Operating Instructions

Diesel engine
12V4000Mx3x
16V4000Mx3x

MS15035/00E
Engine model kW/cyl. Application group
12V4000M53 115 kW/cyl. 1A, continuous operation, unrestricted
12V4000M53R 95 kW/cyl. 1A, continuous operation, unrestricted
12V4000M63 125 kW/cyl. 1A, continuous operation, unrestricted
16V4000M53 115 kW/cyl. 1A, continuous operation, unrestricted
16V4000M53R 95 kW/cyl. 1A, continuous operation, unrestricted
16V4000M63 125 kW/cyl. 1A, continuous operation, unrestricted
16V4000M63L 140 kW/cyl. 1A, Continuous operation, unrestricted
16V4000M63R 120 kW/cyl. 1A, continuous operation, unrestricted

Table 1: Applicability

© 2018 Copyright MTU Friedrichshafen GmbH

This publication is protected by copyright and may not be used in any way, whether in whole or in part, without the prior writ-
ten consent of MTU Friedrichshafen GmbH. This particularly applies to its reproduction, distribution, editing, translation, micro-
filming and storage or processing in electronic systems including databases and online services.
All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen GmbH
reserves the right to change, delete or supplement the information provided as and when required.
 Table of Contents
1 Safety 5.6 Stopping the engine 98
5.7 Operational checks 99
1.1 Important provisions for all products 6 5.8 Emission label – Check 100
1.2 Correct use of all products 8 5.9 Tasks after extended out-of-service periods
1.3 Personnel and organizational requirements 9 (>3 weeks) 101
1.4 Initial start-up and operation – Safety 5.10 Checks prior to start-up 102
regulations 10 5.11 Fuel treatment system – Initial start-up 103
1.5 Assembly, maintenance, and repair work – 5.12 Fuel treatment system – Switching on 106
Safety regulations 12 5.13 Fuel treatment system – Shutdown 107
1.6 Fire and environmental protection, fluids 5.14 Emergency engine stop 108
and lubricants 16 5.15 After shutdown 109
1.7 Standards for warning notices in the text 5.16 Plant – Cleaning 110
and highlighted information 18
6 Maintenance
2 Transport
6.1 Maintenance task reference table [QL1] for
2.1 Transport 19 EPA regions 111
2.2 Lifting requirements 20 6.2 Maintenance task reference table [QL1] for
2.3 Crankshaft transport locking device 24 Non EPA regions 113

3 General Information 7 Troubleshooting

3.1 Tightening specifications for screws, nuts 7.1 Troubleshooting 115
and bolts 27 7.2 Control cabinet of fuel treatment system –
3.2 Engine side and cylinder designations 40 Troubleshooting 118
3.3 Product description 41 7.3 Engine governor ADEC (ECU 7) fault
3.4 Engine – Overview 46 messages for Series 4000 engines, marine
3.5 Sensors, actuators and injectors on 12V application 119
engines – Overview 50 7.4 ADEC engine governor – Fault codes 120
3.6 Sensors, actuators and injectors on 16V
engines – Overview 60
8 Task Description
4 Technical Data 8.1 SOLAS 146
8.1.1 SOLAS shielding as per MTN 5233 –
4.1 Product data 12V4000M53 70 Installation 146
4.2 Product data 12V4000M63 75 8.1.2 SOLAS shielding – Installation 147
4.3 Product data 16V4000M53 80 8.1.3 Installation locations for SOLAS shielding 148
4.4 Product data 16V4000M63 85 8.1.4 Adhesive tape for SOLAS shielding –
4.5 Firing order 90 Application 157
4.6 Engine – Main dimensions 91 8.2 Engine 158
8.2.1 Engine – Barring manually 158
5 Operation 8.2.2 Barring engine with starting system 160
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5.1 Controls 93 8.3 Cylinder Liner 161

5.2 Putting the engine into operation after 8.3.1 Cylinder liner – Endoscopic examination 161
8.3.2 Cylinder liner – Instructions and comments on
extended out-of-service periods (>3 months) 94
endoscopic and visual examination 163
5.3 Putting the engine into operation after
scheduled out-of-service-period 95 8.4 Crankcase Breather 165
5.4 Starting the engine 96 8.4.1 Crankcase breather – Oil mist separator
5.5 Re-starting the engine following an replacement 165
automatic safety shutdown 97 8.5 Valve Drive 166

MS15035/00E 2018-08 | Table of Contents | 3

 8.5.1 Valve gear – Lubrication 166 8.17.2 Engine coolant – Change 226
8.5.2 Valve clearance – Check and adjustment 167 8.17.3 Engine coolant – Draining 227
8.5.3 Cylinder head cover – Removal and 8.17.4 Engine coolant – Filling 230
installation 170 8.17.5 HT coolant pump – Relief bore check 232
8.17.6 Engine coolant – Sample extraction and
8.6 Injection Pump / HP Pump 171 analysis 233
8.6.1 HP fuel pump – Filling with engine oil 171
8.17.7 Preheating unit 234
8.6.2 HP fuel pump – Relief bore check 173
8.17.8 Preheater – Overhaul 237
8.7 Injection Valve / Injector 174 8.17.9 Preheater – Function and leak-tightness check 238
8.7.1 Injector – Replacement 174
8.18 Raw Water Pump with Connections 239
8.7.2 Injector – Removal and installation (jacketed
8.18.1 Raw water pump – Relief bore check 239
fuel system) 175
8.19 Battery-Charging Generator 240
8.8 Fuel System 182 8.19.1 Battery-charging generator drive – Coupling
8.8.1 Fuel system – Venting 182
condition check 240
8.9 Fuel Filter 184 8.20 Auxiliary PTO 241
8.9.1 Additional fuel filter – Overview 184
8.20.1 Bilge pump – Relief bore check 241
8.9.2 Supplementary fuel filter – Replacement 185
8.9.3 Fuel filter – Replacement 187 8.21 Engine Mounting / Support 242
8.9.4 Fuel prefilter – Differential pressure gage 8.21.1 Engine mounting – Checking resilient element 242
check and adjustment 189
8.9.5 Fuel prefilter – Draining 190
8.22 Fuel Supply System 243
8.22.1 Water drain valve – Check 243
8.9.6 Fuel prefilter – Flushing 192
8.22.2 Differential pressure gage – Alarm function
8.9.7 Fuel prefilter with water separator – Filter
check 244
element replacement 194
8.22.3 Water level probe (3-in-1 rod electrode) –
8.9.8 Fuel prefilter with water separator – O-ring
Check 245
replacement in rotary slide valve 197
8.22.4 Pump capacity – Check 246
8.10 Exhaust Turbocharger 198 8.22.5 Coalescer filter element ‒ Replacement 247
8.10.1 Compressor wheel – Cleaning 198
8.23 Wiring (General) for Engine/Gearbox/Unit 249
8.11 Charge-Air Cooling 206 8.23.1 Engine wiring harness – Overview 249
8.11.1 Intercooler – Checking condensate drain for 8.23.2 Engine cabling – Check 257
water discharge and obstruction 206
8.24 Accessories for (Electronic) Engine
8.12 Air Filter 207 Governor / Control System 258
8.12.1 Air filter – Replacement 207 8.24.1 Limit switch for start interlock – Check 258
8.12.2 Air filter – Removal and installation 208 8.24.2 Engine Control Unit ECU 7 – Checking plug
connections 259
8.13 Air Intake 209
8.24.3 Engine Monitoring Unit EMU 7 – Plug
8.13.1 Contamination indicator – Signal ring position
connection check 260
check 209
8.24.4 Interface module EIM plug connections –
8.14 Starting Equipment 210 Check 261
8.14.1 Starter – Condition check 210 8.24.5 Engine governor ECU 7 – Removal and
installation 262
8.15 Lube Oil System, Lube Oil Circuit 211 8.24.6 EMU 7 – Removal and installation 263
8.15.1 Engine oil level – Check 211
8.24.7 Engine Interface Module EIM 2 – Diagnostic
8.15.2 Engine oil – Change 212
features 264
8.15.3 Engine oil – Sample extraction and analysis 214
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8.24.8 Engine Interface Module EIM 2 – Removal and

8.16 Oil Filtration / Cooling 216 installation 267
8.16.1 Oil indicator filter – Cleaning and check 216 8.24.9 CDC parameters – Reset 268
8.16.2 Engine oil filter – Replacement 219
8.16.3 Centrifugal oil filter – Cleaning and filter
sleeve replacement 221
9 Appendix A

8.17 Coolant Circuit, General, High-Temperature 9.1 List of abbreviations 269

Circuit 225 9.2 MTU Contact/Service Partners 271
8.17.1 Engine coolant level – Check 225

4 | Table of Contents | MS15035/00E 2018-08

 10 Appendix B 10.2 Index 279
10.1 Special Tools 272
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MS15035/00E 2018-08 | Table of Contents | 5

 1 Safety
1.1 Important provisions for all products
General
This product may pose a risk of injury or damage in the following cases:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Changes or modifications which are neither made nor authorized by the manufacturer
• Noncompliance with the safety instructions and warning notices

Nameplates
The product is identified by nameplate, model designation or serial number. This data must match the speci-
fications in these instructions.
Nameplates, model designation or serial number can be found on the product.
All EU-certified engines delivered by MTU come with a second nameplate. This second nameplate is deliv-
ered "loosely" with the engine. If the nameplate secured to the engine after installation in the vehicle/system
is not visible without the removal of components, the system integrator must install the second nameplate in
a clearly visible area on the vehicle/system.

Emission specifications and emission label

Responsibility for compliance with emission regulations
Modification or removal of any mechanical/electronic components or the installation of additional compo-
nents including the execution of calibration processes that might affect the emission characteristics of the
product are prohibited by emission regulations. Emission-related components must only be serviced, ex-
changed or repaired if the components used for this purpose are approved by the manufacturer.
Noncompliance with these specifications will invalidate the design type approval or certification issued by
the emissions regulation authorities. The manufacturer does not accept any liability for violations of the
emission regulations.
The product must be operated over its entire life cycle according to the conditions defined as "Intended use"
(→ Page 8).

Emission certification applicable to engines with EPA Nonroad Tier 4 emission

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

6 | Safety | MS15035/00E 2018-08

 Replacing components with emission labels
On all MTU engines fitted with emission labels, these labels must remain on the engine throughout its opera-
tional life.
Exception: Engines used exclusively in land-based, military applications other than by US government agen-
cies.
Please note the following when replacing components with emission labels:
• The relevant emission labels must be affixed to the spare part.
• Emission labels shall not be transferred from the replaced part to the spare part.
• The emission labels must be removed from the replaced part and destroyed.
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MS15035/00E 2018-08 | Safety | 7

 1.2 Correct use of all products
Correct use
The product is intended for use in accordance with its contractually-defined purpose as described in the rele-
vant technical documents only.
Intended use entails operation:
• Within the permissible operating parameters in accordance with the (→ Technical data)
• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubricants
Specifications of the manufacturer)
• With preservation approved by the manufacturer in accordance with the (→ Preservation and Represerva-
tion Specifications of the manufacturer)
• With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU con-
tact/Service partner)
• In the original as-delivered configuration or in a configuration approved by the manufacturer in writing (al-
so applies to engine control/parameters)
• In compliance with all safety regulations and in adherence with all warning notices in this manual
• In compliance with the maintenance work and intervals specified in the (→ Maintenance Schedule)
throughout the useful life of the product
• In compliance with the maintenance and repair instructions contained in this manual, in particular with
regard to the specified tightening torques
• With the exclusive use of technical personnel trained in commissioning, operation, maintenance and re-
pair
The product must not be operated in explosive atmospheres unless the engine fulfills the conditions for such
use and approval has been granted.
Any other use, particularly misuse, is considered as being contrary to the intended purpose. Such improper
use increases the risk of injury and damage when working with the product. The manufacturer shall not be
held liable for any damage resulting from improper, non-intended use.
The specifications of the manufacturer will be amended or supplemented as necessary. Prior to operation,
make sure that the latest version is used. The latest version can be found on the websites:
• For drive systems: http://www.mtu-online.com
• For power generation: http://www.mtuonsiteenergy.com

Modifications or conversions
Unauthorized changes to the product represent a contravention of its intended use and compromise safety.
Changes or modifications shall only be considered to comply with the intended use when expressly author-
ized by the manufacturer. The manufacturer shall not be held liable for any damage resulting from unauthor-
ized changes or modifications.
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8 | Safety | MS15035/00E 2018-08

 1.3 Personnel and organizational requirements
Organizational measures of the user/manufacturer
This manual must be issued to all personnel involved in operation, maintenance, repair, assembly, installa-
tion, or transportation.
Keep this manual handy in the vicinity of the product such that it is accessible to operating, maintenance,
repair, assembly, installation, and transport personnel at all times.
Personnel must receive instruction on product handling and repair based on this manual. In particular, per-
sonnel must have read and understood the safety requirements and warnings before starting work.
This is important in the case of personnel who only occasionally perform work on or around the product.
Such personnel must be instructed repeatedly.

Personnel requirements
All work on the product must be carried out by trained, instructed and qualified personnel only:
• Training at the Training Center of the manufacturer
• Qualified personnel from the areas mechanical engineering, plant construction, and electrical engineering
and also for work with live parts
The operator must define the responsibilities of the personnel involved in operation, maintenance, repair, as-
sembly, installation, and transport in writing.
Personnel shall not report for duty under the influence of alcohol, drugs or strong medication.

Clothing and personal protective equipment

Always wear appropriate personal protective equipment, e.g. safety shoes, ear protectors, protective gloves,
goggles, breathing mask. Follow the instructions concerning personal protective equipment in the descrip-
tions of the individual activities.
Safe handling of Substances of Very High Concern pursuant to the REACH regulation (Registration, Evalua-
tion, Authorization and restriction of Chemicals): We recommend wearing protective gloves at all times in
order to reduce risk when working.
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MS15035/00E 2018-08 | Safety | 9

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

Safety regulations during operation

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

Malfunctions and emergency stop

Practice emergency procedures, especially emergency stopping, at regular intervals.
Take the following steps if any system malfunctions are detected or signaled by the system:
• Inform supervisor(s) in charge.
• Analyze the message.
• Respond by taking any necessary emergency action, e.g. emergency stop.
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After a safety shutdown, the engine must only be started after the cause of the shutdown has been eliminat-
ed.
Contact Service if the root cause of the malfunction cannot be clearly identified.

Operation
Do not remain in the operating room when the product is running unless absolutely necessary. Keep your
stay as short as possible.
Keep a safe distance away from the product if possible. Do not touch the product unless expressly instructed
to do so following a written procedure.

10 | Safety | MS15035/00E 2018-08

 Do not inhale the exhaust gases of the product.
The following requirements must be fulfilled before the product is started:
• Wear ear protectors.
• Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binding agent.

Operation of electrical equipment

When electrical equipment is in operation, certain components of these appliances are electrically live.
Follow the applicable operating and safety instructions when operating the devices and heed warnings at all
times.
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MS15035/00E 2018-08 | Safety | 11

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

Safety regulations when performing assembly, maintenance, and repair work

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

Setting down, lifting and climbing

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Carry out work only on assemblies or plants which are properly secured.
Use appropriate lifting equipment for all components. Use all specified attachment points and observe the
center of gravity.
Never work on engines or components when they are held in place by lifting equipment.
Make sure components or assemblies are placed on stable surfaces. Adopt suitable measures to prevent
components/tools from falling down.
Assume a safe standing position when performing assembly work.
Never use the product as a climbing aid.

12 | Safety | MS15035/00E 2018-08

 When working high on the equipment, always use suitable ladders and work platforms. Special instructions
for outdoor areas: There must be no risk of slipping e.g. due to icing.

Removing, installing and cleanliness

Pay particular attention to cleanliness at all times.
Completely wipe up escaped fluids and lubricants due to the risk of slipping.
Take special care when removing ventilation or plug screws from the product.
Ensure that O-rings are not installed in a slanted/twisted condition.
Carry out appropriate cleaning procedures to clean and inspect components requiring special cleanness
(e.g. components carrying oil, fuel, or air).
Note cooling time for components which are heated for installation or removal (risk of burning).
Ensure that all mounts and dampers are installed correctly.
Remove any accumulation of condensate after assembling chilled components. Coat the components with a
suitable corrosion inhibitor as necessary.

Lines
Ensure that lines for all fluids and lubricants and their connections are clean.
Always seal connections with caps or covers if a line is removed or opened.
Fit new seals when re-installing lines.
Never bend lines and avoid damaging lines, particularly the fuel lines.
Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent contact
with other components. Do not place fuel or oil lines near hot components.

Miscellaneous
Sufficient ventilation must be guaranteed during the work.
Wear a breathing mask offering protection against soot, dust, and mineral fibers (filter class P3) when work-
ing on exhaust components. Clean the work area with a dust extraction machine of class H. Wear protective
gloves and goggles for protection against acidic condensate.
Do not touch elastomeric seals (e.g. Viton sealing rings) with your bare hands if they have a carbonized or
resinous appearance.
Elastomer components (e.g. engine mounts, damping elements, couplings and V-belts) must not be painted.
Only install them after painting the engine or mask them prior to painting.
The following applies to starters with copper-beryllium alloy pinions:
• Wear a respirator mask (filter class P3). Do not blow out the interior of the flywheel housing or the starter
with compressed air. Clean the flywheel housing inside with a class H dust extraction device.
• Observe the safety data sheet.

Safety regulations after performing assembly, maintenance, and repair work

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

MS15035/00E 2018-08 | Safety | 13

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

Hydraulic installation and removal

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

Working with batteries

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

Always obtain the permission of the person in charge before commencing assembly, maintenance, and repair
work or switching off any part of the electronic system required to do so.
De-energize the relevant areas prior to working on assemblies.
ESD (Electrostatic Discharge): Work on components which could be damaged by electrostatic discharge
must always be carried out with appropriate equipment. Appropriate equipment is e.g. electrically conductive
work surfaces or antistatic wristbands.

14 | Safety | MS15035/00E 2018-08

 Do not damage wiring during removal work. When reconnecting, ensure that cabling cannot be damaged dur-
ing operation by:
• Contact with sharp edges
• Chafing on components
• Contact with hot surfaces.
Do not secure cables on lines carrying fluids.
Do not use cable ties to secure lines.
Always use connector pliers to tighten union nuts on connectors.
Subject the device as well as the product to functional testing on completion of all repair work. The emergen-
cy stop function must be tested in particular. The functional check of the emergency stop, during which the
voltage supply of the ECU is switched off, must only be carried out when the product is cold.
Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Package
faulty electronic components or assemblies properly before dispatching for repair:
• Moisture-proof
• Shock-proof
• Wrapped in antistatic foil (as necessary)

Working with laser equipment

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

Measuring component dimensions

Workpieces, components and measuring equipment lie in the specified tolerance range at a reference tem-
perature of 20 °C.
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MS15035/00E 2018-08 | Safety | 15

 1.6 Fire and environmental protection, fluids and lubricants
Fire prevention and fire
Fire, naked light and smoking are prohibited.
In case of a fire, stop the fuel supply if this is possible without endangering personnel.
The product has hot surfaces that can ignite combustible gases and other substances in the immediate area.
The operating company must install and operate the product a safe distance away from danger sources and
observe any relevant safety regulations or recommendations. Products that comply with the SOLAS Conven-
tion do not constitute such as danger.
After working with combustible fluids and lubricants (e.g. cleaning agents), ensure the area is well ventilated.
The resultant steam/air mixture must be sufficiently diluted to prevent a potentially explosive atmosphere.
Eliminate leaks of fluids and lubricants immediately. Fluids and lubricants on hot components can cause
fires, so keep the product clean at all times. Do not leave rags saturated with fluids and lubricants on the
product. Do not store combustible materials near the product.
Incorrect refueling of the reducing agent system with fuel can result in fire.
Before welding, clean the area to be welded with a nonflammable fluid. Do not carry out welding work on
pipes and components carrying oil or fuel.
When starting the engine with an external power source, connect the ground lead last and remove it first. To
avoid sparks in the vicinity of the battery, connect the ground cable from the external power source to the
ground cable of the engine or to the ground terminal of the starter.
Ensure that suitable extinguishing agents (fire extinguishers) are always available and that staff are familiar
with their correct handling.
A fire can result in the creation of toxic substances. Always wear protective gloves when handling compo-
nents and wear additional personal protective equipment is necessary.

Noise
Wear ear protectors in workplaces with a sound pressure level in excess of 85 dB (A).
Noise can lead to an increased risk of accidents if acoustic signals, warning shouts or sounds indicating dan-
ger are compromised.

Environmental protection and disposal

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

Fluids and lubricants/auxiliary materials (process materials)

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

16 | Safety | MS15035/00E 2018-08

 Registration, evaluation, approval and restriction of chemicals (REACH
ordinance)
Particularly hazardous substances used with our products are named in a list:
www.mtu-online.com/mtu/technische-info → SVHC as per REACH in MTU products

Compressed air
• Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII and B) out of con-
tainers, risks causing an explosion.
• Wear goggles when blowing dirt off workpieces or blowing away chips.
• Blowing compressed air into thin-walled containers (e.g. containers made of sheet metal, plastic or glass)
for drying purposes or to check for leaks risks bursting them.
• Pay special attention to the pressure in the compressed air system or pressure vessel.
• Assemblies or products which are to be connected must be designed to withstand this pressure. Install
pressure-reducing or safety valves set to the admissible pressure if this is not the case.
• Hose couplings and connections must be securely attached.
• Provide the snout of the air nozzle with a protective disk (e.g. rubber disk).
• Release residual pressure before removing a compressed air device from the supply line. To depressurize
compressed-air lines, shut off the lines first, then release the residual pressure.
• Carry out a leak test in the specified manner.

Painting
• Observe the relevant safety data sheet for all materials.
• When carrying out painting work outside the spray stands provided with fume extraction systems, ensure
that the area is well ventilated. Make sure that neighboring work areas are not adversely affected.
• Avoid open flames in the surrounding area.
• No smoking.
• Observe fire-prevention regulations.
• Always wear a mask providing protection against paint and solvent vapors.

Liquid nitrogen
• Observe the relevant safety data sheet for all materials.
• Work with liquid nitrogen may be carried out only by qualified personnel.
• Store liquid nitrogen only in small quantities and always in specified containers without fixed covers.
• Avoid body contact (eyes, hands).
• Wear protective clothing, protective gloves, closed shoes and safety goggles.
• Make sure that the working area is well ventilated.
• Avoid knocking or jolting the containers, valves and fittings or workpieces in any way.

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

• Observe the relevant safety data sheet for all materials.
• When working with acids and alkaline solutions, wear goggles or face mask, gloves and protective cloth-
ing.
• Do not inhale vapors.
TIM-ID: 0000040536 - 018

• If reducing agent is swallowed, rinse out mouth and drink plenty of water.
• Remove any wet clothing immediately.
• After skin contact, wash affected body areas with plenty of water.
• Rinse eyes immediately with eyedrops or clean mains water. Consult a doctor as soon as possible.
Contamination of reducing agent with other process materials: Store reducing agent in separate contain-
ers and use separate drip trays. Even extremely slight contamination can lead to malfunctions in the ex-
haust aftertreatment system.
Mistakenly filling the tank of the reducing agent system with fuel can cause leakage at the seals and in
the hoses.

MS15035/00E 2018-08 | Safety | 17

 1.7 Standards for warning notices in the text and highlighted
information
DANGER
In the event of immediate danger.
Consequences: Death, serious or permanent injury!
• Remedial action.

WARNING
In the event of a situation involving potential danger.
Consequences: Death, serious or permanent injury!
• Remedial action.

CAUTION
In the event of a situation involving potential danger.
Consequences: Minor or moderate injuries!
• Remedial action.

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

Warning notices
1. This manual with all safety instructions and warning notices must be issued to all personnel involved in oper-
ation, maintenance, repair, assembly, installation, or transportation.
2. The highest level warning notice is used if several hazards apply at the same time. Warnings related to per-
sonal injury shall be considered to include a warning of potential damage.

Highlighted information
Important
This field contains product information which is important or useful for the user.
This information must not refer to hazards related to personal injury or material damage.
TIM-ID: 0000040578 - 006

18 | Safety | MS15035/00E 2018-08

 2 Transport
2.1 Transport
Taking the engine's center of gravity into account
For information regarding the center of gravity of the engine, refer to the installation/arrangement drawing
of the engine/genset/system.

Transport
• Lift the engine/genset/system only with the lifting eyes provided.
• Only use transport and lifting devices approved by MTU.
• The engine/genset/system must only be transported in installation position.
• Max. permissible diagonal pull 10°.
• If the engine/genset/system is supplied with special aluminum foil packing, lift it at the lifting eyes of the
trestle or use a means of transportation which is appropriate for the given weight (forklift truck).
• Prior to transporting the engine/genset/system, it is imperative to install the transport locking device for
the crankshaft.
• Prior to transporting the engine/genset/system, it is imperative to install the transport locks for the en-
gine mounts.
• Secure the engine/genset/system such as to preclude tipping during transport.
• Secure the engine/system/genset as to preclude slipping and tipping when driving up or down inclines
and ramps.

Setting the engine down after transport

• Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate.
• Never set an engine/genset/system down on the oil pan unless expressively authorized to do so by MTU
on a case-to-case basis.
• Place the engine/genset/system on a firm, flat surface only.
TIM-ID: 0000002614 - 005

MS15035/00E 2018-08 | Transport | 19

 2.2 Lifting requirements
DANGER
Suspended load.
Danger to life!
• Use suitable equipment and lifting devices.
• Never stand beneath a suspended load and keep a safe distance.
• Wear personal protective equipment (e.g. protective helmet, safety shoes).

Lifting requirements 12V, heat exchanger installed, vertical air intake

1 Maximum permissible diag- 2 Center of gravity

onal pull 10° (*)
(*) Max. permissible diagonal pull must be observed:
• Max. permissible diagonal pull in longitudinal direction is 10 degrees; simultaneous diagonal pull in trans-
verse direction is impermissible.
• Max. permissible diagonal pull in transverse direction is 10 degrees; simultaneous diagonal pull in longitu-
dinal direction is impermissible.
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20 | Transport | MS15035/00E 2018-08

 Lifting requirements 12V, separate heat exchanger, horizontal air intake

1 Maximum permissible diag- 2 Center of gravity

onal pull 10° (*)
(*) Max. permissible diagonal pull must be observed:
• Max. permissible diagonal pull in longitudinal direction is 10 degrees; simultaneous diagonal pull in trans-
verse direction is impermissible.
• Max. permissible diagonal pull in transverse direction is 10 degrees; simultaneous diagonal pull in longitu-
dinal direction is impermissible.
TIM-ID: 0000067837 - 002

MS15035/00E 2018-08 | Transport | 21

 Lifting requirements 16V, heat exchanger installed, vertical air intake

1 Maximum permissible diag- 2 Center of gravity

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

TIM-ID: 0000067837 - 002

22 | Transport | MS15035/00E 2018-08

 Lifting requirements 16V, separate heat exchanger, horizontal air intake

1 Maximum permissible diag- 2 Center of gravity

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

Take note of the engine center of gravity

Refer to the installation/arrangement drawings for details of the center of gravity of the system or engine.
TIM-ID: 0000067837 - 002

MS15035/00E 2018-08 | Transport | 23

 2.3 Crankshaft transport locking device
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Torque wrench, 10–60 Nm F30452769 1
Torque wrench, 60–320 Nm F30452768 1
Engine oil

Transport locking devices

Note: The transport locking device on both sides protects the crankshaft bearings from shocks and vibration dam-
age during engine transport.

For installation and removal of the transport locking device, follow the in-
structions below:
1. The transport locking device must remain installed on both engine sides 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 engine sides accord-
ing to the instructions.
3. If the engine is to be moved together with the generator, the transport locking device for the generator must
also be installed.
4. Always use the screws supplied with or installed in the transport locking device to secure it on the engine.
5. Starting or barring the engine is allowed only with the transport locking device removed. If the generator is
already mounted on the engine, ensure that the transport locking device of the generator is also removed.

Removing guard plates and en-

gine mounting brackets (if appli-
cable) on driving end (KS)
1. Remove screws (4) on both sides and take off
with washers (3), guard plates (1) and engine
supports (2).
2. Store the removed parts of the transport
locking device carefully for possible reuse.
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24 | Transport | MS15035/00E 2018-08

 Installing the transport locking
device on driving end (KS)

Note: Install plate (6) on the upper part of the openings only.
1. Secure the plates (6) with screws (4) and washers (5) at the lateral openings on both sides of the flywheel
housing and tighten to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw M16 Tightening torque (Engine oil) 250 nm +25 nm

2. Screw locknut (2) onto screws (1) up to the end of the thread.
3. The long side of holder (3) must point downwards. Insert holder (3) through the openings of plate (6).
Note: Holder (3) must lock only the flywheel, not the ring gear.
4. Screw in screw (1) in bores of holder (3) until holder (3) is locked in position.
Note: Screw (1) must be tightened stepwise and alternately on both sides of the flywheel housing.
5. Tighten screw (1) to specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw M10 Tightening torque (Engine oil) 30 Nm +3 Nm

6. Install locknut (2) of screw (1) on plate (6) and tighten.

Removing the transport locking

device from driving end (KS)
1. Release the locknuts (2) on both sides of the
flywheel housing, remove screw (1) and take
off holder (3).
2. Remove screws (4) and take off with wash-
ers (5) and plates (6).
3. Store the removed parts of the transport
TIM-ID: 0000004010 - 016

locking device carefully together with this

documentation for possible reuse.

MS15035/00E 2018-08 | Transport | 25

 Installing guard plates and en-
gine mounting brackets (if appli-
cable) on driving end (KS)

Note: Always use the screws supplied with the equipment or removed from the guard plates and engine supports
to secure them on the engine.
u Install engine supports (2) on both sides with guard plates (1) washers (3) and screws (4) and tighten to
specified tightening torque tightening.
Name Size Type Lubricant Value/Standard
Screw M16 Tightening torque (Engine oil) 250 Nm +25 Nm

TIM-ID: 0000004010 - 016

26 | Transport | MS15035/00E 2018-08

 3 General Information
3.1 Tightening specifications for screws, nuts and bolts
Tightening torques for setscrew and connections as per MTN 5008 standard
This standard applies to setscrews not subject to dynamic loads and the associated nuts according to:
• MMN 384
• ISO 4762 (DIN 912)
• ISO 4014 (DIN 931-1)
• ISO 4017 (DIN 933)
• DIN EN ISO 8765 (EN 28765; DIN 960)
• DIN EN ISO 8676 (EN 28676; DIN 961)
• DIN 6912
This standard applies to studs not subject to dynamic loads and the associated nuts according to:
• DIN 833
• DIN 835
• DIN EN ISO 5395 (DIN 836)
• DIN 938
• DIN 939
This standard applies to screws with hexalobular heads according to:
• DIN 34800
• DIN 34801
The standard does not apply to heat-resistant screws in the hot component zone.
Tightening torques MA are specified for screws of strength class 8.8 (surface condition bare, phosphatized or
galvanized) and 10.9 (surface condition bare or phosphatized).
The values in the table are based on a friction coefficient µtot = 0.125.
Threads and mating faces of screws and nuts must be coated with engine oil prior to assembly.
When hand-tightening (defined torque), an assembly tolerance of -5+15% of the figures in the table is permit-
ted.
When machine-tightening, the permissible assembly tolerance is ±15%.

Tightening torques for setscrews

Hand-tightening Machine-tightening
Thread
8.8 MA (Nm) 10.9 M A (Nm) 8.8 MA (Nm) 10.9 M A (Nm)
M6 9 12 8 11
M8 21 31 20 28
M8 x 1 23 32 21 30
M10 42 60 40 57
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M10 x 1.25 45 63 42 60
M12 74 100 70 92
M12 x 1.25 80 110 75 105
M12 x 1.5 76 105 72 100
M14 115 160 110 150
M14 x 1.5 125 180 120 170
M16 180 250 170 235
M16 x 1.5 190 270 180 255

MS15035/00E 2018-08 | General Information | 27

 Hand-tightening Machine-tightening
Thread
8.8 MA (Nm) 10.9 M A (Nm) 8.8 MA (Nm) 10.9 M A (Nm)
M18 250 350 240 330
M18 x 1.5 280 400 270 380
M20 350 500 330 475
M20 x 1.5 390 550 350 520
M22 480 680 450 650
M22 x 1.5 520 730 490 700
M24 600 850 570 810
M24 x 1.5 680 950 640 900
M24 x 2 660 900 620 850
M27 900 1250 850 1175
M27 x 2 960 1350 900 1275
M30 1200 1700 1100 1600
M30 x 2 1350 1900 1250 1800
MA = tightening torques

Tightening torques for studs

screwed into
Thread Steel M A Gray cast iron MA AI alloy MA
(Nm) (Nm) (Nm)
M6 9 6 6
M8 11 9 10
M10 17 13 13
M12 27 23 18
M14 37 33 33
M16 55 45 –
MA = tightening torques

Tightening torques for setscrews and nuts made of stainless steel

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

28 | General Information | MS15035/00E 2018-08

 Tightening torque for self-locking hex nuts
Thread MA (Nm) Lubricants
M6 7.5 +1 –
M8 17 +2 –
M10 35 +4 –
M12 59 +6 –
M14 100 +10 –
M16 140 +14 –
M20 290 +29 –
MA = tightening torques

Tightening torque for stress bolt connections as per MTN 5007 standard
This standard applies to stress pin bolts and stress bolts which are subjected to static and dynamic load of
strength class 10.9 as well as to the associated nuts.
Shaft and transition dimensions as per MMN 209 standard and material and machining as per MMN 389
standard (bright surface or phosphatized).
The values in the table are based on a friction coefficient µtot = 0.125.
Threads and mating faces of screws and nuts must be coated with engine oil prior to assembly.
An assembly tolerance of +10% of the figures in the table is permitted due to unavoidable deviations during
the tightening process.
The values in the tables are for manual tightening using a torque wrench.

Thread Not torsion-protected MA(Nm) Torsion-protected MA (Nm)

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

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

MS15035/00E 2018-08 | General Information | 29

 Thread Not torsion-protected MA(Nm) Torsion-protected MA (Nm)
M30 1250 1575
*Protect screw shaft from torsion when tightening.
MA= tightening torques.

Tightening torques for plug screws as per MTN 5183-1 standard

This standard applies to plug screws to DIN 908, DIN 910 and DIN 7604 with threaded end to DIN 3852
Form A (sealed with sealing ring to DIN 7603-Cu).

TIM-ID: 0000002333 - 018

30 | General Information | MS15035/00E 2018-08

 Tightening torques MA are given for screw plugs made of steel (St) with surface protected by a phosphate
coating and oiled or galvanized.
Threads and mating faces beneath heads must be coated with engine oil prior to assembly.
An assembly tolerance of +10% of the figures in the table is permitted due to unavoidable deviations during
the tightening process.
Tightening torques for plug screws to DIN 908, DIN 910 and DIN 7604A (with short threaded end).
screwed into
Thread Steel/gray cast iron MA AI alloy MA
(Nm) (Nm)
M10 x 1 15 15
M12 x 1.5 25 25
M14 x 1.5 35 30
M16 x 1.5 40 35
M18 x 1.5 50 40
M20 x 1.5 60 50
M22 x 1.5 70 70
M24 x 1.5 85 80
M26 x 1.5 100 100
M27 x 2 100 100
M30 x 1.5 110 110
M30 x 2 120 120
M33 x 2 160 160
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M36 x 1.5 190 180

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

MS15035/00E 2018-08 | General Information | 31

 screwed into
Thread Steel/gray cast iron MA AI alloy MA
(Nm) (Nm)
M64 x 2 400 400
MA = tightening torques

Tightening torque for plug screws DIN 7604C (with long screwed end)
screwed into
Thread Steel/gray cast iron M A AI alloy MA
(Nm) (Nm)
M8 x 1 10 10
M22 x 1.5 80 65
M26 x 1.5 105 90
M30 x 1.5 130 130
M38 x 1.5 140 120
M45 x 1.5 160 140
MA = tightening torques

Tightening torque for banjo screws as per MTN 5183-2 standard

This standard applies to banjo screws to MMN 223 and N 15011 sealed with sealing ring to DIN 7603-Cu.

TIM-ID: 0000002333 - 018

32 | General Information | MS15035/00E 2018-08

 The stated tightening torques MA apply to steel (St) banjo screws with a phosphatized surface and oiled or
galvanized and for copper-aluminum alloy.
Threads and mating faces beneath heads must be coated with engine oil prior to assembly.
An assembly tolerance of +10% of the figures in the table is permitted due to unavoidable deviations during
the tightening process.

Tightening torques for steel banjo screws

inserted in steel/gray cast iron/aluminum alloy
Thread MA
(Nm)
M8 x 1 10
M10 x 1 15
M12 x 1.5 20
M14 x 1.5 25
M16 x 1.5 25
M18 x 1.5 30
M22 x 1.5 60
M26 x 1.5 90
M30 x 1.5 130
M38 x 1.5 140
M45 x 1.5 160
MA = tightening torques
TIM-ID: 0000002333 - 018

Tightening torques for copper-aluminum alloy banjo screws

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

MS15035/00E 2018-08 | General Information | 33

 Tightening torques for male connectors as per MTN 5183-3 standard
This standard applies to male unions to DIN 2353 Series L with threaded end to DIN 3852 Form A (sealed by
sealing ring to DIN 7603-Cu).

Tightening torques MA are given for male unions made of steel (St) with phosphatized surface coating and
oiled, or galvanized.
Threads and mating faces beneath heads must be coated with engine oil prior to assembly.
An assembly tolerance of +10% of the figures in the table is permitted due to unavoidable deviations during
the tightening process.
inserted in steel/gray cast iron MA
Thread
(Nm)
M10 x 1 15
M12 x 1.5 20
M14 x 1.5 35
M16 x 1.5 50
M18 x 1.5 60
M22 x 1.5 70
M26 x 1.5 100
M32 x 2 160
M42 x 2 260
M48 x 2 320
MA = tightening torques
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34 | General Information | MS15035/00E 2018-08

 Tightening torques for union nuts as per DIN 3859-2
1 Union nut
2 Screw fixture
3 O-ring
4 Linear ball bearing

Union nut: On installing the ball-type union, after tightening the union nut firmly by hand (noticeable increase
in force), it should be tightened another 1/4 turn (90°) past this point.

Tightening torques for spigot unions with O-ring to ISO 6149-2

Thread Torque (Nm) +10%

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

MS15035/00E 2018-08 | General Information | 35

 Thread Torque (Nm) +10%
M27 x 2 170
M33 x 2 310
M42 x 2 330
M48 x 2 420
M60 x 2 500
1)
Only for sealing off installation spaces for screw-in valves (see ISO 6149-47 and ISO 7789)

Tightening torques for screwed plugs with O-ring as per ISO 6149-3

Thread Torque (Nm) +10%

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

36 | General Information | MS15035/00E 2018-08

 Tightening torques for plug screw joints as per MTN 5183-6

screwed into
Thread Steel/gray cast iron MA AI alloy MA
(Nm) (Nm)
M10 x 1 20 10 +2
M12 x 1.5 35 14 +2
M14 x 1.5 45 15 +3
M16 x 1.5 55 18 +3
M18 x 1.5 70 23 +3
M22 x 1.5 100 33 +4
M27 x 2 170 57 +5
M33 x 2 310 103 +10
M42 x 2 330 110 +11
M48 x 2 420 140 +14
M60 x 2 – 200 +20
MA = tightening torques

Assembly instructions and tightening torque for hose fittings with union nuts
These instructions do not apply to ORFS fittings. In contrast to the instructions for pipe unions, hose fittings
with sealing heads and the matching adapters must be fitted and connected as follows.
Hose fitting, metallic sealing with union nut: tighten union nut by hand then tighten a further max. 1/4 of a
TIM-ID: 0000002333 - 018

turn with a wrench.

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

MS15035/00E 2018-08 | General Information | 37

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

Sealing head with BSP union nut

BSPP thread Torque (Nm)
G1/4 20
G3/8 34
G1/2 60
G5/8 69
G3/4 115
G1 140
G1.1/4 210
G1.1/2 290
G2 400

SAE sealing cone with union nut JIC 37°

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

38 | General Information | MS15035/00E 2018-08

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

MS15035/00E 2018-08 | General Information | 39

 3.2 Engine side and cylinder designations

1 Left engine side (A-side) 3 Right engine side (B-side)

2 Engine free end in accord- 4 Engine driving end in ac-
ance with DIN ISO 1204 cordance with
(KGS = Kupplungsgegen- DIN ISO 1204 (KS = Kup-
seite) plungsseite)
Engine sides are always designated (in accordance with DIN ISO 1204) as viewed from driving end (4).
For cylinder designation (in accordance with DIN ISO 1204), the letter "Ax" refers to the cylinders on the left-
hand side of the engine (1) and letter "Bx" refers to the cylinders on the right-hand side (3). The cylinders of
each bank are numbered consecutively, starting with x=1 at driving end (4).
The numbering of other engine components also starts with 1 at driving end (4).
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40 | General Information | MS15035/00E 2018-08

 3.3 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 (ADEC).

Fuel system
Electronically controlled common-rail-injection system with HP pump, pressure accumulator (rail) and single
injectors with integrated individual store.
The electronic control unit controls
• Injection start
• Injection quantity
• Injection pressure

Exhaust system
The exhaust system is equipped with triple-walled, water-cooled exhaust lines.
The triple-walled design 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 exhaust
turbocharger is cut-in and cut-out on 12V and 16V engines with electronically-controlled, hydraulically-actu-
ated flaps.

Cooling system
Split-circuit engine cooling system with remote or engine-mounted heat exchanger.
Heating of the charge air in idle and low-load operation prevents white smoke formation.
Seawater flows only through engine coolant cooler and fuel cooler as well as the raw water pump (if fitted).

Service block
The service components are mounted at the auxiliary PTO end.
The layout permits easy access for maintenance.
Service components:
• Raw water pump (if fitted), coolant pump
TIM-ID: 0000069190 - 001

• Centrifugal lube oil filter

• Coolant expansion tank (only on engines with engine-mounted heat exchanger)
• Coolant filter

Electronic system
Electronic control and monitoring system with integrated safety and test system with interfaces to Remote
Control System (RCS) and to Monitoring and Control System (MCS).

MS15035/00E 2018-08 | General Information | 41

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

Serial RS422 interface for diagnosis

The engine interface comprises two parts. The first part of signals is integrated in the engine wiring harness
with a 62-pin Tyco connector X52. The second part refers to signals associated with higher currents. These
signals are led out via M threaded pins and also integrated in the engine wiring harness.
Functions
• ECU supply
• EMU supply
• Plant signals (ECU7 connector X1)
• Bus interface (2x MCS5 CAN)
• CAN dialog output (1xMCS5 CAN)
• Emergency stop from EMU and ECU
• Electric starter
• Terminal 45 starter A/B (engaged)
• Pneumatic starter
• Starting air pressure valve
• Starting air pressure sensor
• Barring device (Barring Gear 1 and 2)
• Battery-charging generator (with exciter control)
• Optional emergency-air shutoff flaps
• Activation signal to air shutoff flaps 1+2
• Feedback signal from air shutoff flaps 1+2

Electronic engine governor (ECU)

Functions:
• Engine speed control with fuel and speed limitation dependent on engine status and operating conditions
• Control of sequential turbocharging, cylinder bank cut-out and air recirculation function
• Data processing logistics for analog and binary signals
• Interface for data transfer to CAN field bus for remote control and ship-side monitoring
TIM-ID: 0000069190 - 001

Electronic Engine Monitoring Unit (EMU)

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

42 | General Information | MS15035/00E 2018-08

 Low-load operation

1 Low-load operation 2 Cleaning cycle 3 ditto

MTU marine engine Series 4000M53R to …M93L may be operated in low-load operation. State-of-the-art de-
sign and equipment features, e.g. TE coolant circuit, sequential turbocharging, jacketed, coolant-cooled ex-
haust lines, Common Rail fuel injection and cylinder cutout allow engine operation at low load.
nevertheless, low-load operation at engine load below 15% of the nominal rating is permitted for max.
100 hours. In order to avoid inadmissible oil carbon and/or carbon particle deposits in the engine, it is rec-
ommended to carry out a cleaning cycle for at least 20 minutes after extended low-load operation periods.
During the cleaning cycle, engine speed (power) must be increased step by step until all exhaust turbocharg-
ers are running. The figure shows the basic speed/power run-up procedure for the cleaning cycle to be car-
ried out.

SOLAS – Fire protection specifications

Installation locations for SOLAS shielding (→ Page 148)

Special connections
The following types of connections are spray-proof in case of leakage even without covers and have been
TIM-ID: 0000069190 - 001

confirmed as being SOLAS-compliant by GL and DnV.

MS15035/00E 2018-08 | General Information | 43

 Plugs and sensors (a)
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 liquid 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 pres-
sure.

Plug-in pipe union (b)

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 (2) defect occurs.
The union is confirmed as being SOLAS-compliant by DnV and GL.
TIM-ID: 0000069190 - 001

44 | General Information | MS15035/00E 2018-08

 HP connections

1 Jacket pipe 8 Thrust ring 15 Union nut

2 HP fuel line 9 Union nut 16 Thrust ring
3 O-ring 10 Union nut 17 HP line outer pipe
4 Union nut 11 Connecting piece 18 Internal pipe of HP line
5 Recess for O-ring 12 Snap ring 19 Ball-type seal area
6 Thrust ring 13 Thrust ring 20 Leak-fuel connection
7 Leakage overflow bore 14 Shim washers
The HP fuel line is sealed by the thrust ring (8).
In case of leakage around the thrust ring (8) or the HP line (5) fuel escapes into the leakage chamber.
The leaking fuel is drained off without pressure via the leakage overflow-bore (7). The leakage chamber is
sealed toward the outside by the O-rings (3).
This prevents leakage egress.
The union is confirmed as being SOLAS-compliant by DnV and GL.
TIM-ID: 0000069190 - 001

MS15035/00E 2018-08 | General Information | 45

 3.4 Engine – Overview
Engines with remote raw water cooler and horizontal air intake
The following overviews also apply to 12V4000Mx3.

1 Engine management and 10 Recirculation line 19 Battery-charging generator

monitoring 11 Exhaust manifold 20 HP fuel pump
2 Oil cooler 12 Engine mounting 21 Oil filter
3 Centrifugal oil filter 13 Charge-air line 22 Bilge pump (option)
4 Crankcase breather 14 Oil pan 23 Coolant outlet to remote
5 Dry-type air filter 15 Oil filler neck cooling system
6 Exhaust turbocharger 16 Crankcase 24 Coolant inlet from remote
7 Exhaust outlet 17 Cylinder head cooling system
8 Air pipe to charge-air cooler 18 Fuel filter KGS Free end
9 Charge-air cooler
TIM-ID: 0000009990 - 008

46 | General Information | MS15035/00E 2018-08

 Engines with installed raw water cooler and horizontal air intake

1 Raw-water outlet 10 Exhaust outlet 19 Cylinder head

2 Engine management and 11 Air pipe to charge-air cooler 20 Crankcase
monitoring 12 Recirculation line 21 Fuel filter
3 Plate-core heat exchanger 13 Exhaust manifold 22 Battery-charging generator
4 Oil cooler 14 Charge-air cooler 23 HP fuel pump
5 Coolant expansion tank 15 Charge-air line 24 Oil filter
6 Centrifugal oil filter 16 Engine mounting 25 Bilge pump (option)
7 Crankcase breather 17 Oil pan 26 Raw-water inlet
8 Dry-type air filter 18 Oil filler neck KGS Free end
9 Exhaust turbocharger
TIM-ID: 0000009990 - 008

MS15035/00E 2018-08 | General Information | 47

 Engines with remote raw water cooler and vertical air intake

1 Coolant outlet to remote 10 Exhaust turbocharger 19 Cylinder head

cooling system 11 Exhaust outlet 20 Fuel filter
2 Coolant inlet from remote 12 Air pipe to charge-air cooler 21 Oil filter
cooling system 13 Charge-air cooler 22 HP fuel pump
3 Engine management and 14 Engine mounting 23 Battery-charging generator
monitoring 15 Charge-air line 24 Bilge pump (option)
4 Oil cooler 16 Oil pan KGS Free end
5 Centrifugal oil filter 17 Oil filler neck
6 Crankcase breather 18 Crankcase
7 Dry-type air filter
8 Exhaust manifold
9 Recirculation line
TIM-ID: 0000009990 - 008

48 | General Information | MS15035/00E 2018-08

 Engines with installed raw water cooler and vertical air intake

1 Raw-water outlet 10 Recirculation line 19 Crankcase

2 Engine management and 11 Exhaust turbocharger 20 Cylinder head
monitoring 12 Exhaust outlet 21 Fuel filter
3 Oil cooler 13 Air pipe to charge-air cooler 22 Oil filter
4 Plate-core heat exchanger 14 Charge-air cooler 23 HP fuel pump
5 Coolant expansion tank 15 Charge-air line 24 Battery-charging generator
6 Centrifugal oil filter 16 Engine mounting 25 Bilge pump (option)
7 Crankcase breather 17 Oil pan 26 Raw-water inlet
8 Dry-type air filter 18 Oil filler neck KGS Free end
9 Exhaust manifold

Engine model designation

Explanation of engine model designation 12/16V4000Mxyz
12, 16 number of cylinders
V Cylinder arrangement: V-engine
4000 Series
M Application (M= Marine)
TIM-ID: 0000009990 - 008

x Application load profile (0, 1, 2, 3...9)

y Design index (0, 1, 2, 3...9)
z R (power / speed reduction)
L (enhanced power / speed)
S (60 Hz)
F (50 Hz)

MS15035/00E 2018-08 | General Information | 49

 3.5 Sensors, actuators and injectors on 12V engines – Overview
Engines with remote raw water cooler and horizontal air intake
Left engine side 12V4000Mx3

1 B50 (P-Crankcase) 4 B10 (P-Charge air) 7 B34.1 (P-Fuel after filter)

2 B3 (T-Intake air) 5 B34.3 (fuel pressure before 8 F46 (leak fuel level)
3 B44.1 (N-Turbocharger A) filter) (only if supplementary
fuel filter is fitted)
6 B34.2 (P-Fuel before filter)
TIM-ID: 0000012941 - 004

50 | General Information | MS15035/00E 2018-08

 Free end 12V4000Mx3

1 B33 (fuel temperature in 5 B5.1 (P-Lube oil after filter) 9 B6.2 (coolant temperature)
common rail) 6 B48 (P-Fuel in common rail) (optional)
2 B7 (T-Lube oil) 7 B1 (N-Camshaft) 10 B6 (T-Coolant)
3 B5.2 (lube oil pressure after 8 B54 (oil refill pump pres- 11 XD1 connector (dialog unit)
filter) (optional) sure) (optional)
4 B5.3 (lube-oil pressure be-
fore filter)
TIM-ID: 0000012941 - 004

MS15035/00E 2018-08 | General Information | 51

 Right engine side 12V4000Mx3

1 B44.2 (N-Turbocharger B) 3 B16 (P-Coolant)

2 Y27 (turbocharger control 4 B9 (T-Charge Air)
valve)

TIM-ID: 0000012941 - 004

52 | General Information | MS15035/00E 2018-08

 Driving end 12V4000Mx3

1 B4.21 (T-Exhaust, A side) 3 B13 (N-Crankshaft) 5 S37.1 (S-Safety switch)

2 B4.22 (T-Exhaust, B bank) 4 S37.2 (S-Safety switch) 6 B13.2 (N-Crankshaft speed)
(optional)
TIM-ID: 0000012941 - 004

MS15035/00E 2018-08 | General Information | 53

 Plan view 12V4000Mx3

1 B5.8 (P-Lube before exhaust 3 B4 (T-Individual exhaust

turbocharger A) temperature A1-A6, B1-B6)
2 B49/Y26 (T-Charge-air be- (optional)
fore recirculation valve/ 4 B5.9 (P-Lube oil before tur-
recirculation valve A) bocharger B)

TIM-ID: 0000012941 - 004

54 | General Information | MS15035/00E 2018-08

 Engines with installed raw water cooler and horizontal air intake
Left engine side 12V4000Mx3

1 B50 (P-Crankcase) 5 B10 (P-Charge air) 9 F46 (leak fuel level)

2 B49/Y26 (charge-air tem- 6 B34.3 (fuel pressure before 10 B33 (fuel temperature in
perature before recircula- filter) (only if supplementary common rail)
tion valve/recirculation fuel filter is fitted)
valve A) 7 B34.2 (P-Fuel before filter)
3 B3 (T-Intake air) 8 B34.1 (P-Fuel after filter)
4 B44.1 (N-Turbocharger A)
TIM-ID: 0000012941 - 004

MS15035/00E 2018-08 | General Information | 55

 Free end 12V4000Mx3

1 B48 (P-Fuel in common rail) 5 B5.3 (P-Lube oil before fil- 9 B6 (T-Coolant)
2 B7 (T-Lube oil) ter) 10 XD1 connector (dialog unit)
3 B5.2 (P-Lube oil after filter) 6 B1 (N-Camshaft)
(optional) 7 B54 (P-Oil refill pump) (op-
4 B5.1 (P-Lube oil after filter) tional)
8 B6.2 (T-Coolant tempera-
ture) (optional)

TIM-ID: 0000012941 - 004

56 | General Information | MS15035/00E 2018-08

 Right engine side 12V4000Mx3

1 B44.2 (N-Turbocharger B) 3 B16 (P-Coolant) 5 B9 (T-Charge Air)

2 Y27 (turbocharger control 4 B21 (raw-water pressure)
valve) (optional)
TIM-ID: 0000012941 - 004

MS15035/00E 2018-08 | General Information | 57

 Driving end 12V4000Mx3

1 B4.21 (T-Exhaust, A side) 3 B13 (N-Crankshaft) 5 S37.1 (S-Safety switch)

2 B4.22 (T-Exhaust, B bank) 4 S37.2 (S-Safety switch) 6 B13.2 (N-Crankshaft) (op-
tional)

TIM-ID: 0000012941 - 004

58 | General Information | MS15035/00E 2018-08

 Plan view 12V4000Mx3

1 B5.8 (P-Lube before exhaust 3 F33 (H-Coolant)

turbocharger A) 4 B5.9 (P-Lube oil before tur-
2 B4 (cylinder exhaust tem- bocharger B)
perature A1-A6, B1-B6) (op-
tional)
TIM-ID: 0000012941 - 004

MS15035/00E 2018-08 | General Information | 59

 3.6 Sensors, actuators and injectors on 16V engines – Overview
Engines with remote raw water cooler and horizontal air intake
Left engine side 16V4000Mx3

1 B50 (P-Crankcase) 4 B10 (P-Charge air) 7 B34.1 (P-Fuel after filter)

2 B3 (T-Intake air) 5 B34.3 (fuel pressure before 8 F46 (leak fuel level)
3 B44.1 (N-Turbocharger A) filter) (only if supplementary
fuel filter is fitted)
6 B34.2 (P-Fuel before filter)
TIM-ID: 0000018445 - 005

60 | General Information | MS15035/00E 2018-08

 Free end 16V4000Mx3

1 B33 (T-Fuel in common rail) 5 B5.1 (P-Lube oil after filter) 9 B6.2 (T-Coolant) (optional)
2 B7 (T-Lube oil) 6 B48 (P-Fuel in common rail) 10 B6 (T-Coolant)
3 B5.2 (P-Lube oil after filter) 7 B1 (N-Camshaft) 11 XD1 connector (dialog unit)
(optional) 8 B54 (P-Oil refill pump) (op-
4 B5.3 (P-Lube oil before fil- tional)
ter)
TIM-ID: 0000018445 - 005

MS15035/00E 2018-08 | General Information | 61

 Right engine side 16V4000Mx3

1 B44.2 (N-Turbocharger B) 3 B16 (P-Coolant)

2 Y27 (turbocharger control 4 B9 (T-Charge Air)
valve)

TIM-ID: 0000018445 - 005

62 | General Information | MS15035/00E 2018-08

 Driving end 16V4000Mx3

1 B4.21 (T-Exhaust, A side) 3 B13 (N-Crankshaft) 5 S37.1 (S-Safety switch)

2 B4.22 (T-Exhaust, B bank) 4 S37.2 (S-Safety switch) 6 B13.2 (N-Crankshaft) (op-
tional)
TIM-ID: 0000018445 - 005

MS15035/00E 2018-08 | General Information | 63

 Plan view 16V4000Mx3

1 B5.8 (P-Lube before exhaust 3 B4 (cylinder exhaust tem-

turbocharger A) perature A1-A6, B1-B6) (op-
2 B49/Y26 (T-Charge-air be- tional)
fore recirculation valve/ 4 B5.9 (P-Lube oil before tur-
recirculation valve A) bocharger B)

TIM-ID: 0000018445 - 005

64 | General Information | MS15035/00E 2018-08

 Engines with installed raw water cooler and horizontal air intake
Left engine side 16V4000Mx3

1 B50 (P-Crankcase) 5 B10 (P-Charge air) 9 F46 (leak fuel level)

2 B49/Y26 (charge-air tem- 6 B34.3 (fuel pressure before 10 B33 (T-Fuel in common rail)
perature before recircula- filter) (only if supplementary
tion valve/recirculation fuel filter is fitted)
valve A) 7 B34.2 (P-Fuel before filter)
3 B3 (T-Intake air) 8 B34.1 (P-Fuel after filter)
4 B44.1 (N-Turbocharger A)
TIM-ID: 0000018445 - 005

MS15035/00E 2018-08 | General Information | 65

 Free end 16V4000Mx3

1 B48 (P-Fuel in common rail) 5 B5.3 (P-Lube oil before fil- 9 B6 (T-Coolant)
2 B7 (T-Lube oil) ter) 10 XD1 connector (dialog unit)
3 B5.2 (P-Lube oil after filter) 6 B1 (N-Camshaft)
(optional) 7 B54 (P-Oil refill pump) (op-
4 B5.1 (P-Lube oil after filter) tional)
8 B6.2 (T-Coolant) (optional)

TIM-ID: 0000018445 - 005

66 | General Information | MS15035/00E 2018-08

 Right engine side 16V4000Mx3

1 B44.2 (N-Turbocharger B) 3 B16 (P-Coolant) 5 B9 (T-Charge Air)

2 Y27 (turbocharger control 4 B21 (raw-water pressure)
valve) (optional)
TIM-ID: 0000018445 - 005

MS15035/00E 2018-08 | General Information | 67

 Driving end 16V4000Mx3

1 B4.21 (T-Exhaust, A side) 3 B13 (N-Crankshaft) 5 S37.1 (S-Safety switch)

2 B4.22 (T-Exhaust, B side) 4 S37.2 (S-Safety switch) 6 B13.2 (N-Crankshaft) (op-
tional)

TIM-ID: 0000018445 - 005

68 | General Information | MS15035/00E 2018-08

 Plan view 16V4000Mx3

1 B5.8 (P-Lube before exhaust 3 F33 (H-Coolant)

turbocharger A) 4 B5.9 (P-Lube oil before tur-
2 B4 (cylinder exhaust tem- bocharger B)
perature A1-A6, B1-B6) (op-
tional)
TIM-ID: 0000018445 - 005

MS15035/00E 2018-08 | General Information | 69

 4 Technical Data
4.1 Product data 12V4000M53
Legend
DL Reference value: Continuous power. Continuous driving performance under standard conditions
BL Reference value: Fuel stop power. Maximum engine power. With some applications, not drivable on
continuous basis (adjustment reserve)
A Design value. Value required to design an external system (plant)
R Guideline value. Typical average value for information, only conditionally suitable for design
L Limit value. Value which must not be undershot (lower limit value, min. value) or exceeded (upper lim-
it value, max. value), not suitable for design
N Not yet defined value. Value not yet named/will not be named
- Not applicable. Module does not apply to this product type
X Applicable. Module applies to this product type
> Actual value must be greater than the specified value.
< Actual value must be smaller than the specified value.
* Insufficiently guaranteed value (tolerance +/- 10%).
** Insufficiently guaranteed value (tolerance +/- 5%).

ID Product type Application Engine speed Listed output

1 12V4000M53 Marine / ship main 1800 rpm 1380 kW Ref. 25 °C/25 °C;
propulsion 1851 bhp Heat exchanger instal-
1A continuous power, led on the engine
unlimited IMO Tier II (Marpol
convention)
EU nonroad St IIIA
(97/68/EC)
IMO Tier I Marpol
Comp
IMO Tier II Marpol
Comp
EPA Marine T2 Comp
(40CFR94)
2 12V4000M53 Marine / ship main 1800 rpm 1380 kW Ref. 25 °C/25 °C;
propulsion 1851 bhp Heat exchanger sepa-
1A continuous power, rate from engine
unlimited IMO Tier II (Marpol
convention)
EU nonroad St IIIA
(97/68/EC)
IMO Tier I Marpol
Comp
IMO Tier II Marpol
TIM-ID: 0000018490 - 002

Comp
EPA Marine T2 Comp
(40CFR94)

70 | Technical Data | MS15035/00E 2018-08

 ID Product type Application Engine speed Listed output
3 12V4000M53 Marine / ship main 1800 rpm 1380 kW Ref. 45 °C/32 °C;
propulsion 1851 bhp Heat exchanger instal-
1A continuous power, led on the engine
unlimited IMO Tier II (Marpol
convention)
EU nonroad St IIIA
(97/68/EC)
IMO Tier I Marpol
Comp
IMO Tier II Marpol
Comp
EPA Marine T2 Comp
(40CFR94)
4 12V4000M53 Marine / ship main 1800 rpm 1380 kW Ref. 45 °C/32 °C;
propulsion 1851 bhp Heat exchanger sepa-
1A continuous power, rate from engine
unlimited IMO Tier II (Marpol
convention)
EU nonroad St IIIA
(97/68/EC)
IMO Tier I Marpol
Comp
IMO Tier II Marpol
Comp
EPA Marine T2 Comp
(40CFR94)

Reference conditions
ID 1 2 3 4
Intake air temperature °C 25 25 45 45
Charge-air coolant temperature °C - - - -
Barometric pressure mbar 1000 1000 1000 1000
Site altitude above sea level m 100 100 100 100
Raw water inlet temperature °C 25 25 32 32

Performance data
ID 1 2 3 4
Rated engine speed A rpm 1800 1800 1800 1800
Fuel stop power ISO 3046 A kW 1380 1380 1380 1380

General conditions (for max. power)

TIM-ID: 0000018490 - 002

ID 1 2 3 4
Intake depression (new filter) A mbar 15 15 15 15
Intake depression, max. L mbar 30 30 30 30

MS15035/00E 2018-08 | Technical Data | 71

 Model related data (basic design)
ID 1 2 3 4
Cylinder arrangement: V angle Degrees 90 90 90 90
(°)
Bore mm 170 170 170 170
Stroke mm 210 210 210 210
Displacement of a cylinder Liters 4.77 4.77 4.77 4.77
Total displacement Liters 57.2 57.2 57.2 57.2

Raw-water circuit (open circuit)

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

Lube oil system

ID 1 2 3 4
Lube oil operating pressure before en- R bar 5.3 5.3 5.3 5.3
gine, from
Lube oil operating pressure before en- R bar 6.3 6.3 6.3 6.3
gine, to
Lube oil operating pressure (low idle) R bar 2.5 2.5 2.5 2.5
(meas. point: before engine)

Fuel system
ID 1 2 3 4
Fuel pressure at engine inlet connection, L bar -0.1 -0.1 -0.1 -0.1
min. (when engine is starting)
Fuel pressure at engine inlet connection, L bar -0.3 -0.3 -0.3 -0.3
min. (when engine is running)
Fuel pressure at engine inlet connection, L bar 1.5 1.5 1.5 1.5
max. (when engine is starting)
Fuel supply flow, max. normal operation R liters/min 7.3 10.3 7.3 10.3

General operating data

ID 1 2 3 4
TIM-ID: 0000018490 - 002

Firing speed, from R rpm 80 80 80 80

Firing speed, to R rpm 120 120 120 120

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

72 | Technical Data | MS15035/00E 2018-08

 Starter (with air/hydraulic starter motor)
ID 1 2 3 4
Starting-air pressure before starter mo- R bar 8 8 8 8
tor, min.
Starting air pressure before starter mo- R bar 9 9 9 9
tor, max.

Inclinations, standard oil system (reference: waterline)

ID 1 2 3 4
Longitudinal inclination, continuous max. L Degrees 17 17 17 17
driving end down (option: max. operating (°)
inclinations)
Longitudinal inclination, temporary max. L Degrees 19.5 19.5 19.5 19.5
driving end down (option: max. operating (°)
inclinations)
Longitudinal inclination, continuous max. L Degrees 15 15 15 15
driving end up (option: max. operating in- (°)
clinations)
Longitudinal inclination, temporary max., L Degrees 17.5 17.5 17.5 17.5
driving end up (option: max. operating in- (°)
clinations)
Transverse inclination, continuous max. L Degrees 15 15 15 15
(option: max. operating inclinations) (°)
Transverse inclination, temporary max. L Degrees 22.5 22.5 22.5 22.5
(option: max. operating inclinations) (°)

Capacities
ID 1 2 3 4
Engine coolant, engine side (with cooling R Liters 305 - 305 -
system)
Engine oil capacity, initial filling (standard R Liters 265 265 265 265
oil system) (option: max. operating incli-
nations)
Oil pan capacity at dipstick mark “min.” L Liters 195 195 195 195
(standard oil system) (option: max. oper-
ating inclinations)
Oil pan capacity at dipstick mark “max.” L Liters 235 235 235 235
(standard oil system) (option: max. oper-
ating inclinations)
TIM-ID: 0000018490 - 002

Weights / main dimensions

ID 1 2 3 4
Engine dry weight (with standard acces- R kg 7950 7600 7950 7600
sories installed, w/o coupling)
Heaviest component to be lifted during R kg 460 460 460 460
extended component maintenance (W5)

MS15035/00E 2018-08 | Technical Data | 73

 Sound
ID 1 2 3 4
Exhaust noise, unsilenced - BL (free-field R dB(A) 106 106 106 106
sound pressure level Lp, 1 m distance,
ISO 6798, +3 dB(A) tolerance)
Engine surface noise with attenuated in- R dB(A) 104 104 104 104
take noise (filter) - BL (free-field sound
power level Lp, 1 m distance, ISO 6798,
+2 dB(A) tolerance)

TIM-ID: 0000018490 - 002

74 | Technical Data | MS15035/00E 2018-08

 4.2 Product data 12V4000M63
Legend
DL Reference value: Continuous power. Continuous driving performance under standard conditions
BL Reference value: Fuel stop power. Maximum engine power. With some applications, not drivable on
continuous basis (adjustment reserve)
A Design value. Value required to design an external system (plant)
R Guideline value. Typical average value for information, only conditionally suitable for design
L Limit value. Value which must not be undershot (lower limit value, min. value) or exceeded (upper lim-
it value, max. value), not suitable for design
N Not yet defined value. Value not yet named/will not be named
- Not applicable. Module does not apply to this product type
X Applicable. Module applies to this product type
> Actual value must be greater than the specified value.
< Actual value must be smaller than the specified value.
* Insufficiently guaranteed value (tolerance +/- 10%).
** Insufficiently guaranteed value (tolerance +/- 5%).

ID Product type Application Engine speed Listed output

1 12V4000M63 Marine / ship main 1800 rpm 1500 kW Ref. 25 °C/25 °C;
propulsion 2012 bhp Heat exchanger instal-
1A continuous power, led on the engine
unlimited IMO Tier II (Marpol
convention)
EU nonroad St IIIA
(97/68/EC)
IMO Tier I Marpol
Comp
IMO Tier II Marpol
Comp
EPA Marine T2 Comp
(40CFR94)
2 12V4000M63 Marine / ship main 1800 rpm 1500 kW Ref. 25 °C/25 °C;
propulsion 2012 bhp Heat exchanger sepa-
1A continuous power, rate from engine
unlimited IMO Tier II (Marpol
convention)
EU nonroad St IIIA
(97/68/EC)
IMO Tier I Marpol
Comp
IMO Tier II Marpol
Comp
EPA Marine T2 Comp
(40CFR94)
TIM-ID: 0000010626 - 003

MS15035/00E 2018-08 | Technical Data | 75

 ID Product type Application Engine speed Listed output
3 12V4000M63 Marine / ship main 1800 rpm 1500 kW Ref. 45 °C/32 °C;
propulsion 2012 bhp Heat exchanger instal-
1A continuous power, led on the engine
unlimited IMO Tier II (Marpol
convention)
EU nonroad St IIIA
(97/68/EC)
IMO Tier I Marpol
Comp
IMO Tier II Marpol
Comp
EPA Marine T2 Comp
(40CFR94)
4 12V4000M63 Marine / ship main 1800 rpm 1500 kW Ref. 45 °C/32 °C;
propulsion 2012 bhp Heat exchanger sepa-
1A continuous power, rate from engine
unlimited IMO Tier II (Marpol
convention)
EU nonroad St IIIA
(97/68/EC)
IMO Tier I Marpol
Comp
IMO Tier II Marpol
Comp
EPA Marine T2 Comp
(40CFR94)

Reference conditions
ID 1 2 3 4
Intake air temperature °C 25 25 45 45
Charge-air coolant temperature °C - - - -
Barometric pressure mbar 1000 1000 1000 1000
Site altitude above sea level m 100 100 100 100
Raw water inlet temperature °C 25 25 32 32

Performance data
ID 1 2 3 4
Rated engine speed A rpm 1800 1800 1800 1800
Fuel stop power ISO 3046 A kW 1500 1500 1500 1500

General conditions (for max. power)

TIM-ID: 0000010626 - 003

ID 1 2 3 4
Intake depression (new filter) A mbar 15 15 15 15
Intake depression, max. L mbar 30 30 30 30

76 | Technical Data | MS15035/00E 2018-08

 Model related data (basic design)
ID 1 2 3 4
Cylinder arrangement: V angle Degrees 90 90 90 90
(°)
Bore mm 170 170 170 170
Stroke mm 210 210 210 210
Displacement of a cylinder Liters 4.77 4.77 4.77 4.77
Total displacement Liters 57.2 57.2 57.2 57.2

Raw-water circuit (open circuit)

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

Lube oil system

ID 1 2 3 4
Lube oil operating temperature before R °C 86 86 87 87
engine, from
Lube oil operating temperature before R °C 94 94 95 95
engine, to
Lube oil operating pressure before en- R bar 5.3 5.3 5.3 5.3
gine, from
Lube oil operating pressure before en- R bar 6.3 6.3 6.3 6.3
gine, to
Lube oil operating pressure (low idle) R bar 2.5 2.5 2.5 2.5
(meas. point: before engine)

Fuel system
ID 1 2 3 4
Fuel pressure at engine inlet connection, L bar -0.1 -0.1 -0.1 -0.1
min. (when engine is starting)
Fuel pressure at engine inlet connection, L bar -0.3 -0.3 -0.3 -0.3
min. (when engine is running)
Fuel pressure at engine inlet connection, L bar 1.5 1.5 1.5 1.5
max. (when engine is starting)
Fuel supply flow, max. normal operation R liters/min 7.8 10.8 7.8 10.8
TIM-ID: 0000010626 - 003

General operating data

ID 1 2 3 4
Firing speed, from R rpm 80 80 80 80
Firing speed, to R rpm 120 120 120 120

MS15035/00E 2018-08 | Technical Data | 77

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

Starter (with air/hydraulic starter motor)

ID 1 2 3 4
Starting-air pressure before starter mo- R bar 8 8 8 8
tor, min.
Starting air pressure before starter mo- R bar 9 9 9 9
tor, max.

Inclinations, standard oil system (reference: waterline)

ID 1 2 3 4
Longitudinal inclination, continuous max. L Degrees 17 17 17 17
driving end down (option: max. operating (°)
inclinations)
Longitudinal inclination, temporary max. L Degrees 19.5 19.5 19.5 19.5
driving end down (option: max. operating (°)
inclinations)
Longitudinal inclination, continuous max. L Degrees 15 15 15 15
driving end up (option: max. operating in- (°)
clinations)
Longitudinal inclination, temporary max., L Degrees 17.5 17.5 17.5 17.5
driving end up (option: max. operating in- (°)
clinations)
Transverse inclination, continuous max. L Degrees 15 15 15 15
(option: max. operating inclinations) (°)
Transverse inclination, temporary max. L Degrees 22.5 22.5 22.5 22.5
(option: max. operating inclinations) (°)

Capacities
ID 1 2 3 4
Engine coolant, engine side (with cooling R Liters 305 - 305 -
system)
Engine oil capacity, initial filling (standard R Liters 265 265 265 265
oil system) (option: max. operating incli-
nations)
Oil pan capacity at dipstick mark “min.” L Liters 195 195 195 195
(standard oil system) (option: max. oper-
ating inclinations)
TIM-ID: 0000010626 - 003

Oil pan capacity at dipstick mark “max.” L Liters 235 235 235 235
(standard oil system) (option: max. oper-
ating inclinations)

78 | Technical Data | MS15035/00E 2018-08

 Weights / main dimensions
ID 1 2 3 4
Engine dry weight (with standard acces- R kg 7950 7600 7950 7600
sories installed, w/o coupling)
Heaviest component to be lifted during R kg 460 460 460 460
extended component maintenance (W5)

Sound
ID 1 2 3 4
Exhaust noise, unsilenced - BL (free-field R dB(A) 107 107 107 107
sound pressure level Lp, 1 m distance,
ISO 6798, +3 dB(A) tolerance)
Engine surface noise with attenuated in- R dB(A) 105 105 105 105
take noise (filter) - BL (free-field sound
power level Lp, 1 m distance, ISO 6798,
+2 dB(A) tolerance)
TIM-ID: 0000010626 - 003

MS15035/00E 2018-08 | Technical Data | 79

 4.3 Product data 16V4000M53
Legend
DL Reference value: Continuous power. Continuous driving performance under standard conditions
BL Reference value: Fuel stop power. Maximum engine power. With some applications, not drivable on
continuous basis (adjustment reserve)
A Design value. Value required to design an external system (plant)
R Guideline value. Typical average value for information, only conditionally suitable for design
L Limit value. Value which must not be undershot (lower limit value, min. value) or exceeded (upper lim-
it value, max. value), not suitable for design
N Not yet defined value. Value not yet named/will not be named
- Not applicable. Module does not apply to this product type
X Applicable. Module applies to this product type
> Actual value must be greater than the specified value.
< Actual value must be smaller than the specified value.
* Insufficiently guaranteed value (tolerance +/- 10%).
** Insufficiently guaranteed value (tolerance +/- 5%).

ID Product type Application Engine speed Listed output

1 16V4000M53 Marine / ship main 1800 rpm 1840 kW Ref. 25 °C/25 °C;
propulsion 2467 bhp Heat exchanger instal-
1A continuous power, led on the engine
unlimited IMO Tier II (Marpol
convention)
EU nonroad St IIIA
(97/68/EC)
IMO Tier I Marpol
Comp
IMO Tier II Marpol
Comp
EPA Marine T2 Comp
(40CFR94)
2 16V4000M53 Marine / ship main 1800 rpm 1840 kW Ref. 25 °C/25 °C;
propulsion 2467 bhp Heat exchanger sepa-
1A continuous power, rate from engine
unlimited IMO Tier II (Marpol
convention)
EU nonroad St IIIA
(97/68/EC)
IMO Tier I Marpol
Comp
IMO Tier II Marpol
Comp
EPA Marine T2 Comp
(40CFR94)
TIM-ID: 0000018491 - 002

80 | Technical Data | MS15035/00E 2018-08

 ID Product type Application Engine speed Listed output
3 16V4000M53 Marine / ship main 1800 rpm 1840 kW Ref. 45 °C/32 °C;
propulsion 2467 bhp Heat exchanger instal-
1A continuous power, led on the engine
unlimited IMO Tier II (Marpol
convention)
EU nonroad St IIIA
(97/68/EC)
IMO Tier I Marpol
Comp
IMO Tier II Marpol
Comp
EPA Marine T2 Comp
(40CFR94)
4 16V4000M53 Marine / ship main 1800 rpm 1840 kW Ref. 45 °C/32 °C;
propulsion 2467 bhp Heat exchanger sepa-
1A continuous power, rate from engine
unlimited IMO Tier II (Marpol
convention)
EU nonroad St IIIA
(97/68/EC)
IMO Tier I Marpol
Comp
IMO Tier II Marpol
Comp
EPA Marine T2 Comp
(40CFR94)

Reference conditions
ID 1 2 3 4
Intake air temperature °C 25 25 45 45
Charge-air coolant temperature °C - - - -
Barometric pressure mbar 1000 1000 1000 1000
Site altitude above sea level m 100 100 100 100
Raw water inlet temperature °C 25 25 32 32

Performance data
ID 1 2 3 4
Rated engine speed A rpm 1800 1800 1800 1800
Fuel stop power ISO 3046 A kW 1840 1840 1840 1840

General conditions (for max. power)

TIM-ID: 0000018491 - 002

ID 1 2 3 4
Intake depression (new filter) A mbar 15 15 15 15
Intake depression, max. L mbar 30 30 30 30

MS15035/00E 2018-08 | Technical Data | 81

 Model related data (basic design)
ID 1 2 3 4
Cylinder arrangement: V angle Degrees 90 90 90 90
(°)
Bore mm 170 170 170 170
Stroke mm 210 210 210 210
Displacement of a cylinder Liters 4.77 4.77 4.77 4.77
Total displacement Liters 76.3 76.3 76.3 76.3

Raw-water circuit (open circuit)

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

Lube oil system

ID 1 2 3 4
Lube oil operating pressure before en- R bar 5.3 5.3 5.3 5.3
gine, from
Lube oil operating pressure before en- R bar 6.3 6.3 6.3 6.3
gine, to
Lube oil operating pressure (low idle) R bar 2.5 2.5 2.5 2.5
(meas. point: before engine)

Fuel system
ID 1 2 3 4
Fuel pressure at engine inlet connection, L bar -0.1 -0.1 -0.1 -0.1
min. (when engine is starting)
Fuel pressure at engine inlet connection, L bar -0.3 -0.3 -0.3 -0.3
min. (when engine is running)
Fuel pressure at engine inlet connection, L bar 1.5 1.5 1.5 1.5
max. (when engine is starting)
Fuel supply flow, max. normal operation R liters/min 9.3 13.3 9.3 13.3

General operating data

ID 1 2 3 4
TIM-ID: 0000018491 - 002

Firing speed, from R rpm 80 80 80 80

Firing speed, to R rpm 120 120 120 120

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

82 | Technical Data | MS15035/00E 2018-08

 Starter (with air/hydraulic starter motor)
ID 1 2 3 4
Starting-air pressure before starter mo- R bar 8 8 8 8
tor, min.
Starting air pressure before starter mo- R bar 9 9 9 9
tor, max.

Inclinations, standard oil system (reference: waterline)

ID 1 2 3 4
Longitudinal inclination, continuous max. L Degrees 17 17 17 17
driving end down (option: max. operating (°)
inclinations)
Longitudinal inclination, temporary max. L Degrees 19.5 19.5 19.5 19.5
driving end down (option: max. operating (°)
inclinations)
Longitudinal inclination, continuous max. L Degrees 12 12 12 12
driving end up (option: max. operating in- (°)
clinations)
Longitudinal inclination, temporary max., L Degrees 14.5 14.5 14.5 14.5
driving end up (option: max. operating in- (°)
clinations)
Transverse inclination, continuous max. L Degrees 15 15 15 15
(option: max. operating inclinations) (°)
Transverse inclination, temporary max. L Degrees 22.5 22.5 22.5 22.5
(option: max. operating inclinations) (°)

Capacities
ID 1 2 3 4
Engine coolant, engine side (with cooling R Liters 350 - 350 -
system)
Engine oil capacity, initial filling (standard R Liters 280 280 280 280
oil system) (option: max. operating incli-
nations)
Oil pan capacity at dipstick mark “min.” L Liters 211 211 210 210
(standard oil system) (option: max. oper-
ating inclinations)
Oil pan capacity at dipstick mark “max.” L Liters 250 250 250 250
(standard oil system) (option: max. oper-
ating inclinations)
TIM-ID: 0000018491 - 002

Weights / main dimensions

ID 1 2 3 4
Engine dry weight (with standard acces- R kg 9260 8950 9260 8950
sories installed, w/o coupling)
Heaviest component to be lifted during R kg 460 460 460 460
extended component maintenance (W5)

MS15035/00E 2018-08 | Technical Data | 83

 22. Sound
ID 1 2 3 4
Exhaust noise, unsilenced - BL (free-field R dB(A) 111 111 111 111
sound pressure level Lp, 1 m distance,
ISO 6798, +3 dB(A) tolerance)

TIM-ID: 0000018491 - 002

84 | Technical Data | MS15035/00E 2018-08

 4.4 Product data 16V4000M63
Legend
DL Reference value: Continuous power. Continuous driving performance under standard conditions
BL Reference value: Fuel stop power. Maximum engine power. With some applications, not drivable on
continuous basis (adjustment reserve)
A Design value. Value required to design an external system (plant)
R Guideline value. Typical average value for information, only conditionally suitable for design
L Limit value. Value which must not be undershot (lower limit value, min. value) or exceeded (upper lim-
it value, max. value), not suitable for design
N Not yet defined value. Value not yet named/will not be named
- Not applicable. Module does not apply to this product type
X Applicable. Module applies to this product type
> Actual value must be greater than the specified value.
< Actual value must be smaller than the specified value.
* Insufficiently guaranteed value (tolerance +/- 10%).
** Insufficiently guaranteed value (tolerance +/- 5%).

ID Product type Application Engine speed Listed output

1 16V4000M63 Marine / ship main 1800 rpm 2000 kW Ref. 25 °C/25 °C;
propulsion 2682 bhp Heat exchanger instal-
1A continuous power, led on the engine
unlimited IMO Tier II (Marpol
convention)
EU nonroad St IIIA
(97/68/EC)
IMO Tier I Marpol
Comp
IMO Tier II Marpol
Comp
EPA Marine T2 Comp
(40CFR94)
2 16V4000M63 Marine / ship main 1800 rpm 2000 kW Ref. 25 °C/25 °C;
propulsion 2682 bhp Heat exchanger sepa-
1A continuous power, rate from engine
unlimited IMO Tier II (Marpol
convention)
EU nonroad St IIIA
(97/68/EC)
IMO Tier I Marpol
Comp
IMO Tier II Marpol
Comp
EPA Marine T2 Comp
(40CFR94)
TIM-ID: 0000010816 - 003

MS15035/00E 2018-08 | Technical Data | 85

 ID Product type Application Engine speed Listed output
3 16V4000M63 Marine / ship main 1800 rpm 2000 kW Ref. 45 °C/32 °C;
propulsion 2682 bhp Heat exchanger instal-
1A continuous power, led on the engine
unlimited IMO Tier II (Marpol
convention)
EU nonroad St IIIA
(97/68/EC)
IMO Tier I Marpol
Comp
IMO Tier II Marpol
Comp
EPA Marine T2 Comp
(40CFR94)
4 16V4000M63 Marine / ship main 1800 rpm 2000 kW Ref. 45 °C/32 °C;
propulsion 2682 bhp Heat exchanger sepa-
1A continuous power, rate from engine
unlimited IMO Tier II (Marpol
convention)
EU nonroad St IIIA
(97/68/EC)
IMO Tier I Marpol
Comp
IMO Tier II Marpol
Comp
EPA Marine T2 Comp
(40CFR94)

Reference conditions
ID 1 2 3 4
Intake air temperature °C 25 25 45 45
Charge-air coolant temperature °C - - - -
Barometric pressure mbar 1000 1000 1000 1000
Site altitude above sea level m 100 100 100 100
Raw water inlet temperature °C 25 25 32 32

Performance data
ID 1 2 3 4
Rated engine speed A rpm 1800 1800 1800 1800
Fuel stop power ISO 3046 A kW 2000 2000 2000 2000

General conditions (for max. power)

TIM-ID: 0000010816 - 003

ID 1 2 3 4
Intake depression (new filter) A mbar 15 15 15 15
Intake depression, max. L mbar 30 30 30 30

86 | Technical Data | MS15035/00E 2018-08

 Model related data (basic design)
ID 1 2 3 4
Cylinder arrangement: V angle Degrees 90 90 90 90
(°)
Bore mm 170 170 170 170
Stroke mm 210 210 210 210
Displacement of a cylinder Liters 4.77 4.77 4.77 4.77
Total displacement Liters 76.3 76.3 76.3 76.3

Raw-water circuit (open circuit)

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

Lube oil system

ID 1 2 3 4
Lube oil operating pressure before en- R bar 5.3 5.3 5.3 5.3
gine, from
Lube oil operating pressure before en- R bar 6.3 6.3 6.3 6.3
gine, to
Lube oil operating pressure (low idle) R bar 2.5 2.5 2.5 2.5
(meas. point: before engine)

Fuel system
ID 1 2 3 4
Fuel pressure at engine inlet connection, L bar -0.1 -0.1 -0.1 -0.1
min. (when engine is starting)
Fuel pressure at engine inlet connection, L bar -0.3 -0.3 -0.3 -0.3
min. (when engine is running)
Fuel pressure at engine inlet connection, L bar 1.5 1.5 1.5 1.5
max. (when engine is starting)
Fuel supply flow, max. normal operation R liters/min 10.0 14.0 10.0 14.0

General operating data

ID 1 2 3 4
TIM-ID: 0000010816 - 003

Firing speed, from R rpm 80 80 80 80

Firing speed, to R rpm 120 120 120 120

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

MS15035/00E 2018-08 | Technical Data | 87

 Starter (with air/hydraulic starter motor)
ID 1 2 3 4
Starting-air pressure upstream of starter R bar 8 8 8 8
motor, min.
Starting-air pressure upstream of starter R bar 9 9 9 9
motor, max.

Inclinations, standard oil system (reference: waterline)

ID 1 2 3 4
Longitudinal inclination, continuous max. L Degrees 17 17 17 17
driving end down (option: max. operating (°)
inclinations)
Longitudinal inclination, temporary max. L Degrees 19.5 19.5 19.5 19.5
driving end down (option: max. operating (°)
inclinations)
Longitudinal inclination, continuous max. L Degrees 12 12 12 12
driving end up (option: max. operating in- (°)
clinations)
Longitudinal inclination, temporary max., L Degrees 14.5 14.5 14.5 14.5
driving end up (option: max. operating in- (°)
clinations)
Transverse inclination, continuous max. L Degrees 15 15 15 15
(option: max. operating inclinations) (°)
Transverse inclination, temporary max. L Degrees 22.5 22.5 22.5 22.5
(option: max. operating inclinations) (°)

Capacities
ID 1 2 3 4
Engine coolant, engine side (with cooling R Liters 350 - 350 -
system)
Engine oil capacity, initial filling (standard R Liters 280 280 280 280
oil system) (option: max. operating incli-
nations)
Oil pan capacity at dipstick mark “min.” L Liters 211 211 210 210
(standard oil system) (option: max. oper-
ating inclinations)
Oil pan capacity at dipstick mark “max.” L Liters 250 250 250 250
(standard oil system) (option: max. oper-
ating inclinations)
TIM-ID: 0000010816 - 003

Weights / main dimensions

ID 1 2 3 4
Engine dry weight (with standard acces- R kg 9260 8950 9260 8950
sories installed, w/o coupling)
Heaviest component to be lifted during R kg 460 460 460 460
extended component maintenance (W5)

88 | Technical Data | MS15035/00E 2018-08

 Sound
ID 1 2 3 4
Exhaust noise, unsilenced - BL (free-field R dB(A) 110 110 110 110
sound pressure level Lp, 1 m distance,
ISO 6798, +3 dB(A) tolerance)
TIM-ID: 0000010816 - 003

MS15035/00E 2018-08 | Technical Data | 89

 4.5 Firing order
Cylinders Firing order
12V A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1
16V A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B7

TIM-ID: 0000023263 - 003

90 | Technical Data | MS15035/00E 2018-08

 4.6 Engine – Main dimensions

Engines with horizontal air intake

With remote heat exchanger
Engine model Length (A) Width (B) without Width (B) with si- Height (C)
silencer lencer
12V 4000 M53/63 approx. 2638 mm approx. 1690 mm approx. 1850 mm approx. 2071 mm
16V 4000 M53/63 approx. 3108 mm approx. 1690 mm approx. 1850 mm approx. 2064 mm

With engine-mounted heat exchanger

TIM-ID: 0000069560 - 001

Engine model Length (A) Width (B) without Width (B) with si- Height (C)
silencer lencer
12V 4000 M53/63 approx. 2857 mm approx. 1690 mm approx. 1850 mm approx. 2071 mm
16V 4000 M53/63 approx. 3388 mm approx. 1690 mm approx. 1850 mm approx. 2064 mm

MS15035/00E 2018-08 | Technical Data | 91

 Engines with vertical air intake
With remote heat exchanger
Engine model Length (A) Width (B) Height (C) without Height (C) with si-
silencer lencer
12V 4000 M53/63 approx. 2628 mm approx. 1613 mm approx. 2368 mm approx. 2448 mm
16V 4000 M53/63 approx. 3108 mm approx. 1613 mm approx. 2361 mm approx. 2441 mm

With engine-mounted heat exchanger

Engine model Length (A) Width (B) Height (C) without Height (C) with si-
silencer lencer
12V 4000 M53/63 approx. 2861 mm approx. 1613 mm approx. 2368 mm approx. 2448 mm
16V 4000 M53/63 approx. 3388 mm approx. 1613 mm approx. 2361 mm approx. 2441 mm

TIM-ID: 0000069560 - 001

92 | Technical Data | MS15035/00E 2018-08

 5 Operation
5.1 Controls
Automation system controls
Refer to automation system operating instructions
TIM-ID: 0000016959 - 003

MS15035/00E 2018-08 | Operation | 93

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

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

months)
Item Task
Engine Depreserve (→ Preservation and Represervation Specifications A001070/..).
Valve drive Lubricate valve gear every ≥ 6 months (→ Page 166).
Lube oil system Check engine oil level (→ Page 211);
Preheat engine oil if required.
Fuel prefilter Prime with fuel (→ Page 194)
Fuel prefilter, pressure Align adjustable pointer with position of pressure indicator (→ Page 189).
gauge
HP fuel pump Only for engines without oil priming pump:
Fill HP fuel pump with fresh engine oil (→ Page 171).
Raw water pump (if located Prime with water (approx. 3 to 4 liters).
above waterline (only appli-
cable to engines with en-
gine-mounted heat exchang-
er or with optional remote
heat exchanger))
Coolant circuit If engine is out of service for more than one year, change engine coolant
(→ Page 226).
Coolant circuit Check coolant level (→ Page 225).
Coolant circuit Preheat coolant with preheating unit.
Engine control system Refer to automation system operating instructions.
ECU Check plug connections (→ Page 259).
EMU Check plug connections (→ Page 260)
EIM Check plug connections (→ Page 261).
TIM-ID: 0000010092 - 006

94 | Operation | MS15035/00E 2018-08

 5.3 Putting the engine into operation after scheduled out-of-
service-period
Preconditions
☑ Engine is stopped and starting disabled.

Putting into operation

Item Task
Lube oil system Check engine oil level (→ Page 211);
Preheat engine oil if required.
Coolant system Check coolant level (→ Page 225).
Coolant system Preheat coolant with preheating unit.
Fuel prefilter Drain (→ Page 190);
Check that suction-side pressure indicated at the fuel prefilter pressure
gauge is within the limit (→ Page 189).
Engine control system Refer to automation system operating instructions.
ECU Check plug connections (→ Page 259).
EIM Check plug connections (→ Page 261).
EMU Check plug connections (→ Page 260).
TIM-ID: 0000010655 - 004

MS15035/00E 2018-08 | Operation | 95

 5.4 Starting the engine
Start the engine via the automation system
Refer to automation system operating instructions

TIM-ID: 0000017525 - 003

96 | Operation | MS15035/00E 2018-08

 5.5 Re-starting the engine following an automatic safety
shutdown
NOTICE
Re-starting the engine following an automatic safety shutdown.
Risk of severe engine damage!
• Before starting the engine, make sure the root cause of the safety shutdown was eliminated.
• If the root cause cannot be identified or eliminated, contact Service.

Note: • If an engine has been shutdown by a fault (red alarm), the engine may only be re-started when the fault
has been identified and eliminated.

Procedure following an automatic safety shutdown

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

MS15035/00E 2018-08 | Operation | 97

 5.6 Stopping the engine
Stopping the engine via the automation system
Refer to automation system operating instructions

TIM-ID: 0000017528 - 004

98 | Operation | MS15035/00E 2018-08

 5.7 Operational checks
DANGER
Components are moving or rotating.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Operate the engine at low load only. Keep clear of the danger zone of the engine.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

Operational checks
Item Task
Engine under load Check engine visually for leaks and general condition; Check air pipework be-
Engine at nominal speed tween air filter and exhaust turbocharger for leaks and damage.
Check for abnormal running noise, vibration, and exhaust color (→ Page 115).
Air filter Check signal ring position of service indicator (→ Page 209).
Replace air filter (→ Page 207), if the signal ring is completely visible in the
service indicator control window.
HP fuel pump Check relief bores for fuel discharge (→ Page 173).
HT coolant pump Check relief bore for oil and coolant discharge and obstructions
(→ Page 232).
Fuel prefilter (optional) Check reading on differential pressure gage (→ Page 189);
Drain water and contaminants (→ Page 192).
Raw water pump (only on Check relief bore for oil and coolant discharge and obstructions
engines with engine-mount- (→ Page 239).
ed or optional remote heat
exchanger)
Bilge pump (optional) Check relief bore for oil and coolant discharge and obstructions
(→ Page 241).
TIM-ID: 0000018474 - 005

MS15035/00E 2018-08 | Operation | 99

 5.8 Emission label – Check

Emission label – Check

Note: If there are any irregularities, notify your MTU contact person/service partner without delay.
1. Check that emission labels are present (there can be more than one).
2. Check emission label for intactness.
3. Check that emission label is fully legible.
4. Check content of emission label:
• Does the label on the engine match the label document in the Business Portal/Equipment?
• Does the engine number on the emission label match the engine identification plate?
• Does the Manufacturing Date match the year of manufacture on the identification plate?

TIM-ID: 0000063752 - 002

100 | Operation | MS15035/00E 2018-08

 5.9 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 103).
2. Shut down fuel treatment system (→ Page 107).
TIM-ID: 0000007730 - 006

MS15035/00E 2018-08 | Operation | 101

 5.10 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 106).
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

102 | Operation | MS15035/00E 2018-08

 5.11 Fuel treatment system – Initial start-up

Overview of fuel treatment system

1 Pressure-free overflow 9 Ball valve, outlet 17 Automatic water drain

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

Switching on fuel treatment system

1. Switch on fuel treatment system (→ Page 106).
2. Check differential pressure at differential pressure gage (8). Differential pressure in a new system: 0.1 bar to
0.3 bar.
Result: If no differential pressure is measured, the coalescer filter element is probably being bypassed.
TIM-ID: 0000015773 - 007

1. Remove coalescer filter element (→ Page 247).

2. Check sealing surfaces on coalescer filter element and in the pressure tank.

MS15035/00E 2018-08 | Operation | 103

 Initial start-up: HAT
1. Replace fuel filter on engine (→ Page 187).
Note: Determine the suction pressure upstream of the engine-mounted fuel delivery pump.
2. Install pressure gage in fuel supply line from Yard fuel system to engine.
3. Switch on fuel treatment system and operate it for some minutes (→ Page 106).
Result: Fuel is drawn from the tank (24). It is then cleaned and dewatered via the filter water separator (15). It is
then returned to the tank (24) via the overflow tank (14). Water settled in the tank is separated.
4. Start engine (→ Page 96).
5. Run engine at idling speed.
6. Check suction pressure (see technical data of the engine) at the engine-mounted fuel delivery pump.
Note: If the suction pressure is within the admissible limits and engine operation is satisfactory.
7. Increase engine speed to 1000 rpm and monitor suction pressure.
8. Check suction pressure at the engine-mounted fuel delivery pump.
Result: If the values are within the limits specified by the manufacturer, the system is ready to start filter replace-
ment simulation with the engine running as part of the Harbor Acceptance Tests.

Simulating filter replacement with the engine running: HAT

1. Switch on fuel treatment system (→ Page 106).
2. Start engine (→ Page 96).
3. Run engine at idling speed.
4. Close ball valve (5) at inlet to fuel treatment system.
Result: The pressure upstream of the fuel treatment system increases until the overflow valve at the pump unit
opens and fuel flows through bypass (3) and bypass (2).
5. Open ball valve (19) .
Result: Fuel emerges. If no fuel emerges:
• Open ball valve (5) at inlet to fuel treatment system.
• No function of bypasses (2) and (3); carry out functional test of bypasses (2) and (3) .
6. Check suction pressure (see technical data of the engine) at the fuel delivery pump.
Note: If the suction pressure is within the admissible limits and engine operation is satisfactory.
7. Increase engine speed to 1000 rpm and monitor suction pressure.
Result: If all engine operating values are within the specified limits, open ball valve (5) at inlet to fuel treatment sys-
tem.

Simulating power failure (emergency): HAT

1. Switch on fuel treatment system (→ Page 106).
2. Start engine (→ Page 96).
3. Run engine at idling speed.
4. Switch off pump (21) at switchgear cabinet (20).
Result: The engine-mounted fuel delivery pump draws fuel via bypass (2) directly from tank (24).
5. Check suction pressure at the engine-mounted fuel delivery pump.
Note: If the suction pressure is within the admissible limits and engine operation is satisfactory.
6. Increase engine speed to 1000 rpm and monitor suction pressure.
Result: Simulation was successful if the suction pressure is within the specified limits.
TIM-ID: 0000015773 - 007

104 | Operation | MS15035/00E 2018-08

 Simulating power failure (emergency): SAT
1. Switch on fuel treatment system (→ Page 106).
2. Start engine (→ Page 96).
3. Run engine at idling speed.
4. Switch off pump (21) at switchgear cabinet (20).
Result: The engine-mounted fuel delivery pump draws fuel via bypass (2) directly from tank (24).
5. Check suction pressure at the engine-mounted fuel delivery pump.
Note: If the suction pressure is within the admissible limits and engine operation is satisfactory.
6. Operate engine at full load and monitor suction pressure.
Result: Simulation was successful if the suction pressure is within the specified limits.
TIM-ID: 0000015773 - 007

MS15035/00E 2018-08 | Operation | 105

 5.12 Fuel treatment system – Switching on
Preconditions
☑ The on-board power supply is switched on.

NOTICE
Risk of damage to engine/system.
Risk of severe damage to property!
• Before switching on, ensure that the engine/system is ready for operation.
• Before switching on, ensure that all housings are closed.
• Before switching on, ensure that no work is in progress anywhere on the entire system.

Fuel treatment system – Switching on

1. Carry out checks prior to start-up (→ Page 102).
2. Switch on master switch on switchgear cabinet.
Result: Signal lamp “Control voltage present” lights up.
3. Switch on switch for pump.
Result: Signal lamp “Pump running” lights up.

TIM-ID: 0000007731 - 006

106 | Operation | MS15035/00E 2018-08

 5.13 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

MS15035/00E 2018-08 | Operation | 107

 5.14 Emergency engine stop
NOTICE
An emergency stop subjects the engine system to an extremely high load.
Risk of overheating, damage to components!
• Trigger an emergency stop only in emergency situations.

Emergency stop
1. Refer to automation system operating instructions.
2. Follow instructions.

TIM-ID: 0000017530 - 006

108 | Operation | MS15035/00E 2018-08

 5.15 After shutdown
Preconditions
☑ MTU Preservation and Represervation Specifications (A001070/..) are available.

After shutdown
Item Task
Coolant circuit Drain coolant (→ Page 227) if:
• freezing temperatures are to be expected and the engine is to remain out
of service for an extended period but the coolant has no antifreeze addi-
tive;
• engine room is not heated;
• coolant is not kept at a suitable temperature;
• antifreeze concentration is insufficient for the engine-room temperature;
• antifreeze concentration is 50% and engine-room temperature is below
-40 °C.
Raw water (only on engines Drain
with engine-mounted heat • if freezing temperatures are to be expected and the engine is to remain
exchanger) out of service for an extended period.
Engine control system Switch off.
Air intake and exhaust sys- Out-of-service-period > 1 week
tem
• Seal engine on air and exhaust sides.
Out-of-service-period > 1 month
• Carry out engine preservation (→ MTU Preservation and Represervation
Specifications A001070/..).
TIM-ID: 0000010168 - 005

MS15035/00E 2018-08 | Operation | 109

 5.16 Plant – Cleaning
Preconditions
☑ Engine is stopped and starting disabled.
☑ No operating voltage applied.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
High-pressure cleaner (→ Tools Catalog) 1
Cleaner (Hakupur 50/136) X00056700 1

WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.

WARNING
Water jet from high-pressure cleaning unit.
Risk of eye injury, risk of scalding!
• Do not direct water jet at persons.
• Wear protective clothing, protective gloves, and goggles/safety mask.

NOTICE
Cleaning agents should not be left to take effect for too long.
Damage to components is possible!
• Observe manufacturer's instructions.

NOTICE
Blowing down product with compressed air.
Entry of dirt and damage to components is possible!
• Do not aim compressed air gun directly at seals or electronic components such as connectors or
ECUs.

Cleaning the plant

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

• The temperature of the cleaning medium must not exceed 80 °C.

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

110 | Operation | MS15035/00E 2018-08

 6 Maintenance
6.1 Maintenance task reference table [QL1] for EPA regions
The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Mainte-
nance Schedule is a stand-alone publication.
The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance
Schedule.
Option

Task Maintenance tasks

W0500 Check engine oil level. (→ Page 211)

W0501 Carry out visual inspection of engine for general condition (→ Page 99)
and leaks.
W0503 Inspect service indicator of air filter. (→ Page 209)
W0504 Check the inspection bores of the HP fuel pump. (→ Page 99)
W0505 Check relief bores of coolant pump(s). (→ Page 232)
W0506 Check for abnormal running noises, exhaust gas color and (→ Page 99)
vibration.
W0507 Drain off water and contamination from fuel prefilter. (→ Page 99)
W0508 X Check differential pressure gauge of fuel prefilter. (→ Page 99)
W1001 Fit new fuel filter or new fuel filter insert. (→ Page 187)
W1005 X Fit new air filters. (→ Page 207)
W1006 Replace fuel injectors. (→ Page 174)
W1008 X Fit new engine oil filters each time the engine oil is changed (→ Page 219)
or, at the latest, on expiry of the time limit (given in years).
W1009 Check thickness of oil residue layer. Clean. Fit new sleeve, (→ Page 221)
at the latest, each time the engine oil is changed.
W1011 Inspect cylinder chambers using endoscope. (→ Page 161)
W1016 X Check condition of coupling. (→ Page 240)
W1055 X Fit new oil separators. (→ Page 165)
W1076 Clean compressor wheel. (→ Page 198)
W1207 Check valve clearance, adjust if required. ATTENTION! Initial (→ Page 167)
adjustment after 1,000 operating hours and subsequently
1,000 operating hours after each cylinder-head overhaul..
W1244 X Check function of bar electrode. (→ Page 245)
TIM-ID: 0000083706 - 001

W1245 X Check alarm function of differential pressure gauge. (→ Page 244)

W1246 X Check pump capacity. (→ Page 246)
W1463 Carry out visual inspection of engine mounts for general (→ Page 242)
condition.
W1477 X Overhaul preheater / jacket water heater. (→ Page 237)
W1481 Replace intermediate fuel filter of filter element of inter- (→ Page 184)
mediate fuel filter.
W1675 X Fit new fuel prefilter or new fuel prefilter insert. (→ Page 194)

MS15035/00E 2018-08 | Maintenance | 111

 Option
Task Maintenance tasks

W1713 Injector: reset drift compensation parameters (CDC). (→ Page 268)

W1864 X Check and clean oil indicator filter. (→ Page 216)

Table 2: Maintenance task reference table [QL1]

TIM-ID: 0000083706 - 001

112 | Maintenance | MS15035/00E 2018-08

 6.2 Maintenance task reference table [QL1] for Non EPA regions
The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Mainte-
nance Schedule is a stand-alone publication.
The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance
Schedule. Option
Task Maintenance tasks

W0500 Check engine oil level. (→ Page 211)

W0501 Carry out visual inspection of engine for general condition (→ Page 99)
and leaks.
W0502 Inspect intercooler drain system. (→ Page 206)
W0503 Inspect service indicator of air filter. (→ Page 209)
W0504 Check the inspection bores of the HP fuel pump. (→ Page 99)
W0505 Check relief bores of coolant pump(s). (→ Page 232)
W0506 Check for abnormal running noises, exhaust gas color and (→ Page 99)
vibration.
W0507 Drain off water and contamination from fuel prefilter. (→ Page 99)
W0508 X Check differential pressure gauge of fuel prefilter. (→ Page 99)
W1001 Fit new fuel filter or new fuel filter insert. (→ Page 187)
W1005 X Fit new air filters. (→ Page 207)
W1006 Replace fuel injectors. (→ Page 174)
W1008 X Fit new engine oil filters each time the engine oil is changed (→ Page 219)
or, at the latest, on expiry of the time limit (given in years).
W1009 Check thickness of oil residue layer. Clean. Fit new sleeve, (→ Page 221)
at the latest, each time the engine oil is changed.
W1011 Inspect cylinder chambers using endoscope. (→ Page 161)
W1016 X Check condition of coupling. (→ Page 240)
W1047 X Check and clean oil indicator filter. (→ Page 216)
W1076 Clean compressor wheel. (→ Page 198)
W1207 Check valve clearance, adjust if required. ATTENTION! Initial (→ Page 167)
adjustment after 1,000 operating hours and subsequently
1,000 operating hours after each cylinder-head overhaul..
W1244 X Check function of bar electrode. (→ Page 245)
W1245 X Check alarm function of differential pressure gauge. (→ Page 244)
W1246 X Check pump capacity. (→ Page 246)
TIM-ID: 0000083734 - 001

W1463 Carry out visual inspection of engine mounts for general (→ Page 242)
condition.
W1477 X Overhaul preheater / jacket water heater.
W1481 Replace intermediate fuel filter of filter element of inter-
mediate fuel filter.
W1581 X Replace impactor.

MS15035/00E 2018-08 | Maintenance | 113

 Option
Task Maintenance tasks

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

W1713 Injector: reset drift compensation parameters (CDC). (→ Page 268)

Table 3: Maintenance task reference table [QL1]

TIM-ID: 0000083734 - 001

114 | Maintenance | MS15035/00E 2018-08

 7 Troubleshooting
7.1 Troubleshooting
Engine does not turn when starter is actuated
Cause Corrective action
Battery low or faulty u Charge or replace (see separate documentation).
Battery: Cable connections faulty u Check firm seating of cable connections (see separate
documentation).
Engine cabling or starter faulty u Check firm seating of cable connections, contact Service.
Engine cabling faulty u Check (→ Page 257).
Loose plug connections on Engine u Check plug connections (→ Page 259).
Control Unit
Loose plug connections on Engine u Check plug connections (→ Page 261).
Interface Module (EIM)
Fuse F1 (→ Page 249)in engine u Check fuse (replace as necessary) and re-start the system by
wiring harness faulty (fuse lamp actuating the key switch.
on EIM flashes with relevant
flashing code)
Engine blocked (engine cannot be u Contact Service.
barred manually)

Engine turns on starting but does not fire

Cause Corrective action
Poor rotation by starter: Battery u Charge or replace battery (see separate documentation).
low or faulty
Engine cabling faulty u Check (→ Page 257).
Engine Control Unit faulty u Contact Service.

Engine fires unevenly

Cause Corrective action
Injector faulty u Replace (→ Page 174).
Engine cabling faulty u Check (→ Page 257).
Engine Control Unit faulty u Contact Service.

Engine does not reach nominal speed

TIM-ID: 0000010520 - 005

Cause Corrective action

Fuel filter clogged u Replace (→ Page 187).
Air supply: Air filter clogged u Check signal ring position of service indicator (→ Page 209).
Fuel injection: Injector faulty u Replace (→ Page 174).
Engine cabling faulty u Check (→ Page 257).
Engine: Overload u Contact Service.

MS15035/00E 2018-08 | Troubleshooting | 115

 Engine speed not steady
Cause Corrective action
Fuel injection: Injector faulty u Replace (→ Page 174).
Speed transmitter faulty u Contact Service.
Engine Control Unit faulty u Contact Service.

Charge-air temperature too high

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

Charge-air pressure too low

Cause Corrective action
Air supply: Air filter clogged u Check signal ring position of service indicator (→ Page 209).
Intercooler dirty u Contact Service.
Exhaust turbocharger faulty u Contact Service.

Coolant leaks at intercooler

Cause Corrective action
Intercooler leaking, major coolant u Contact Service.
discharge

Black exhaust gas

Cause Corrective action
Air supply: Air filter clogged u Check signal ring position of service indicator (→ Page 209).
Fuel injection: Injector faulty u Replace (→ Page 174).
Engine: Overload u Contact Service.

Blue exhaust gas

Cause Corrective action
Too much oil in engine u Drain engine oil (→ Page 212).
Oil separator or oil-preseparator u Replace.
of crankcase breather clogged
TIM-ID: 0000010520 - 005

Exhaust turbocharger, cylinder u Contact Service.

head, piston rings, cylinder liner
faulty

116 | Troubleshooting | MS15035/00E 2018-08

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

MS15035/00E 2018-08 | Troubleshooting | 117

 7.2 Control cabinet of fuel treatment system – Troubleshooting
Water alarm
Cause Corrective action
When the maximum water level is 1. Press illuminated pushbutton 'Water alarm' for acknowledgment.
reached, the water level electrode 2. In addition to the automatic water drain function, water can also be
opens the water drain valve and drained manually: Press illuminated pushbutton 'Water drain'.
water is discharged. If the opening The water drain valve opens.
period of the valve exceeds a
preset limit (4 minutes), the pump
will switch off and an alarm is
initiated.

Pump fault
Cause Corrective action
The drive motor is equipped with u Reset motor protection relay.
an overload protection. If the
maximum permissible current
consumption is exceeded, e.g. in
case of a blockage or dry-running,
the motor protection relay
triggers and the pump is switched
off.

Pre-alarm
Cause Corrective action
The differential pressure u Replace coalescer filter element (→ Page 247).
exceeded 1.3 bar.

Replace filter element

Cause Corrective action
The max. permissible differential 1. Replace coalescer filter element (→ Page 247).
pressure exceeded 1.5 bar. If the 2. Press illuminated pushbutton 'Water alarm' for acknowledgment.
coalescer filter element is not
replaced, pressure will increase
further and the safety valve will
open. Fuel will be led via the
bypass directly into the overflow
tank.
TIM-ID: 0000007734 - 009

118 | Troubleshooting | MS15035/00E 2018-08

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

The fault code (1) comprises 3 digits.

Fault messages may also be caused by faulty sensors/actuators. Contact Service to have sensors/actuators
tested and replaced as necessary if troubleshooting as described in the table (→ Page 120) proves unsuc-
cessful.
For explanations of alarm configuration parameters, refer to PR 2.8008.100.
Fault code list (→ Page 120).
TIM-ID: 0000016867 - 006

MS15035/00E 2018-08 | Troubleshooting | 119

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

Cause Corrective action

Idle speed of one of the u Contact Service.
secondary turbochargers is too
high.

38 – AL ETC Speed Deviation

ZKP-Number: 1.8004.205

Cause Corrective action

Speeds of one of the secondary 1. Reduce power.
turbochargers deviates from 2. Contact Service.
primary turbocharger speed.

39 – AL ETC2 CutIn Failure

ZKP-Number: 1.8004.204

Cause Corrective action

ETC2 could not be cut in. 1. Reduce power.
2. Contact Service.

81 – AL Rail Leakage
ZKP-Number: 1.8004.046

Cause Corrective action

Pressure gradient in rail is too low u Contact Service.
during starting or too high during
stopping (HP system leaky or air
in the system)

102 – AL Cons. Counter Defect

ZKP-Number: 1.8004.624

Cause Corrective action

Consumption meter faulty. u Contact Service.
TIM-ID: 0000018389 - 004

104 – AL Eng Hours Counter Defect

ZKP-Number: 1.8004.623

Cause Corrective action

Hourmeter faulty. u Contact Service.

120 | Troubleshooting | MS15035/00E 2018-08

 141 – AL Power too high
ZKP-Number: 1.1088.007

Cause Corrective action

This alarm occurs if the average u Reduce power.
value of power over the last 24
hours exceeded the maximum
value specified in PR1.1088.001.

142 – AL MCR exceeded 1 hour

ZKP-Number: 1.1088.006

Cause Corrective action

This alarm occurs if the MCR was u Reduce power.
exceeded for more than 1 hour
within the last 12 hours.

201 – SD T-Coolant
ZKP-Number: 1.8004.570

Cause Corrective action

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

202 – SD T-Fuel
ZKP-Number: 1.8004.572

Cause Corrective action

Coolant temperature sensor 1. Check sensor and cabling (B33), replace as necessary.
faulty; Short circuit or wire break 2. Error cleared after restarting the engine.

203 – SD T-Charge Air

ZKP-Number: 1.8004.571

Cause Corrective action

Charge-air temperature sensor 1. Check sensor and cabling (B9), replace as necessary.
faulty; Short circuit or wire break 2. Error cleared after restarting the engine.

204 – SD Level Lube Oil

TIM-ID: 0000018389 - 004

ZKP-Number: 1.8004.602

Cause Corrective action

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

MS15035/00E 2018-08 | Troubleshooting | 121

 205 – SD T-Coolant Intercooler
ZKP-Number: 1.8004.574

Cause Corrective action

Charge-air cooler coolant u Check sensor and cabling (B26), replace as necessary.
temperature sensor faulty; Short
circuit or wire break

206 – SD T-Exhaust A
ZKP-Number: 1.8004.576

Cause Corrective action

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

207 – SD T-Exhaust B
ZKP-Number: 1.8004.577

Cause Corrective action

Exhaust temperature sensor on B- u Check sensor and cabling (B4.22), replace as necessary.
side faulty; Short circuit or wire
break

208 – SD P-Charge Air

ZKP-Number: 1.8004.566

Cause Corrective action

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

211 – SD P-Lube Oil

ZKP-Number: 1.8004.563

Cause Corrective action

Lube oil pressure sensor faulty; 1. Check sensor and cabling (B5), replace as necessary.
Short circuit or wire break 2. Error cleared after restarting the engine.

212 – SD P-Coolant
TIM-ID: 0000018389 - 004

ZKP-Number: 1.8004.564

Cause Corrective action

Coolant pressure sensor faulty; 1. Check sensor and cabling (B16), replace as necessary.
Short circuit or wire break 2. Error cleared after restarting the engine.

122 | Troubleshooting | MS15035/00E 2018-08

 213 – SD P-Coolant charge-air cooler
ZKP-Number: 1.8004.569

Cause Corrective action

Charge-air cooler coolant 1. Check sensor and cabling (B43), replace as necessary.
pressure sensor faulty; Short 2. Error cleared after restarting the engine.
circuit or wire break

214 – SD P-CrankCase
ZKP-Number: 1.8004.568

Cause Corrective action

Crankcase pressure sensor faulty; 1. Check sensor and cabling (B50), replace as necessary.
Short circuit or wire break 2. Error cleared after restarting the engine.

215 – SD P-HD
ZKP-Number: 1.8004.567

Cause Corrective action

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

216 – SD T-Lube Oil

ZKP-Number: 1.8004.575

Cause Corrective action

Lube oil temperature sensor 1. Check sensor and cabling (B7), replace as necessary.
faulty; Short circuit or wire break 2. Error cleared after restarting the engine.

219 – SD T-Intake Air

ZKP-Number: 1.8004.573

Cause Corrective action

Intake air temperature sensor 1. Check sensor and cabling (B3), replace as necessary.
faulty; Short circuit or wire break 2. Error cleared after restarting the engine.

220 – SD Level Coolant Water

ZKP-Number: 1.8004.584
TIM-ID: 0000018389 - 004

Cause Corrective action

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

MS15035/00E 2018-08 | Troubleshooting | 123

 221 – SD P-Diff-Lube Oil
ZKP-Number: 1.8004.585

Cause Corrective action

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

222 – SD Level Leakage Fuel

ZKP-Number: 1.8004.582

Cause Corrective action

Leak-off fuel level sensor faulty; 1. Check sensor and cabling (F46), replace as necessary.
Short circuit or wire break 2. Error cleared after restarting the engine.

223 – SD Level Coolant Intercooler

ZKP-Number: 1.8004.583

Cause Corrective action

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

227 – SD P-Lube Oil before Filter

ZKP-Number: 1.8004.620

Cause Corrective action

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

228 – SD P-Fuel before Filter

ZKP-Number: 1.8004.595

Cause Corrective action

Fuel pressure sensor faulty; Short 1. Check sensor and cabling (B5.3), replace as necessary.
circuit or wire break 2. Error cleared after restarting the engine.

229 – AL Stop Camshaft Sensor Defect

TIM-ID: 0000018389 - 004

ZKP-Number: 1.8004.562

Cause Corrective action

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

124 | Troubleshooting | MS15035/00E 2018-08

 230 – SD Crankshaft Speed
ZKP-Number: 1.8004.498

Cause Corrective action

Crankshaft sensor faulty; Short 1. Check sensor and cabling (B13), replace as necessary.
circuit or wire break 2. Error cleared after restarting the engine.

231 – SD Camshaft Speed

ZKP-Number: 1.8004.499

Cause Corrective action

Camshaft sensor faulty; Short 1. Check sensor and cabling (B1), replace as necessary.
circuit or wire break 2. Error cleared after restarting the engine.

232 – SD Charger 1 Speed

ZKP-Number: 1.3011.128

Cause Corrective action

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

233 – SD Charger 2 Speed

ZKP-Number: 1.3011.129

Cause Corrective action

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

239 – SD P-Diff Fuel

ZKP-Number: 1.8004.598

Cause Corrective action

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

240 – SD P-Fuel
TIM-ID: 0000018389 - 004

ZKP-Number: 1.8004.565

Cause Corrective action

Fuel pressure sensor faulty; Short 1. Check sensor and cabling (B34), replace as necessary.
circuit or wire break 2. Error cleared after restarting the engine.

MS15035/00E 2018-08 | Troubleshooting | 125

 241 – SD T-Circulating air
ZKP-Number: 1.8004.581

Cause Corrective action

Recirculation temperature sensor 1. Check sensor and cabling (B49), replace as necessary.
faulty; Short circuit or wire break 2. Error cleared after restarting the engine.

242 – SD T-Coolant (R)

ZKP-Number: 1.8004.622

Cause Corrective action

Redundant coolant temperature 1. Check sensor and cabling, replace as necessary.
sensor faulty; Short circuit or wire 2. Error cleared after restarting the engine.
break

244 – SD P-Lube Oil (R)

ZKP-Number: 1.8004.621

Cause Corrective action

Redundant lube oil pressure 1. Check sensor and cabling, replace as necessary.
sensor faulty; Short circuit or wire 2. Error cleared after restarting the engine.
break

301 – AL Timing Cylinder A1

ZKP-Number: 1.8004.500

Cause Corrective action

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

302 – AL Timing Cylinder A2

ZKP-Number: 1.8004.501

Cause Corrective action

Time-of-flight measuring fault of u If alarm occurs frequently, replace solenoid valve of injector
injector in cylinder A2: Time-of
flight measured value extremely
low or extremely high.
TIM-ID: 0000018389 - 004

303 – AL Timing Cylinder A3

ZKP-Number: 1.8004.502

Cause Corrective action

Time-of-flight measuring fault of u If alarm occurs frequently, replace solenoid valve of injector
injector in cylinder A3: Time-of
flight measured value extremely
low or extremely high.

126 | Troubleshooting | MS15035/00E 2018-08

 304 – AL Timing Cylinder A4
ZKP-Number: 1.8004.503

Cause Corrective action

Time-of-flight measuring fault of u If alarm occurs frequently, replace solenoid valve of injector
injector in cylinder A4: Time-of
flight measured value extremely
low or extremely high.

305 – AL Timing Cylinder A5

ZKP-Number: 1.8004.504

Cause Corrective action

Time-of-flight measuring fault of u If alarm occurs frequently, replace solenoid valve of injector
injector in cylinder A5: Time-of
flight measured value extremely
low or extremely high.

306 – AL Timing Cylinder A6

ZKP-Number: 1.8004.505

Cause Corrective action

Time-of-flight measuring fault of u If alarm occurs frequently, replace solenoid valve of injector
injector in cylinder A6: Time-of
flight measured value extremely
low or extremely high.

307 – AL Timing Cylinder A7

ZKP-Number: 1.8004.506

Cause Corrective action

Time-of-flight measuring fault of u If alarm occurs frequently, replace solenoid valve of injector
injector in cylinder A7: Time-of
flight measured value extremely
low or extremely high.

308 – AL Timing Cylinder A8

ZKP-Number: 1.8004.507

Cause Corrective action

TIM-ID: 0000018389 - 004

Time-of-flight measuring fault of u If alarm occurs frequently, replace solenoid valve of injector
injector in cylinder A8: Time-of
flight measured value extremely
low or extremely high.

MS15035/00E 2018-08 | Troubleshooting | 127

 309 – AL Timing Cylinder A9
ZKP-Number: 1.8004.508

Cause Corrective action

Time-of-flight measuring fault of u If alarm occurs frequently, replace solenoid valve of injector
injector in cylinder A9: Time-of
flight measured value extremely
low or extremely high.

310 – AL Timing Cylinder A10

ZKP-Number: 1.8004.509

Cause Corrective action

Time-of-flight measuring fault of u If alarm occurs frequently, replace solenoid valve of injector
injector in cylinder A10: Time-of
flight measured value extremely
low or extremely high.

311 – AL Timing Cylinder B1

ZKP-Number: 1.8004.510

Cause Corrective action

Time-of-flight measuring fault of u If alarm occurs frequently, replace solenoid valve of injector
injector B1: Time-of flight
measured value extremely low or
extremely high.

312 – AL Timing Cylinder B2

ZKP-Number: 1.8004.511

Cause Corrective action

Time-of-flight measuring fault of u If alarm occurs frequently, replace solenoid valve of injector
injector B2: Time-of flight
measured value extremely low or
extremely high.

313 – AL Timing Cylinder B3

ZKP-Number: 1.8004.512

Cause Corrective action

TIM-ID: 0000018389 - 004

Time-of-flight measuring fault of u If alarm occurs frequently, replace solenoid valve of injector
injector B3: Time-of-flight
measurement value is extremely
small or extremely large.

128 | Troubleshooting | MS15035/00E 2018-08

 314 – AL Timing Cylinder B4
ZKP-Number: 1.8004.513

Cause Corrective action

Time-of-flight measuring fault of u If alarm occurs frequently, replace solenoid valve of injector
injector B4: Time-of flight
measured value extremely low or
extremely high.

315 – AL Timing Cylinder B5

ZKP-Number: 1.8004.514

Cause Corrective action

Time-of-flight measuring fault of u If alarm occurs frequently, replace solenoid valve of injector
injector B5: Time-of flight
measured value extremely low or
extremely high.

316 – AL Timing Cylinder B6

ZKP-Number: 1.8004.515

Cause Corrective action

Time-of-flight measuring fault of u If alarm occurs frequently, replace solenoid valve of injector
injector B6: Time-of flight
measured value extremely low or
extremely high.

317 – AL Timing Cylinder B7

ZKP-Number: 1.8004.516

Cause Corrective action

Time-of-flight measuring fault of u If alarm occurs frequently, replace solenoid valve of injector
injector B7: Time-of flight
measured value extremely low or
extremely high.

318 – AL Timing Cylinder B8

ZKP-Number: 1.8004.517

Cause Corrective action

TIM-ID: 0000018389 - 004

Time-of-flight measuring fault of u If alarm occurs frequently, replace solenoid valve of injector
injector B8: Time-of flight
measured value extremely low or
extremely high.

MS15035/00E 2018-08 | Troubleshooting | 129

 319 – AL Timing Cylinder B9
ZKP-Number: 1.8004.518

Cause Corrective action

Time-of-flight measuring fault of u If alarm occurs frequently, replace solenoid valve of injector
injector B9: Time-of flight
measured value extremely low or
extremely high.

320 – AL Timing Cylinder B10

ZKP-Number: 1.8004.519

Cause Corrective action

Time-of-flight measuring fault of u If alarm occurs frequently, replace solenoid valve of injector
injector B10: Time-of flight
measured value extremely low or
extremely high.

321 – AL Wiring Cylinder A1

ZKP-Number: 1.8004.520

Cause Corrective action

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

322 – AL Wiring Cylinder A2

ZKP-Number: 1.8004.521

Cause Corrective action

Short-circuit in injector cabling to 1. Rectify injector solenoid valve short circuit (positive to negative)
cylinder A2. Result: Misfiring (e.g. by exchanging injectors).
2. Error cleared after restarting the engine.

323 – AL Wiring Cylinder A3

ZKP-Number: 1.8004.522

Cause Corrective action

Short-circuit in injector cabling to 1. Rectify injector solenoid valve short circuit (positive to negative)
cylinder A3. Result: Misfiring (e.g. by exchanging injectors).
TIM-ID: 0000018389 - 004

2. Error cleared after restarting the engine.

324 – AL Wiring Cylinder A4

ZKP-Number: 1.8004.523

Cause Corrective action

Short-circuit in injector cabling to 1. Rectify injector solenoid valve short circuit (positive to negative)
cylinder A4. Result: Misfiring (e.g. by exchanging injectors).
2. Error cleared after restarting the engine.

130 | Troubleshooting | MS15035/00E 2018-08

 325 – AL Wiring Cylinder A5
ZKP-Number: 1.8004.524

Cause Corrective action

Short-circuit in injector cabling to 1. Rectify injector solenoid valve short circuit (positive to negative)
cylinder A5. Result: Misfiring (e.g. by exchanging injectors).
2. Error cleared after restarting the engine.

326 – AL Wiring Cylinder A6

ZKP-Number: 1.8004.525

Cause Corrective action

Short-circuit in injector cabling to 1. Rectify injector solenoid valve short circuit (positive to negative)
cylinder A6. Result: Misfiring (e.g. by exchanging injectors).
2. Error cleared after restarting the engine.

327 – AL Wiring Cylinder A7

ZKP-Number: 1.8004.526

Cause Corrective action

Short-circuit in injector cabling to 1. Rectify injector solenoid valve short circuit (positive to negative)
cylinder A7. Result: Misfiring (e.g. by exchanging injectors).
2. Error cleared after restarting the engine.

328 – AL Wiring Cylinder A8

ZKP-Number: 1.8004.527

Cause Corrective action

Short-circuit in injector cabling to 1. Rectify injector solenoid valve short circuit (positive to negative)
cylinder A8. Result: Misfiring (e.g. by exchanging injectors).
2. Error cleared after restarting the engine.

329 – AL Wiring Cylinder A9

ZKP-Number: 1.8004.528

Cause Corrective action

Short-circuit in injector cabling to 1. Rectify injector solenoid valve short circuit (positive to negative)
cylinder A9. Result: Misfiring (e.g. by exchanging injectors).
2. Error cleared after restarting the engine.
TIM-ID: 0000018389 - 004

330 – AL Wiring Cylinder A10

ZKP-Number: 1.8004.529

Cause Corrective action

Short-circuit in injector cabling to 1. Rectify injector solenoid valve short circuit (positive to negative)
cylinder A10. Result: Misfiring (e.g. by exchanging injectors).
2. Error cleared after restarting the engine.

MS15035/00E 2018-08 | Troubleshooting | 131

 331 – AL Wiring Cylinder B1
ZKP-Number: 1.8004.530

Cause Corrective action

Cabling fault in injector cabling to 1. Rectify injector solenoid valve short circuit (positive to negative)
cylinder B1. Result: Misfiring (e.g. by exchanging injectors).
2. Error cleared after restarting the engine.

332 – AL Wiring Cylinder B2

ZKP-Number: 1.8004.531

Cause Corrective action

Cabling fault in injector cabling to 1. Rectify injector solenoid valve short circuit (positive to negative)
cylinder B2. Result: Misfiring (e.g. by exchanging injectors).
2. Error cleared after restarting the engine.

333 – AL Wiring Cylinder B3

ZKP-Number: 1.8004.532

Cause Corrective action

Cabling fault in injector cabling to 1. Rectify injector solenoid valve short circuit (positive to negative)
cylinder B3. Result: Misfiring (e.g. by exchanging injectors).
2. Error cleared after restarting the engine.

334 – AL Wiring Cylinder B4

ZKP-Number: 1.8004.533

Cause Corrective action

Cabling fault in injector cabling to 1. Rectify injector solenoid valve short circuit (positive to negative)
cylinder B4. Result: Misfiring (e.g. by exchanging injectors).
2. Error cleared after restarting the engine.

335 – AL Wiring Cylinder B5

ZKP-Number: 1.8004.534

Cause Corrective action

Cabling fault in injector cabling to 1. Rectify injector solenoid valve short circuit (positive to negative)
cylinder B5. Result: Misfiring (e.g. by exchanging injectors).
2. Error cleared after restarting the engine.
TIM-ID: 0000018389 - 004

336 – AL Wiring Cylinder B6

ZKP-Number: 1.8004.535

Cause Corrective action

Cabling fault in injector cabling to 1. Rectify injector solenoid valve short circuit (positive to negative)
cylinder B6. Result: Misfiring (e.g. by exchanging injectors).
2. Error cleared after restarting the engine.

132 | Troubleshooting | MS15035/00E 2018-08

 337 – AL Wiring Cylinder B7
ZKP-Number: 1.8004.536

Cause Corrective action

Cabling fault in injector cabling to 1. Rectify injector solenoid valve short circuit (positive to negative)
cylinder B7. Result: Misfiring (e.g. by exchanging injectors).
2. Error cleared after restarting the engine.

338 – AL Wiring Cylinder B8

ZKP-Number: 1.8004.537

Cause Corrective action

Cabling fault in injector cabling to 1. Rectify injector solenoid valve short circuit (positive to negative)
cylinder B8. Result: Misfiring (e.g. by exchanging injectors).
2. Error cleared after restarting the engine.

339 – AL Wiring Cylinder B9

ZKP-Number: 1.8004.538

Cause Corrective action

Cabling fault in injector cabling to 1. Rectify injector solenoid valve short circuit (positive to negative)
cylinder B9. Result: Misfiring (e.g. by exchanging injectors).
2. Error cleared after restarting the engine.

340 – AL Wiring Cylinder B10

ZKP-Number: 1.8004.539

Cause Corrective action

Cabling fault in injector cabling to 1. Rectify injector solenoid valve short circuit (positive to negative)
cylinder B10. Result: Misfiring (e.g. by exchanging injectors).
2. Error cleared after restarting the engine.

341 – AL Open Load Cylinder A1

ZKP-Number: 1.8004.540

Cause Corrective action

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

342 – AL Open Load Cylinder A2

ZKP-Number: 1.8004.541

Cause Corrective action

Disruption fault in injector cabling 1. Check continuity of injector cabling or exclude open load in
to cylinder A2. Result: Misfiring solenoid valve circuit (e.g. by injector replacement)
2. Error clearance: After each working cycle.

MS15035/00E 2018-08 | Troubleshooting | 133

 343 – AL Open Load Cylinder A3
ZKP-Number: 1.8004.542

Cause Corrective action

Disruption fault in injector cabling 1. Check continuity of injector cabling or exclude open load in
to cylinder A3. Result: Misfiring solenoid valve circuit (e.g. by injector replacement)
2. Error clearance: After each working cycle.

344 – AL Open Load Cylinder A4

ZKP-Number: 1.8004.543

Cause Corrective action

Disruption fault in injector cabling 1. Check continuity of injector cabling or exclude open load in
to cylinder A4. Result: Misfiring solenoid valve circuit (e.g. by injector replacement)
2. Error clearance: After each working cycle.

345 – AL Open Load Cylinder A5

ZKP-Number: 1.8004.544

Cause Corrective action

Disruption fault in injector cabling 1. Check continuity of injector cabling or exclude open load in
to cylinder A5. Result: Misfiring solenoid valve circuit (e.g. by injector replacement)
2. Error clearance: After each working cycle.

346 – AL Open Load Cylinder A6

ZKP-Number: 1.8004.545

Cause Corrective action

Disruption fault in injector cabling 1. Check continuity of injector cabling or exclude open load in
to cylinder A6. Result: Misfiring solenoid valve circuit (e.g. by injector replacement)
2. Error clearance: After each working cycle.

347 – AL Open Load Cylinder A7

ZKP-Number: 1.8004.546

Cause Corrective action

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

348 – AL Open Load Cylinder A8

ZKP-Number: 1.8004.547

Cause Corrective action

Disruption fault in injector cabling 1. Check injector wiring for disruption or rule out any discontinuity in
to cylinder A8. Result: Misfiring the solenoid valve (e.g. by replacing the injector)
2. Error clearance: After each working cycle.

134 | Troubleshooting | MS15035/00E 2018-08

 349 – AL Open Load Cylinder A9
ZKP-Number: 1.8004.548

Cause Corrective action

Disruption fault in injector cabling 1. Check injector wiring for disruption or rule out any discontinuity in
to cylinder A9. Result: Misfiring the solenoid valve (e.g. by replacing the injector)
2. Error clearance: After each working cycle.

350 – AL Open Load Cylinder A10

ZKP-Number: 1.8004.549

Cause Corrective action

Disruption fault in injector cabling 1. Check injector wiring for disruption or rule out any discontinuity in
to cylinder A10. Result: Misfiring the solenoid valve (e.g. by replacing the injector)
2. Error clearance: After each working cycle.

351 – AL Open Load Cylinder B1

ZKP-Number: 1.8004.550

Cause Corrective action

Disruption fault in injector cabling 1. Check injector wiring for disruption or rule out any discontinuity in
to cylinder B1. Result: Misfiring the solenoid valve (e.g. by replacing the injector)
2. Error clearance: After each working cycle.

352 – AL Open Load Cylinder B2

ZKP-Number: 1.8004.551

Cause Corrective action

Disruption fault in injector cabling 1. Check injector wiring for disruption or rule out any discontinuity in
to cylinder B2. Result: Misfiring the solenoid valve (e.g. by replacing the injector)
2. Error clearance: After each working cycle.

353 – AL Open Load Cylinder B3

ZKP-Number: 1.8004.552

Cause Corrective action

Disruption fault in injector cabling 1. Check injector wiring for disruption or rule out any discontinuity in
to cylinder B3. Result: Misfiring the solenoid valve (e.g. by replacing the injector)
2. Error clearance: After each working cycle.
TIM-ID: 0000018389 - 004

354 – AL Open Load Cylinder B4

ZKP-Number: 1.8004.553

Cause Corrective action

Disruption fault in injector cabling 1. Check injector wiring for disruption or rule out any discontinuity in
to cylinder B4. Result: Misfiring the solenoid valve (e.g. by replacing the injector)
2. Error clearance: After each working cycle.

MS15035/00E 2018-08 | Troubleshooting | 135

 355 – AL Open Load Cylinder B5
ZKP-Number: 1.8004.554

Cause Corrective action

Disruption fault in injector cabling 1. Check injector wiring for disruption or rule out any discontinuity in
to cylinder B5. Result: Misfiring the solenoid valve (e.g. by replacing the injector)
2. Error clearance: After each working cycle.

356 – AL Open Load Cylinder B6

ZKP-Number: 1.8004.555

Cause Corrective action

Disruption fault in injector cabling 1. Check injector wiring for disruption or rule out any discontinuity in
to cylinder B6. Result: Misfiring the solenoid valve (e.g. by replacing the injector)
2. Error clearance: After each working cycle.

357 – AL Open Load Cylinder B7

ZKP-Number: 1.8004.556

Cause Corrective action

Disruption fault in injector cabling 1. Check injector wiring for disruption or rule out any discontinuity in
to cylinder B7. Result: Misfiring the solenoid valve (e.g. by replacing the injector)
2. Error clearance: After each working cycle.

358 – AL Open Load Cylinder B8

ZKP-Number: 1.8004.557

Cause Corrective action

Disruption fault in injector cabling 1. Check injector wiring for disruption or rule out any discontinuity in
to cylinder B8. Result: Misfiring the solenoid valve (e.g. by replacing the injector)
2. Error clearance: After each working cycle.

359 – AL Open Load Cylinder B9

ZKP-Number: 1.8004.558

Cause Corrective action

Disruption fault in injector cabling 1. Check injector wiring for disruption or rule out any discontinuity in
to cylinder B9. Result: Misfiring the solenoid valve (e.g. by replacing the injector)
2. Error clearance: After each working cycle.
TIM-ID: 0000018389 - 004

360 – AL Open Load Cylinder B10

ZKP-Number: 1.8004.559

Cause Corrective action

Disruption fault in injector cabling 1. Check injector wiring for disruption or rule out any discontinuity in
to cylinder B10. Result: Misfiring the solenoid valve (e.g. by replacing the injector)
2. Error clearance: After each working cycle.

136 | Troubleshooting | MS15035/00E 2018-08

 361 – AL Power Stage Low
ZKP-Number: 1.8004.496

Cause Corrective action

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

362 – AL Power Stage High

ZKP-Number: 1.8004.497

Cause Corrective action

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

363 – AL Stop Power Stage

ZKP-Number: 1.8004.560

Cause Corrective action

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

365 – AL Stop MV-Wiring Ground

ZKP-Number: 1.8004.561

Cause Corrective action

Injector cabling fault. If bit u Check wiring, replace wiring harness as necessary.
"1.1020.021" (Power Stage
Failure: Stop Engine) is set,
engine will be shut down as
additional measure. Possible
TIM-ID: 0000018389 - 004

causes:
1. Short circuit of positive
connection of one or more
injectors to ground
2. Short circuit of negative
connection of one or more
injectors to ground.

MS15035/00E 2018-08 | Troubleshooting | 137

 371 – AL Wiring TO 1
ZKP-Number: 1.8004.634

Cause Corrective action

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

372 – AL Wiring TO 2
ZKP-Number: 1.8004.635

Cause Corrective action

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

373 – AL Wiring TO 3
ZKP-Number: 1.8004.636

Cause Corrective action

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

374 – AL Wiring TO 4
ZKP-Number: 1.8004.637

Cause Corrective action

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

390 – AL MCR exceeded

ZKP-Number: 1.1085.009

Cause Corrective action

DBR/MCR feature: MCR 1. If the alarm occurs temporarily, no action required.
(maximum continuous rating) was 2. If the alarm is permanently active, contact Service.
exceeded.

396 – TD T-Coolant
ZKP-Number: 1.8004.626
TIM-ID: 0000018389 - 004

Cause Corrective action

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

138 | Troubleshooting | MS15035/00E 2018-08

 397 – TD P-Lube Oil
ZKP-Number: 1.8004.625

Cause Corrective action

Maximum deviation of lube oil 1. Check sensor and cabling, replace as necessary.
pressure values from sensors 2. Contact Service.

417 – SD Level Water Fuel Prefilter

ZKP-Number: 1.8004.594

Cause Corrective action

Water level sensor in fuel prefilter u Check sensor and cabling, replace as necessary.
faulty; Short circuit or wire break

419 – SD T-Coolant b.Engine

ZKP-Number: 1.8004.604

Cause Corrective action

Coolant inlet temperature sensor u Check sensor and cabling (B3), replace as necessary.
faulty; Short circuit or wire break

444 – SD U-PDU
ZKP-Number: 1.8004.578

Cause Corrective action

Injector power stage sensor u Replace ECU7.
defect; Internal fault in ECU7

445 – SD P-Ambient Air

ZKP-Number: 1.8004.580

Cause Corrective action

Ambient air pressure sensor 1. Check pressure sensor and cabling, replace as necessary.
faulty. 2. Replace engine governor.

464 – SD P-AUX 1
ZKP-Number: 1.8004.589

Cause Corrective action

TIM-ID: 0000018389 - 004

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

MS15035/00E 2018-08 | Troubleshooting | 139

 468 – SD T-AUX 1
ZKP-Number: 1.8004.579

Cause Corrective action

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

469 – SD AUX 1
ZKP-Number: 1.8004.590

Cause Corrective action

Analog input signal for Aux 1 u Check signal transmitter and cabling, replace as necessary.
faulty; Short circuit or wire break

470 – SD T-ECU
ZKP-Number: 1.8004.587

Cause Corrective action

Temperature sensor for ECU u Check sensor and cabling, replace as necessary.
faulty; Short circuit or wire break

471 – SD Coil Current

ZKP-Number: 1.8004.592

Cause Corrective action

Control of HP fuel control block u Check sensor and cabling, replace as necessary.
faulty; Short circuit or wire break

473 – AL Wiring PWM_CM2

ZKP-Number: 1.8004.593

Cause Corrective action

Cable break or short circuit on 1. Check cabling.
channel PWM_CM2. 2. Contact Service.

475 – AL CR Trigger Engine Stop

ZKP-Number: 1.8010.009

Cause Corrective action

TIM-ID: 0000018389 - 004

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

140 | Troubleshooting | MS15035/00E 2018-08

 476 – AL Crash Rec. Init. Error
ZKP-Number: 1.8010.007

Cause Corrective action

Crash recorder initialization error. 1. Check setting with DiaSys.
2. Contact Service.

482 – SD T-Exhaust C
ZKP-Number: 1.8004.596

Cause Corrective action

Exhaust temperature sensor on A- u Check sensor and cabling (B4.23), replace as necessary.
side faulty; Short circuit or wire
break

483 – SD T-Exhaust D
ZKP-Number: 1.8004.597

Cause Corrective action

Exhaust temperature sensor on A- u Check sensor and cabling (B4.24), replace as necessary.
side faulty; Short circuit or wire
break

492 – AL ETC4 CutIn Failure

ZKP-Number: 1.8004.202

Cause Corrective action

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

493 – AL ETC3 CutIn Failure

ZKP-Number: 1.8004.203

Cause Corrective action

ETC3 could not be cut in. u Check control valve on ETC 3.

500 – AL Wiring POM Starter 1

ZKP-Number: 1.4500.900

Cause Corrective action

TIM-ID: 0000018389 - 004

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

MS15035/00E 2018-08 | Troubleshooting | 141

 501 – AL Wiring POM Starter 2
ZKP-Number: 1.4500.901

Cause Corrective action

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

502 – AL Open Load POM Alternator

ZKP-Number: 1.4500.902

Cause Corrective action

Open load was detected at the u Check connection between POM and starter.
connection of the battery-
charging generator on the POM.

503 – AL Battery not Charging

ZKP-Number: 1.4500.903

Cause Corrective action

The battery-charging generator u Check battery-charging generator and cabling.
does not charge the battery.

504 – AL CAN POM node Lost

ZKP-Number: 1.4500.904

Cause Corrective action

POM missing on CAN bus. u Check connection and POM. If alarm occurs in combination with
alarm 508, the resistor in the POM cabling is missing.

506 – AL Low Starter Voltage

ZKP-Number: 1.4500.906

Cause Corrective action

battery voltage is too low to u Check battery-charging generator and cabling.
accomplish a starting procedure.

507 – AL POM Error

TIM-ID: 0000018389 - 004

ZKP-Number: 1.4500.907

Cause Corrective action

A general POM error occurred. u Replace POM.

142 | Troubleshooting | MS15035/00E 2018-08

 508 – AL Wrong POM-ID
ZKP-Number: 1.4500.908

Cause Corrective action

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

519 – Oillevel Calibration Error

ZKP-Number: 1.0158.921

Cause Corrective action

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

525 – SD P-Lube Oil (R2)

ZKP-Number: 1.8004.638

Cause Corrective action

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

526 – SD T-Coolant (R2)

ZKP-Number: 1.8004.639

Cause Corrective action

Redundant coolant temperature u Check sensor and cabling, replace as necessary.
sensor faulty; Short circuit or wire
break

527 – TD EngineSpd. Sensor Deviation

ZKP-Number: 1.0480.093

Cause Corrective action

Maximum deviation of speed 1. Check cabling of speed sensors. Observe additional messages.
TIM-ID: 0000018389 - 004

sensors 2. Contact Service.

528 – SD Engine Speed 3rd Sensor

ZKP-Number: 1.2500.102

Cause Corrective action

Redundant crankshaft sensor u Check sensor and cabling, replace as necessary.
faulty; Short circuit or wire break

MS15035/00E 2018-08 | Troubleshooting | 143

 576 – AL ESCM Override
ZKP-Number: 1.1075.083

Cause Corrective action

Violation of corrected MCR or u Reduce power.
DBR/MCR curve. Engine overload!

577 – SD T-Lube Oil Pan

ZKP-Number: 1.0137.900

Cause Corrective action

Temperature sensor in oil pan u Check sensor and cabling, replace as necessary.
defective; Short circuit or wire
break

582 – AL Emergency Stop Failed

ZKP-Number: 1.1005.006

Cause Corrective action

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

588 – SD P-Oil Refill Pump

ZKP-Number: 1.0159.910

Cause Corrective action

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

596 – AL Develop PR Set

ZKP-Number: 1.8004.645

Cause Corrective action

The parameter set used is a test u The alarm remains active until a series-production parameter set
parameter set. was installed.
TIM-ID: 0000018389 - 004

600 – SD T-Exhaust A+B

ZKP-Number: 1.8004.646

Cause Corrective action

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

144 | Troubleshooting | MS15035/00E 2018-08

 601 – SD ETC1+ETC2
ZKP-Number: 1.3011.227

Cause Corrective action

SD ETC1 and ETC2 u Check sensor and cabling, replace as necessary.

625 – SD P-Fuel before Prefilter

ZKP-Number: 1.8004.600

Cause Corrective action

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

MS15035/00E 2018-08 | Troubleshooting | 145

 8 Task Description
8.1 SOLAS
8.1.1 SOLAS shielding as per MTN 5233 – Installation
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Shield A5 735233000101 18
Shield A6 735233000102 2
Shield A7 735233000103 3
Shield A8 735233000104 4
Shield B2 735233000200 2
Shield B4 735233000202 1
Shield B6 735233000204 2
Shield E5 735233000500 4

Installing SOLAS shielding

1. Pinpoint installation location (→ Page 148).
2. Install suitable shielding.
3. Press shielding until locked.

TIM-ID: 0000069191 - 001

146 | Task Description | MS15035/00E 2018-08

 8.1.2 SOLAS shielding – Installation
Preconditions
☑ Engine is stopped and starting disabled.
☑ Engine is cooled down to ambient temperature.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Oil filter shield X00040625 5
Shield for switchable oil filter X00040625 4

Installing SOLAS shield

1. Pinpoint installation location.
2. Install suitable shielding.
TIM-ID: 0000068940 - 001

MS15035/00E 2018-08 | SOLAS | 147

 8.1.3 Installation locations for SOLAS shielding
General information
Primarily fit SOLAS shielding as per MTN 5233 (→ Page 146).
Shield unions with adhesive tape if SOLAS shielding as per MTN 5233 is not possible (→ Page 157).
When affixing adhesive connections ensure that escaping fluid can flow out without pressure (→ Page 157).

Fuel system, fuel lines with fuel pressure >1.8 bar

Item Type of shielding Installation location

1* Shield A8 After LP fuel pump
* This shield must be installed on the assembly line. This location is no longer accessible, or only with great
difficulty, following assembly of the air pipework and/or fuel filters.

TIM-ID: 0000069196 - 002

148 | SOLAS | MS15035/00E 2018-08

 Item Type of shielding Installation location
1* Shield A8 Fuel filter head holder
* This shield must be installed on the assembly line. This location is no longer accessible, or only with great
difficulty, following assembly of the air pipework and/or fuel filters.

Item Type of shielding Installation location

1 Shield E5 Fuel line on HP pump
2 Shield E5 Fuel line downstream of fuel filter head
TIM-ID: 0000069196 - 002

Item Type of shielding Installation location

1 2 x shielding A8 Fuel line at fuel filter head holder

MS15035/00E 2018-08 | SOLAS | 149

 Item Type of shielding Installation location
1* 2 x shielding B6 Fuel line at fuel filter head
* This shield must be installed on the assembly line. This location is no longer accessible, or only with great
difficulty, following assembly of the air pipework.

Lube oil system, oil lines with oil pressures exceeding 1.8 bar

Item Type of shielding Installation location

TIM-ID: 0000069196 - 002

1 2 x shielding A5 Switching cylinder exhaust flap ETC B1

150 | SOLAS | MS15035/00E 2018-08

 Item Type of shielding Installation location
1 2 x shielding A5 Switching cylinder air flap ETC B1
2 3 x shielding A5 T adapter for flap control ETC B1

Item Type of shielding Installation location

1 5 x shielding A5 Distributor piece
2 2 x shielding A5 Oil return
TIM-ID: 0000069196 - 002

MS15035/00E 2018-08 | SOLAS | 151

 Item Type of shielding Installation location
1 Shield A7 Oil return

Item Type of shielding Installation location

1* Shield A7 Oil line to ETC
2* Shield A5 Oil line to flap control
3 Shield A5 Oil line to recirculation valve
TIM-ID: 0000069196 - 002

4* 2 x shielding E5 Oil line from main gallery

* These shields must be installed on the assembly line. These positions can no longer be accessed after
assembly of intake housing.

152 | SOLAS | MS15035/00E 2018-08

 Item Type of shielding Installation location
1 2 x shielding A5 Air recirculation valve

Item Type of shielding Installation location

1 Shield A6 Oil supply line to HP pump: on HP pump
TIM-ID: 0000069196 - 002

MS15035/00E 2018-08 | SOLAS | 153

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

Item Type of shielding Installation location

1 Shield A6 ETC oil supply
TIM-ID: 0000069196 - 002

2 Shield A7 ETC oil supply

154 | SOLAS | MS15035/00E 2018-08

 Item Type of shielding Installation location
1 2 x shielding A6 ETC oil supply

Item Type of shielding Installation location

1* Shield B2 Oil line on equipment carrier
2 Shield B2 Oil line on pressure reducing valve
* This shield must be installed on the assembly line. Assembly in this position is no longer possible after
TIM-ID: 0000069196 - 002

painting.

MS15035/00E 2018-08 | SOLAS | 155

 Item Type of shielding Installation location
1 Cover Oil/easy-change fuel filter

TIM-ID: 0000069196 - 002

156 | SOLAS | MS15035/00E 2018-08

 8.1.4 Adhesive tape for SOLAS shielding – Application
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Adhesive tape

Applying adhesive tape – gener-

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

Sealing cone unions

Note: For installation positions of sealing cone un-
ions, see (→ Page 148).
1. Wrap three layers of adhesive tape from the
middle of the sealing cone union to area (A)
for at least 30 mm, ensuring that the adhe-
sive tape overlaps at least half its own width.
2. Wrap three layers of adhesive tape from the
middle of the sealing cone union to area (B)
for at least 30 mm, ensuring that the adhe-
sive tape overlaps at least half its own width.
TIM-ID: 0000038330 - 002

Plug-in connections
Note: For installation positions of plug-in connections, see (→ Page 148).
1. Apply adhesive tape flush.
2. Apply three layers of adhesive tape such that at least 30 mm are covered from the middle of the screw to the
line.

MS15035/00E 2018-08 | SOLAS | 157

 8.2 Engine
8.2.1 Engine – Barring manually
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

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

DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Before barring the engine, make sure that there are no persons in the engine's danger zone.
• After finishing work on the engine, make sure that all safety devices are put back in place and all
tools are removed from the engine.

Engine – Barring manually

1. Release screws (1) and remove end cover (2)
from flywheel housing.

TIM-ID: 0000000917 - 014

158 | Engine | MS15035/00E 2018-08

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

MS15035/00E 2018-08 | Engine | 159

 8.2.2 Barring engine with starting system
Barring using the automation system
Refer to automation system operating instructions

TIM-ID: 0000017532 - 004

160 | Engine | MS15035/00E 2018-08

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

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Barring tool F6555766 1
Ratchet with extension F30006212 1
Endoscope Y20097353 1

Preparatory steps
1. Remove cylinder head cover (→ Page 170).
2. Remove injector (→ Page 175).

Positioning crankshaft at BDC

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

Endoscopic examination of cylinder liner

Findings Measure
• Thin carbon coating around carbon scraper ring No actions required.
• Slight localized additive deposits at top edge
• Localized smooth areas at bottom edge
• Carbon deposits on entire circumference between top piston ring and
bottom edge of carbon scraper ring
• First signs of marks left by top piston ring
• Bright mark on entire circumference
• Faultless, even honing pattern
• First signs of marks left by lower cooling bores
• Running pattern seems darker
• Dark areas with even or varying degrees of discoloration Further endoscopic examina-
• Beginning and end of the discoloration are not sharply defined and do tion required as part of mainte-
not cover the entire stroke area nance work.
• Dark areas in the upper section of the cooling bore, remaining circum-
ference are faultless
• Piston rings are faultless
• On the entire circumference, apart from light areas of discoloration (do Cylinder liner must be replaced,
TIM-ID: 0000003304 - 006

not impair operation) clearly darker stripes that start at the top piston contact Service.
ring
• Heat discoloration in the direction of stroke and honing pattern dam-
age
• Heat discoloration of piston rings

MS15035/00E 2018-08 | Cylinder Liner | 161

 1. Compile endoscopic report using the table.
2. Use technical terms to describe the liner surface (→ Page 163).
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 175).
2. Install cylinder head cover (→ Page 170).

TIM-ID: 0000003304 - 006

162 | Cylinder Liner | MS15035/00E 2018-08

 8.3.2 Cylinder liner – Instructions and comments on endoscopic and visual
examination
Terms used for endoscopic examination
Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic examina-
tion report.
Findings Explanations/Action
Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing products,
particles, broken-off burrs). Removed cylinders clearly show such scoring on the
running surface under endoscope magnification. Cannot be felt with the fingernail.
Findings not critical
Single scores Clearly visible scores caused by hard particles. They usually start in the TDC area
and cross through the honing pattern in the direction of stroke.
Findings not critical
Scored area These areas consist of scores of different length and depth next to one another. In
most cases, they are found at the 6-o'clock and 12-o'clock positions (inlet/
exhaust) along the transverse engine axis.
Findings not critical
Polished area Polished areas are on the running surface but almost the whole honing pattern is
still visible. Polished areas appear brighter and more shiny than the surrounding
running surface.
Findings not critical
Bright area Bright areas are on the running surface and show local removal of the honing pat-
tern. Grooves from the honing process are not visible any more.
Discoloration This is caused by oxidation (surface discoloration through oil or fuel) and tempera-
ture differences around the liner. It appears rather darker within the honed struc-
ture in contrast to the bright metallic running surface. The honing pattern is undis-
turbed. Discolorations extend in stroke direction and may be interrupted.
Findings not critical
Corrosion fields / Corrosion fields / spots result from moisture (condensate) with the valves in the
spots overlap (open) position. They are clearly visible due to the dark color of the honing
groove bottom.
This corrosion is not critical unless there is corrosion pitting.
Black lines Black lines are a preliminary stage of burn marks. They are visible as a clear discol-
oration from TDC to BDC in the running surface and the start of localized damage
to the honing pattern.
Cylinder liners with a large number of black lines around the running surface have
limited service life and should be replaced.
Burn mark These are caused by a disturbance in the liner / ring tribo system. Usually they run
over the whole ring-travel area (TDC/BDC), starting at the first TDC-ring and be-
coming more visible from the second TDC-ring 2 onwards and less pronounced
from TDC-ring 1. The honing pattern is usually no longer visible and displays a
TIM-ID: 0000000014 - 017

clearly defined (straight) edge to the undisturbed surface. The damaged surface is
usually discolored. The circumferential length varies.
Liners with burn marks starting in TDC ring 1 have to be replaced.
Seizure marks, scuff- Irregular circumference lengths and depths. Can be caused either by the piston
ing skirt or the piston crown. Material deposits on the liner (smear), heavy discolora-
tion. Severe, visible scoring.
Replace liner.

Table 4: Endoscopic examination – Terms used

MS15035/00E 2018-08 | Cylinder Liner | 163

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

TIM-ID: 0000000014 - 017

164 | Cylinder Liner | MS15035/00E 2018-08

 8.4 Crankcase Breather
8.4.1 Crankcase breather – Oil mist separator replacement
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Engine oil
Oil mist separator (→ Spare Parts Catalog)
O-ring (→ Spare Parts Catalog)

WARNING
Oil is hot.
Oil can contain residue/substances which are harmful to health.
Risk of injury and poisoning!
• Allow the product to cool to below 50 °C before beginning work.
• Wear protective clothing, protective gloves and goggles/safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.

Oil mist separator – Replace-

ment
1. Remove screws (1) and take off together with
retainer (2).
2. Replace oil mist separator (3).
3. Replace O-ring (4) if necessary.
4. Replace further oil mist separators in the
same way.
TIM-ID: 0000018590 - 010

MS15035/00E 2018-08 | Crankcase Breather | 165

 8.5 Valve Drive
8.5.1 Valve gear – Lubrication
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Engine oil

Valve gear – Lubrication

1. Remove cylinder head covers (→ Page 170).
2. Fill oil chambers of valve bridges with oil.
3. Fill oil chambers of rocker arms and adjusting
screws with oil.
4. Install cylinder head covers (→ Page 170).

TIM-ID: 0000000921 - 010

166 | Valve Drive | MS15035/00E 2018-08

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

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Feeler gage Y20010128 1
Valve setting gage Y4349603 1
Torque wrench, 60–320 Nm F30452768 1
Socket wrench, 24 mm F30039526 1
Engine oil

Preparatory steps
1. Remove cylinder head covers (→ Page 170).
2. Install barring device (→ Page 158).
Note: The pointer (1) is in the lower opening of the
flywheel housing (arrow).
3. Use barring device to turn crankshaft in en-
gine direction of rotation until marking
OT/A1 on the rear side of the flywheel and
pointer (1) are aligned.
TIM-ID: 0000012224 - 009

MS15035/00E 2018-08 | Valve Drive | 167

 Note: Danger of confusion: Additional marking
OT/A1 (1) on outer circumference, if applica-
ble.
4. Additional OT/A1 (1) marking on the outer
circumference of flywheel must not be used.

Diagram for 12V engines (two

crankshaft positions)

Diagram for 16V engines (two

crankshaft positions)
TIM-ID: 0000012224 - 009

168 | Valve Drive | MS15035/00E 2018-08

 Checking valve clearance in two crankshaft positions
1. Check TDC position of piston in cylinder A1:
• If the rocker arms are unloaded on cylinder A1, the piston is in firing TDC.
• If the rocker arms are loaded on cylinder A1, the piston is in overlap TDC.
2. Check valve clearance adjustment with engine cold:
• Inlet (long rocker arm) = 0.2 ±0.05 mm
• Exhaust (short rocker arm) = 0.5 ±0.05 mm
3. Check all valve clearances in two crankshaft positions (firing TDC and overlap TDC of cylinder A1) as per
diagram:
1 Cylinder A1 is in firing TDC
2 Cylinder A1 is in overlap TDC
I Inlet valve
X Exhaust valve
4. Use feeler gage or valve setting gage to determine the distance between valve bridge and rocker arm.
5. If the deviation from the reference value exceeds 0.1 mm, adjust valve clearance.

Adjusting valve clearance

1. Loosen locknut (1).
2. Insert feeler gage (3) between valve bridge
and rocker arm.
Note: Replace or rectify adjusting screws and/or
locknuts which do not move freely.
3. Using Allen key, set adjusting screw (2) so
that the specified valve clearance is provided.
Note: Feeler gage must just pass through the gap.
4. Pull feeler gage (3) between valve bridge and
rocker arm.

5. Tighten locknut (1) to the specified tightening torque, holding adjusting screw (2) firmly.
Name Size Type Lubricant Value/Standard
Locknut M16x1.5 Tightening torque (Engine oil) 90 Nm +9 Nm

6. Check valve clearance, adjust if necessary.

Final steps
1. Remove barring device (→ Page 158).
2. Install cylinder head cover (→ Page 170).
3. Enable engine start.
TIM-ID: 0000012224 - 009

MS15035/00E 2018-08 | Valve Drive | 169

 8.5.3 Cylinder head cover – Removal and installation
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Torque wrench, 10–60 Nm F30510423
Ratchet bit F30027341
Assembly compound (Kluthe Hakuform 30-15) X00067260 1
Engine oil
O-ring (→ Spare Parts Catalog)

Removing cylinder head cover

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

Installing cylinder head cover

1. Clean installation surface.
2. Check O-ring (6) for damage, replace as necessary.
3. Coat O-ring (6) with assembly compound.
4. Insert O-ring (6) in groove on cylinder head cover (1).
5. Place cylinder head cover (7) on cylinder head.
6. Install cylinder head cover with screws (3, 4) and washers (2, 5).
7. Tighten screws (3), (4) to specified tightening torque using a torque wrench.
Name Size Type Lubricant Value/Standard
TIM-ID: 0000012309 - 017

Screw M10 Tightening torque (Engine oil) 42 Nm

170 | Valve Drive | MS15035/00E 2018-08

 8.6 Injection Pump / HP Pump
8.6.1 HP fuel pump – Filling with engine oil
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Torque wrench, 10–60 Nm F30452769 1
Fuel suction device F30378207 1
Engine oil

WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.

WARNING
Liquid or gaseous media, e.g. fuel, are poisonous.
Escaping vapors of highly volatile media, e.g. fuel or ether.
Risk of fatal injury through swallowing; risk of poisoning through inhalation; irritation to eyes
and skin!
• Seek medical attention immediately; do not induce vomiting.
• Do not inhale vapors or mist.
• Wear protective clothing, protective gloves, and safety glasses.
• If contact is made with skin, wash off with water and soap.

WARNING
Oils/oil vapors are combustible/explosive.
Risk of fire and explosion!
• Avoid open flames, electric sparks and ignition sources.
• Do not smoke.

NOTICE
HP fuel pump not filled with engine oil.
Damage to components, major material damage!
• Ensure that th HP fuel pump is filled with engine oil before it is installed or put into operation.

NOTICE
Contaminated components.
Risk of damage to component!
TIM-ID: 0000001640 - 016

• Check components for special cleanliness and clean if necessary.

MS15035/00E 2018-08 | Injection Pump / HP Pump | 171

 Preparatory steps
u Loosen nut (2) and remove oil line (1) from
HP pump.

HP pump – Filling
1. Remove union (1).
Note: Excess engine oil runs into gear box.
2. Use fuel suction device to fill HP pump with
2 liters of clean engine oil.

3. Screw in union (1) and use torque wrench to tighten to specified tightening torque.
Name Size Type Lubricant Value/Standard
Neck M16x1.5 Tightening torque 40 Nm

Final steps
u Install oil line.
TIM-ID: 0000001640 - 016

172 | Injection Pump / HP Pump | MS15035/00E 2018-08

 8.6.2 HP fuel pump – Relief bore check
DANGER
Components are moving or rotating.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Operate the engine at low load only. Keep clear of the danger zone of the engine.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

HP fuel pump, checking relief

bore
1. Visually inspect relief bore (1) for fuel dis-
charge.
2. If fuel discharge is found or indicated, con-
tact Service.
TIM-ID: 0000012375 - 009

MS15035/00E 2018-08 | Injection Pump / HP Pump | 173

 8.7 Injection Valve / Injector
8.7.1 Injector – Replacement
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Injector (→ Spare Parts Catalog)

Replacing injector
u Remove injector and install new injector (→ Page 175).

TIM-ID: 0000000022 - 017

174 | Injection Valve / Injector | MS15035/00E 2018-08

 8.7.2 Injector – Removal and installation (jacketed fuel system)
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Installation/removal jig F6789889 1
Milling cutter F30452739 1
Torque wrench, 10–60 Nm F30452769 1
Ratchet bit F30027340 1
Torque wrench, 60–320 Nm F30452768 1
Ratchet bit F30027342 1
Assembly compound (Molykote P 37) 50564 1
Assembly compound (Kluthe Hakuform 30-15) X00067260 1
Multi-purpose grease 40320 1
Engine oil
Damping ring (→ Spare Parts Catalog) 1
O-ring (→ Spare Parts Catalog) 2
O-ring (→ Spare Parts Catalog) 1
Sealing ring (→ Spare Parts Catalog) 1
O-ring (→ Spare Parts Catalog) 1

WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.

WARNING
Liquid or gaseous media, e.g. fuel, are poisonous.
Escaping vapors of highly volatile media, e.g. fuel or ether.
Risk of fatal injury through swallowing; risk of poisoning through inhalation; irritation to eyes
and skin!
• Seek medical attention immediately; do not induce vomiting.
• Do not inhale vapors or mist.
• Wear protective clothing, protective gloves, and safety glasses.
• If contact is made with skin, wash off with water and soap.
TIM-ID: 0000000925 - 031

WARNING
Hot components/surfaces.
Risk of burns!
• Allow the engine to cool down to below 50 °C before beginning work.
• Wear suitable protective equipment/thermal gloves.
• Avoid unprotected contact with hot surfaces.

MS15035/00E 2018-08 | Injection Valve / Injector | 175

 WARNING
Internal load and residual pressure in the HP fuel system. Parts may be expelled at high speed on re-
lease.
Fuel may spurt out.
Risk of injury by flying parts and sprayed fuel!
• Only use specified tools and devices.
• Always wear protective goggles / safety mask.

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

Preparatory steps
1. Allow HP system to cool down.
2. Shut off fuel supply to engine.
3. Remove cylinder head cover (→ Page 170).

Removing injector
1. Disconnect cable connector on injector.

Note: When the plug screw (1) is removed, fuel

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

176 | Injection Valve / Injector | MS15035/00E 2018-08

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

9. Install installation/removal jig on cylinder

head.
10. Remove injector with installation/removal jig
and take off hold-down clamp.
11. Remove installation/removal jig.

Note: The sealing ring (4) for sealing the combus-

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

ring (1) from injector.

15. Clean all mating and sealing surfaces.
16. Cover all connections and bores, or seal with
suitable plugs.

MS15035/00E 2018-08 | Injection Valve / Injector | 177

 Installing injector
Note: • The new sealing ring is included in the
scope of supply of the injector (new part).
• Use a multi-purpose grease without solids
content.
1. Install new sealing ring (1) with multi-purpose
grease and ensure that the installation posi-
tion is correct.

Note: If the milling cutter is pressed with excessive

force into the seat of the injector, this can
cause damage to the cylinder head.
2. Remove oil carbon from sealing face on cylin-
der head and protective sleeve by using the
milling cutter with little force.
Note: Remove seal plugs on HP line only before in-
stallation of the adapter.
3. Remove seal plug.
Note: The damper ring is already in place for new
assembly. Coat damper ring with assembly
compound.
4. Fit damper ring (1) on injector and coat with
assembly compound (Molykote P 37).
Note: The O-rings are already in place for new as-
sembly. Coat O-rings with assembly com-
pound.
5. Fit new O-rings (3) and (2) on injector and
coat with assembly compound (Kluthe Haku-
form 30-15).
Note: Make sure that the sealing ring does not fall
into the water sleeve.
6. Ensure that the sealing ring (4) is correctly
seated.
7. Insert injector with hold-down clamp into cyl-
inder head, ensuring that the HP line connec-
tion is correctly aligned.
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 8. Press in injector with installation/removal jig.
9. Remove installation/removal jig.

10. Coat screw mating face (2) and thread with

engine oil.
11. Fit hold-down clamp (1) in correct position, fit
screw (2) and tighten by hand.
Note: Make sure parts are perfectly clean.
12. Apply engine oil to thread, sealing taper and
thrust ring of adapter (3).
13. Coat O-ring on adapter (3) with assembly
compound (Kluthe Hakuform 30-15).
14. Install adapter (3).

15. Use torque wrench to tighten screw (2) to specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw M12 Tightening torque (Engine oil) 100 Nm+10 Nm

16. Use torque wrench to tighten adapter (3) to specified tightening torque.
Name Size Type Lubricant Value/Standard
Adapter Tightening torque (Engine oil) 100 Nm+10 Nm
TIM-ID: 0000000925 - 031

Note: Make sure parts are perfectly clean.

17. Coat thread and sealing cone of HP line (5) with engine oil.
18. Coat O-rings with assembly compound (Kluthe Hakuform 30-15).
19. Thread in HP line (5), ensuring that the sealing areas are not damage.

MS15035/00E 2018-08 | Injection Valve / Injector | 179

 20. Use torque wrench to tighten jacketed HP line (5) according to tightening sequence to specified tightening
torque. Tightening sequence:
1 Adapter (4)
2 Rail (6)
Name Size Type Lubricant Value/Standard
Union nut / thrust Tightening torque (Engine oil) 40 Nm +5 Nm
screw

Note: Do not hold in place by hand.

21. Turn union nuts (4) and (6) back by approx. 45° angle of rotation and – without releasing the tool – tighten
immediately again to the specified tightening torque, following the same sequence. Tightening sequence:
1 Adapter (4)
2 Rail (6)
Name Size Type Lubricant Value/Standard
Union nut / thrust Tightening torque (Engine oil) 40 Nm +5 Nm
screw

22. Screw in plug screw (1) and use torque wrench to tighten to specified tightening torque.
Name Size Type Lubricant Value/Standard
Plug screw M10 Tightening torque (Engine oil) 15 Nm +3 Nm
TIM-ID: 0000000925 - 031

180 | Injection Valve / Injector | MS15035/00E 2018-08

 23. Fit cable connector on injector.

For new assembly: CDC parameters – Reset

Note: Failure to reset drift compensation (CDC) will void the emissions certification of the engine.
u Reset drift compensation (CDC) with DiaSys® (→ Dialog system DiaSys® E531920/..). If DiaSys® is not
available, contact Service.

Final steps
1. Install cylinder head cover (→ Page 170).
2. Open fuel supply to engine.
TIM-ID: 0000000925 - 031

MS15035/00E 2018-08 | Injection Valve / Injector | 181

 8.8 Fuel System
8.8.1 Fuel system – Venting
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Diesel fuel

DANGER
Components are moving or rotating.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Operate the engine at low load only. Keep clear of the danger zone of the engine.

WARNING
Liquid or gaseous media, e.g. fuel, are poisonous.
Escaping vapors of highly volatile media, e.g. fuel or ether.
Risk of fatal injury through swallowing; risk of poisoning through inhalation; irritation to eyes
and skin!
• Seek medical attention immediately; do not induce vomiting.
• Do not inhale vapors or mist.
• Wear protective clothing, protective gloves, and safety glasses.
• If contact is made with skin, wash off with water and soap.

WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.
TIM-ID: 0000012552 - 007

182 | Fuel System | MS15035/00E 2018-08

 Venting LP fuel system
1. Turn three-way cock (3) into position (C)
where both filters are operational.
2. Open threaded vent plugs (1).
3. Unlock fuel priming pump (2), screw out han-
dle by turning it counterclockwise.
4. Operate fuel priming pump (2) until bubble-
free fuel emerges from the threaded vent
plugs (1).
5. Close threaded vent plugs (1).
6. Screw in handle by turning it clockwise.
7. Verify that fuel priming pump (2) is locked:
Handle must be tightened.
8. Put filters back into operation:
A Right filter cut in
B Left filter cut in
Result: One filter is in operation when the engine is
running.
TIM-ID: 0000012552 - 007

MS15035/00E 2018-08 | Fuel System | 183

 8.9 Fuel Filter
8.9.1 Additional fuel filter – Overview

1 Storage tank 3 Passive fuel prefilter with 5 Additional fuel filter, switch-
2 Day tank water separator able
4 LP pump 6 Main engine filter, switcha-
ble

TIM-ID: 0000012629 - 005

184 | Fuel Filter | MS15035/00E 2018-08

 8.9.2 Supplementary fuel filter – Replacement
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

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

DANGER
Components are moving or rotating.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Operate the engine at low load only. Keep clear of the danger zone of the engine.

WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

NOTICE
Damage to component!
Severe material damage!
• For filter replacement with the engine running, operate the engine at low engine load.
• The filter which is to be replaced must be cut out for a brief period only.

Replacing fuel filter with the en-

gine stopped
1. Cut out the filter to be replaced (2) using
three-way cock (3):
B Left-hand filter switched off
C Right-hand filter switched off
TIM-ID: 0000068614 - 002

2. Remove the cut-out oil filter (2) using an oil

filter wrench.
3. Clean sealing surface on filter head.
4. Check sealing ring of new filter (2) and coat
with fuel.
5. Screw on filter (2) and tighten manually.
6. Turn three-way cock (3) into position (A)
where both filters are operational.
7. Replace other fuel filters in the same way.
8. Open vent screws (1) to vent fuel system.

MS15035/00E 2018-08 | Fuel Filter | 185

 Replacing fuel filter with the engine running
1. Cut out the filter to be replaced (2) using three-way cock (3):
B Left-hand filter switched off
C Right-hand filter switched off
2. Remove the cut-out oil filter (2) using an oil filter wrench.
3. Clean sealing surface on filter head.
4. Check sealing ring of new filter (2) and coat with fuel.
5. Screw on filter (2) and tighten manually.
6. Turn three-way cock (3) into position (A) where both filters are operational.
7. Replace other fuel filters in the same way.

TIM-ID: 0000068614 - 002

186 | Fuel Filter | MS15035/00E 2018-08

 8.9.3 Fuel filter – Replacement
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

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

DANGER
Components are moving or rotating.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Operate the engine at low load only. Keep clear of the danger zone of the engine.

WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

NOTICE
Damage to component!
Severe material damage!
• For filter replacement with the engine running, operate the engine at low engine load.
• The filter which is to be replaced must be cut out for a brief period only.

Replacing fuel filter with the en-

gine stopped
A Both filters cut in
B Left filter cut out
C Right filter cut out
1 Fuel filter
TIM-ID: 0000012704 - 004

MS15035/00E 2018-08 | Fuel Filter | 187

 1. Cut out the filter to be replaced.
2. Unscrew cut-out easy-change filter with oil filter wrench.
3. Clean sealing surface on filter head.
4. Check sealing ring of the new easy-change filter and moisten it with fuel.
5. Fit SOLAS shield (→ Page 41).
6. Screw on easy-change filter and tighten by hand.
7. Set three-way cock to operating position (both filters cut in).
8. Replace other fuel filters in the same way.
9. Vent fuel system.

Replacing fuel filter with the en-

gine running
1. Cut out the filter to be replaced.
B Left-hand filter cut out
C Right-hand filter cut out
2. Unscrew cut-out easy-change filter with oil fil-
ter wrench.
3. Clean sealing surface on filter head.
4. Check sealing ring of the new easy-change fil-
ter and moisten it with fuel.
5. Fit SOLAS shield (→ Page 41).
6. Screw on easy-change filter (1) and tighten
by hand.
7. Set three-way cock to operating position
(both filters cut in).
8. Replace other fuel filters in the same way.

TIM-ID: 0000012704 - 004

188 | Fuel Filter | MS15035/00E 2018-08

 8.9.4 Fuel prefilter – Differential pressure gage check and adjustment
DANGER
Components are moving or rotating.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Operate the engine at low load only. Keep clear of the danger zone of the engine.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

Adjusting differential pressure

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

Fuel prefilter – Differential pressure check

1. With the engine running at full load or rated power, read off pressure at gage (1).
2. If differential pressure as indicated between position of adjustable pointer (2) and pressure-indicating point-
er (3) of pressure gage is ≥ 0.3 bar, flush filter element of the cut-in filter (→ Page 192).
TIM-ID: 0000004925 - 011

MS15035/00E 2018-08 | Fuel Filter | 189

 8.9.5 Fuel prefilter – Draining
DANGER
Components are moving or rotating.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Operate the engine at low load only. Keep clear of the danger zone of the engine.

WARNING
Liquid or gaseous media, e.g. fuel, are poisonous.
Escaping vapors of highly volatile media, e.g. fuel or ether.
Risk of fatal injury through swallowing; risk of poisoning through inhalation; irritation to eyes
and skin!
• Seek medical attention immediately; do not induce vomiting.
• Do not inhale vapors or mist.
• Wear protective clothing, protective gloves, and safety glasses.
• If contact is made with skin, wash off with water and soap.

WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

Draining fuel prefilter

1. Cut out the filter to be drained (A or B):
1 Filter A cut out
2 Filter B cut out

TIM-ID: 0000018510 - 010

190 | Fuel Filter | MS15035/00E 2018-08

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

6. Open rotary slide valve (2) a little (turning to

approx. 30°) to introduce fuel into the filter
housing with the new filter element.
7. Close vent valve (1) as soon as fuel emerges
from vent pipe (4).
8. Turn the rotary slide valve to the upright posi-
tion (3) until it engages.
Result: Both filters are cut in.
9. Set differential pressure gage (→ Page 189).
TIM-ID: 0000018510 - 010

MS15035/00E 2018-08 | Fuel Filter | 191

 8.9.6 Fuel prefilter – Flushing
Preconditions
☑ Positive pressure at the prefilter inlet.

DANGER
Components are moving or rotating.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Operate the engine at low load only. Keep clear of the danger zone of the engine.

WARNING
Liquid or gaseous media, e.g. fuel, are poisonous.
Escaping vapors of highly volatile media, e.g. fuel or ether.
Risk of fatal injury through swallowing; risk of poisoning through inhalation; irritation to eyes
and skin!
• Seek medical attention immediately; do not induce vomiting.
• Do not inhale vapors or mist.
• Wear protective clothing, protective gloves, and safety glasses.
• If contact is made with skin, wash off with water and soap.

WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

Fuel prefilter – Flushing

1. Cut out contaminated filter (A or B).
1 Filter A cut out
2 Filter B cut out TIM-ID: 0000012728 - 012

192 | Fuel Filter | MS15035/00E 2018-08

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

5. Open rotary slide valve (2) a little (turning to

approx. 30°) to introduce fuel into the filter
housing with the new filter element.
6. Close vent valves (1) as soon as fuel emerges
from vent pipe (4).
7. Turn the rotary slide valve to the upright posi-
tion (3) until it engages.
Result: Both filters are cut in.
8. Set differential pressure gauge (→ Page 189).
TIM-ID: 0000012728 - 012

MS15035/00E 2018-08 | Fuel Filter | 193

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

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Torque wrench, 10–60 Nm F30452769 1
Ratchet adapter F30027340 1
Filter element (→ Spare Parts Catalog)
O-ring (→ Spare Parts Catalog)

DANGER
Components are moving or rotating.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Operate the engine at low load only. Keep clear of the danger zone of the engine.

WARNING
Tank is pressurized.
Risk of eye injuries resulting from fluid escaping under high pressure!
• Open tank slowly.
• Wear goggles or safety mask.

WARNING
Liquid or gaseous media, e.g. fuel, are poisonous.
Escaping vapors of highly volatile media, e.g. fuel or ether.
Risk of fatal injury through swallowing; risk of poisoning through inhalation; irritation to eyes
and skin!
• Seek medical attention immediately; do not induce vomiting.
• Do not inhale vapors or mist.
• Wear protective clothing, protective gloves, and safety glasses.
• If contact is made with skin, wash off with water and soap.

WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.

WARNING
Hot components/surfaces.
Risk of burns!
• Allow the engine to cool down to below 50 °C before beginning work.
TIM-ID: 0000012750 - 015

• Wear suitable protective equipment/thermal gloves.

• Avoid unprotected contact with hot surfaces.

NOTICE
Damage to component!
Severe material damage!
• For filter replacement with the engine running, operate the engine at low engine load.
• The filter which is to be replaced must be cut out for a brief period only.

194 | Fuel Filter | MS15035/00E 2018-08

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

2. Open vent valve (3) of the filter to be re-

placed.
3. Unlock drain valve (4) by pressing toggle and
open it.
4. Drain water and contaminants from filter.
5. Close drain valve.
6. Loosen screws (1) and (2).
7. Turn filter housing aside around screw (2) un-
til filter element is accessible.
8. Remove filter element (5) with spring (6).
9. Insert a new filter element in the filter hous-
ing.
10. Insert new O-ring and turn filter housing back
into position.
11. Tighten screws (1) and (2) finger-tight.

12. Tighten screws evenly to specified torque using a torque wrench (max. half a turn per screw).
Name Size Type Lubricant Value/Standard
Screw Tightening torque 40 Nm
TIM-ID: 0000012750 - 015

MS15035/00E 2018-08 | Fuel Filter | 195

 13. Open rotary slide valve (2) a little (turning to
approx. 30°) to introduce fuel into the filter
housing with the new filter element.
14. Close vent valve (1) as soon as fuel emerges
from vent pipe (4).
15. Turn the rotary slide valve to the upright posi-
tion (3) until it engages.
Result: Both filters are cut in.
16. Set differential pressure gage (→ Page 189).

TIM-ID: 0000012750 - 015

196 | Fuel Filter | MS15035/00E 2018-08

 8.9.8 Fuel prefilter with water separator – O-ring replacement in rotary slide valve
Preconditions
☑ Engine is stopped and starting disabled.
☑ System is at atmospheric pressure.

Special tools, Material, Spare parts

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

WARNING
Tank is pressurized.
Risk of eye injuries resulting from fluid escaping under high pressure!
• Open tank slowly.
• Wear goggles or safety mask.

WARNING
Liquid or gaseous media, e.g. fuel, are poisonous.
Escaping vapors of highly volatile media, e.g. fuel or ether.
Risk of fatal injury through swallowing; risk of poisoning through inhalation; irritation to eyes
and skin!
• Seek medical attention immediately; do not induce vomiting.
• Do not inhale vapors or mist.
• Wear protective clothing, protective gloves, and safety glasses.
• If contact is made with skin, wash off with water and soap.

WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.

Fuel prefilter with water separa-

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

6. For assembly, follow the reverse sequence of

working steps as described for disassembly.

MS15035/00E 2018-08 | Fuel Filter | 197

 8.10 Exhaust Turbocharger
8.10.1 Compressor wheel – Cleaning
Preconditions
☑ Engine is stopped and starting disabled

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Torque wrench, 10–60 Nm F30452769 1
Ratchet adapter F30027340 1
Cleaner 40377 1
Engine oil
Engine coolant
Sealing rings (→ Spare Parts Catalog) 3
Sealing rings (→ Spare Parts Catalog) 4

WARNING
Chemical substances.
Risk of irritation or burning of eyes, skin and airways!
• Observe information provided in the relevant safety data sheet.
• Wear protective gear as specified in the relevant safety data sheet.

NOTICE
Inappropriate cleaning tool.
Risk of damage to component!
• Observe manufacturer's instructions.
• Use appropriate cleaning tool.

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

Preparatory steps – Horizontal air intake

1. Drain engine coolant (→ Page 227).
2. Remove air filter (→ Page 208).
3. Seal all openings with suitable covers.
TIM-ID: 0000018629 - 007

198 | Exhaust Turbocharger | MS15035/00E 2018-08

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

6. Loosen clamp (1).

7. Remove intake housing (3) with actuating cyl-
inder (2).

8. Remove coolant lines (1) from compressor

housing (3).
9. Remove coolant ventilation line (2) from com-
pressor housing (3).
TIM-ID: 0000018629 - 007

MS15035/00E 2018-08 | Exhaust Turbocharger | 199

 10. Undo screws (1).
11. Remove compressor housing (2).

Cleaning compressor wheel

Note: Do not use wire brushes, scrapers or similar
tools for cleaning!
1. Clean compressor housing with a smooth
paint brush or brush.
2. Clean compressor wheel (2) and bearing
housing (1).
3. Thoroughly remove cleaner from all compo-
nents.
4. Fit new sealing rings between bearing hous-
ing/compressor housing and plug-in sleeves
if necessary.

Final steps – Horizontal air in-

take
1. Install compressor housing (2).
TIM-ID: 0000018629 - 007

200 | Exhaust Turbocharger | MS15035/00E 2018-08

 2. Tighten screws (1) to specified torque using a torque wrench.
Name Size Type Lubricant Value/Standard
Screw Tightening torque (Engine oil) 20 Nm + 2.5 Nm

3. Install coolant ventilation line and coolant lines on compressor housing.

4. Install intake housing (3) with actuating cylin-
der (2).

5. Align clamp (1) and tighten to specified torque using a torque wrench.
Name Size Type Lubricant Value/Standard
Clamp Tightening torque 15 Nm + 2 Nm
TIM-ID: 0000018629 - 007

6. Install oil lines (2). Tighten threaded adapter at actuating cylinder to specified torque using a torque wrench.
Name Size Type Lubricant Value/Standard
Threaded adapter 10 G 1/4 Tightening torque (Engine oil) 40 Nm +4 Nm
A

7. Install charge-air pipework (1) between exhaust turbocharger and intercooler.

8. Install air filter (→ Page 208).
9. Fill with engine coolant (→ Page 230).

MS15035/00E 2018-08 | Exhaust Turbocharger | 201

 Preparatory steps – Vertical air intake
1. Drain engine coolant (→ Page 227).
2. Remove air filter (→ Page 208).
3. Seal all openings with suitable covers.
4. Remove charge-air pipework (1) from exhaust
turbocharger to intercooler.
5. Remove oil lines (2).

6. Loosen clamp (1).

7. Remove intake housing (3) with actuating cyl-
inder (2).

TIM-ID: 0000018629 - 007

202 | Exhaust Turbocharger | MS15035/00E 2018-08

 8. Remove coolant lines (1) from compressor
housing (3).
9. Remove coolant ventilation line (2) from com-
pressor housing (3).

10. Undo screws (1).

11. Remove compressor housing (2).

Cleaning compressor wheel

Note: Do not use wire brushes, scrapers or similar
tools for cleaning!
1. Clean compressor housing with a smooth
paint brush or brush.
2. Clean compressor wheel (2) and bearing
housing (1).
3. Thoroughly remove cleaner from all compo-
nents.
TIM-ID: 0000018629 - 007

4. Fit new sealing rings between bearing hous-

ing/compressor housing and plug-in sleeves
if necessary.

MS15035/00E 2018-08 | Exhaust Turbocharger | 203

 Final steps – Vertical air intake
1. Install compressor casing (2).

2. Tighten screws (1) to specified torque using a torque wrench.

Name Size Type Lubricant Value/Standard
Screw Tightening torque (Engine oil) 20 Nm + 2.5 Nm

3. Install coolant ventilation line and coolant lines on compressor housing.

4. Install intake housing (3) with actuating cylin-
der (2).

5. Align clamp (1) and tighten to specified torque using a torque wrench.
Name Size Type Lubricant Value/Standard
Clamp Tightening torque 15 Nm + 2 Nm
TIM-ID: 0000018629 - 007

204 | Exhaust Turbocharger | MS15035/00E 2018-08

 6. Install oil lines (2). Tighten threaded adapter at actuating cylinder to specified torque using a torque wrench.
Name Size Type Lubricant Value/Standard
Threaded adapter 10 G 1/4 Tightening torque (Engine oil) 40 Nm +4 Nm
A

7. Install charge-air pipework (1) between exhaust turbocharger and intercooler.

8. Install air filter (→ Page 208).
9. Fill with engine coolant (→ Page 230).
TIM-ID: 0000018629 - 007

MS15035/00E 2018-08 | Exhaust Turbocharger | 205

 8.11 Charge-Air Cooling
8.11.1 Intercooler – Checking condensate drain for water discharge and obstruction
DANGER
Components are moving or rotating.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Operate the engine at low load only. Keep clear of the danger zone of the engine.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.

Intercooler – Checking conden-

sate drain for water discharge
and obstruction
1. With the engine running, check if air emerges
from drain bore(s) on the left and right sides
on engine driving end.
Result: If no air emerges:
• Clean condensate drain bore(s).
• Blow out with compressed air.
2. 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 175).
2. Bar engine manually (→ Page 158).
3. Bar engine with starting system to blow out combustion chambers (→ Page 158).
4. Install injectors (→ Page 175).
TIM-ID: 0000013214 - 007

206 | Charge-Air Cooling | MS15035/00E 2018-08

 8.12 Air Filter
8.12.1 Air filter – Replacement
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Air filter (→ Spare Parts Catalog)

Replacing air filter

1. Remove old air filter and install new air filter (→ Page 208).
2. Reset signal ring of contamination indicator (→ Page 209).
TIM-ID: 0000005447 - 010

MS15035/00E 2018-08 | Air Filter | 207

 8.12.2 Air filter – Removal and installation
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Torque wrench, 10–60 Nm F30452769 1

Air filter
1. Loosen clamp (2).
2. Remove air filter (1) and clamp (2) from con-
necting flange of housing (3).
3. Verify that there are no objects in the flange
of the intake housing (3) and clean it.
4. Attach air filter (1) with clamp (2) onto intake
housing (3).
5. Tighten clamp (2).

Air filter with intake silencer

1. Loosen clamp (2).
2. Remove air filter (1) and clamp (2) from in-
take silencer (3).
3. Clean intake silencer (3) and check for ob-
structions.
4. Attach air filter (1) with clamp (2) onto intake
silencer (1). TIM-ID: 0000013401 - 008

5. Tighten clamp (2) to specified tightening torque.

Name Size Type Lubricant Value/Standard
Clamp S254/25x Tightening torque 15 Nm +3 Nm
1,25

208 | Air Filter | MS15035/00E 2018-08

 8.13 Air Intake
8.13.1 Contamination indicator – Signal ring position check
Preconditions
☑ Engine is stopped and starting disabled.

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

Checking signal ring position

1. If the signal ring is completely visible in the
viewing window (2), replace air filter
(→ Page 207).
2. After installation of new filter, press reset
button (1).
Result: Engaged plunger with signal ring returns to
initial position.
TIM-ID: 0000005484 - 010

MS15035/00E 2018-08 | Air Intake | 209

 8.14 Starting Equipment
8.14.1 Starter – Condition check
Preconditions
☑ Engine is stopped and starting disabled.

Starter – Condition check

1. Check securing screws of starter and nut on cable connection for secure seating and tighten if required.
2. Check cabling (→ Page 257).

TIM-ID: 0000000905 - 019

210 | Starting Equipment | MS15035/00E 2018-08

 8.15 Lube Oil System, Lube Oil Circuit
8.15.1 Engine oil level – Check
Preconditions
☑ Engine is stopped and starting disabled.

WARNING
Oil is hot.
Oil can contain residue/substances which are harmful to health.
Risk of injury and poisoning!
• Allow the product to cool to below 50 °C before beginning work.
• Wear protective clothing, protective gloves and goggles/safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.

Checking engine oil level after

extended standstill
1. Pull out dipstick from guide tube and wipe it.
2. Insert oil dipstick into guide tube up to the
stop, pull it out after approx. 10 seconds and
check oil level.
Note: After extended standstill, the oil level may be
up to 2 cm above mark (1). This may be
caused e.g. by oil from oil filters and heat ex-
changers flowing back into the oil pan. After
extended standstill, the oil level "2 cm above
mark (2)" is the minimum oil level.
3. Oil level must be at least 2 cm above
mark (2).
4. If necessary, top up with oil, maximum to
mark (1) (→ Page 212).
5. Insert oil dipstick into guide tube up to the
stop.

Checking oil level immediately after engine stop

1. 5 minutes after stopping the engine, pull out oil dipstick from guide tube and wipe it.
2. Insert oil dipstick into guide tube up to the stop, pull it out after approx. 10 seconds and check oil level.
3. Oil level must be between marks (1) and (2).
4. If necessary, top up with oil, maximum to mark (1) (→ Page 212).
5. Insert oil dipstick into guide tube up to the stop.
TIM-ID: 0000000931 - 017

MS15035/00E 2018-08 | Lube Oil System, Lube Oil Circuit | 211

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

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Torque wrench, 40–200 Nm F30027337 1
Ratchet bit F30027341 1
Engine oil
Sealing ring (→ Spare Parts Catalog)

WARNING
Oil is hot.
Oil can contain residue/substances which are harmful to health.
Risk of injury and poisoning!
• Allow the product to cool to below 50 °C before beginning work.
• Wear protective clothing, protective gloves and goggles/safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.

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

Oil change with semirotary hand pump: Engine oil extraction

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

Draining residual oil at gearcase

1. Provide a suitable vessel in which to collect
the engine oil.
2. Remove drain plugs (1) and (2) and drain en-
gine oil:
• Approx. 12 liters at (1)
• Approx. 5 liters at (2)
TIM-ID: 0000014099 - 007

3. Install drain plug(s) with new sealing ring.

212 | Lube Oil System, Lube Oil Circuit | MS15035/00E 2018-08

 4. Tighten drain plugs (1) and (2) to specified torque using a torque wrench:
Name Size Type Lubricant Value/Standard
Screw M26x1.5 Tightening torque (Engine oil) 100 Nm+10 Nm

Filling with new engine oil

1. Open cap (1) on filler neck.
2. Pour oil in at filler neck up to “max.” mark on
oil dipstick.
3. Close cap on filler neck.
4. Check engine oil level (→ Page 211).
5. Bar engine with starting system after engine
oil change (→ Page 160).
TIM-ID: 0000014099 - 007

MS15035/00E 2018-08 | Lube Oil System, Lube Oil Circuit | 213

 8.15.3 Engine oil – Sample extraction and analysis
Preconditions
☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.

Special tools, Material, Spare parts

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

DANGER
Components are moving or rotating.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Operate the engine at low load only. Keep clear of the danger zone of the engine.

WARNING
Oil is hot.
Oil can contain residue/substances which are harmful to health.
Risk of injury and poisoning!
• Allow the product to cool to below 50 °C before beginning work.
• Wear protective clothing, protective gloves and goggles/safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

Engine oil sample extraction

and analysis (engine with stand-
ard oil filter)
Note: Only take the engine oil sample by opening
an oil drain screw with the engine stationary.
1. With the engine shut down, open the screw,
e.g. at the oil filter.
2. Drain approx. 1 liter engine oil into a clean
container.
3. Seal oil drain screw again with a new sealing
ring.
4. Using the equipment and chemicals in the
MTU test kit, analyze the engine oil for:
• Dispersion capability (spot test)
TIM-ID: 0000014113 - 007

• Proportion of water
• Fuel dilution

214 | Lube Oil System, Lube Oil Circuit | MS15035/00E 2018-08

 Engine oil, sample extraction
and analysis
1. With the engine running at operating temper-
ature, open screw on centrifugal oil filter car-
rier by 1 to 2 rotations.
2. Drain approx. 2 liters engine oil to flush out
the oil sludge.
3. Drain approx. 1 liter engine oil into a clean
container.
4. Close screw.
5. Using the equipment and chemicals in the
MTU test kit, analyze the engine oil for:
• Dispersion capability (spot test)
• Proportion of water
• Fuel dilution

Engine oil, sample extraction

and analysis (engine with
switchable oil filter)
1. With the engine running at operating temper-
ature, open screw on flange of centrifugal oil
filter by 1 to 2 rotations.
2. Drain approx. 2 liters engine oil to flush out
the oil sludge.
3. Drain approx. 1 liter engine oil into a clean
container.
4. Close screw.
5. Using the equipment and chemicals in the
MTU test kit, analyze the engine oil for:
• Dispersion capability (spot test)
• Proportion of water
• Fuel dilution
TIM-ID: 0000014113 - 007

MS15035/00E 2018-08 | Lube Oil System, Lube Oil Circuit | 215

 8.16 Oil Filtration / Cooling
8.16.1 Oil indicator filter – Cleaning and check
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Cleaner (Snow-White 11-0) X00054118 1
Cleaner (Hakupur 50/136) X00056700 1
Engine oil
Strainer (→ Spare Parts Catalog)
Square-section ring (→ Spare Parts Catalog)
O-ring (→ Spare Parts Catalog)

WARNING
Oil is hot.
Oil can contain residue/substances which are harmful to health.
Risk of injury and poisoning!
• Allow the product to cool to below 50 °C before beginning work.
• Wear protective clothing, protective gloves and goggles/safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.

WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.

NOTICE
Inappropriate cleaning tool.
Risk of damage to component!
• Observe manufacturer's instructions.
• Use appropriate cleaning tool.
TIM-ID: 0000036227 - 010

216 | Oil Filtration / Cooling | MS15035/00E 2018-08

 Removing basket strainer – var-
iant A
1. Clean oil indicator filter before disassembling
it.
2. Remove screws (1).
3. Take off cover (2) and O-ring (3).
4. Remove spring (4) and strainer (6) from filter
housing and allow oil to drip into container.

Cleaning strainer
1. Shake coarse contamination out of strainer (6).
2. Clean all metallic parts with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 50/136).
Note: Do not damage the fabric of the strainer.
3. Use a soft brush to remove stubborn deposits from strainer as necessary.
4. Blow out strainer (6) with compressed air from outside to inside.

Checking strainer
Item Findings Task
Strainer Metallic residues • Clean
• Monitor engine operation
• Check strainer daily
• Contact Service.
Strainer Damaged Replace
Square-section ring Damaged Replace
O-ring Damaged Replace

Installing strainer
1. Coat square-section ring (5) on strainer (6) with engine oil and install strainer (6).
2. Coat O-ring (3) with engine oil and install in filter housing.
3. Install spring (4).
4. Fill housing with new engine oil.
5. Install cover (2) and secure with screws (1) and washers.
TIM-ID: 0000036227 - 010

MS15035/00E 2018-08 | Oil Filtration / Cooling | 217

 Removing basket strainer – var-
iant B
Note: Cover (2) is under tension due to spring (4).
1. Remove screws (1).
2. Take off cover (2) and O-ring (3).
3. Remove spring (4).
4. Take strainer (5) out of filter housing.

Cleaning strainer
1. Shake coarse contamination out of strainer (5).
2. Clean all metallic parts with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 50/136).
Note: Do not damage the fabric of the strainer.
3. Use a soft brush to remove stubborn deposits from strainer as necessary.
4. Blow out strainer (5) with compressed air from outside to inside.

Checking strainer
Item Findings Task
Strainer Metallic residues • Clean
• Monitor engine operation
• Check strainer daily
• Contact Service.
Strainer Damaged Replace
Square section ring Damaged Replace
Spring Damaged Replace
O-ring Damaged Replace

Installing strainer
1. Coat square section ring on basket strainer (5) with engine oil and install basket strainer (5).
2. Coat O-ring (3) with engine and install in filter housing.
3. Move spring (4) into fitting position.
4. Install cover (2) and secure with screws (1).
TIM-ID: 0000036227 - 010

218 | Oil Filtration / Cooling | MS15035/00E 2018-08

 8.16.2 Engine oil filter – Replacement
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Filter wrench F30379104
Engine oil
Oil filter (→ Spare Parts Catalog)

DANGER
Components are moving or rotating.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Operate the engine at low load only. Keep clear of the danger zone of the engine.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

WARNING
Oil is hot.
Oil can contain residue/substances which are harmful to health.
Risk of injury and poisoning!
• Allow the product to cool to below 50 °C before beginning work.
• Wear protective clothing, protective gloves and goggles/safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.

NOTICE
Damage to component!
Severe material damage!
• For filter replacement with the engine running, operate the engine at low engine load.
• The filter which is to be replaced must be cut out for a brief period only.

Engine oil filter – Replacement

1. Stop engine (→ Page 98) and disable engine
start.
2. Unscrew engine oil filter using filter wrench.
3. Clean sealing surface on connecting piece.
4. Check condition of the new engine oil filter
sealing ring and coat it with engine oil.
5. Fit SOLAS shield (→ Page 41).
6. Screw on engine oil filter and tighten by
hand.
TIM-ID: 0000014238 - 009

7. Replace other engine oil filters in the same

way.
8. Crank engine on starting system after every
engine oil change and filter replacement
(→ Page 160).
9. Check engine oil level (→ Page 211).

MS15035/00E 2018-08 | Oil Filtration / Cooling | 219

 Engine oil filter with diverter
(option) – Oil filter replacement
with engine at standstill
1. Stop engine (→ Page 98) and disable engine
start.
2. Unscrew engine oil filter using filter wrench.
3. Clean sealing surface on connecting piece.
4. Check condition of the new engine oil filter
sealing ring and coat it with engine oil.
5. Fit SOLAS shield (→ Page 41).
6. Screw on engine oil filter and tighten by
hand.
7. Replace other engine oil filters in the same
way.
8. Crank engine on starting system after every
engine oil change and filter replacement
(→ Page 160).
9. Check engine oil level (→ Page 211).

Engine oil filter with diverter

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

2. Unscrew engine oil filter using filter wrench.

3. Clean sealing surface on connecting piece.
4. Check condition of the new engine oil filter
sealing ring and coat it with engine oil.
5. Fit SOLAS shield (→ Page 41).
6. Screw on engine oil filter and tighten by
hand.
7. Replace other engine oil filters in the same
way.
TIM-ID: 0000014238 - 009

8. Check engine oil level (→ Page 211).

220 | Oil Filtration / Cooling | MS15035/00E 2018-08

 8.16.3 Centrifugal oil filter – Cleaning and filter sleeve replacement
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Torque wrench, 4–20 Nm F30044239 1
Torque wrench, 10–60 Nm F30452769 1
Torque wrench, 60–320 Nm F30452768 1
Ratchet bit F30027340 1
Oil filter wrench F30455924 1
Cold cleaner (Hakutex 60) X00056750 1
Assembly compound (Kluthe Hakuform 30-15) X00067260 1
Filter sleeves (→ Spare Parts Catalog)
Sealing rings (→ Spare Parts Catalog)

WARNING
Oil is hot.
Oil can contain residue/substances which are harmful to health.
Risk of injury and poisoning!
• Allow the product to cool to below 50 °C before beginning work.
• Wear protective clothing, protective gloves and goggles/safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.

WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.
TIM-ID: 0000065398 - 004

MS15035/00E 2018-08 | Oil Filtration / Cooling | 221

 Centrifugal oil filter, cleaning
and filter sleeve replacement
1. Remove clamp (17).
2. Release Tommy nut (2) and remove cover (1).
3. Carefully lift rotor (14), allow oil to drain and
remove from housing.
Note: Do not clamp rotor in a bench vise.
4. Holding rotor unit (14) firmly, release rotor
cover nut (3).
5. Take off rotor cover (3).
6. Measure layer thickness of oil residues on fil-
ter sleeve (6).
Result: If the oil residue exceeds the maximum layer
thickness of 45 mm, shorten the mainte-
nance interval.
7. Remove filter sleeve (6).
8. Disassemble rotor tube (7), conical disk (8)
and rotor base (13).
9. Wash rotor cover (3), rotor tube (7), conical
disk (8) and rotor base (13) with cold cleaner.
10. Blow out with compressed air.
11. Check sealing rings (9, 10, 12) and replace if
necessary.
12. Coat sealing rings (9, 10) with assembly com-
pound and insert in grooves on bearing shaft
(11).
13. Assemble rotor tube (7), conical disk (8) and
rotor base (13) with sealing ring (12).
Note: Observe markings and information on paper
element!
14. Insert new filter sleeve (6) in rotor tube (7)
with the smooth paper surface facing the out-
er wall.
15. Check sealing rings (4, 5) and replace if nec-
essary.
16. Insert sealing ring (5) in rotor tube (7) and
sealing ring (4) in rotor cover (3). TIM-ID: 0000065398 - 004

222 | Oil Filtration / Cooling | MS15035/00E 2018-08

 Note: Do not clamp rotor unit in a bench vise.Use an oil filter wrench.
17. Install rotor cap (3) tighten nut for rotor cover (3) with torque wrench to specified tightening torque.
Name Size Type Lubricant Value/Standard
Nut M12 Tightening torque 80 Nm ±12 Nm

18. Place rotor (14) in housing (15) and check for ease of movement.
19. Check sealing ring (16), replace as necessary.
20. Fit sealing ring (16) on housing (15).
21. Fit hood (1).
22. Tighten Tommy nut (2) by hand.
23. Install clamp (17) and tighten to specified torque using a torque wrench.
Name Size Type Lubricant Value/Standard
Clamp Tightening torque 20 Nm ±3 Nm

24. Tighten cover nut (2) to specified torque using a torque wrench.
Name Size Type Lubricant Value/Standard
Screw Tightening torque 7 Nm ±1 Nm
TIM-ID: 0000065398 - 004

MS15035/00E 2018-08 | Oil Filtration / Cooling | 223

 Cleaning centrifugal oil filter
and replacing filter sleeve (en-
gines with switchable oil filter)
1. Undo and remove screw (1).
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. Shorten maintenance interval if maximum
layer thickness of oil residues ex-
ceeds 30 mm.
9. Remove standpipe (12) from lower rotor sec-
tion (13).
10. Wash hood (2), rotor cap (8), stiffener
plate (10), standpipe (12), lower rotor sec-
tion (13) and nozzles (14) with cleaner and
blow out with compressed air. Do not use
sharp objects for cleaning.
11. Check nozzles (14) for obstructions.
12. Push standpipe (12) onto rotor lower sec-
tion (13).
13. Insert new filter sleeve (9) with stiffener
plate (10) into rotor cap (8), ensuring that the
smooth surface of the filter sleeve (9) faces
the rotor cap (8).
14. Check sealing ring (11), replace as necessa-
ry. Coat sealing ring with assembly com-
pound 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), insert in hous-
ing (6) and check for ease of movement.
18. Check sealing ring (4), replace as necessary.
Fit sealing ring on housing (6).
19. Fit hood (2).
20. Tighten screw (1) by hand.
21. Install clamp (3) and use torque wrench to tighten to specified tightening torque.
Name Size Type Lubricant Value/Standard
TIM-ID: 0000065398 - 004

Clamp Tightening torque 8 Nm to 9 Nm

22. Tighten screw (1) to specified torque using a torque wrench.

Name Size Type Lubricant Value/Standard
Screw Tightening torque 5 Nm to 7 Nm

224 | Oil Filtration / Cooling | MS15035/00E 2018-08

 8.17 Coolant Circuit, General, High-Temperature Circuit
8.17.1 Engine coolant level – Check
Preconditions
☑ Engine is stopped and starting disabled.
☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.

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

Checking engine coolant level at filler neck:

1. Turn breather valve on coolant expansion tank (for engines with remote heat exchanger: the expansion tank
is part of the remote cooling system) counterclockwise up to the first stop and allow pressure to escape.
2. Continue to turn breather valve counterclockwise and remove.
3. Check coolant level (coolant must be visible at the bottom edge of the cast-in eye in the filler neck).

Checking engine coolant level at

external cooler:
1. Check coolant level (coolant must be visible
at marker plate).
2. Top up with treated coolant as necessary
(→ Page 230).
3. Check and clean breather valve.
4. Set breather valve onto filler neck and close
it.

Checking engine coolant level by means of level sensor:

1. Switch on engine control system and check readings on the display.
2. Top up with treated coolant as necessary (→ Page 230).
TIM-ID: 0000014605 - 003

MS15035/00E 2018-08 | Coolant Circuit, General, High-Temperature Circuit | 225

 8.17.2 Engine coolant – Change
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Coolant

Engine coolant change

1. Drain engine coolant (→ Page 227).
2. Fill with engine coolant (→ Page 230).

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226 | Coolant Circuit, General, High-Temperature Circuit | MS15035/00E 2018-08

 8.17.3 Engine coolant – Draining
Preconditions
☑ Engine is stopped and starting disabled.

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

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

Engine coolant – Draining

1. Turn breather valve on expansion tank (for engines with remote heat exchanger: the expansion tank is part of
the remote cooling system) counterclockwise up to the first stop and allow pressure to escape.
2. Continue to turn breather valve counterclockwise and remove.
3. Draw off precipitated corrosion inhibitor oil from the expansion tank through filler neck.
4. Open vent valves on carrier housing (1).
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MS15035/00E 2018-08 | Coolant Circuit, General, High-Temperature Circuit | 227

 5. Open vent valve on exhaust pipework (driving
end) (1).

6. Open vent valve on seawater cooler (1) (or re-

mote heat exchanger).

7. Open drain plug (1) and drain coolant at

crankcase. TIM-ID: 0000014593 - 005

228 | Coolant Circuit, General, High-Temperature Circuit | MS15035/00E 2018-08

 8. Open drain screw (1) and drain coolant on
coolant pump elbow.

Final steps
1. Seal all open vent and drain points.
2. Set breather valve onto filler neck and close it.
TIM-ID: 0000014593 - 005

MS15035/00E 2018-08 | Coolant Circuit, General, High-Temperature Circuit | 229

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

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Engine coolant

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

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

Preparatory steps
Note: On engines with a separate heat exchanger,
the expansion tank is connected separately
from the engine to the external cooling sys-
tem.
1. Turn breather valve on filler neck of expan-
sion tank counterclockwise to first stop and
allow pressure to escape.
2. Continue to turn breather valve counterclock-
wise and remove.

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230 | Coolant Circuit, General, High-Temperature Circuit | MS15035/00E 2018-08

 Filling coolant through filler
neck
1. Open vent points on charge-air cooler, ex-
haust turbochargers and on plate-core heat
exchanger (arrows).
Note: On engines with a separate heat exchanger,
the expansion tank is connected separately
from the engine to the external cooling sys-
tem.
2. Fill in engine coolant via filler neck on expan-
sion tank until engine coolant level remains
constant at top edge of filler neck.
3. When coolant emerges from the vent points,
close vent points one by one, proceeding
from the lowest point upwards.
4. Check proper condition of breather valve and
clean sealing faces if required.
5. Set breather valve onto filler neck and turn
until the first stop.
6. Start engine (→ Page 96).
7. After 10 seconds of running the engine with-
out load, shut down the engine (→ Page 98).
8. Turn breather valve counterclockwise and re-
move.
9. Check coolant level (→ Page 225) and top up
engine coolant as required:
a) Repeat the steps from starting the en-
gine (→ Step 6) until no coolant needs to
be topped up any more.
b) Check proper condition of breather valve
and clean sealing faces if required.
c) Position breather valve on filler neck and
close.

Final steps
1. Start the engine and run it without load for some minutes.
2. Check coolant level (→ Page 225) and top up engine coolant as required.
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 8.17.5 HT coolant pump – Relief bore check
DANGER
Components are moving or rotating.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Operate the engine at low load only. Keep clear of the danger zone of the engine.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

HT coolant pump – Relief bore

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

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232 | Coolant Circuit, General, High-Temperature Circuit | MS15035/00E 2018-08

 8.17.6 Engine coolant – Sample extraction and analysis
Preconditions
☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
MTU test kit F6798833 1

DANGER
Components are moving or rotating.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Operate the engine at low load only. Keep clear of the danger zone of the engine.

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

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

Engine coolant – Sample extrac-

tion and analysis
1. Open drain valve on engine coolant pump el-
bow with the engine running.
2. Drain off approx. 1 liter engine coolant.
Result: Sampling point is clean.
3. Drain approx. 1 liter engine oil into a clean
container.
TIM-ID: 0000014608 - 010

4. Tighten shut-off cock (arrow) with torque wrench to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Spindle 11a/f Tightening torque 12 Nm

5. Using the equipment and chemicals of the MTU test kit, examine engine coolant for:
• antifreeze concentration
• concentration of corrosion protection oil
• pH value
6. For engine coolant change intervals, see (→ MTU Fluids and Lubricants Specifications).

MS15035/00E 2018-08 | Coolant Circuit, General, High-Temperature Circuit | 233

 8.17.7 Preheating unit
Hotstart preheating unit

1 Plastic cap (drain) 4 Shutoff valve 7 Thermostat

2 On/Off switch 5 Continuous flow heater 8 Circulation pump
3 Plastic cap (supply line) 6 Vent valve
Cylinders Rated voltage / frequency Heating power kW
12V 230 V / 50 Hz 9
400 V / 50 Hz 9
230 V / 60 Hz 9
440 V / 60 Hz 9
16V 230 V / 50 Hz 12
400 V / 50 Hz 12
230 V / 60 Hz 12
440 V / 60 Hz 12

Function
TIM-ID: 0000014749 - 006

The preheating unit is intended to warm up the engine coolant. The circulating pump (8) ensures the circula-
tion of the preheated engine coolant through the engine.
The continuous flow heater (5) comprises a heating element. The thermostat (7) switches off the preheating
unit via contactors when the engine coolant temperature has reached the setting of the thermostat (7).
In the event of excessive coolant temperature, the temperature limiter of the thermostat (7) opens the con-
trol loop. The preheating unit is switched off.
The unit must be reset manually after the fault has been rectified.

234 | Coolant Circuit, General, High-Temperature Circuit | MS15035/00E 2018-08

 Hilzinger preheating unit

1 On/Off switch
Cylinders Rated voltage / frequency Heating power kW
12V and 16V 230 V / 50 Hz 9
400 V / 50 Hz 9
230 V / 60 Hz 9
440 V / 60 Hz 9
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 Hilzinger preheating unit, side view

1 Flange (supply and return) 3 Non-return flap 5 Thermostat

2 Junction box 4 Continuous flow heater 6 Circulation pump

Function
The preheating unit is intended to warm up the engine coolant. The circulation pump (6) ensures the circula-
tion of the preheated coolant through the engine.
The continuous flow heater (4) comprises a heating element. A non-return flap (3) prevents coolant from
flowing through the preheating unit when the engine is running.
When the coolant temperature has reached the value of the thermostat setting (5), the thermostat (5)
switches off the preheating unit via contactors.
In the event of excessive coolant temperature, the temperature limiter of the thermostat (5) opens the con-
trol loop. The preheating unit is switched off.
The unit must be reset manually after the fault has been rectified.
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236 | Coolant Circuit, General, High-Temperature Circuit | MS15035/00E 2018-08

 8.17.8 Preheater – Overhaul
Preconditions
☑ Engine is stopped and starting disabled.

DANGER
Electric voltage supply for operation.
Danger of burns and fatal electric shock!
• Make certain that the power supply to the product is switched off before starting work. Secure
against unintentional switching on!

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

Overhauling preheater
1. Disconnect power supply to heating element.
2. Close shut-off valve in coolant line before and after preheater.
3. Drain coolant at drain valve into a clean container.
4. Clean and flush coolant circuit.
5. Check hoses for cracks and other damage. Replace as necessary.
6. Check wiring for damage and overheating.
7. Remove heating element.
8. Clean heating element and tank.
9. Remove pump from volute (if applicable) and check for residues in impeller and lines.
10. Install heating element.
11. Connect heating element to power supply.
12. Connect hoses and open shut-off valves.
13. Check preheater for leakage and correct operation (→ Page 238).
14. Check coolant level (→ Page 225).
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 8.17.9 Preheater – Function and leak-tightness check
Preconditions
☑ Preheater is switched on.

WARNING
Coolant is hot and highly pressurized.
Risk of injury! Risk of scalding!
• Allow engine to cool down.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.

Checking operation
Note: The coolant temperature must correlate to the control range of the thermostat when the preheater is ready
for operation.
1. Check coolant preheating temperature.
2. Set the thermostat accordingly if the temperatures are not in the control range.

Checking for leaks

1. Check leak-tightness at coolant inlet and outlet.
2. Tighten any leaking unions.

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238 | Coolant Circuit, General, High-Temperature Circuit | MS15035/00E 2018-08

 8.18 Raw Water Pump with Connections
8.18.1 Raw water pump – Relief bore check
DANGER
Components are moving or rotating.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Operate the engine at low load only. Keep clear of the danger zone of the engine.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

Raw water pump – Relief bore

check
1. Check relief bore for oil and coolant dis-
charge.
2. Stop engine (→ Page 98) and disable engine
start.
3. Clean the relief bore with a wire if it is conta-
minated.
• Admissible engine coolant discharge: up to
10 drops per hour
• Admissible oil discharge: up to 5 drops per
hour
4. If discharge exceeds the specified limits, con-
tact Service.
TIM-ID: 0000015173 - 006

MS15035/00E 2018-08 | Raw Water Pump with Connections | 239

 8.19 Battery-Charging Generator
8.19.1 Battery-charging generator drive – Coupling condition check
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Endoscope Y20097353 1

Battery-charging generator drive, coupling condition check

1. Install barring tool (→ Page 158).
2. Guide endoscope optics between guard
plate (1) and battery-charging generator car-
rier (2) (arrow).
Note: Seek the assistance of a second person
3. Bar engine slowly by hand.
4. Examine the resilient coupling over the entire
circumference for plastic deformation and
cracks.
5. If there is serious deformation or crack for-
mation, contact Service.
6. Remove barring gear (→ Page 158).

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240 | Battery-Charging Generator | MS15035/00E 2018-08

 8.20 Auxiliary PTO
8.20.1 Bilge pump – Relief bore check
DANGER
Components are moving or rotating.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Operate the engine at low load only. Keep clear of the danger zone of the engine.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

Bilge pump – Relief bore check

1. Check relief bores for oil and water dis-
charge.
2. Stop engine (→ Page 98) and disable engine
start.
3. Clean relief bores with a wire if dirty.
• Permissible water discharge: up to 10
drops per hour;
• Permissible oil discharge: up to 5 drops
per hour
4. If discharge exceeds the specified limits:
Contact Service.
TIM-ID: 0000015791 - 007

MS15035/00E 2018-08 | Auxiliary PTO | 241

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

Engine mounting – Check

Item Findings Action
Visually inspect resilient elements. • Damage Replace (contact Service).
• Brittleness
• Deformation
• Crack formation
• Swelling

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 8.22 Fuel Supply System
8.22.1 Water drain valve – Check

Water drain valve – Check

1. Open water drain valve.
2. Check water outlet for obstructions.
3. Close water drain valve.
TIM-ID: 0000007733 - 007

MS15035/00E 2018-08 | Fuel Supply System | 243

 8.22.2 Differential pressure gage – Alarm function check
WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.

Checking differential pressure gage alarm function

1. Switch on fuel treatment system (→ Page 106).
2. Set the alarm points at the differential pressure gage to zero.
Result: Alarm is issued after preset time.
3. Reset alarm points at differential pressure gage.

TIM-ID: 0000007737 - 007

244 | Fuel Supply System | MS15035/00E 2018-08

 8.22.3 Water level probe (3-in-1 rod electrode) – Check
Preconditions
☑ System is put out of service and emptied.

WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.

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

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

MS15035/00E 2018-08 | Fuel Supply System | 245

 8.22.4 Pump capacity – Check
WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.

Checking pump capacity

1. Install suitable pressure gauge in the intake connection of the pump.
2. Check pump pressure.
a) Switch on fuel treatment system (→ Page 106).
Note: The pressure limiting valve at the pump might respond and open. Audible noise is caused by overflowing fuel
and can be disregarded.
b) Close ball valve at the outlet of the fuel treatment system.
c) Check pressure at the pressure gauge in the inlet to the fuel treatment system and note down.
3. Checking pump pressure with reduced suction.
a) Reduce suction pressure of pump to -0.8 bar with the shut-off valve at the pump intake side.
b) Check pressure at the pressure gauge in the inlet to the fuel treatment system and note down.
c) Open ball valve at inlet and outlet of fuel treatment system.
4. Calculate wear limit.
Example:
Measured value (normal condition). 3 bar
Measured value (reduced suction condition). 2.6 bar
The wear limit has been reached when the measured value (reduced suction) is 10% lower than the meas-
ured pressure (normal). Repair pump (Contact Service).

TIM-ID: 0000007740 - 009

246 | Fuel Supply System | MS15035/00E 2018-08

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

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Torque wrench, 8–40 Nm F30043446 1
Ratchet adapter F30027340 1
Fuel
Engine oil
Coalescer filter element (→ Spare Parts Catalog)
Gasket (→ Spare Parts Catalog)

WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.

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

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

Replacing coalescer filter ele-

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

7. Remove cover with seal (10).

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

MS15035/00E 2018-08 | Fuel Supply System | 247

 16. Tighten nut (3) to specified torque using a torque wrench.
Name Size Type Lubricant Value/Standard
Nut M16 Tightening torque (Engine oil) 30 Nm +3 Nm

17. Fit seal (10).

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

TIM-ID: 0000007735 - 013

248 | Fuel Supply System | MS15035/00E 2018-08

 8.23 Wiring (General) for Engine/Gearbox/Unit
8.23.1 Engine wiring harness – Overview
Engine wiring harnesses – Terminal assignment
Description Terminal assignment
Sensors B1 Camshaft speed
B3 Intake air temperature
B4.21 Exhaust temperature, A side
B4.22 Exhaust temperature, B-side
B5.1 Oil pressure downstream of filter
B5.3 Oil pressure upstream of filter
B5.8 Lube oil pressure before ETC, A-side (optional)
B6 Coolant temperature
B7 Oil temperature
B9 Charge-air temperature
B10 Charge-air pressure
B13 Crankshaft speed
B16 Coolant pressure
B33 Fuel temperature
B34.1 Fuel pressure after filter
B34.2 Fuel pressure before filter
B34.3 Fuel pressure before external filter
B44.1 Rotation speed, exhaust turbocharger A
B44.2 Rotation speed, exhaust turbocharger B
B48 HP fuel pressure
B49 Charge air before recirculation
B50 Crankcase pressure
B54 Replenishment pump pressure
Level monitor F33 Coolant level
XF33 Coolant level adaptation
XXF33 Coolant level, hull-mounted cooling system
F46 Fuel overflow level
Pump M8 Fuel pump
Limit switch S37.1 Start interlock A
S37.2 Start interlock B
TIM-ID: 0000038739 - 003

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 Description Terminal assignment
Adaptation X1 ECU
X2 ECU-7 governor
X3 ECU Power
X4 ECU-7 governor
X37 Cranking start interlock
X52 EIM engine box
XB19 Starting air pressure
XD1 Dialog
XG03 Battery-charging generator
XY1 Starting system
Valves Y26 Charge-air recirculation
Y27 Exhaust turbocharger
Injectors Y39A1 to Y39AX Engine A side
Y39B1 to Y39BX Engine B side

TIM-ID: 0000038739 - 003

250 | Wiring (General) for Engine/Gearbox/Unit | MS15035/00E 2018-08

 Engine wiring harness for sensors, 12V engine

1 M8 13 B4.22 25 B4.21
2 B1 14 B9 26 B10
3 B6 15 S37.1 27 B13
4 X2 16 B34.3 28 S37.2
5 XF33 17 B34.2 29 B7
6 X37 18 B34.1 30 B5.1
7 B54 19 B50 31 B48
8 F33 20 Y26 32 B33
9 XXF33 21 B44.1 33 F46
10 B16 22 B49 34 XG03
11 B44.2 23 B3
12 Y27 24 B5.3
TIM-ID: 0000038739 - 003

MS15035/00E 2018-08 | Wiring (General) for Engine/Gearbox/Unit | 251

 Engine wiring harness for sensors, 16V engine

1 M8 13 B4.22 25 B4.21
2 B1 14 B9 26 B10
3 B6 15 S37.1 27 B13
4 X2 16 B34.3 28 S37.2
5 XF33 17 B34.2 29 B7
6 X37 18 B34.1 30 B5.1
7 B54 19 B50 31 B48
8 B44.2 20 Y26 32 B33
9 Y27 21 B44.1 33 F46
10 F33 22 B49 34 XG03
11 XXF33 23 B3
12 B16 24 B5.3
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252 | Wiring (General) for Engine/Gearbox/Unit | MS15035/00E 2018-08

 Engine wiring harness for injectors, 12V engine

1 Y39A1 6 Y39A6 11 Y39B3

2 Y39A2 7 X4 12 Y39B2
3 Y39A3 8 Y39B6 13 Y39B1
4 Y39A4 9 Y39B5
5 Y39A5 10 Y39B4
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 Engine wiring harness for injectors, 16V engine

1 Y39A1 7 Y39A7 13 Y39B5

2 Y39A2 8 Y39A8 14 Y39B4
3 Y39A3 9 X4 15 Y39B3
4 Y39A4 10 Y39B8 16 Y39B2
5 Y39A5 11 Y39B7 17 Y39B1
6 Y39A6 12 Y39B6

TIM-ID: 0000038739 - 003

254 | Wiring (General) for Engine/Gearbox/Unit | MS15035/00E 2018-08

 Engine wiring harness for EIM

1 XD1 4 X52 7 XB19

2 X1 5 XY1 8 X37
3 X3 6 X11
TIM-ID: 0000038739 - 003

MS15035/00E 2018-08 | Wiring (General) for Engine/Gearbox/Unit | 255

 Engine wiring harness for electric starter

1 Connection terminals, EIM 2 Fuse F1 3 Connection terminals, start-

er

TIM-ID: 0000038739 - 003

256 | Wiring (General) for Engine/Gearbox/Unit | MS15035/00E 2018-08

 8.23.2 Engine cabling – Check
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Solvent (isopropyl alcohol) X00058037 1

Engine cabling – Check

1. Check securing screws of cable clamps on engine and tighten loose screw connections.
2. Ensure that cables are securely seated in clamps and cannot move freely.
3. Check if all cable clips are closed and intact.
4. Replace faulty cable clips.
5. Check cable clamps for secure fit, tighten loose clamps.
6. Replace faulty cable clamps.
7. Visually inspect the following electrical components for damage:
• Connector housings
• Contacts
• Plug connectors
• Cables and terminals
• Plug-in contacts
Result: If cable conductors are damaged, contact Service.
Note: Close connectors that are not plugged in with the protective cap supplied.
8. Use isopropyl alcohol to clean dirty connector housings, plug connectors and contacts.
9. Ensure that all connecting plugs of the sensors are correctly engaged.
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 8.24 Accessories for (Electronic) Engine Governor / Control System
8.24.1 Limit switch for start interlock – Check
Preconditions
☑ Engine is stopped and starting disabled.

Note: In the OFF position, the limit switch activates a start interlock, i.e. the engine cannot be started.
Limit switch for start interlock –
Check
1. Check whether switches (3) and guard
plate (2) with engine support (1) are installed
on both sides of flywheel housing (4).
2. Check whether both switches (3) are actuat-
ed.
3. If switches (3) and/or guard plate (2) with en-
gine support (1) is/are not installed:
• Screw on guard plate (2) with engine sup-
port (1).
• Then screw on switch (3), ensuring that
the switch (3) is actuated by the guard
plate (2).
4. If switch (3) and guard plate (2) are installed,
but switch (3) is in the OFF position:
• Make certain that the guard plate (2) at
the side of the switch (3) is not distorted.
• Loosen guard plate (2) and screw on such
that the switch (3) is actuated.

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258 | Accessories for (Electronic) Engine Governor / Control System | MS15035/00E 2018-08
 8.24.2 Engine Control Unit ECU 7 – Checking plug connections
Preconditions
☑ Engine is stopped and starting disabled.

Check plug connections on ECU

7
1. Check all connectors on ECU for firm seating.
Ensure that the clips (1) are engaged.
2. Check screws (2) of cable clamps on ECU for
firm seating. Ensure that cable clamps are
not faulty.
TIM-ID: 0000016847 - 006

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 8.24.3 Engine Monitoring Unit EMU 7 – Plug connection check
Preconditions
☑ Engine is stopped and starting disabled.

Checking EMU plug connections

1. Check both connectors on EMU (2) for firm
seating. Make sure that frames (3) are engag-
ed.
2. Check screws (1) of cable clamps on EMU (2)
for firm seating. Make sure that cable clamps
are not defective.

TIM-ID: 0000016798 - 005

260 | Accessories for (Electronic) Engine Governor / Control System | MS15035/00E 2018-08
 8.24.4 Interface module EIM plug connections – Check
Preconditions
☑ Engine is stopped and starting disabled.

Checking EIM plug connections

1. Check both Tyco plugs (62-pole) (2) on EIM
for firm seating. Ensure that clips (3) are en-
gaged.
2. Check screws (1) of cable clamps on EIM for
firm seating. Ensure that cable clamps are
not faulty.
TIM-ID: 0000017034 - 004

MS15035/00E 2018-08 | Accessories for (Electronic) Engine Governor / Control System | 261
 8.24.5 Engine governor ECU 7 – Removal and installation
Preconditions
☑ Engine is stopped and starting disabled.
☑ Engine electronics is powered off.

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

Removing engine governor from

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

Installing engine governor on engine

1. Install in reverse order. Ensure correct assignment of plugs and sockets.
2. Check resilient mount before installing.
Result: If resilient mount is porous or defective then replace it.
TIM-ID: 0000000049 - 009

262 | Accessories for (Electronic) Engine Governor / Control System | MS15035/00E 2018-08
 8.24.6 EMU 7 – Removal and installation
Preconditions
☑ Engine is stopped and starting disabled.
☑ Engine electronics is powered off.

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

Removing ECU with EMU from

engine
1. Note or mark assignment of cables and
plugs.
2. Remove all screws (2).
3. Undo clips (3) on connectors.
4. Remove all male connectors.
5. Remove screws (1).
6. Remove ECU (5) with EMU (4).

Removing EMU
1. Unscrew screws on base of EMU (4).
2. Remove EMU (4) from ECU (5).

Installing EMU
1. Place EMU (4) on ECU (5).
2. Screw in and tighten screws on base of EMU (4).

Installing ECU with EMU on engine

1. Install in reverse order. Ensure correct assignment of plugs and sockets.
2. Check resilient mount before installing.
Result: If resilient mount is porous or defective then replace it.
TIM-ID: 0000016799 - 008

MS15035/00E 2018-08 | Accessories for (Electronic) Engine Governor / Control System | 263
 8.24.7 Engine Interface Module EIM 2 – Diagnostic features
Diagnostic lamp (DILA)
A diagnostic lamp (LED, blue) is integrated in the housing of the Engine Interface Module (EIM 2).
It indicates the operating status of the EIM 2.
Functions of diagnostic lamp DILA
DILA glows Engine Interface Module (EIM 2) is OK.
DILA dark EIM 2 supply voltage missing or diagnostic lamp activation is faulty.
DILA flashes Hardware or software fault in the Engine Interface Module

The diagnostic lamp (DILA) signals the following states:

1 Time in seconds 4 Application loader active 7 No firmware

2 Timing: 1/8 s 5 External RAM defective 8 Application crashed
3 Ready for operation 6 External FLASH defective

Fuse lamp (SILA)

A second indicator is the fuse lamp.
TIM-ID: 0000038009 - 005

This is also integrated in the housing of the Engine Interface Module. It indicates the status of the fuses.
An orange LED is provided to allow diagnosis of a “tripped fuse” fault directly at the unit as it is often difficult
to pinpoint a fault in the field without cabling diagrams.
This LED is activated by the controller.
Functions of fuse lamp SILA
SILA dark Normal operating state
SILA flashes orange One or more fuses have tripped.

The fuse lamp (SILA) signals the following states:

264 | Accessories for (Electronic) Engine Governor / Control System | MS15035/00E 2018-08
 1 Preamble 6VSP current path failed (S5) 11 ES pushbutton current path
2 Engine Control Unit current 7SLD current path failed (S6) failed – 24 V external (S10)
path failed (S1) 8DDV current path failed (S7) 12 Key switch current path
3 MCS current path failed 9Gear monitoring current failed (S11)
(S2) path failed (S8) 13 SDAF 1 and 2 current path
4 EMU current path failed 10 Emergency stop current failed (S12)
(S3) path failed – 24 V internal 14 PIM current path failed
5 Starter voltage: Terminal (S9) (S13)
30, 31 not connected and 15 Spare current path failed
PR 10.0600.001 has value (S14) (for EIM 2 with ECU 9
1 or 2 (S4) only)
The failed current paths are signaled consecutively following the preamble (1) (LED on for 4 seconds). There
is a pause lasting 4 seconds in between.
TIM-ID: 0000038009 - 005

MS15035/00E 2018-08 | Accessories for (Electronic) Engine Governor / Control System | 265
 Sample flashing sequences

A Fuse S5 failure (1/2 second B Fuse S1 and fuse S4 failure

steps) (1/2 second steps)
Note:
These bit patterns are continuously transmitted.
The CAN message “Status of internal power supply” also contains information on the current path states of
the EIM 2.

TIM-ID: 0000038009 - 005

266 | Accessories for (Electronic) Engine Governor / Control System | MS15035/00E 2018-08
 8.24.8 Engine Interface Module EIM 2 – Removal and installation
Preconditions
☑ Engine is stopped and starting disabled.

Removing Engine Interface Mod-

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

Installing Engine Interface Module on engine

1. Install in reverse order. When doing so, observe correct assignment between cables and connectors.
2. Check seal before installing.
Result: Replace seal if porous or defective.

Downloading software
1. The new EIM 2 still does not have appropriate FSW and parameter/descriptor module (the diagnostic lamp
(DILA) indicates flashing code 4 when the power supply is connected, (→ Page 264)).
2. The FSW and the parameter/descriptor module must first be downloaded from the central database (CDB)
based on the relevant engine number using the DiaSys ® software tool, and then loaded in the EIM 2.
TIM-ID: 0000017035 - 006

MS15035/00E 2018-08 | Accessories for (Electronic) Engine Governor / Control System | 267
 8.24.9 CDC parameters – Reset
Preconditions
☑ Engine is stopped and starting disabled.

Note: Failure to reset drift compensation (CDC parameters) will void the emissions certification.

Resetting CDC parameters with DiaSys®

u (→ Dialog system DiaSys® E531920/..).

Resetting CDC parameters without DiaSys®

u If no DiaSys® is available, contact Service.

TIM-ID: 0000044684 - 001

268 | Accessories for (Electronic) Engine Governor / Control System | MS15035/00E 2018-08
 9 Appendix A
9.1 List of abbreviations
Abbrevia- Meaning Explanation
tion
ADEC Advanced Diesel Engine Control Engine Control Unit
AL Alarm Alarm (general)
ANSI American National Standards Institute Association of American standardization organiza-
tions
ATL Abgasturbulader Exhaust turbocharger
BR Baureihe Series
BV Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU Publication
No. A01061/..
CAN Controller Area Network Data bus system, bus standard
CDC Calibration Drift Compensation Setting for drift correction with DiaSys in Engine Con-
trol Unit
CPP Controllable Pitch Propeller
DILA Diagnostic lamp On EIM
DIN Deutsches Institut für Normung e. V. German National Standards Institute, at the same
time identifier of German standards (DIN = “Deutsche
Industrie-Norm”)
DIS Display Unit Display panel
DL Default Lost Alarm: Default CAN bus failure
ECS Engine Control System Engine management system
ECU Engine Control Unit Engine governor
EDM Engine Data Module Memory module for engine data
EIM Engine Interface Module Interface to engine monitoring system
EIL Engine Ident Label Electronic nameplate which identifies the engine
EMU Engine Monitoring Unit
EPA Environmental Protection Agency US regulatory body which implements federal laws
on environmental protection and develops standards
to ensure compliance with these laws
ETK Spare parts catalog
FPP Fixed Pitch Propeller
GCU Gear Control Unit
GMU Gear Monitoring Unit
TIM-ID: 0000002050 - 007

HAT Harbor Acceptance Test

HI High Range violation alarm (1st upper limit)
HIHI High High Range violation alarm (2nd upper limit)
HT High Temperature
ICFN ISO – Continuous rating – Fuel stop Power specification in accordance with DIN-ISO
power – Net 3046-7
IDM Interface Data Module Memory module for interface data

MS15035/00E 2018-08 | Appendix A | 269

 Abbrevia- Meaning Explanation
tion
IIG Initial Injector Equalization Entering of injector code with DiaSys in engine gover-
nor
IMO International Maritime Organization
ISO International Organization for Stand- International umbrella organization for all national
ardization standardization institutes
KGS Kraftgegenseite Engine free end in accordance with DIN ISO 1204
KS Kraftseite Engine driving end in accordance with DIN ISO 1204
LCD Liquid Crystal Display, Liquid Crystal
Device
LCU Local Control Unit LOP subassembly
LED Light Emitting Diode
LMU Local Monitoring Unit LOP subassembly
LO Low Range violation alarm (1st lower limit value)
LOLO Low Low Range violation alarm (2nd lower limit value)
LOP Local Operating Panel Control console, control panel
LOS Local Operating Station
MCS Monitoring and Control System
MG Message
MPU Microprocessor Unit, Microprocessing
Unit
OT Oberer Totpunkt Top Dead Center
P-xyz Pressure-xyz Pressure measuring point xyz
PAN Panel Control panel
PCU Propeller Control Unit Propeller controller
PIM Peripheral Interface Module
RCS Remote Control System
RL Redundancy Lost Alarm: Redundant CAN bus failure
SAE Society of Automotive Engineers U.S. standardization organization
SAT Sea Acceptance Test
SD Sensor Defect Alarm: Sensor failure
SDAF Shut Down Air Flap(s) Emergency air-shutoff flap(s)
SILA Fuse lamp on EIM
SOLAS International Convention for the Safety
of Life at Sea
SS Safety System Safety system alarm
TIM-ID: 0000002050 - 007

SSK Schnellschlussklappe(n) Emergency air-shutoff flap(s)

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

270 | Appendix A | MS15035/00E 2018-08

 9.2 MTU Contact/Service Partners
The worldwide network of the sales organization with subsidiaries, sales offices, representatives and custom-
er service centers ensure fast and direct support on site and ensure the high availability of our products.

Local Support
Experienced and qualified specialists place their knowledge and expertise at your disposal.
For locally available support, go to the MTU Internet site: http://www.mtu-online.com

24h Hotline
With our 24h hotline and high flexibility, we're your contact around the clock: during each operating phase,
preventive maintenance and corrective operations in case of a malfunction, for information on changes in
conditions of use and for supplying spare parts.
Your contact person in our Customer Assistance Center:
E-mail: info@mtu-online.com
Tel.: +49 7541 9077777
Fax.: +49 7541 9077778
Asia/Pacific: +65 6100 2688
North and Latin America: +1 248 560 8000

Spare Parts Service

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

MS15035/00E 2018-08 | Appendix A | 271

 10 Appendix B
10.1 Special Tools
Barring tool
Part No.: F6555766
Qty.: 1
Used in: 8.2.1 Engine – Barring manually (→ Page 158)
Qty.: 1
Used in: 8.3.1 Cylinder liner – Endoscopic examination
(→ Page 161)

Endoscope
Part No.: Y20097353
Qty.: 1
Used in: 8.3.1 Cylinder liner – Endoscopic examination
(→ Page 161)
Qty.: 1
Used in: 8.19.1 Battery-charging generator drive – Coupling condi-
tion check (→ Page 240)

Feeler gage
Part No.: Y20010128
Qty.: 1
Used in: 8.5.2 Valve clearance – Check and adjustment
(→ Page 167)
DCL-ID: 0000051760 - 001

272 | Appendix B | MS15035/00E 2018-08

 Filter wrench
Part No.: F30379104
Qty.: 1
Used in: 8.9.2 Supplementary fuel filter – Replacement
(→ Page 185)
Qty.: 1
Used in: 8.9.3 Fuel filter – Replacement (→ Page 187)
Qty.:
Used in: 8.16.2 Engine oil filter – Replacement (→ Page 219)

Fuel suction device

Part No.: F30378207
Qty.: 1
Used in: 8.6.1 HP fuel pump – Filling with engine oil (→ Page 171)

High-pressure cleaner
Part No.:
Qty.: 1
Used in: 5.16 Plant – Cleaning (→ Page 110)

Installation/removal jig
Part No.: F6789889
Qty.: 1
Used in: 8.7.2 Injector – Removal and installation (jacketed fuel
system) (→ Page 175)
DCL-ID: 0000051760 - 001

MS15035/00E 2018-08 | Special Tools | 273

 Milling cutter
Part No.: F30452739
Qty.: 1
Used in: 8.7.2 Injector – Removal and installation (jacketed fuel
system) (→ Page 175)

MTU test kit

Part No.: 5605892099/00
Qty.: 1
Used in: 8.15.3 Engine oil – Sample extraction and analysis
(→ Page 214)

MTU test kit

Part No.: F6798833
Qty.: 1
Used in: 8.17.6 Engine coolant – Sample extraction and analysis
(→ Page 233)

Oil filter wrench

Part No.: F30455924
Qty.: 1
Used in: 8.16.3 Centrifugal oil filter – Cleaning and filter sleeve re-
placement (→ Page 221)
DCL-ID: 0000051760 - 001

274 | Special Tools | MS15035/00E 2018-08

 Ratchet adapter
Part No.: F30027340
Qty.: 1
Used in: 8.9.7 Fuel prefilter with water separator – Filter element
replacement (→ Page 194)
Qty.: 1
Used in: 8.10.1 Compressor wheel – Cleaning (→ Page 198)
Qty.: 1
Used in: 8.22.5 Coalescer filter element ‒ Replacement
(→ Page 247)

Ratchet bit
Part No.: F30027341
Qty.:
Used in: 8.5.3 Cylinder head cover – Removal and installation
(→ Page 170)
Qty.: 1
Used in: 8.15.2 Engine oil – Change (→ Page 212)

Ratchet bit
Part No.: F30027340
Qty.: 1
Used in: 8.7.2 Injector – Removal and installation (jacketed fuel
system) (→ Page 175)
Qty.: 1
Used in: 8.16.3 Centrifugal oil filter – Cleaning and filter sleeve re-
placement (→ Page 221)

Ratchet bit
Part No.: F30027342
Qty.: 1
Used in: 8.7.2 Injector – Removal and installation (jacketed fuel
system) (→ Page 175)
DCL-ID: 0000051760 - 001

MS15035/00E 2018-08 | Special Tools | 275

 Ratchet with extension
Part No.: F30006212
Qty.: 1
Used in: 8.2.1 Engine – Barring manually (→ Page 158)
Qty.: 1
Used in: 8.3.1 Cylinder liner – Endoscopic examination
(→ Page 161)

Socket wrench, 24 mm
Part No.: F30039526
Qty.: 1
Used in: 8.5.2 Valve clearance – Check and adjustment
(→ Page 167)

Torque wrench, 10–60 Nm

Part No.: F30452769
Qty.: 1
Used in: 2.3 Crankshaft transport locking device (→ Page 24)
Qty.: 1
Used in: 8.6.1 HP fuel pump – Filling with engine oil (→ Page 171)
Qty.: 1
Used in: 8.7.2 Injector – Removal and installation (jacketed fuel
system) (→ Page 175)
Qty.: 1
Used in: 8.9.7 Fuel prefilter with water separator – Filter element
replacement (→ Page 194)
Qty.: 1
Used in: 8.10.1 Compressor wheel – Cleaning (→ Page 198)
Qty.: 1
Used in: 8.12.2 Air filter – Removal and installation (→ Page 208)
Qty.: 1
DCL-ID: 0000051760 - 001

Used in: 8.16.3 Centrifugal oil filter – Cleaning and filter sleeve re-
placement (→ Page 221)

276 | Special Tools | MS15035/00E 2018-08

 Torque wrench, 10–60 Nm
Part No.: F30510423
Qty.:
Used in: 8.5.3 Cylinder head cover – Removal and installation
(→ Page 170)

Torque wrench, 40–200 Nm

Part No.: F30027337
Qty.: 1
Used in: 8.15.2 Engine oil – Change (→ Page 212)

Torque wrench, 4–20 Nm

Part No.: F30044239
Qty.: 1
Used in: 8.16.3 Centrifugal oil filter – Cleaning and filter sleeve re-
placement (→ Page 221)

Torque wrench, 60–320 Nm

Part No.: F30452768
Qty.: 1
Used in: 2.3 Crankshaft transport locking device (→ Page 24)
Qty.: 1
Used in: 8.5.2 Valve clearance – Check and adjustment
DCL-ID: 0000051760 - 001

(→ Page 167)
Qty.: 1
Used in: 8.7.2 Injector – Removal and installation (jacketed fuel
system) (→ Page 175)
Qty.: 1
Used in: 8.16.3 Centrifugal oil filter – Cleaning and filter sleeve re-
placement (→ Page 221)

MS15035/00E 2018-08 | Special Tools | 277

 Torque wrench, 8–40 Nm
Part No.: F30043446
Qty.: 1
Used in: 8.22.5 Coalescer filter element ‒ Replacement
(→ Page 247)

Valve setting gage

Part No.: Y4349603
Qty.: 1
Used in: 8.5.2 Valve clearance – Check and adjustment
(→ Page 167)

DCL-ID: 0000051760 - 001

278 | Special Tools | MS15035/00E 2018-08

 10.2 Index
Preheating unit 234 Cylinder
– Designation 40
A Cylinder head cover
Actuators – Installation 170
– Overview 60 – Removal 170
Additional fuel filter Cylinder liner
– Overview 184 – Endoscopic examination 161
ADEC (ECU 7) – Endoscopic inspection
– Fault messages 119 – Instructions and comments on endoscopic and visu-
Adhesive tape for SOLAS shielding al examination 163
– Application 157
D
After shutdown 109
Air filter Diagnostic lamp (DILA)
– Removal and installation 208 – EIM 2 264
– Replacement 207 Diagnostics
– EIM 2 264
B Differential pressure gage
Battery-charging generator drive – Adjustment
– Check 240 – Fuel prefilter 189
Bilge pump – Alarm function check 244
– Relief bore check 241 – Check
– Fuel prefilter 189
C Drift compensation
Cabling – Reset 268
– Check
E
– On engine 257
CDC parameters ECU 7
– Reset 268 – Installation 262
Centrifugal oil filter – Removal 262
– Cleaning 221 Emission label
Checks – Check 100
– Prior to start-up 102 EMU 7
Coalescer filter element – Installation 263
– Replacement 247 – Removal 263
Compressor wheel Endoscopic inspection
– Cleaning 198 – Cylinder liner
Contact persons 271 – Instructions and comments 163
Contamination indicator Engine
– Signal ring position check 209 – Barring
Controls 93 – Manually 158
Coolant – With starting system 160
– Change 226 – Emergency stop 108
Cooler – Main dimensions 91
– Start 96
DCL-ID: 0000051760 - 001

– Charge-air
– Checking condensate drain for water discharge and – Stopping 98
obstruction 206 Engine cabling
Coupling – Check 257
– Check 240 Engine Control Unit ECU 7
Crankcase breather – Checking plug connections 259
– Oil mist separator Engine coolant
– Replacement 165 – Change 226
Crankshaft – Draining 227
– Transport locking device – Filling 230
– Installation/removal 24 – Sample analysis 233
– Sample extraction 233

MS15035/00E 2018-08 | Index | 279

 Engine coolant level Fuel prefilter with water separator
– Check 225 – Draining 190
EnGInE DATA – Filter element
– 12V4000M63, EPA Tier 2, EU Stage IIIA, IMO Tier II – Flushing 192
75 – Replacement 194
Engine data – Replacement
– 16V4000M63, EPA Tier 2, EU Stage IIIA, IMO Tier II – O-ring in rotary slide valve 197
85 Fuel system
– Engine data 12V4000M53, EPA Tier 2, EU Stage IIIA, – Venting 182
IMO Tier II 70 Fuel treatment system
– Engine data 16V4000M53, EPA Tier 2, EU Stage IIIA, – Initial start-up 103
IMO Tier II 80 – Shutdown 107
Engine driving end – Switching on 106
– Definition 40 Fuse lamp (SILA)
Engine free end – EIM 2 264
– Definition 40
Engine governor ADEC (ECU 7) H
– Fault messages 119 Hotline 271
Engine governor ECU 7 HP pump
– Installation 262 – Filling with engine oil 171
– Removal 262 – Relief bore check 173
Engine Monitoring Unit EMU 7 HT coolant pump
– Plug connection check 260 – Check
Engine mounting – Relief bore 232
– Check 242
Engine oil I
– Change 212 Injector
– Sample extraction and analysis 214 – Installation 175
Engine oil filter – Removal 175
– Replacement 219 – Replacement 174
Engine oil level Intercooler
– Check 211 – Checking condensate drain for water discharge and
Engine sides obstruction 206
– Designation 40 Interface module EIM
Engine wiring harness – Check 261
– Overview 249 Interface module EIM 2
Engine – Overview 46 – Removal and installation 267

F L
Fault messages Lifting requirements 20
– Engine governor ADEC (ECU 7) 119 Limit switch for start interlock
Filter sleeve – Check 258
– Replacement 221 List of abbreviations 269
Firing order 90
M
Fuel
– Treatment system Maintenance Schedule
– Switching on 106 – Maintenance task reference table [QL1] 111, 113
MTU contact persons 271
DCL-ID: 0000051760 - 001

– Troubleshooting 118
– treatment system
O
– Shutdown 107
Fuel filter Oil indicator filter
– Replacement 187 – Check 216
Fuel prefilter – Cleaning 216
– Adjustment Operational checks 99
– Differential pressure gage 189
P
– Check
– Differential pressure gage 189 Plant
– Cleaning 110

280 | Index | MS15035/00E 2018-08

 Plug connections Transport locking device
– Check 261 – Crankshaft
Preheater – Installation/removal 24
– Overhaul 237 Transportation
– Function and leak-tightness – Lifting requirements 20
– check 238 Troubleshooting 115
Product description 41 – Fuel treatment system 118
Pump capacity
– Check 246 V
Putting the engine into operation after extended out-of- Valve clearance
service periods (>3 months) 94 – Adjustment 167
Putting the engine into operation after scheduled out-of- – Check 167
service-period 95 Valve gear
– Lubrication 166
R
Raw water pump W
– Relief bore check 239 Warning notices, standards 18
Water drain valve
S – Check 243
Safety regulations Water level probe (3-in-1 rod electrode)
– Assembly work 12 – Check 245
– Auxiliary materials 16
– Environmental protection 16
– Fire prevention 16
– Fluids and lubricants 16
– Important provisions 6, 8
– Initial start-up 10
– Maintenance work 12
– Operation 10
– Organizational requirements 9
– Personnel requirements 9
– Repair work 12
Safety requirements
– Warning notices, standards 18
Sensors
– Overview 60
Sensors and actuators – Overview 50
Service partners 271
SOLAS shielding
– Adhesive tape application 157
– Installation 147
– As per MTN 5233 146
– Installation locations 148
Spare parts service 271
Starter
– Condition check 210
Supplementary fuel filter
DCL-ID: 0000051760 - 001

– Replacement 185

T
Tasks after extended out-of-service periods (>3 weeks)
101
Tightening specifications
– Nuts 27
– Screws and bolts 27
– Screws, nuts and bolts 27
transport 19

MS15035/00E 2018-08 | Index | 281