (→ MTU Fluids and Lubricants Specifica‐
TIM-ID: 0000000938 - 006
tions).

7.17 Raw Water Pump with Connections
7.17.1 Raw water pump – Relief bore check
DANGER
WARNING
Checking relief bore on raw water

pump
1. Check relief bore for oil and raw water dis‐
charge.
gine start, observe general safety instruc‐
tions for 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.
Contact Service.
TIM-ID: 0000007282 - 004

7.18 Battery-Charging Generator
7.18.1 Battery-charging generator drive – Coupling condition check
Preconditions
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.
TIM-ID: 0000007390 - 006

7.19 Engine Mounting / Support
7.19.1 Engine mounts – Checking securing screws for firm seating
Preconditions
Engine mounts – Checking securing screws for firm seating

1. Check securing screws for firm seating.
2. Tighten loose threaded connections.
TIM-ID: 0000007548 - 007

7.19.2 Engine mounts – Resilient element check
Preconditions
☑ Engine is filled with coolant and engine oil.

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.
TIM-ID: 0000007556 - 004

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.
Nut M27 x 2 Tightening torque (Engine oil) 580 Nm +50 Nm
5. Fit protective cap (2).
TIM-ID: 0000007556 - 004

7.20 Auxiliary PTO
7.20.1 Bilge pump – Relief bore check
DANGER
WARNING
Bilge pump – Relief bore check

1. Check relief bores for oil and water dis‐
charge.
gine start.
3. Clean the relief bores with a wire if dirty.
• Permissible water discharge: Up to 10
drops per hour.
• Permissible oil discharge: Up to 5 drops
per hour.
Contact Service.
TIM-ID: 0000007771 - 003

7.21 Fuel Supply System
7.21.1 Water drain valve – Check
Checking water drain valve

1. Open water drain valve.
2. Check water outlet for obstructions.
3. Close water drain valve.
TIM-ID: 0000007733 - 006

7.21.2 Differential pressure gauge – Check
WARNING
• Do not smoke.
Checking differential pressure gauge

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.
TIM-ID: 0000007737 - 005

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

1. Disconnect plug from water level probe.
2. Unscrew water level probe.
4. Immerse water level probe into a tank filled with water until water level reaches the thread.
Result: Water drain valve opens.
5. Leave water level probe in tank.
Result: Alarm must be triggered with the preset delay.
7. Remove water level probe from tank.
8. Screw in water level probe.
9. Connect plug for water level probe.
10. Put the fuel treatment system into operation.
TIM-ID: 0000007739 - 006

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

1. Install suitable pressure gauge at the neck of the intake side of the pump.
2. Check pump pressure.
a) Switch on fuel treatment system (→ Page 63).
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 it.
3. Check pump pressure with reduced suction.
a) Reduce suction pressure of pump to -0.8 bar with the shutoff valve at the pump intake side.
b) Check pressure at the pressure gauge in the inlet to the fuel treatment system and note it.
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).
TIM-ID: 0000007740 - 007

7.21.5 Coalescer filter element – Replacement
Preconditions
☑ System is switched off and starting disabled.

Diesel fuel
Engine oil
Coalescer filter element (→ Spare Parts Catalog)
WARNING
• Do not smoke.
CAUTION
Contamination of components.
• Observe manufacturer's instructions.
• Check components for special cleanness.
CAUTION
Incorrect installation of components and lines.
• Ensure that components/lines are installed so that they are never under tension or strain.
• Ensure correct installation position of components.
Replacing coalescer filter element

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).
8. Remove nut (3), washer (8) and end
TIM-ID: 0000007735 - 006
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).

16. Tighten nut (3) to specified tightening torque using a torque wrench.
Nut M16 Tightening torque (Engine oil) 30 Nm +3 Nm
17. Fit gasket (10).
18. Install cover.
19. Install screw (1), washer (2) and nut (9).
20. Tighten nut (9).
21. Open ball valve at the inlet and outlet of the fuel treatment system.
Result: The fuel treatment system is ready for operation.
TIM-ID: 0000007735 - 006

7.22 Wiring (General) for Engine/Gearbox/Unit
7.22.1 Engine wiring – Check
Preconditions

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.
TIM-ID: 0000000029 - 018

7.23 Accessories for (Electronic) Engine Governor / Control
System
7.23.1 Engine governor and connectors – Cleaning
Preconditions

Cleaning engine governor and

connectors
1. Remove heavy soiling from housing surface
with isopropyl alcohol.
2. Remove dirt from surface of connectors (1),
connector sockets and shrink-formed com‐
ponents (2) using a cloth moistened with
isopropyl alcohol.
3. Check legibility of cable labels. Clean or re‐
place illegible labels.
Cleaning heavily soiled connectors

on engine governor
1. Use connector pliers (2) to disengage bayo‐
net union nut (4) and withdraw connector
(3).
2. Clean connector housings, connector sock‐
et housings (1) and all contacts with iso‐
propyl alcohol.
3. When connectors, sockets and all contacts
TIM-ID: 0000000948 - 009
are dry: Fit connectors and check engine

governor plug connections (→ Page 153).

7.23.2 Engine monitoring unit and connectors – Cleaning
Preconditions

Engine monitoring unit and

connectors – Cleaning
1. Remove coarse dirt from housing surface
with isopropyl alcohol.
2. Remove dirt from surface of connectors (1),
connector sockets and shrink sleeves (2)
using a cloth moistened with isopropyl alco‐
hol.
3. Check legibility of cable labels. Clean or re‐
place illegible labels.
Cleaning severely contaminated

EMU connectors
1. Use connector pliers (2) to disengage bayo‐
net union nut (4) and withdraw connector
(3).
2. Clean connector housings, connector sock‐
et housings (1) and all contacts with iso‐
propyl alcohol.
3. When connectors, sockets and all contacts
are dry: Fit connectors and check plug con‐
nections on EMU (→ Page 154).
TIM-ID: 0000008391 - 006

7.23.3 Start interlock limit switch – Check
Preconditions
Note: Being in OFF-position, the limit switch initiates start interlock, i.e. the engine cannot be started.
Start interlock limit switch – Check
1. Check if switch housing (1) and cover plate
(3) are mounted and the switch (2) is in ON-
position.
2. If switch housing (1) and/or cover plate (3)
is/are not mounted:
• Secure cover plate (3) with screws.
• Then install switch housing (1) with
screws, ensuring that the switch (2) is
actuated by the cover plate (3).
3. If switch housing (1) and cover plate (3) are
mounted, but switch (2) is in OFF-position:
• Make certain that the cover plate (3) at
the side of the switch (2) is not distorted.
• Loosen switch housing (1) and fit it with
screws in a position providing that the
switch (2) is ON.
• If this is not feasible, contact Service.
TIM-ID: 0000008444 - 004

7.23.4 Checking engine control unit plug connections
Preconditions

Checking engine control unit plug

connections
1. Use connector pliers (3) to make certain
that all plug-in connections on engine con‐
trol unit are securely seated.
2. Tighten loose bayonet couplings (2) with
connector pliers (3) by turning them clock‐
wise until they latch into place.
3. Make sure that unassigned sockets are
closed off with cover caps.
4. Contact Service if bayonet union nut is de‐
fective.
TIM-ID: 0000000949 - 003

7.23.5 Engine monitoring unit – Plug connection check
Preconditions

Checking engine monitoring unit

plug connections
1. Use connector pliers (3) to make certain
that all engine monitoring unit plug connec‐
tions are securely seated.
2. Tighten loose bayonet union nuts (2) with
connector pliers (3) by turning them clock‐
wise until they lock into place.
3. Make sure that unassigned sockets are
closed off with cover caps.
4. If bayonet couplings are defective, contact
Service.
TIM-ID: 0000008394 - 003

7.23.6 Engine control unit – Removal and installation
Preconditions

Covering caps for Cannon sockets
Removing control unit from engine

1. Note or mark assignment of cables to con‐
nector sockets.
2. Use connector pliers (2) to disengage the
bayonet union nuts (4) of the connectors (3)
by turning them counterclockwise.
3. Remove all connectors.
4. Close connector sockets with appropriate
covering caps (1).
TIM-ID: 0000008487 - 004

5. Disconnect ground strap from engine con‐
trol unit grounding stud (7).
6. If the screws (4) are easily accessible:
1. Remove screws (4).
2. Remove engine control unit housing (3)
from mounting plates (2).
3. Unscrew mounting plates (2), cable
shock absorbers (5) and further fasten‐
ing parts (6) as one unit from engine.
7. If the screws (4) are not easily accessible:
1. Unscrew screws (1).
2. Remove engine control unit housing (3)
together with mounting plates (2).
3. Unscrew cable shock absorbers (5) and
further fastening parts (6) as one unit
from engine.
Installing engine control unit on engine

1. Install in reverse order. Ensure correct assignment of plugs and sockets.
2. Use connector pliers to turn the bayonet union nuts of the connectors clockwise until they lock into place.
TIM-ID: 0000008487 - 004

7.24 Emergency Instrumentation (Local Operating Panel)
7.24.1 LOP – Visual inspection
Preconditions
Preparatory steps
1. If READY FOR OPERATION button is illuminated brightly, press switch briefly.
Result: READY FOR OPERATION button returns to basic brightness.
2. Switch master power switch to OFF.
3. Disconnect battery in accordance with battery manufacturer's instructions.
Checking housing and internal

assemblies for secure seating
1. Open LOP front door.
2. Check securing screws (1, 3, 4, 7) for firm
seating. Tighten loose threaded connec‐
tions.
3. Check internal assemblies for firm seating,
this applies in particular to printed circuit
board (2) and PIMs (5, 6). Tighten loose
threaded connections.
4. Close LOP front door.
TIM-ID: 0000031189 - 002

Checking plug connections
1. Check all connected cables to verify that
the two securing elements (1) are engaged
on the lugs (2) so that the respective male
connector (3) is held firmly in place in the
socket.
2. If this is not the case, press the securing el‐
ements (1) concerned in the direction of the
arrow until they engage noticeably.
Checking unassigned connector

sockets
1. Ensure that non-assigned connector sock‐
ets are protected with covering caps.
2. Make certain that the two securing ele‐
ments (1) are engaged in the lugs (2) so
that the covering cap (3) is held firmly in
place in the socket.
3. If this is not the case, press the securing el‐
ements (1) concerned in the direction of the
arrow until they engage noticeably.
Checking buttons and display

1. Buttons: Ensure that
• Button caps are not damaged (cracks or
similar damage)
• Buttons move easily;
• Button housings are seated securely;
• Seals (2) between PAN control panels
and LOP housing are not damaged.
TIM-ID: 0000031189 - 002
2. Display: Ensure that

• Front glass is not damaged or pressed
in;
• Seal (1) between display housing and
LOP housing is not damaged.
3. Have damaged components replaced im‐
mediately by Service.

Performing lamp test
1. Connect battery in accordance with battery
manufacturer's instructions.
2. Switch master power switch to ON.
3. Switch on Engine Control System.
4. Keep LAMP TEST button pressed:
Result: Indicators and controls light up.
5. Have damaged lamps immediately replaced
by Service.
TIM-ID: 0000031189 - 002

7.24.2 LOP – Test procedures
Preconditions
Preparatory steps
1. Connect battery in accordance with battery
manufacturer's instructions.
2. Switch master power switch to ON.
3. Switch on engine management system
ECS-5.
Result: • LOCAL OPERATION pushbutton (1) is il‐
luminated brightly (local control mode is
active);.
Switching between Local and Remote mode (automatic on-board network)

1. Press LOCAL OPERATION pushbutton (1).
Result: • LOCAL OPERATION pushbutton (1) flashes: Setting does not correspond with feedback signal from
Engine Control Unit.
• LOCAL OPERATION pushbutton (1) is illuminated at basic brightness: Remote mode active.
2. Press LOCAL OPERATION pushbutton (1) again.
Result: LOCAL OPERATION pushbutton (1) is illuminated brightly (Local mode is active);.
TIM-ID: 0000008872 - 004

Overspeed test with the engine at
standstill
Note: Overspeed test with the engine at standstill
can only be carried out if the engine is
equipped with Engine Monitoring Unit.
1. Press OVERSPEED TEST illuminated
pushbutton (3). Observe speed limit and
speed simulated by Engine Monitoring Unit
on display.
Result: • Engine Control Unit is de-energized by
the safety system.
• Engine governing is completely deacti‐
vated.
• On engines with emergency air-shutoff
flaps: Flaps close.
• EMERGENCY STOP illuminated push‐
button (2) flashes;. Alarm signalling by
horn, flashing light etc. is initiated.
ALARM ACKNOWLEDGE pushbutton
(1) is illuminated brightly.
2. Press ALARM ACKNOWLEDGE pushbut‐
ton (1).
Result: Audible and visual alarm signaling stops.
ton (1) again.
Result: Power supply to Engine Control Unit is pro‐
vided.
4. On engines with emergency air-shutoff
flaps: Open flaps.
Emergency stop simulation with the

engine at standstill
1. Open cap of EMERGENCY STOP pushbut‐
ton (2).
2. Press EMERGENCY STOP pushbutton (2).
Result: • Engine Control Unit is deenergized by
the safety system.
• Engine governing is completely deacti‐
vated.
• On engines with emergency air-shutoff
flaps: Flaps close.
• EMERGENCY STOP pushbutton (2)
flashes;. Alarm signalling by horn, flash‐
ing light etc. is initiated. ALARM AC‐
KNOWLEDGE pushbutton (1) is illumi‐
TIM-ID: 0000008872 - 004
nated brightly.
ton (1).
Result: Audible and visual alarm signaling stops.
ton (1) again.
Result: Power supply to Engine Control Unit is pro‐
vided.
5. On engines with emergency air-shutoff
flaps: Open flaps.

8 Appendix A
8.1 Abbreviations
Abbrevia‐ Meaning Explanation

tion
AL Alarm Alarm (general)
ANSI American National Standards Institute Association of American standardization organiza‐
tions
ATL Abgasturbolader Exhaust turbocharger (ETC)
BR Baureihe Series
BV Betriebsstoffvorschrift MTU Fluids and Lubricants Specifications, Publica‐
tion No. A01061/..
CAN Controller Area Network Data bus system, bus standard
DIN Deutsches Institut für Normung e. V. At the same time identifier of German standards
(DIN = “Deutsche Industrie-Norm”)
DIS Display Unit
DL Default Lost Alarm: Default CAN bus failure
ECS Engine Control System
ECU Engine Control Unit Engine governor
EDM Engine Data Module Memory module for engine data
EMU Engine Monitoring Unit
ETK Ersatzteilkatalog Spare Parts Catalog (SPC)
HI High Alarm: Measured value exceeds 1st maximum limit
HIHI High High Alarm: Measured value exceeds 2nd maximum lim‐
it value
HT High Temperature
ICFN ISO – Continuous rating – Fuel stop Power specification in accordance with DIN-ISO
power – Net 3046-7
IDM Interface Data Module Memory module for interface data
IMO International Maritime Organization
ISO International Organization for Stand‐ International umbrella organization for all national
ardization standardization institutes
KGS Kraftgegenseite Engine free end in accordance with DIN ISO 1204
KS Kraftseite Engine driving end in accordance with DIN ISO
TIM-ID: 0000002048 - 003
1204
LCD Liquid Crystal Display, Liquid Crystal
Device
LCU Local Control Unit LOP subassembly
LED Light Emitting Diode
LMU Local Monitoring Unit LOP subassembly
LO Low Alarm: Measured value lower than 1st minimum
limit value
162 | Appendix A | MS15021/01E 2012-02

Abbrevia‐ Meaning Explanation
tion
LOLO Low Low Alarm: Measured value lower than 2nd minimum
limit value
LOP Local Operating Panel Control console, control panel
LOS Local Operating Station
MCS Monitoring and Control System
MCU Management Computer Unit Computer for control stand, 19"/9.5" unit size
MG Message
MPU Microprocessor Unit, Microprocessing
Unit
OT Oberer Totpunkt Top Dead Center (TDC)
P-xyz Pressure-xyz Pressure measuring point xyz
PAN Panel Control panel
PIM Peripheral Interface Module
RL Redundancy Lost Alarm: Redundant CAN bus failure
SAE Society of Automotive Engineers U.S. standardization organization
SD Sensor Defect Alarm: Sensor failure
SDAF Shut Down Air Flaps
SS Safety System Safety system alarm
SSK Schnellschlussklappe(n) German designation for shutdown air flaps
T-xyz Temperature-xyz Temperature measuring point xyz
TD Transmitter Deviation Alarm: Deviation in transmitter values
UT Unterer Totpunkt Bottom Dead Center (BDC)
WZK Werkzeugkatalog Tool Catalog (TC)
TIM-ID: 0000002048 - 003
MS15021/01E 2012-02 | Appendix A | 163

8.2 MTU contacts/service partners
Service
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:Service-support@mtu-online.com
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 depot at Headquarters, as well as decentralized depots among our subsidiaries, representa‐
tives and contractual workshops.
Your contact at Headquarters:
E-mail: spare.parts@mtu-online.com
Phone: +49 7541 908555
Fax: +49 7541 908121
TIM-ID: 0000000873 - 012
164 | Appendix A | MS15021/01E 2012-02

9 Appendix B
9.1 Special Tools
Barring device
Part No.: F6555766
Qty.: 1
Used in: 7.1.1 Engine – Barring manually (→ Page 80)
Box wrench
Part No.: F30379609
Qty.: 1
Used in: 7.19.2 Engine mounts – Resilient element check (→ Page 140)
Calipers
Part No.: Y20001743
Qty.: 1
Connector pliers
Part No.: 0135315483
Qty.: 1
Used in: 7.1.2 Engine cranking on starter (→ Page 81)
Qty.: 1
Used in: 7.23.1 Engine governor and connectors – Cleaning (→ Page 150)
Qty.: 1
Used in: 7.23.2 Engine monitoring unit and connectors – Cleaning (→ Page 151)
Qty.: 1
Used in: 7.23.4 Checking engine control unit plug connections (→ Page 153)
Qty.: 1
Used in: 7.23.5 Engine monitoring unit – Plug connection check (→ Page 154)
Qty.: 1
Used in: 7.23.6 Engine control unit – Removal and installation (→ Page 155)
Feeler gauge
Part No.: Y20010128
Qty.: 1
DCL-ID: 0000015771 - 001
Used in: 7.4.2 Valve clearance – Check and adjustment (→ Page 90)
Qty.: 1
Filling device
Part No.: B80144852
Qty.: 1
Used in: 7.7.1 Fuel system – Venting and filling (→ Page 103)
MS15021/01E 2012-02 | Appendix B | 165

Filter wrench
Part No.: F30379104
Qty.: 1
Used in: 7.15.2 Centrifugal oil filter – Cleaning and filter sleeve replacement (→ Page 126)
Installation and removal device for injector

Part No.: F6790161
Qty.: 1
Used in: 7.6.2 Injector – Removal and installation (→ Page 98)
Milling cutter
Part No.: F30452739
Qty.: 1
MTU test kit

Part No.: 5605892099/00
Qty.: 1
Used in: 7.14.3 Engine oil – Sample extraction and analysis (→ Page 123)
Qty.: 1
Used in: 7.16.7 Engine coolant – Sample extraction and analysis (→ Page 136)
Oil filter wrench

Part No.: F30379104
Qty.: 1
Used in: 7.8.1 Fuel filter – Replacement (→ Page 105)
Qty.: 1
Used in: 7.15.1 Engine oil filter - Replacement (→ Page 124)
Ratchet adapter
Part No.: F30027340
Qty.: 1
Used in: 7.3.1 Crankcase breather – Oil separator replacement, diaphragm check and replace‐
ment (→ Page 86)
Ratchet adapter
Part No.: F30027341
Qty.: 1
DCL-ID: 0000015771 - 001
Used in: 7.14.2 Engine oil – Change (→ Page 121)
Ratchet adapter
Part No.: F30027339
Qty.: 1
Qty.: 1
Used in: 7.21.5 Coalescer filter element – Replacement (→ Page 147)
166 | Appendix B | MS15021/01E 2012-02

Ratchet with extension
Part No.: F30006212
Qty.: 1
Used in: 7.1.1 Engine – Barring manually (→ Page 80)
Rigid endoscope
Part No.: Y20097353
Qty.: 1
Used in: 7.2.1 Cylinder liner – Endoscopic examination (→ Page 82)
Ring socket wrench

Part No.: F30039518
Qty.: 1
Slotted nut screwdriver

Part No.: F30452578
Qty.: 1
Steam jet cleaner

Part No.: -
Qty.: 1
Used in: 4.14 Plant – Cleaning (→ Page 69)
Torque wrench 10-60 Nm

Part No.: F30510423
Qty.: 1
Torque wrench 60-320 Nm

Part No.: F30047446
Qty.: 1
Torque wrench, 0.5-5 Nm

Part No.: 0015384230
Qty.: 1
DCL-ID: 0000015771 - 001
Torque wrench, 10-60 Nm

Part No.: F30510423
Qty.: 1
Used in: 1.4 Crankshaft transport locking device (→ Page 8)
Qty.: 1
MS15021/01E 2012-02 | Appendix B | 167

Part No.: F30027337
Qty.: 1
Used in: 7.14.2 Engine oil – Change (→ Page 121)

Part No.: F30027336
Qty.: 1
Used in: 7.21.5 Coalescer filter element – Replacement (→ Page 147)

Part No.: F30027336
Qty.: 1
Used in: 7.3.1 Crankcase breather – Oil separator replacement, diaphragm check and replace‐
ment (→ Page 86)
Qty.: 1

Part No.: F30047446
Qty.: 1
Used in: 1.4 Crankshaft transport locking device (→ Page 8)
Qty.: 1
DCL-ID: 0000015771 - 001
168 | Appendix B | MS15021/01E 2012-02

9.2 Index
8 V 4000 M40A engine data 34, 37, 40 E
8 V 4000 M40B engine data 43, 46, 49 Emergency stop from LOP 66
Engine
A
– Barring manually 80
Abbreviations 162 – Cranking on starter 81
Actuators – Main dimensions 53
– Overview 29 – Starting 62
After stopping the engine 67 – Stopping at the LOP 65
Air filter – Wiring check 149
– Installation 115 Engine control unit
– Removal 115 – Removal and installation 155
– Replacement 114 Engine coolant
Air flap – Change 130
– Check for ease of movement 117 – Draining 131
Auxiliary materials, fire prevention and environmental – Filling 132
protection 16 – Level check 129
– Sample extraction and analysis 136
B
Engine coolant pump
Battery-charging generator drive – Relief bore check 135
– Coupling condition check 138 Engine governor
Bilge pump – Cleaning 150
– Relief bore check 142 Engine monitoring unit
C – Cleaning 151
– Plug connection check 154
Centrifugal oil filter
Engine mounts
– Cleaning and filter sleeve replacement 126
– Resilient element check 140
Checks
Engine mounts
– Prior to start-up 59
– Checking securing screws for firm seating 139
Coalescer
Engine oil
– filter element
– Change 121
– Replacement 147
– Sample extraction and analysis 123
Coalescer filter element
Engine oil filter
– Replacement 147
– Replacement 124
Connectors
Engine oil level
– Cleaning 150, 151
– Check 120
Contact persons 164
Engine overview 28
Contamination indicator
Engine side and cylinder
– Signal ring position check 116
– Designation 20
Crankcase breather
Engine wiring
– Diaphragm check and replacement 86
– Check 149
– Oil separator replacement 86
Engine – Preparations for putting into operation
Crankcase breather – oil separator replacement 88
– After extended out-of-service periods (>3 months)
Crankshaft transport locking device
56
– Removal/installation 8
Exhaust flap
Cylinder head cover
– Check for easy movement 118
DCL-ID: 0000015771 - 001
– Removal and installation 95

Cylinder liner F
– Endoscopic examination 82 Firing order 52
– Instructions and comments on endoscopic and visual Fuel
examination 84 – prefilter
D – Flushing 109
– Treatment system
Differential pressure gauge
– Troubleshooting 71
– Check 144
– treatment system
– Shutdown 68
– Switching on 63
MS15021/01E 2012-02 | Appendix B | 169

Fuel filter Pump capacity
– Replacement 105 – Check 146
Fuel prefilter Putting into operation
– Differential pressure gauge – Fuel treatment system 60
– Check and adjustment 107 Putting the engine into operation
– Draining 108 – After scheduled out-of-service-period 57
– Filter element
– Replacement 111 R
– Flushing 109 Raw water pump
Fuel system – Venting and filling 103 – Relief bore check 137
Fuel treatment system Repair work
– Putting into operation 60 – Safety regulations 13
– Shutdown 68
– Switching on 63 S
Safety instructions 19
G Safety regulations 11, 13
General conditions 5 Sensors
– Overview 29
H Service partners 164
HP pump Start interlock limit switch
– Relief bore check 96 – Check 152
Starter
I – Condition check 119
Injector Startup
– Installation 98 – Safety regulations 11
– Removal 98
– Replacement 97 T
Injectors Tasks
– Overview 29 – After extended out-of-service periods 58
Inspection port cover Tasks after extended out-of-service periods (>3 weeks)
– Explosion hazard 12 58
Intercooler – checking condensate drain line for coolant Transportation 7
discharge and obstruction 113 Troubleshooting 72
– Fuel treatment system 71
L
LOP V
– Controls 54 Valve clearance
– Test procedures 160 – Adjustment 90
– Visual inspection 157 – Check 90
LOP fault messages 75 Valve gear
– Lubrication 89
M Venting points 128
Main dimensions
– Engine 53 W
Maintenance work Water drain valve
– Safety regulations 13 – Check 143
MTU contact persons 164 Water level probe (3-in-1 rod electrode)
– Check 145
DCL-ID: 0000015771 - 001
O Wiring - engine
Operation – Check 149
– Safety regulations 11
Operational checks 64
P
Personnel and organizational requirements 6
Plant
– Cleaning 69
Product description 21
170 | Appendix B | MS15021/01E 2012-02

Operating Instructions: Diesel Engine 8 V 4000 M40A 8 V 4000 M40B Application Group 3B

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Operating Instructions

7.4 Valve Drive 89

MS15021/01E 2012-02 | Table of Contents | 3

7.8 Fuel Filter 105 7.19 Engine Mounting / Support 139

7.9 Charge-Air Cooling 113 7.21 Fuel Supply System 143

7.16 Coolant Circuit, General, High-

7.16.6 Engine coolant pump – Relief bore check 135

4 | Table of Contents | MS15021/01E 2012-02

MS15021/01E 2012-02 | Safety | 5

Working clothes and protective equipment

TIM-ID: 0000000874 - 017

6 | Safety | MS15021/01E 2012-02

Only use the lifting eyes provided to lift the engine.

Setting down the engine following transportation

MS15021/01E 2012-02 | Safety | 7

Special tools, Material, Spare parts

Transport locking device

Removing guard plates and engine

8 | Safety | MS15021/01E 2012-02

Removing the transport locking

locking device together with this documen‐

MS15021/01E 2012-02 | Safety | 9

TIM-ID: 0000004010 - 008

10 | Safety | MS15021/01E 2012-02

Safety requirements for initial operation

Safety requirements for operators

Operation of electrical equipment

MS15021/01E 2012-02 | Safety | 11

TIM-ID: 0000022931 - 006

12 | Safety | MS15021/01E 2012-02

Safety regulations for maintenance and repair work

MS15021/01E 2012-02 | Safety | 13

Hydraulic installation and removal

Working on electrical/electronic assemblies

Working with laser equipment

14 | Safety | MS15021/01E 2012-02

MS15021/01E 2012-02 | Safety | 15

ized specialist company).

16 | Safety | MS15021/01E 2012-02

Acids and alkaline solutions

MS15021/01E 2012-02 | Safety | 17

TIM-ID: 0000002828 - 004

18 | Safety | MS15021/01E 2012-02

MS15021/01E 2012-02 | Safety | 19

1 KGS = Free end 3 KS = Driving end

20 | General Information | MS15021/01E 2012-02

Description of the engine

• Raw water pump, coolant pump

MS15021/01E 2012-02 | General Information | 21

Electronic Engine Monitoring Unit (EMU), optional

Electronic Gear Control Unit (GCU), ship-side wall mounting

Monitoring in engine room

TIM-ID: 0000002179 - 003

22 | General Information | MS15021/01E 2012-02

Fuel system, fuel lines with fuel pressure >1.8 bar

1 Return line 3 Non-return valve 5 Fuel line on HP fuel

MS15021/01E 2012-02 | General Information | 23