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Technical Documentation

Diesel Engine
16 V 1163 TB73L

Operating Instructions
MS15017/00E
Printed in Germany
© 2006 Copyright MTU Friedrichshafen GmbH
Diese Veröffentlichung einschließlich aller ihrer Teile ist urheberrechtlich geschützt. Jede Verwertung oder Nutzung bedarf der vorherigen
schriftlichen Zustimmung der MTU Friedrichshafen GmbH. Das gilt insbesondere für Vervielfältigung, Verbreitung, Bearbeitung, Übersetzung,
Mikroverfilmungen und die Einspeicherung und / oder Verarbeitung in elektronischen Systemen, einschließlich Datenbanken und Online-Diensten.
Das Handbuch ist zur Vermeidung von Störungen oder Schäden beim Betrieb zu beachten und daher vom Betreiber dem jeweiligen Wartungs- und
Bedienungspersonal zur Verfügung zu stellen.
Änderungen bleiben vorbehalten.

Printed in Germany
© 2006 Copyright MTU Friedrichshafen GmbH
This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior written permission of MTU
Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, microfilming and storage or processing on electronic
systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage during operation.
Subject to alterations and amendments.

Imprimé en Allemagne
© 2006 Copyright MTU Friedrichshafen GmbH
Tout droit réservé pour cet ouvrage dans son intégralité. Toute utilisation ou exploitation requiert au préalable l’accord écrit de MTU Friedrichshafen
GmbH. Ceci s’applique notamment à la reproduction, la diffusion, la modification, la traduction, l’archivage sur microfiches, la mémorisation et / ou le
traitement sur des systèmes électroniques, y compris les bases de données et les services en ligne.
Le manuel devra être observé en vue d’éviter des incidents ou des endommagements pendant le service. Aussi recommandons-nous à l’exploitant
de le mettre à la disposition du personnel chargé de l’entretien et de la conduite.
Modifications réservées.

Impreso en Alemania
© 2006 Copyright MTU Friedrichshafen GmbH
Esta publicación se encuentra protegida, en toda su extensión, por los derechos de autor. Cualquier utilización de la misma, así como su
reproducción, difusión, transformación, traducción, microfilmación, grabación y/o procesamiento en sistemas electrónicos, entre los que se incluyen
bancos de datos y servicios en línea, precisa de la autorización previa de MTU Friedrichshafen GmbH.
El manual debe tenerse presente para evitar fallos o daños durante el servicio, y, por dicho motivo, el usario debe ponerlo a disposición del personal
de mantenimiento y de servicio.
Nos reservamos el derecho de introducir modificaciones.

Stampato in Germania
© 2006 Copyright MTU Friedrichshafen GmbH
Questa pubblicazione è protetta dal diritto d’autore in tutte le sue parti. Ciascun impiego o utilizzo, con particolare riguardo alla riproduzione, alla
diffusione, alla modifica, alla traduzione, all’archiviazione in microfilm e alla memorizzazione o all’elaborazione in sistemi elettronici, comprese
banche dati e servizi on line, deve essere espressamente autorizzato per iscritto dalla MTU Friedrichshafen GmbH.
II manuale va consultato per evitare anomalie o guasti durante il servizio, per cui va messo a disposizione dall’utente al personale addetto alla
manutenzione e alla condotta.
Con riserva di modifiche.

Impresso na Alemanha
© 2006 Copyright MTU Friedrichshafen GmbH
A presente publicação, inclusive todas as suas partes, está protegida pelo direito autoral. Qualquer aproveitamento ou uso exige a autorização
prévia e por escrito da MTU Friedrichshafen GmbH. Isto diz respeito em particular à reprodução, divulgação, tratamento, tradução, microfilmagem, e
a memorização e/ou processamento em sistemas eletrônicos, inclusive bancos de dados e serviços on-line.
Para evitar falhas ou danos durante a operação, os dizeres do manual devem ser respeitados. Quem explora o equipamento economicamente
consequentemente deve colocá-lo à disposição do respetivo pessoal da conservação, e à dispositção dos operadores.
Salvo alterações.
Wichtig – Important – Importante

Bitte die Karte „Inbetriebnahmemeldung“ abtrennen und ausgefüllt an MTU Friedrichshafen GmbH
zurücksenden.
Die Informationen der Inbetriebnahmemeldung sind Grundlage für den vertraglich vereinbarten Logistik-
Support (Gewährleistung, Ersatzteile etc.).

Please complete and return the “Commissioning Note” card below to MTU Friedrichshafen GmbH.
The Commissioning Note information serves as a basis for the contractually agreed logistic support
(warranty, spare parts, etc.).

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


GmbH.
Les informations contenues dans la signalisation de mise en service constituent la base pour l'assistance en
exploitation contractuelle (garantie, rechanges, etc.).

Rogamos separen la tarjeta “Aviso de puesta en servicio“ y la devuelvan rellenada a MTU


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

Ritagliare “Avviso di messa in servizio“ e rispedirlo debitamente compilato alla MTU Friedrichshafen
GmbH.
Le informazioni ivi registrate sono la base per il supporto logistico contrattuale (garanzia, ricambi, ecc.).

É gentileza cortar o cartão "Participação da colocação em serviço", preenché-lo e devolvé-lo a MTU


Friedrichshafen.
Os dados referentes à colocação em serviço representam a base para o suporte logístico (garantia, peças
sobressalentes, etc.) estabelecido contratualmente.

Postcard

MTU Friedrichshafen GmbH


Department SCSD
88040 Friedrichshafen
GERMANY

Bitte in Blockschrift ausfüllen!
Please use block capitals!
Prière de remplir en lettres capitales!
¡A rellenar en letras de imprenta!
Scrivere in stampatello!
Favor preencher com letras de forma!

Motornr.: Auftragsnr.: Inbetriebnahme-


Engine No.: MTU works order No.:
o
No du moteur: N° de commande: meldung
N de motor: N° de pedido:
Motore N.: N. commessa: Commissioning
No. do motor: No. do pedido:
Note
Motortyp: Inbetriebnahmedatum:
Engine model: Date put into operation: Notice de mise
Type du moteur: Mise en service le: en service
Tipo de motor: Fecha de puesta en servicio:
Motore tipo: Messa in servizio il:
Tipo do motor: Data da colocação em serviço: Aviso de puesta
en servicio
Eingebaut in: Schiffstyp / Schiffshersteller:
Installation site: Vessel/type/class / Shipyard:
Lieu de montage: Type du bateau / Constructeur: Avviso di messa
Lugar de montaje: Tipo de buque / Constructor: in servizio
Installato: Tipo di barca / Costruttore
Incorporado em: Tipo de embarcação/estaleiro naval:
Participação da
Endabnehmer/Anschrift: colocação em
End user`s address: serviço
Adresse du client final:
Dirección del cliente final:
Indirizzo del cliente finale:
Usuário final/endereço:

Bemerkung:
Remarks:
Remarques:
Observaciones:
Commento:
Observações:
Table of Contents 01

1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05
1.1 General conditions ....................................................... 05
1.2 Personnel and organizational requirements .................................. 06
1.3 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07
1.4 Safety precautions when working on the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08
1.5 Auxiliary materials, fire prevention and environmental protection ................ 11
1.6 Standards for warning notices in the publication .............................. 13
2 Product Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1 Engine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1.1 Engine layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.2 Engine Side and Cylinder Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2.1 Engine side and cylinder designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.3 Main Engine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.3.1 Main engine dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.4 Firing Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.4.1 Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.5 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.5.1 16V 1163TB73L engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.1 LOP – Overview ......................................................... 23
3.2 Pump control – Control and display elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.3 Putting the engine into operation after extended out-of-service periods (>3
months) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.4 Putting the engine into operation after scheduled out-of-service period ........... 32
3.5 Starting the engine from LOP .............................................. 33
3.6 Operational checks ...................................................... 34
3.7 Stopping the engine from LOP ............................................. 35
3.8 Emergency stop from LOP ................................................ 36
3.9 After stopping the engine ................................................. 37
3.10 PPC, LPU – Functional check .............................................. 38
4 Engine Control System ECS-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.1 Normal Operation: LOS or LOP with Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.1.1 Local control mode – Engaging/disengaging the gearbox . . . . . . . . . . . . . . . . . . 39
4.1.2 Local control mode – Changing engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5 Maintenance .................................................................. 41
5.1 Preface ................................................................ 41
5.2 50-hours service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

MS15017/00E 06-11 © MTU


02 Table of Contents

5.3 Maintenance schedule matrix .............................................. 44


5.4 Maintenance tasks ....................................................... 48
6 Troubleshooting ............................................................... 51
6.1 Troubleshooting ......................................................... 51
6.2 Fault indication and fault messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
6.3 Oil priming pump, oil refill pump – Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
7 Task Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
7.1 Engine ................................................................. 85
7.1.1 Engine – Barring manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
7.1.2 Engine – Barring with starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
7.2 Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
7.2.1 Combustion chambers – Blowing out condensate . . . . . . . . . . . . . . . . . . . . . . . . 88
7.3 Valve Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
7.3.1 Valve clearance – Check and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
7.3.2 Cylinder head cover – Removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . 91
7.4 Injector ................................................................ 92
7.4.1 Injector – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
7.4.2 Injector – Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
7.4.3 Injector – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
7.4.4 Injector – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
7.4.5 Injector – Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
7.4.6 Injector – Nozzle replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
7.4.7 Injector – Removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
7.5 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
7.5.1 Leak-fuel tank – Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
7.5.2 Fuel system – Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
7.6 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
7.6.1 Fuel filter – Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
7.6.2 Fuel prefilter – Differential pressure check and adjustment of gauge ......... 107
7.6.3 Fuel prefilter – draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
7.6.4 Fuel prefilter – flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
7.6.5 Fuel prefilter – Filter element replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
7.7 Charge-air Cooling, General, Left Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
7.7.1 Intercooler – Checking condensate drain line for coolant discharge and
obstruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
7.8 Air Filter ................................................................ 116
7.8.1 Air filter and dust bowl – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
7.8.2 Air filter replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
7.8.3 Air filter removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
7.9 Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
7.9.1 Service indicator – Signal ring position check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
7.9.2 Emergency air shut-off flaps – Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
7.9.3 Emergency air shut-off flaps – Electric control check . . . . . . . . . . . . . . . . . . . . . . 121
7.9.4 Emergency air shut-off flaps – Opening/closing manually . . . . . . . . . . . . . . . . . . 122

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Table of Contents 03

7.10 Exhaust Flap with Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123


7.10.1 Exhaust turbocharger control – Control linkage lubrication . . . . . . . . . . . . . . . . . . 123
7.10.2 Air-flow and exhaust flow control flaps – Functional test . . . . . . . . . . . . . . . . . . . 124
7.11 Starting Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
7.11.1 Pressure reducing station – Putting into operation . . . . . . . . . . . . . . . . . . . . . . . . 125
7.11.2 Pressure reducing station – Venting and putting out of operation . . . . . . . . . . . . . 127
7.11.3 Pressure reducing station – Filter cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
7.11.4 Starter – Condition check .......................................... 129
7.11.5 Start pilot – Start fuel replenishment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
7.11.6 Start pilot – Fluid level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
7.12 Lube-oil System, Lube-oil Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
7.12.1 Engine oil – Level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
7.12.2 Engine oil – Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
7.12.3 Engine oil – Sample extraction and analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
7.12.4 Oil sludge inspection for metallic residues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
7.12.5 Lube oil priming pump – Checking direction of rotation . . . . . . . . . . . . . . . . . . . . 137
7.13 Oil Filtration/Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
7.13.1 Disk-pack filter – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
7.13.2 Engine oil filter – Cleaning filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
7.13.3 Engine oil filter – Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
7.13.4 Piston cooling-oil filter – Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
7.13.5 Centrifugal oil filter – Cleaning and filter-sleeve replacement . . . . . . . . . . . . . . . . 144
7.13.6 Centrifugal oil filter bracket – Removal and installation . . . . . . . . . . . . . . . . . . . . 147
7.13.7 Engine oil bypass filter – Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
7.14 Cooling Circuit, General, HT Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
7.14.1 Drain and venting points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
7.14.2 Vent line – Checking for obstructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
7.14.3 Heat exchanger – Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
7.14.4 Engine coolant – Level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
7.14.5 Engine coolant – Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
7.14.6 Engine coolant – Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
7.14.7 Engine coolant system – Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
7.14.8 Engine coolant pump – Relief bore check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
7.14.9 Engine coolant – Sample extraction and analysis . . . . . . . . . . . . . . . . . . . . . . . . 161
7.14.10 Coolant system – Strainer removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
7.15 Raw Water Pump with Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
7.15.1 Raw water pump – Relief bore check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
7.15.2 Automatic seawater inductor – Functional test . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
7.16 Engine Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
7.16.1 Engine mounts – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
7.16.2 Engine mounts – securing screws check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
7.17 General Cabling for Engine / Gearbox / Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
7.17.1 Engine wiring check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
7.17.2 Sensors and actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
7.18 Accessories for Engine Governor (Electronic) / Control System ................. 173
7.18.1 ECS – Connectors and housing cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

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04 Table of Contents

7.18.2 Plug-in connections – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174


7.18.3 ECS – Removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
7.19 Displays and Controls, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
7.19.1 Limit switch – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
7.19.2 Indicator lamp - LED replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
7.19.3 Fluid level monitor – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
7.20 Emergency Instrumentation (LOP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
7.20.1 Engine control system – Operational tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
8 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
8.1 Special tools ............................................................ 183
8.2 Standard tools – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
9 Annex ....................................................................... 193
9.1 Manufacturer’s documentation ............................................. 193
9.2 MTU contact person/service partner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
9.3 Index .................................................................. 195

MS15017/00E 06-11 © MTU


Safety 05

1 Safety

1.1 General conditions


General
In addition to the instructions in this publication, the applicable country-specific legislation and other compulsory
regulations regarding accident prevention must be observed. This engine is a state-of-the art product and conforms
with all applicable specifications and regulations. Nevertheless, persons and property may be at risk in the event of:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Modifications or conversions
• Non-compliance with the Safety Instructions
Correct use
The engine is intended exclusively for the application specified in the contract or defined at the time
of delivery. Any other use is considered improper use. The manufacturer will accept no liability for
any resultant damage. The responsibility is borne by the user alone.
Correct use also includes observation of and compliance with the maintenance specifications.
Modifications or Conversions
Modifications made by the customer to the engine may affect safety.
MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or conversions.
Spare parts
Only genuine MTU spare parts must be used to replace components or assemblies. In the
event of any damage caused by the use of other spare parts, no liability nor warranty claims
vis-à-vis the engine manufacturer will be accepted.

MS15017/00E 06-11 © MTU


06 Safety

1.2 Personnel and organizational requirements


Personnel
Work on the engine must only be carried out by properly qualified and instructed personnel.
The specified legal minimum age must be observed.
Responsibilities of the operating, maintenance and repair personnel must be specified.
Organization
This publication must be issued to all personnel involved in operation, maintenance, repair or transportation.
It must be kept at hand near the engine and accessible at any time to all personnel involved
in operation, maintenance, repair or transportation.
The personnel must be instructed on engine operation and repair by means of this publication,
and in particular the safety instructions must be explained.
This is especially important for personnel who work on the engine only on an occasional basis.
Such personnel must be given instructions repeatedly.
Working clothes and protective equipment
Wear proper work clothing for all work.
Depending on the kind of work, use additional protective equipment, e.g. protective goggles, gloves, helmet, apron.
Work clothing must be tight fitting so that it does not catch on rotating or projecting components.
Do not wear jewelry (e.g. rings, chains etc.).

MS15017/00E 06-11 © MTU


Safety 07

1.3 Transport
Transport
Lift the engine only with the lifting eyes provided.
Use only the transport and lifting equipment approved by MTU.
Take note of the engine center of gravity.
The engine must only be transported in installation position, max. permissible diagonal pull 10°.
In the case of special packaging with aluminum foil, suspend the engine on the lifting eyes of the
transport pallet or transport with equipment for heavy loads (forklift truck).
Prior to transporting the engine, it is imperative to install transportation locking
devices for crankshaft and engine mounts.
Secure the engine against tilting during transportation. The engine must be especially secured
against slipping or tilting when going up or down inclines and ramps.
Setting the engine down after transport
Place the engine only on an even, firm surface.
Ensure appropriate consistency and load-bearing capacity of the ground or support surface.
Never place an engine on the oil pan, unless expressively authorized by MTU on a case-to-case basis to do so.

MS15017/00E 06-11 © MTU


08 Safety

1.4 Safety precautions when working on the engine


Safety precautions when putting the equipment into operation
Prior to initial operation, the product must have been installed correctly and approved according to MTU specifications.
Before putting the device or the system into operation, always ensure
• that all maintenance and repair work is completed
• that all loose components have been removed from rotating parts
• that nobody is standing in the danger zone of moving engine components.
Immediately after putting the device or system into operation, make sure that all control and display
instruments as well as the signaling and alarm systems work properly.
Safety requirements for operators
Procedures for cases of emergency must be practised regularly.
The operator must be familiar with the controls and displays.
The operator must know the consequences of each operation to be carried out.
The operator must carry out the individual operations according to the documentation.
During operation, the displays and monitoring units must be permanently observed with regard to present
operating status, violation of limit values and warning or alarm messages.
The following steps must be taken if a malfunction of the system is recognized or reported by the system:
• notify the supervisory personnel in charge
• analyze the message
• if required, carry out emergency operations e.g. emergency engine stop.
Engine operation
When the engine is running, always wear ear protectors.
Ensure that the engine room is well ventilated.
Mop up any leaked or spilt fluids and lubricants immediately or soak up with a suitable bonding agent.
Exhaust gases from combustion engines are poisonous. Inhalation of poisonous exhaust gases is a health
hazard. The exhaust pipework must be free of leaks and discharge the gases to atmosphere.
During engine operation, do not touch battery terminals, generator terminals or cables.
Inadequate protection of electrical components can lead to electric shocks and serious injuries.
When the engine is running, never release coolant, oil, fuel, compressed-air or hydraulic lines.
Maintenance and repair
Strict adherence to the maintenance and repair schedule is an essential safety factor.
Never carry out maintenance and repair work with the engine running unless expressly instructed to do so.
Lock-out/tag-out the engine to preclude undesired starting. Disconnect the battery when electrical starters are fitted.
Close the main valve on the compressed-air system and vent the compressed air line when air starters are fitted. Post
the "Do Not Start" sign in the operating room or affix it to the controlling device! Persons not involved must keep clear.
Never attempt to rectify faults or carry out repairs if you do not have the necessary experience or special tools
required. Have maintenance and repair work carried out by qualified and authorized personnel only.
Use only proper, calibrated tools.
Do not work on engines or components which are only held by lifting equipment or crane. Always support by
suitable means which conform with the applicable regulations before commencing maintenance or repair work.
Before barring the engine, make sure that nobody is standing in the danger zone. After completing
work on the engine, check that all protective devices/safety guards have been installed and that
all tools and loose parts have been removed from the engine.
Fluids emerging under high pressure can penetrate clothing and skin and may cause serious injury. Before
starting work, relieve pressure in systems and H.P. lines which are to be opened.
Never bend a fuel line and do not install bent lines. Keep fuel injection lines and connections clean.
Always seal connections with caps or covers if a line is removed or opened.
Take care not to damage fuel lines during maintenance and repair work. To tighten the connections when installing
the lines, use the correct tightening torque and ensure that all retainers and dampers are installed correctly.

MS15017/00E 06-11 © MTU


Safety 09

Ensure that all fuel injection lines and pressurized oil lines have sufficient distance to other
components to avoid contact with them. Do not place fuel or oil lines near hot components,
except when necessary for design reasons during installation.
Elastomers (e.g. "Viton" sealing rings) are stable under normal operating conditions. The material decomposes
when exposed to fire or temperatures exceeding 300 °C. Hydrogen fluoride vapors are released in this
case. The resulting acid leads to serious burning if it contacts the skin. Do not touch elastomeric seals
if they have carbonized or resinous appearance. Wear protective gloves!
Take care with hot fluids in lines, pipes and chambers ⇒ Risk of injury!
Note cooling period for components which are heated for installation or removal ⇒ Risk of injury!
Never touch hot parts of the compressor and exhaust system ⇒ Risk of burning!
Take special care when removing ventilation or plugs from engine. In order to avoid discharge of
highly pressurized liquids, hold a cloth over the screw or plug. It is even more dangerous if the
engine has recently been shut down, as the liquids can still be hot.
Take special care when draining hot fluids. ⇒ Risk of injury!
When draining, collect fluids in a suitable container, mop up any spilt fluids or wipe or
soak them with a suitable bonding agent.
When changing the engine oil or working on the fuel system, ensure that the engine room is adequately ventilated.
When working high on the engine, always use suitable ladders and work platforms. Make
sure components are placed on stable surfaces.
In order to prevent back injuries when lifting heavy components adults, depending on age and sex,
should only lift weights between max. 10 kg and 30 kg, therefore:
• Use lifting gear or seek assistance.
• Ensure that all chains, hooks, slings, etc. are tested and authorized, are sufficiently strong and that
hooks are correctly positioned. Lifting eyes must not be unevenly loaded.
Welding work
Never carry out welding work on the engine or engine-mounted units.
Never use the engine as a ground connection. This prevents the welding current passing through
the engine resulting in burnt/scorched bearings, sliding surfaces and tooth flanks which may
lead to bearing seizure and/or other material damage.
Never route the welding lead over or near the wiring harnesses of MTU systems. The welding current may otherwise
induce an interference voltage in the wiring harnesses which could conceivably damage the electrical system.
The welding unit ground connection must not be more than 60 cm from the weld point.
If components (e.g. exhaust manifold) are to be welded, they must be removed from the engine.
It is not necessary to remove the connector and the connections when carrying out welding operation
on MTU electronics if the master switch for power supply is switched from "ON" to "OFF" and the wire
is disconnected from the negative and positive poles on the battery.
Hydraulic installation and removal
Only the hydraulic installation and removal equipment specified in the work schedule and
in the assembly instructions must be used.
The max. permissible push-on pressure specified for the equipment must not be exceeded.
The H.P. lines for hydraulic installation and removal are tested with 3800 bar.
Do not attempt to bend or apply force to lines.
Before starting work, pay attention to the following:
• Vent the hydraulic installation/removal tool, the pumps and the lines at the relevant points for the system to
be used (e.g. open vent plugs, pump until bubble-free air emerges, close vent plugs).
• For hydraulic installation, screw on the tool with the piston retracted.
• For hydraulic removal, screw on the tool with the piston extended.
For a hydraulic installation/removal tool with central expansion pressure supply, screw spindle
into shaft end until correct sealing is achieved.
During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of the
component to be installed/removed. As long as the system is under pressure, there is the risk that the
component to be installed/removed may be suddenly released from the pressure connection.
Before use, the tools must be checked at regular intervals (crack test).

MS15017/00E 06-11 © MTU


10 Safety

Working on electrical/electronic assemblies


Always obtain the permission of the person in charge before commencing maintenance and repair
work or switching off any part of the electronic system required to do so.
De-energize the appropriate areas prior to working on assemblies. Any measures requiring a power
supply are expressly defined as such at the appropriate place in the manual.
Gases released from the battery are explosive. Avoid sparks and naked flames. Do not allow battery
acids to come in contact with skin or clothing. Wear protective goggles. Do not place tools on the
battery. Before connecting the cable to the battery, check battery polarity. Battery pole reversal may lead
to injury through the sudden discharge of acid or bursting of the battery body.
Do not damage wiring during removal work and when reinstalling wiring and ensure that during operation it is
not damaged by contact with sharp objects, by rubbing against other component or by a hot surface.
Do not secure wiring to fluid-carrying lines.
On completion of the maintenance and repair work, any cables which have become loose
must be correctly connected and secured.
On completion of all repair work, the component and system must be subjected to a function check.
Separate testing of the repaired component without system integration is insufficient.
If wires are installed beside mechanical components and there is a risk of chafing, use
cable clamps to properly support the wires.
For this purpose, no cable binders must be used as, during maintenance and / or repair work,
the binders can be removed but not installed a second time.
Spare parts shall be properly stored prior to replacement, i.e. particularly protected against moisture. Defective
electronic components and assemblies must be suitably packed when dispatched for repair, i.e. particularly
protected against moisture and impact and wrapped in antistatic foil if necessary.
Working with laser equipment
When working with laser equipment, always wear special laser-protection goggles.
Laser equipment can generate extremely intensive, concentrated radiation by the effect of stimulated emission
in the range of visible light or in the infrared or ultraviolet spectral range. The photochemical, thermal and
optomechanical effects of the laser can cause damage. The main danger is irreparable damage to the eyes.
Laser equipment must be fitted with the protective devices necessary for safe
operation according to type and application.
For conducting light-beam procedures and measurement work, only the following laser devices must be used:
• Laser devices of classes 1, 2 or 3A,
• Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700 nm), a
maximum output of 5 mW, and in which the beam axis and surface are designed to prevent any risk to the eyes.
Operation of electrical equipment
When operating electrical equipment, certain components of this equipment are live.
Noncompliance with the warning instructions given for this equipment may result in
serious injury or damage to property.

MS15017/00E 06-11 © MTU


Safety 11

1.5 Auxiliary materials, fire prevention and environmental


protection
Fire prevention
Rectify any fuel or oil leaks immediately; even splashes of oil or fuel on hot components can cause fires -
therefore always keep the engine in a clean condition. Do not leave cloths soaked with fluids and lubricants
lying around on the engine. Do not store combustible materials near the engine.
Do not carry out welding work on pipes and components carrying oil or fuel. Before
welding, clean with a noncombustible fluid.
When starting the engine with a foreign power source, connect the ground lead last and remove it first.
To avoid sparks in the vicinity of the battery, connect the ground lead from the foreign power source
to the ground lead of the engine or to the ground terminal of the starter.
Always keep suitable fire-fighting equipment (fire extinguishers) at hand and familiarize yourself with their use.
Noise
Noise can lead to an increased risk of accident if acoustic signals, warning shouts or
sounds indicating danger are drowned.
At all workplaces with a sound pressure level over 85 dB (A), always wear ear protectors
(protective wadding, plugs or capsules).
Environmental protection
Dispose of used fluids, lubricants, materials and filters in accordance with local regulations.
Manipulation of the injection control system can influence the engine performance and exhaust emissions.
As a result, compliance with environmental regulations may no longer be guaranteed.
Only fuels of the specified quality required to achieve emission limits must be used.
In Germany, the VAwS (= regulations governing the use of materials that may affect water quality) is applicable,
which means work must only be carried out by authorized specialist companies (MTU is such a company).
Auxiliary materials
Use only fluids and lubricants that have been tested and approved by MTU.
Fluids and lubricants must be kept in suitable, properly designated containers. When using fluids, lubricants and
other chemical substances, follow the safety instructions applicable to the product. Take care when handling hot,
chilled or caustic materials. When using inflammable materials, avoid sparks, flames and do not smoke.
Lead
• When working with lead or lead-containing pastes, avoid direct contact to the skin and do not inhale lead vapors.
• Adopt suitable measures to avoid the formation of lead dust!
• Switch on fume extraction system.
• After coming into contact with lead or lead-containing materials, wash hands!
Acids and alkaline solutions
• When working with acids and alkalis, wear protective goggles or face mask, gloves and protective clothing.
• Immediately remove clothing wetted by acids and alkalis!
• Rinse injuries with plenty of water!
• Rinse eyes immediately with eyedrops or clean tap water.
Paints
• When painting anywhere other than in spray booths equipped with extractors, ensure good
ventilation. Make sure that adjacent work areas are not affected.
• No naked flames!
• No smoking.
• Observe fire prevention regulations!
• Wear masks providing protection against paint and solvent fumes.
Liquid nitrogen
• Store liquid nitrogen only in small quantities and always in regulation containers without fixed covers.
• Do not bring liquid nitrogen in contact with the body (eyes, hands), as this causes frostbite and loss of tissue.
• Wear protective clothing, including gloves, closed shoes and protective goggles!

MS15017/00E 06-11 © MTU


12 Safety

• Ensure that the room is well ventilated. Nitrogen concentration exceeding 88% of
breathing air leads to suffocation.
• Avoid all knocks and jars to the containers, fixtures or workpieces.
Compressed air
Compressed air is air compressed at excess pressure and is stored in vessels from which it can be extracted.
The pressure at which the air is kept can be read off at pressure gauges which must be connected
to the compressed air vessels and the compressed air lines.
When working with compressed air, safety precautions must be constantly observed:
• Pay special attention to the pressure level in the compressed air network and pressure vessel!
• Devices and equipment connected must either be designed for this pressure or, if the permitted
pressure for the connected elements is lower than the pressure required, a pressure reducing
valve and safety valve (set to permitted pressure) must form an intermediate connection. Hose
coupling and connections must be securely attached!
• Always wear protective goggles when blowing off tools or chips!
• The snout of the air nozzle should be provided with a protective disc (e.g. rubber disc), which prevents
air-borne particles being deflected and thereby prevents injury to eyes.
• First shut off compressed air lines before compressed air equipment is disconnected from the
supply line or before equipment or tools are exchanged!
• Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII
and B) out of containers, carries the risk of explosion!
• Forcing compressed air into thin-walled containers (e.g. containers made of tin, plastic and glass)
for drying purposes or to check for leaks, results in a risk of shattering!
• Do not use compressed air to clean contaminated clothing whilst it is being worn.
Used oil
Used oil may contain health-threatening combustion residues.
Rub barrier cream into hands!
Wash hands after contact with used oil.

MS15017/00E 06-11 © MTU


Safety 13

1.6 Standards for warning notices in the publication


In the event of immediate danger.
Consequences: Death or serious injury.
DANGER • Preventive measures
In the event of possibly dangerous situations.
Consequences: Death or serious injury.
WARNING • Preventive measures
In the event of dangerous situations.
Consequences: Slight injury or material damage.
CAUTION • Preventive measures

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

Warning notices
1. Read and become acquainted with all cautions and symbols before operating or repairing this product.
2. Pass on all safety instructions to your operating, maintenance, repair and transport personnel!

MS15017/00E 06-11 © MTU


14 Safety

MS15017/00E 06-11 © MTU


Product Summary 15

2 Product Summary

2.1 Engine Overview

2.1.1 Engine layout


V1163

1 Carrier housing 8 HP intercooler 15 Engine oil pump


2 LP exhaust turbocharger 9 Charge-air preheater 16 Vibration damper
3 Exhaust-flow control flap 10 Emergency air shut-off flap 17 Coolant thermostat
4 HP exhaust turbocharger 11 Fuel injection pump 18 Governor actuator
5 Cylinder head 12 Valve gear 19 Engine oil filter
6 LP intercooler 13 Cylinder liner 20 Engine oil heat exchanger
7 Air-flow control flap 14 Running gear 21 Fuel filter

Engine model designation


Key to the engine model designation, example: 20V 1163 TB73L
• 20 = Number of cylinders
• V = Cylinder configuration
• 1163 = Series
• T = Exhaust turbocharging
• B = External charge-air cooling
• 7 = Marine engine or
• 8 = Marine engine
• 9 = Marine engine

MS15017/00E 06-11 © MTU


16 Product Summary

• 3 = Design index
• L = Increased power

MS15017/00E 06-11 © MTU


Product Summary 17

2.2 Engine Side and Cylinder Designations

2.2.1 Engine side and cylinder designations


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

1 KGS = Free end 3 KS = Driving end


2 Right side 4 Left side

MS15017/00E 06-11 © MTU


18 Product Summary

2.3 Main Engine Dimensions

2.3.1 Main engine dimensions

Main engine dimensions

Engine model Length (A) Width (B) Height (C) Height (D)

12V 1163 TB73L approx. 4035 mm approx. 1700 mm approx. 2795 mm approx. 850 mm

16V 1163 TB73L approx. 4930 mm approx. 1900 mm approx. 3520 mm approx. 940 mm

20V 1163 TB73L approx. 5030 mm approx. 1630 mm approx. 2700 mm approx. 1035 mm

MS15017/00E 06-11 © MTU


Product Summary 19

2.4 Firing Order

2.4.1 Firing order

Firing order, ccw. direction of rotation (not reversible)


12 V A1–B5–A5–B3–A3–B6–A6–B2–A2–B4–A4–B1

16 V A1-B6-A6-B2-A2-B4-A4-B8-A8-B3-A3-B7-A7-B5-A5-B1

20 V A1-B7-A7-B2-A2-B6-A6-B3-A3-B10-A10-B4-A4-B9-A9-B5-A5-B8-A8-B1

Firing order, cw. direction of rotation (not reversible)


12 V A1–B1–A4–B4–A2–B2–A6–B6–A3–B3–A5–B5

16 V A1-B1-A5-B5-A7-B7-A3-B3-A8-B8-A4-B4-A2-B2-A6-B6

20 V A1-B1-A8-B8-A5-B5-A9-B9-A4-B4-A10-B10-A3-B3-A6-B6-A2-B2-A7-B7

MS15017/00E 06-11 © MTU


20 Product Summary

2.5 Technical Data

2.5.1 16V 1163TB73L engine data


Explanation:
DL Ref. value: Continuous power
BL Ref. value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated without change (e.g. of power settings).
N Not yet defined value
- Not applicable
X Applicable
REFERENCE CONDITIONS

Engine model 16V


1163TB73L

Application group 1B

Intake air temperature °C 25

Charge-air coolant temperature °C 25

Raw-water inlet temperature °C 25

Barometric pressure mbar 1000

Site altitude above sea level m 100

POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)

Number of cylinders 16

Rated engine speed A rpm 1230

Fuel stop power ISO 3046 A kW 5200

GENERAL CONDITIONS (for maximum power)

Number of cylinders 16

Intake air depression (new filter) A mbar 15

Intake air depression, max. L mbar 30

MS15017/00E 06-11 © MTU


Product Summary 21

MODEL RELATED DATA (basic design)

Number of cylinders 16

Cylinder arrangement: V angle Degrees 60

Bore mm 230

Stroke mm 280

Displacement per cylinder Liters 11.63

Total displacement Liters 186.1

Inlet valves per cylinder 2

Exhaust valves per cylinder 2

RAW WATER CIRCUIT (open circuit)

Number of cylinders 16

Raw water pump: inlet pressure, min. L bar -0.2

Raw water pump: inlet pressure, max. L bar 3.2

Pressure loss in off-engine raw water system, max. L bar 2.3

LUBE-OIL SYSTEM

Number of cylinders 16

Lube-oil operating temperature before engine, from R °C 60

Lube-oil operating temperature before engine, to R °C 70

Lube-oil operating pressure before engine, from R bar N

Lube-oil operating pressure before engine, to R bar N

Lube-oil operating pressure, low idle (meas. point: before engine) R bar 3

FUEL SYSTEM

Number of cylinders 16

Fuel pressure at engine supply connection, min. (when engine is starting) L bar -0.2

Fuel pressure at engine supply connection, max. (when engine is starting) L bar 0.5

Fuel supply flow rate, max. R liter/min 83

MS15017/00E 06-11 © MTU


22 Product Summary

CAPACITIES

Number of cylinders 16

Engine coolant capacity, engine side (without cooling equipment) R Liters 560

Raw water capacity, engine side R Liters 320

Fuel capacity, engine side R Liters 26

Engine oil capacity, total at initial filling (standard oil system) R Liters 730

Oil change capacity, max. (standard oil system) R Liters 640

Oil pan capacity at dipstick mark "min." (standard oil system) R Liters 440

Oil pan capacity at dipstick mark "max." (standard oil system) R Liters 560

INCLINATIONS, STANDARD OIL SYSTEM (Reference: waterline)

Number of cylinders 8

Longitudinal inclination, continuous max., driving end down (Option: max. operating L Degrees 12
inclinations)

Longitudinal inclination temporary max. driving end down (Design: max. operating L Degrees 15
inclinations)

Transverse inclination, constant max. (Option: max. operating inclinations) L Degrees 22.5

Transverse inclination, temporary max. (Option: max. operating inclinations) L Degrees 30

WEIGHTS / MAIN DIMENSIONS

Number of cylinders 16

Engine dry weight (with attached standard accessories, without coupling) R kg 18500

ACOUSTICS

Number of cylinders 16

Exhaust noise, unsilenced, BL, (free-field sound-pressure level Lp, 1m distance, R dB(A) 110
ISO 6798)

Engine surface noise with attenuated intake noise (filter), BL, (free-field R dB(A) 109
sound-pressure level Lp, 1m distance, ISO 6798)

MS15017/00E 06-11 © MTU


Operation 23

3 Operation

3.1 LOP – Overview

LOP – Display and control elements

Item No. Meaning / Function

1 Left display window

2 Photodiode for room illumination measurement

3 Right display window

4 Control keys for right display

5 EMERGENCY STOP button

6 Key pad for operational tests

7 Key pad for clutch control

8 Key pad for engine control

9 Key pad for engine start / stop

MS15017/00E 06-11 © MTU


24 Operation

Item No. Meaning / Function

10 Key pad for operating modes

11 Control keys for left display

Displays

The windows display operating parameters, switching conditions, actual values, and limit values.
The desired display is called up by pressing the relevant illuminated display control key.
As soon as the ECS recognizes a fault, a visual and/or audible alarm appears on the LOP.
Screen displays in graphic mode (example)
The displays in graphic mode provide an overview of the measured values. Where necessary – e. g.
engine speed, fuel rack travel – the precise numeral value is also displayed.

MS15017/00E 06-11 © MTU


Operation 25

1 Exhaust temperature display ETC A 5 Status display 9 Start interlock active


2 Exhaust temperature display ETC B 6 Cylinder cut-out not active 10 Emergency air shut-off flaps open
3 Fuel rack travel display 7 Starter on 11 Lube oil pressure display
4 Engine speed display 8 Oil priming on 12 Coolant temperature display

Screen displays in text mode


It is possible to call up the precise numerical values of the measuring points by switching over to text mode.

MS15017/00E 06-11 © MTU


26 Operation

Soft keyboard elements

1 Key pad for left display control 4 Key 6 Key pad for ECS, engine and
2 Key pad for right display control 5 Illuminated pushbutton clutch control
3 Spot (LED)

Illumination status of the soft keyboard keys


The illumination status of the keys encodes information on the operating condition of ECS, engine, clutch and LOP.

Status Meaning

Spot not lit, key not lit • Function not active


• Command input disabled

Spot lit, key not lit • Function active


• Command input disabled

Spot not lit, key lit • Function not active


• Command input enabled

Spot flashing, key not lit • Function is being performed


• Command input disabled

Spot lit, key lit • Function active


• Command input enabled

Spot not lit, key flashing • Combined alarm active


• Audible alarm (horn) active
• Alarm acknowledgment enabled

MS15017/00E 06-11 © MTU


Operation 27

Input of control commands


The illumination status of the keys encodes whether or not command input is enabled.
Command input is enabled only when the key is illuminated.
Control command input is performed by pressing the key.
1. Press the illuminated key and hold for approx. 1 second.
2. Release key.
3. Function is active when spot is lit.
LOP – DIS controls
Left display control

Key Action Display Function

NEXT PAGE Scrolls display pages


forwards.

PREV. PAGE Scrolls display pages


backwards.

GRAPHIC Graphic display of Selects graphic mode.


measured values.

TEXT Numeric display of Selects text mode.


measured values.

ALARM DISPLAY Spot and lamp light up red Fault message Selects display of fault
as soon as an alarm is message.
active.

ILLUM. DIM ↑ Holding down the


key increases LCD
background illumination.

ILLUM. DIM ↓ Holding down the


key decreases LCD
background illumination.

ACKNOWL. Key flashes when alarm is Combined alarm and horn Pressing the key the
active. are active. first time stops alarm
signalization.
• Fault message is still
displayed.
Pressing the key a second
time acknowledges an
active alarm.
• Fault message will
be displayed as long
as the alarm is still
active.

STORED ALARM RESET Resets inactive alarms


stored.

LOP FAULT Spot and lamp are lit when Fault message –
a LOP fault is detected.

MS15017/00E 06-11 © MTU


28 Operation

Right display control

Key Action Display Function

NEXT PAGE Scrolls display pages


forwards.

PREV. PAGE Scrolls display pages


backwards.

GRAPHIC Graphic display of Selects graphic mode.


measured values.

TEXT Numeric display of Selects text mode.


measured values.

ALARM DISPLAY Spot and lamp light up red Fault message Selects display of fault
as soon as an alarm is message.
active.

MI SELECT Maintenance indicator Optional

MI ACKNOWL. Maintenance indicator Optional

Controls for ECS, engine and clutch

Key Action Display Function

ECS ACTIVE Spot lit – Main ECS active

BACKUP ACTIVE Spot lit – Backup ECS active

READY FOR OPERATION Spot lit – System is ready for


operation.

START Spot lit – Start sequence initiated.

STOP Spot lit – Stop sequence initiated.

LOCAL CONTROL Spot lit – Local control active.

SPEED↑ Spot lit – Speed increase active.

SPEED↓ Spot lit – Speed decrease active.

CLUTCH AHEAD* Spot lit – Clutch engaged AHEAD.


CLUTCH ENGAGED*
Spot lit – Clutch engaged.

Spot flashing Clutch being engaged.

CLUTCH NEUTRAL* Spot lit – Clutch set to NEUTRAL

CLUTCH DISENG.* Spot lit – Clutch disengaged.

CLUTCH ASTERN* Spot lit – Clutch engaged ASTERN.

Spot flashing – Clutch being engaged.

TEST GOVERNOR Spot lit – Governor test active.

TEST OVERSPEED Spot flashing – Overspeed test active.

TURN ENGINE Spot lit – Turning procedure active.

MS15017/00E 06-11 © MTU


Operation 29

*Example refers to keys for reversing gear

MS15017/00E 06-11 © MTU


30 Operation

3.2 Pump control – Control and display elements

Priming Pump Control (PPC) , refill pump control (LPU) – Control and display elements

1 Indicator lamp "Oil priming pump 4 Switch for oil priming pump
ON", only with PPC (positions: AUTO - 0 - MAN),
2 Indicator lamp "Oil refill pump only with PPC
ON"; only with LPU 5 Door lock
3 Switch for oil refill pump (positions:
AUTO - 0 - MAN), only with LPU

MS15017/00E 06-11 © MTU


Operation 31

3.3 Putting the engine into operation after extended


out-of-service periods (>3 months)
Preconditions
• Engine is stopped and starting disabled.
• MTU Fluids and Lubricants Specification (A001061/..) is available.
Putting the engine into operation after extended out-of-service-periods (>3 months)

Item Task

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

Start interlock Verify that cover is installed and limit switch is activated (→ Page 177).

Combustion chamber Blow out combustion chambers (→ Page 88)

Fuel prefilter Prime (→ Page 112).

Fuel prefilter, pressure gauge Align adjustable pointer with position of pressure indicator (→ Page 107).

Fuel system Open shut-off valve(s) before and after fuel heat exchanger.

Fuel system Vent (→ Page 104).

Fuel heat exchanger Vent (→ Page 155)


.

Lube oil system Check engine oil level (→ Page 132).

Lube oil system Open shut-off valve before bypass filter.

Lube oil system Verify that diverter valves of oil filters are in operating position (→ Page 140),
(→ Page 142).

Lubrication points • Lubricate emergency air shut-off flaps (→ Page 120);


• Lubricate control linkage and air-control flaps of ETCs (→ Page 123).

Coolant circuit Open shut-off valve(s) after coolant expansion tank.

Coolant circuit Check vent lines for obstructions (→ Page 154)


.

Raw water circuit Check vent lines for obstructions (→ Page 154)
.

Preheating unit Put into operation.

Oil priming pump Check direction of rotation (→ Page 137).

Cold-start system Top up start pilot tank (→ Page 130).

Compressed air system Put into operation (→ Page 125)

Crankshaft Verify that transport locking device has been removed.

Engine mounts Verify that transport locking device has been removed.

Engine control system Switch on main switch;


Press READY FOR OPERATION button (→ Page 23).

Engine control system Carry out operational tests (→ Page 181).

MS15017/00E 06-11 © MTU


32 Operation

3.4 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 132);


Preheat engine oil, if required.

Coolant system Check coolant level (→ Page 156).

Coolant system Preheat coolant with preheating unit.

Raw water supply Open supply.

Fuel prefilter Drain (→ Page 108);


Check if suction-side pressure indicated at the fuel prefilter
pressure gauge is within the limit (→ Page 107).

Start pilot Check tank content (→ Page 131).

Compressed air system Open main supply valve.

Compressed air system Check operating pressure.

Compressed air system Drain condensate from compressed air tank.

Mechanical accessories Verify that all protective devices have been removed.

Engine control system Switch on main switch.

Engine control system Carry out operational tests (→ Page 181).

MS15017/00E 06-11 © MTU


Operation 33

3.5 Starting the engine from LOP


Preconditions
• Gearbox is disengaged.
• External start interlock is not activated.
• Emergency air-shut-off flaps (if provided) are open.

Unguarded rotating and moving engine components.


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

Engine noise above 85 dB (A).


Risk of damage to hearing!
WARNING • Wear ear protectors.

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

Item Task

Engine Bar with starting system (→ Page 87).

Starting the engine from LOP

Item Task

Engine Make sure that engine is in unloaded condition.

Control system Switch ON.


LOP:
• LOCAL OPERATION button is illuminated brightly (local operating mode is
active) (→ Page 23);
• CLUTCH NEUTRAL button is illuminated brightly (gearbox is disengaged)
(→ Page 23).

LOP Press READY FOR OPERATION button briefly (→ Page 23).


• READY FOR OPERATION button is illuminated brightly

LOP Press START button briefly (→ Page 23).


• START button of the engine concerned is illuminated brightly;
• Automatic starting procedure is performed;
• Tachometer indicates increasing crankshaft speed;
• After the starting procedure is completed, engine is running at idle speed
and START button is reset to basic illumination.

MS15017/00E 06-11 © MTU


34 Operation

3.6 Operational checks


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

Engine noise above 85 dB (A).


Risk of damage to hearing!
WARNING • Wear ear protectors.

Operational checks

Item Task

Engine under load Visually inspect the engine for leaks and general condition;
Engine at nominal speed Check for abnormal noises and vibrations;
Check exhaust color (→ Page 51).

Fuel prefilter Check if suction-side pressure indicated at the fuel prefilter pressure gauge is
within the limit. (→ Page 107).
Drain off water and dirt (→ Page 108)

Intercooler Check drain line for water discharge and obstruction (→ Page 115).

Air filter Check signal ring position of service indicator (→ Page 119);
Replace air filter (→ Page 117), if the signal ring is completely visible in the
service indicator control window.

HT coolant pump Check relief bore for oil and coolant discharge and dirt (→ Page 160).

Raw-water pump Check relief bore for oil and water discharge and dirt (→ Page 163)

MS15017/00E 06-11 © MTU


Operation 35

3.7 Stopping the engine from LOP


Preconditions
• Engine is running at local mode.

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

Stopping the engine from LOP

Item Task

LOP Disengage clutch (→ Page 23).

LOP Operate engine at idle speed (→ Page 23).

Temperature readings Wait until engine temperature does not sink any further.

LOP Press illuminated STOP key (→ Page 23).


• Spot of STOP key lights up;
• Engine is at a standstill;
• Switching over to Backup ECS is posible;
• Ready-for-operation signal is present;
• Engine start is enabled;
• Switching over to remote control mode is possible;
• Engage AHEAD is possible (only for solenoid valve test);
• Engage ASTERN is possible (only for solenoid valve test);
• Governor test is enabled;
• Turn test is enabled.

MS15017/00E 06-11 © MTU


36 Operation

3.8 Emergency stop from LOP


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

Emergency stop from LOP

Item Task

LOP Press illuminated EMERGENCY STOP button.


• Horn sounds;
• Lamp of ACKNOWL. key flashes;
• Lamp of ALARM DISPLAY key is lit;
• Lamp of STORED ALARM RESET key is lit.
• Emergency air shut-off flaps close;
• Engine and shaft are disengaged;
• Messages AL SDAF CLOSED and SS EMERGENCY STOP WITH SDAF
are displayed;
• Switching over to Backup ECS is possible;
• Switching over to remote control mode is possible.

After emergency stop from LOP

Item Task

LOP Press ACKNOWL. key (→ Page 23).


• Audible and visual signalization stops.

LOP Press ACKNOWL. key once again.


• Alarm is acknowledged.

LOP Press STORED ALARM RESET key.


• The alarms stored in the alarm memory are erased.

Engine Open emergency air shut-off flaps manually (→ Page 122).

MS15017/00E 06-11 © MTU


Operation 37

3.9 After stopping the engine


Preconditions
• MTU Fluids and Lubricants Specification (A001061/..) is available.
After stopping the engine

Item Action

Coolant system Drain coolant if:


• there is a risk of frost and the engine will be out of service for a lengthy
period and the coolant does not contain antifreeze;
• the engine room is not heated;
• the coolant is not maintained at a suitable temperature;
• the antifreeze concentration is insufficient for the engine-room temperature;
• antifreeze concentration is 50 % and engine-room temperature is below
-40 °C.

Raw water Close supply.

Raw water Drain


• if freezing temperatures are expected and the engine is to remain out of
service for an extended period.

Engine control system Switch OFF.

Emergency air shutoff flaps Out-of-service-period > 24 hours


• Close manually.

Engine oil Check level (→ Page 132).

Engine oil filter Operate ratchet lever several times (→ Page 139).

Air intake and exhaust system Out-of-service-period > 1 week


• Seal engine air intakes and exhaust outlets.
Out-of-service-period > 1 month
• Preserve engine (→MTU Fluids and Lubricants Specification A001061/..).

Compressed air system Close main valve.

MS15017/00E 06-11 © MTU


38 Operation

3.10 PPC, LPU – Functional check


Preconditions
• Engine is stopped and starting disabled.
PPC – Functional check
1. Turn selector switch on PPC to position MAN (2).
Result:
• Indicator lamp lights up.
• Oil priming pump is running.
2. Turn selector switch on PPC to position AUTO (3).

LPU – Functional check


1. Turn selector switch on LPU to position MAN (2).
Result:
• Indicator lamp lights up.
• Oil refill pump is running.
2. Turn selector switch on LPU to position AUTO (3).

MS15017/00E 06-11 © MTU


Engine Control System ECS-5 39

4 Engine Control System ECS-5

4.1 Normal Operation: LOS or LOP with Display

4.1.1 Local control mode – Engaging/disengaging the gearbox

Preconditions
• Local control mode is switched on.
• Engine speed is in the engagement window.

Vessel is sailing blind.


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

Engaging the gearbox


1. Make contact with the control stand.
2. Press one of the following keys to engage as required: (→ Page 23):
• To engage ahead: Key CLUTCH AHEAD or CLUTCH ENGAGED
• To engage astern (only reversing gear): Key CLUTCH ASTERN
Result:
• The spot of the key is flashing as long as the clutch is being engaged.
• Key is not lit.
• The gearbox is engaged.

Disengaging the gearbox


1. Reduce the engine speed to idling (→ Page 40).
2. Press key CLUTCH NEUTRAL or CLUTCH DISENG. (→ Page 23).
Result:
• The spot of the key is flashing as long as the clutch is being disengaged.
• Key is not lit.
• The gearbox is disengaged.

MS15017/00E 06-11 © MTU


40 Engine Control System ECS-5

4.1.2 Local control mode – Changing engine speed

Preconditions
• Local control mode is switched on.
• Engine is running.
Changing engine speed
1. Press one of the following keys as required (→ Page 23):
• To increase engine speed: key SPEED ↑
• To decrease engine speed: key SPEED ↓
Result:
• Touching the key briefly increases/decreases engine speed by 1 min-1.
• Touching the key for longer than 0.5 seconds increases engine speed at the (order-specific) adjusting rate.
• The current engine speed is indicated on the display.
2. Release key as soon as the desired engine speed has been reached.
Result: The engine speed remains constant.

MS15017/00E 06-11 © MTU


Maintenance 41

5 Maintenance

5.1 Preface

MTU maintenance concept


The maintenance system for MTU products is based on a preventive maintenance concept. Preventive
maintenance facilitates advance planning and ensures a high level of equipment availability.
The maintenance schedule is based on the load profile / load factor specified below. The time intervals at which
the maintenance work is to be carried out and the relevant checks and tasks involved are average values based
on operational experience and are therefore to be regarded as guidelines only. Special operating conditions and
technical requirements may require additional maintenance work and/or modification of the maintenance intervals.
In order to be authorized to carry out the individual maintenance jobs, maintenance personnel must have achieved a
level of training and qualification appropriate to the complexity of the task in hand. The various Qualification Levels
QL1 to QL4 reflect the levels of training offered in MTU courses and the contents of the tool kits required.
QL1: Operational monitoring and maintenance which can be carried out during a break
in operation without disassembling the engine.
QL2: Component replacement (only corrective).
QL3: Maintenance work which requires partial disassembly of the engine.
QL4: Maintenance work which requires complete disassembly of the engine.
The maintenance schedule matrix normally finishes with extended component maintenance. Following
this, maintenance work is to be continued at the intervals indicated.
The "Task" numbers stated in the list of jobs to be done/action to be taken indicate the relevant
maintenance item. They serve as a reference for the required scope of parts and are also
listed on the labels of the corresponding spare parts.

Notes on maintenance
Specifications for fluids and lubricants, guideline values for their maintenance and change intervals and lists of
recommended fluids and lubricants are contained in the MTU Fluids and Lubricants Specifications A001061 and in
the fluids and lubricants specifications produced by the component manufacturers. They are therefore not included
in the maintenance schedule (exception: deviations from the Fluids and Lubricants Specifications). All fluids and
lubricants used must meet MTU specifications and be approved by the relevant component manufacturer.
Amongst other items, the operator/customer must carry out the following additional maintenance work:
• Protect components made of rubber or synthetic material from oil. Never treat them
with organic detergents. Wipe with a dry cloth only.
• Fuel prefilter:
Maintenance depends on how dirty fuel is. The paper inserts in fuel prefilters must be
changed every two years at the latest (Task 9998).
• Battery:
Battery maintenance depends on the level of use and the ambient conditions. The battery
manufacturer’s instructions must be observed.
The relevant manufacturer’s instructions apply with respect to the maintenance of any components
which do not appear in this maintenance schedule.
Items that are listed in this maintenance schedule but that do not refer to the respective engine model, can be ignored.

Out-of-service periods
If the engine is to remain out of service for more than 1 month, carry out engine preservation procedures in
accordance with the Fluids and Lubricants Specifications, MTU Publication No. A001061.

Application group
1B Fast vessels with high load factors

MS15017/00E 06-11 © MTU


42 Maintenance

Load profile
Load-profile table

Load factor 100% 85% <15%

Corresponding operating time 3% 82% 15%

MS15017/00E 06-11 © MTU


Maintenance 43

5.2 50-hours service

50-hours service
One-time operations after the first 50 operating hours - with a new engine, after component
maintenance or extended component maintenance.

Qual- Interval Item Maintenance tasks Task


ifica- Code
tion [hours] [a]

QL1 – – Add-on components Check tightness of securing screws. –

QL1 – – Valve gear Check valve clearance (→ Page 89). –

QL1 – – Fuel prefilter Replace filter elements of fuel prefilter (→ Page 112). –

QL1 – – Fuel filter Replace fuel filter or fuel filter element (→ Page 105). –

QL1 – – Engine oil Take engine oil sample and analyze (→ Page 135). –

QL1 – – Engine-oil edge-type filter Operate ratchet lever of oil filters several times (→ Page 139). –

QL1 – – Engine coolant circuit Remove strainer element before thermostat (→ Page 162). -

MS15017/00E 06-11 © MTU


44 Maintenance

5.3 Maintenance schedule matrix

0-5,250 operating hours


Item Hours of operation [h]

Limit years

1,000
1,250
1,500
1,750
2,000
2,250
2,500
2,750
3,000
3,250
3,500
3,750
4,000
4,250
4,500
4,750
5,000
5,250
Daily
250
500
750
Engine operation - X

Centrifugal oil filter - X X X X X X X X X X X X X X X X X X X X X

Engine oil bypass filter - X X X X X X X X X X

Edge-type engine oil filter - X X X X X X X X X X

Emergency air shut-off flaps - X X X X X X X X X X

Engine oil filter 2 X X X X X X X X X X

Pressure reducing station - X X X X X

Fluid level monitor - X X X X X

Valve gear - X X X X X

Fuel filter 1 X X X X X

Lubrication points 1 X X X X X

Engine mounting 2 X X X X X

Suction device - X

Fuel injectors - X

Raw water pump - X

Engine coolant pump - X

Air filter 2 X

Exhaust turbocharger -

ETC control -

Injection pump swing followers -

Component maintenance -

Intercooler -

Charge-air preheater -

Charge-air preheater -

Cylinder head -

Cylinder liners -

Engine oil thermostat -

Conrod bearings -

Governor actuator -

Extended component maintenance 18

MS15017/00E 06-11 © MTU


Maintenance 45

5,500-10,750 operating hours


Item Hours of operation [h]

Limit years

10,000
10,250
10,500
10,750
5,500
5,750
6,000
6,250
6,500
6,750
7,000
7,250
7,500
7,750
8,000
8,250
8,500
8,750
9,000
9,250
9,500
9,750
Engine operation -

Centrifugal oil filter - X X X X X X X X X X X X X X X X X X X X X X

Engine oil bypass filter - X X X X X X X X X X X

Edge-type engine oil filter - X X X X X X X X X X X

Emergency air shut-off flaps - X X X X X X X X X X X

Engine oil filter 2 X X X X X X X X X X X

Pressure reducing station - X X X X X

Fluid level monitor - X X X X X

Valve gear - X X X X X

Fuel filter 1 X X X X X

Lubrication points 1 X X X X X

Engine mounting 2 X X X X X

Suction device - X

Fuel injectors - X

Raw water pump - X

Engine coolant pump - X

Air filter 2 X

Exhaust turbocharger - X

ETC control - X

Injection pump swing followers - X

Component maintenance - X

Intercooler - X

Charge-air preheater - X

Charge-air preheater - X

Cylinder head - X

Cylinder liners - X

Engine oil thermostat - X

Conrod bearings - X

Governor actuator - X

Extended component maintenance 18

MS15017/00E 06-11 © MTU


46 Maintenance

11,000-16,250 operating hours


Item Hours of operation [h]

Limit years

12,000
12,250
12,500
12,750
13,000
13,250
13,500
13,750
14,000
14,250
14,500
14,750
15,000
15,250
15,500
15,750
16,000
16,250
11,000
11,250
11,500
11,750
Engine operation -

Centrifugal oil filter - X X X X X X X X X X X X X X X X X X X X X X

Engine oil bypass filter - X X X X X X X X X X X

Edge-type engine oil filter - X X X X X X X X X X X

Emergency air shut-off flaps - X X X X X X X X X X X

Engine oil filter 2 X X X X X X X X X X X

Pressure reducing station - X X X X X X

Fluid level monitor - X X X X X X

Valve gear - X X X X X X

Fuel filter 1 X X X X X X

Lubrication points 1 X X X X X X

Engine mounting 2 X X X X X X

Suction device - X X

Fuel injectors - X X

Raw water pump - X X

Engine coolant pump - X X

Air filter 2 X X

Exhaust turbocharger - X

ETC control - X

Injection pump swing followers - X

Component maintenance - X

Intercooler - X

Charge-air preheater - X

Charge-air preheater - X

Cylinder head - X

Cylinder liners - X

Engine oil thermostat -

Conrod bearings -

Governor actuator -

Extended component maintenance 18

MS15017/00E 06-11 © MTU


Maintenance 47

16,500-21,000 operating hours


Item Hours of operation [h]

Limit years

16,500
16,750
17,000
17,250
17,500
17,750
18,000
18,250
18,500
18,750
19,000
19,250
19,500
19,750
20,000
20,250
20,500
20,750
21,000
Engine operation -

Centrifugal oil filter - X X X X X X X X X X X X X X X X X X X

Engine oil bypass filter - X X X X X X X X X X

Edge-type engine oil filter - X X X X X X X X X X

Emergency air shut-off flaps - X X X X X X X X X X

Engine oil filter 2 X X X X X X X X X X

Pressure reducing station - X X X X X

Fluid level monitor - X X X X X

Valve gear - X X X X X

Fuel filter 1 X X X X X

Lubrication points 1 X X X X X

Engine mounting 2 X X X X X

Suction device - X

Fuel injectors - X

Raw water pump - X

Engine coolant pump - X

Air filter 2 X

Exhaust turbocharger - X

ETC control - X

Injection pump swing followers - X

Component maintenance - X

Intercooler - X

Charge-air preheater - X

Charge-air preheater - X

Cylinder head - X

Cylinder liners - X

Engine oil thermostat - X

Conrod bearings - X

Governor actuator - X

Extended component maintenance 18 X

MS15017/00E 06-11 © MTU


48 Maintenance

5.4 Maintenance tasks


Qual- Interval Item Maintenance tasks Task
ifica- Code
tion [hours] [a]

QL1 Daily - Engine operation Check engine oil level (→ Page 34). W0500

Visually inspect engine for leaks and general condition (→ Page 34). W0501

Check intercooler drain (if installed) (→ Page 34). W0502

Check service indicator of air filter (→ Page 34). W0503

Check relief bores on coolant pump(s) (→ Page 34). W0505

Check for abnormal running noises, exhaust gas discoloration and W0506
vibrations (→ Page 34).

Drain water and contaminants from fuel prefilter (if fitted) (→ Page 34). W0507

Check vacuum gauge reading on fuel prefilter (if installed) W0508


(→ Page 34).

QL1 250 - Centrifugal oil filter Centrifugal oil filter (if fitted): Measure thickness of oil residue layer, W1009
clean and replace filter sleeve (→ Page 144).

QL1 500 - Engine oil bypass filter Replace filter elements, sealing rings and clean housing (if applicable), W1100
accomplish together with engine oil change (→ Page 148).

QL1 500 - Edge-type engine oil filter Operate ratchet lever several times (→ Page 139). W1080

QL1 500 - Emergency air shut-off flaps Check (electric) operation of emergency air shut-off flaps W1024
(→ Page 121).

QL1 500 2 Engine oil filter Drain oil sludge and inspect for metallic residues, replace filter W1096
elements when changing engine oil or when the time limit (years) is
reached, at the latest (→ Page 136).

QL1 1,000 - Pressure reducing station Pressure reducing station: Clean air filter (→ Page 128). W1048

QL1 1,000 - Fluid level monitor Check function of fluid level monitors for engine oil and coolant (if W1023
fitted) (→ Page 180).

QL1 1,000 - Valve gear Check valve clearance (→ Page 89). W1002

QL1 1,000 1 Fuel filter Replace fuel filter or fuel filter element (→ Page 105). W1001

QL1 1,000 1 Lubrication points Grease lubrication points (→ Page 123); (→ Page 120). W1053

QL1 1,000 2 Engine mounting Check buffer clearance of resilient mounts; check securing screws W1026
for secure seating (→ Page 166).

QL1 4,000 - Suction device Check operation (→ Page 164). W1144

QL1 4,000 - Fuel injectors Fuel injection nozzles: Replace hole-type nozzle (→ Page 98). W1017

QL3 4,000 - Raw water pump Inspect parts, replace rotary seal and seals (→Workshop Manual). W1143

QL3 4,000 - Engine coolant pump Check parts, replace rotary seal(s) and seals (→Workshop Manual). W1142

QL1 4,000 2 Air filter Replace air filter (→ Page 117). W1005

QL3 7,000 - Exhaust turbocharger Overhaul exhaust turbocharger (→Workshop Manual). W1038

QL3 7,000 - ETC control Overhaul exhaust-flow control flaps, air-flow control flaps, actuating W1131
cylinders and solenoid valves (→Workshop Manual).

QL3 7,000 - Injection pump swing Check tappets and rollers (visual inspection) (→Workshop Manual). W1145
followers

MS15017/00E 06-11 © MTU


Maintenance 49

Qual- Interval Item Maintenance tasks Task


ifica- Code
tion [hours] [a]

QL3 7,000 - Component maintenance Prior to maintenance work, carry out measuring run, record engine W2012
parameters, drain coolant and flush coolant circuits (→Workshop
Manual).

Clean air ducting (→Workshop Manual). W2002

Check centrifugal oil filter for wear (if fitted) (→Workshop Manual). W2009

Check engine alignment (→Workshop Manual). W2036

Coolant thermostat: Replace thermal actuator (→Workshop Manual). W2038

Clean supplementary engine oil tank, check seals and pipes (if fitted) W2040
(→Workshop Manual).

Starting-air distributor: Check components and adjustment, readjust if W2041


necessary (→Workshop Manual).

Fuel thermostat (if fitted): Replace thermal actuator (→Workshop W2043


Manual).

Exhaust system: Check condition of insulation (→Workshop Manual). W2064

Disassemble coolant cooler, clean, leak-test (→Workshop Manual). W2068

Check function of monitoring devices (→Workshop Manual). W2069

Flexible pipe connections: Check for porosity, replace as necessary W2082


(→Workshop Manual).

Check rocker arms, roller tappets, pushrods and pushrod ball heads W2084
for wear (→Workshop Manual).

Clean starting-air pipework and check for leaks (→Workshop Manual). W2088

Replace fuel injection pumps (→Workshop Manual ). W2095

Renew sealing material of all disassembled components (→Workshop W2062


Manual).

Remove and inspect piston crowns, replace piston rings (→Workshop W2127
Manual).

QL3 7,000 - Intercooler Clean intercooler and leak-test (→Workshop Manual). W1133

QL3 7,000 - Charge-air preheater Clean charge-air preheater and leak-test (→Workshop Manual). W1137

QL3 7,000 - Charge-air preheater Remove control valve, clean and inspect, fit new seals (→Workshop W1136
Manual).

QL3 7,000 - Cylinder head Overhaul cylinder heads, visually inspect piston crowns and running W1063
pattern of cylinder liners (→Workshop Manual).

QL3 7,000 - Cylinder liners Check cylinder liners for polished areas, re-hone or replace as W1212
necessary (→Workshop Manual).

QL3 10,500 - Engine oil thermostat Replace oil thermostat (→Workshop Manual). W1128

QL3 10,500 - Conrod bearings Replace conrod bearings (→Workshop Manual). W1083

QL3 10,500 - Governor actuator Check control linkage (→Workshop Manual). W1148

QL4 21,000 18 Extended component Perform complete engine disassembly. Check engine components W3000
maintenance according to assembly instructions, recondition or replace as
necessary (→Workshop Manual).

Replace all elastomer parts and seals (→Workshop Manual). W3001

Replace crankshaft bearings (→Workshop Manual). W3004

MS15017/00E 06-11 © MTU


50 Maintenance

Qual- Interval Item Maintenance tasks Task


ifica- Code
tion [hours] [a]

Replace camshaft bearings and camshaft thrust bearings W3018


(→Workshop Manual).

Replace engine oil pump (→Workshop Manual). W3073

MS15017/00E 06-11 © MTU


Troubleshooting 51

6 Troubleshooting

6.1 Troubleshooting
Engine does not turn when starter is actuated

Component Probable Cause Task

Battery Low or defective Charge or replace (see manufacturer’s


documentation).

Cable connections defective Check whether cable connections are


properly secured (see manufacturer’s
documentation).

Compressed-air supply Lack of compressed air 1. Check compressed-air supply;


2. Contact Service.

Starter Starter defective Contact Service.

Engine wiring Defective Check (→ Page 167).

LOP Secure seating of assemblies or Perform visual inspection.


connectors not provided

Engine Blocked (engine cannot be barred Contact Service.


manually)

Start-interlock limit switch Limit switch not installed 1. Check if limit switch is installed
(→ Page 177);
Limit switch defective 2. Fit new limit switch.

Wiring defective Check wiring (→ Page 167).

MS15017/00E 06-11 © MTU


52 Troubleshooting

Engine turns but does not fire

Component Probable Cause Task

Starter Poor rotation by starter: 1. Check compressed-air supply;


2. Contact Service.

Engine wiring Defective Check (→ Page 167).

Fuel system Not vented Vent fuel system (→ Page 104).

Fuel prefilter clogged Replace fuel prefilter (→ Page 112)


.

Fuel filter clogged Replace fuel filter (→ Page 105)


.

Non-return valve defective Contact Service.

Fuel line leaking Perform visual inspection.

Fuel supply closed Open fuel supply.

ECS Defective Contact Service.

Governor actuator Defective Contact Service.

Engine fires unevenly

Component Probable Cause Task

Fuel injection equipment Injector defective Replace (→ Page 98).

Injection pump defective Contact Service.

Engine wiring Defective Check (→ Page 167).

Fuel system Not vented Vent fuel system (→ Page 104).

Fuel supply closed Open fuel supply.

Fuel line leaking Perform visual inspection.

Fuel prefilter clogged Replace fuel prefilter (→ Page 112)


.

Fuel filter clogged Replace fuel filter (→ Page 105)


.

MS15017/00E 06-11 © MTU


Troubleshooting 53

Engine does not reach full-load speed

Component Probable Cause Task

Fuel supply Shut off Open shut-off valve before fuel prefilter
completely.

Fuel prefilter clogged Replace (→ Page 112).

Fuel filter clogged Replace (→ Page 105).

Non-return valve defective Contact Service.

Not vented Vent fuel system (→ Page 104).

Fuel line leaking Perform visual inspection.

Air supply Air filter clogged Service indicator - signal ring position check
(→ Page 119).

Exhaust turbocharger control Check function of actuating cylinders


(→ Page 124).

Exhaust turbochargers Perform visual inspection.


contaminated or damaged

Air supply line leaky Perform visual inspection.

Charge-air temperature Intercooler contaminated. 1. Perform visual inspection;


2. Clean drain line; (→ Page 115)
3. Contact Service.

Raw-water pressure present Perform visual inspection.

Raw-water valve open Perform visual inspection.

Fuel injection equipment Injector defective Replace (→ Page 98).

Injection pump defective Contact Service.

Start of delivery of fuel injection Contact Service.


pump

Engine control Engine governor in ECS Contact Service.

Governor actuator Contact Service.

Compression pressure Valve clearance Check and adjust valve clearance


(→ Page 89).

Cylinder head seal defective Contact Service.

Vessel Overloaded Contact Service.

Excessive weight Check vessel’s loading condition;


Reduce load.

Vessel’s trim position Trim vessel.

Marine growth on hull, propeller Clean.


shaft, propeller, rudder

MS15017/00E 06-11 © MTU


54 Troubleshooting

Component Probable Cause Task

Rudder Rudder position Align rudder.

Propeller After propeller replacement: Change.


Propeller is too big.

Engine speed not steady

Component Probable Cause Task

Fuel injection equipment Injector defective Replace (→ Page 98).

Injection pump defective Contact Service.

Fuel system Not vented Vent fuel system (→ Page 104).

ECU Defective Contact Service.

Charge-air temperature too high

Component Probable Cause Task

Engine coolant Incorrect coolant concentration Check (→ Page 161).

Intercooler Contaminated Contact Service.

Engine room Air-intake temperature too high Check fans;


Check air supply / ventilation ducts.

Charge air pressure too low

Component Probable Cause Task

Air supply Air filter clogged Clean filter element (→ Page 116)

Exhaust turbocharger control Check function of actuating cylinders


(→ Page 124).

Intercooler Contaminated Contact Service.

Exhaust turbocharger Defective Contact Service.

Coolant leaks on intercooler

Component Probable Cause Task

Intercooler Leaking, major coolant discharge Contact Service.

MS15017/00E 06-11 © MTU


Troubleshooting 55

Exhaust gas black

Component Probable Cause Task

Air supply Air filter clogged Clean filter element (→ Page 116).

Exhaust turbocharger control Check function of actuating cylinders


(→ Page 124).

Fuel injection equipment Injector defective Check (→ Page 93).

Injection pump defective Contact Service.

Exhaust system Exhaust backpressure Contact Service.

Exhaust pipes, exhaust silencer Contact Service.


contaminated

Exhaust flap control linkage Contact Service.


defective

Compression pressure Valve clearance Adjust valve clearance (→ Page 89).

Valve Worn: Contact Service.

Compression ring Worn: Contact Service.

Vessel Overloaded Contact Service.

Exhaust gas blue

Component Probable Cause Task

Engine oil Too much oil in engine Check engine oil level (→ Page 132).

Exhaust turbocharger Defective Contact Service.


Cylinder head
Piston rings
Cylinder liner Crankcase
breather Valve-stem seal Oil
control ring Valve guide

Exhaust gas white

Component Probable Cause Task

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

Fuel system Water in fuel Drain fuel prefilter (→ Page 108).

Combustion chamber Water ingress in cylinder head. Check cylinder liner for tightness; Contact
Service.

Fuel injection equipment Injector defective Replace (→ Page 98).

Charge-air preheating unit Solenoid and control valve Contact Service.

Intercooler Leaking Contact Service.

MS15017/00E 06-11 © MTU


56 Troubleshooting

Exhaust temperature too high

Component Probable Cause Task

Air supply Air filter clogged Clean filter element (→ Page 116).

Exhaust turbocharger control Check function of actuating cylinders


(→ Page 124).

Charge-air temperature too high, intercooler contaminated Contact Service.

Exhaust system after exhaust Exhaust backpressure Contact Service.


turbochargers
Exhaust pipe, exhaust silencer Contact Service.
contaminated. Exhaust flap
control linkage defective

Fuel injection equipment Injector defective Replace (→ Page 98).

Injection pump defective Contact Service.

Exhaust temperature too low

Component Probable Cause Task

Combustion: Fuel is not fully Injector Replace (→ Page 98).


combusted in the cylinder
Injection pump defective Contact Service:

Starting-air pressure too low

Component Probable Cause Task

Starting system Shut-off valves closed Open shut-off valves.

Starting-air system leaking. Check the following components for leaks:


• Compressed-air tank;
• Compressed-air lines.

Coolant temperature too high

Component Probable Cause Task

Cooling system Engine coolant level Check level (→ Page 156).

Coolant thermostat defective Contact Service.

Coolant circuit contaminated Contact Service.

Vent line contaminated Check for obstructions (→ Page 154).

Coolant temperature Temperature sensor Contact Service.


monitoring

MS15017/00E 06-11 © MTU


Troubleshooting 57

Coolant temperature too low

Component Probable Cause Task

Cooling system Coolant thermostat defective Contact Service.

Preheating temperature too low Set temperature at coolant preheating unit.

Coolant temperature Temperature sensor Contact Service.


monitoring

Engine oil pressure rises

Component Probable Cause Task

Engine oil pressure relief valve Pressure relief valve defective Contact Service.
(opening pressure)

Engine oil monitoring Remote pressure sensor Contact Service.

Engine oil pressure too low

Component Probable Cause Task

Engine oil Engine oil level too low Check engine oil level (→ Page 132).

External lines leaking Visual inspection

Engine oil pressure relief valve Pressure relief valve defective Contact Service.
(opening pressure)

Engine oil filter Engine oil filter element clogged Replace (→ Page 140).

Engine oil monitoring Pressure sensor Contact Service.

Engine oil pump Pump drive defective Contact Service.

Engine oil temperature too high

Component Probable Cause Task

Engine oil heat exchanger Engine oil heat exchanger Contact Service.
contaminated

Engine oil temperature Temperature sensor, remote Contact Service.


monitoring thermometer defective

MS15017/00E 06-11 © MTU


58 Troubleshooting

Piston cooling pressure too low

Component Probable Cause Task

Engine oil Engine oil level too low Check engine oil level (→ Page 132).

External lines leaking Visual inspection

Engine oil diluted with fuel Engine-oil sample extraction and analysis
(→ Page 135).

Engine oil filter Piston cooling-oil filter clogged Replace (→ Page 142).

Engine oil temperature Temperature transmitter, remote Contact Service.


monitoring thermometer defective

Fuel delivery pump Fuel delivery pump and pump Contact Service.
drive defective

Fuel pressure monitoring Pressure transmitter defective Contact Service.

Priming oil pressure is not attained

Component Probable Cause Task

Engine oil Engine oil level too low Check engine oil level (→ Page 132).

External lines leaking Visual inspection

Disk-pack filter clogged Clean filter (→ Page 138).

Oil priming system Not cut in Open shut-off cock.

Oil priming pump Oil priming pump not running. 1. Check power supply;
2. Perform functional test (→ Page 38).

Engine oil temperature Temperature transmitter, remote Contact Service.


monitoring thermometer defective

Fuel delivery pump Fuel delivery pump and pump Contact Service.
drive defective

Fuel pressure monitoring Pressure transmitter defective Contact Service.

Fuel in leak-fuel tank

Component Probable Cause Task

Fuel line Fuel in leak-off fuel tank, fuel lines Empty leak-fuel tank (→ Page 103).
leaking

Leak-fuel monitoring Leak-fuel indicator defective Contact Service.

MS15017/00E 06-11 © MTU


Troubleshooting 59

Low fuel pressure

Component Probable Cause Task

Fuel system Fuel lines leaking 1. Perform visual inspection.


2. Contact Service.

Trip pressure of non-return valve Contact Service.

Fuel prefilter clogged Replace (→ Page 112).

Fuel filter clogged Replace (→ Page 105).

Fuel delivery pump Fuel delivery pump and pump Contact Service.
drive defective

Fuel pressure monitoring Pressure sensor defective Contact Service.

MS15017/00E 06-11 © MTU


60 Troubleshooting

6.2 Fault indication and fault messages


General
Depending on the design status of the system, faults are indicated as follows:
• Audible alarm
• Visible alarm
• Clear-text fault messages
• ECS LEDs
Fault indication – ECS LED indications

No. Color Meaning

1 Red OFF:
• normal operation,
no reset.
PERMANENTLY LIT:
• Assembly is in reset condition
→ Switch ECS off and on;
→ Operation can be continued with
Backup ECS, if LED on Main ECS is
permanently lit;
→ Operation can be continued with
Main ECS, if LED on Backup ECS is
permanently lit;

Contact Service.

MS15017/00E 06-11 © MTU


Troubleshooting 61

No. Color Meaning

2 Green FLASHING:
• Normal operation, rapid flashing when
program is running
OFF or PERMANENTLY LIT:
• ECS faulty
→ Switch ECS off and on;
→ Operation can be continued with
Backup ECS, if LED on Main ECS is
off ot permanently lit;
→ Operation can be continued with
Main ECS, if LED on Backup ECS is
off or permanently lit;

Contact Service.

3 Red/Green GREEN:
• Normal operation,
operating voltage present and ECS
switched on.
RED:
• Operating voltage available, ECS is
internally in power-off status
Key switch (order-specific) is in OFF
position.
OFF:
• No operating voltage available
→ Check supply voltage.

4 - Backup ECS

5 - Main ECS

MS15017/00E 06-11 © MTU


62 Troubleshooting

Fault messages on the LOP and on the ECS

No. Meaning

1 Text message.
• New messages are inserted in the first line.

2 Number of fault message (F = fault)

3 Number of fault group

4 Sequential fault number (SN = sequential number).

5 Total number of registered faults.

6 M = Message from Main ECS


B: = Message from Backup ECS

Alarms can also be caused by defective sensors / actuators. If troubleshooting in accordance with the following
table is not successful, contact Service to have the sensors / actuators checked and, if required, replaced.

Fault code Alarm text Cause of fault Task

0 Internal message (not visible) -

1 Internal message (not visible) -

2 Internal message (not visible) -

3 AL LOP NOT READY Data transmission from/to 1. Check wiring


LOP faulty. (→ Page 167);
Remote control mode: No 2. Contact Service.
consequence.
Local mode: Engine
continues running at set
speed. Emergency stop,
external stop is possible.
Automatic change-over to
remote control mode after
engine shutdown

4 Internal message (not visible) -

MS15017/00E 06-11 © MTU


Troubleshooting 63

Fault code Alarm text Cause of fault Task

5 MG P-CONTROL AIR Control air pressure too low 1. Check compressed-air


LOW at starting, warning supply;
2. Check pressure-reducing
station (→ Page 125);
Contact Service.

6 MG P-PRIMING LOW Priming oil pressure too low, 1. Check selector switch
fault message during starting position on oil priming
sequence pump (→ Page 30);
2. Check direction of
rotation of oil priming
pump (→ Page 137);
Contact Service.

7 MG P-START AIR Starting-air pressure too low, 1. Check compressed-air


LOW engine cannot be started. supply;
2. Check pressure-reducing
station (→ Page 125);
Contact Service.

8 MG START SPEED Engine does not reach 1. Note further alarms;


LOW starting speed, fault message 2. Contact Service.
during starting sequence

9 MG RUNUP SPEED Engine does not reach runup 1. Note further alarms;
LOW speed, fault message during 2. Contact Service.
starting sequence

10 MG IDLE SPEED. Engine does not reach idling 1. Note further alarms;
LOW speed, fault message during 2. Contact Service.
starting sequence

11 AL SDAF CLOSED Emergency air shut-off flaps Open emergency air shut-off
closed flaps manually.

12 AL CYL.CUTOUT DEF. Cylinder cutout valve Contact Service.


activation faulty

13 MG PREHEAT LOW Engine coolant preheating Preheat engine.


temperature too low, fault
message during starting
sequence

14 AL ENGAGE ERROR Engagement procedure not 1. Observe engagement


completed window;
2. (→Gearbox
documentation).

15 AL DISENGAGE Disengagement procedure 1. Observe engagement


ERROR not completed window;
2. (→Gearbox
documentation).

16 AL ETC CUTIN FAULT ETC fault Note further alarms.

17 Not used

18 AL ETC SPEED LIMIT ETC overspeed, reduction or Reduce power.


rapid de-energization of the
fuel rack is initiated

MS15017/00E 06-11 © MTU


64 Troubleshooting

Fault code Alarm text Cause of fault Task

19 MG START External engine start Check start conditions.


INTERLOCK interlock

20 AL SDAF CTRL. DEF. Control of emergency air 1. Check wiring


shut-off flaps faulty (→ Page 167);
2. Check fuses;
3. Contact Service.

21 AL FUEL RACK Incorrect injection amount. 1. Check wiring


BINDING Fuel rack does not move (→ Page 167);
freely, excessive power 2. Contact Service.
consumption of actuator
solenoid

22 SS OVERSPEED Engine shut down by Note further alarms.


emergency air shut-off flaps.
Safety shutdown in case of
overspeeding or overspeed
test.

23 MG EXT. ENGINE Stop input of ECS activated. Note further alarms.


STOP Engine shutdown. The fault If the shutdown was not
message is also issued when initiated by the remote control
the engine is stopped by the system, the cause of the fault
remote control system. If the leading to a shutdown must
engine was not stopped by be determined with the help of
the remote control system, e.g. external monitoring units.
restarting is impossible
until the fault leading to the
shutdown has been rectified.

24 MG F.RACK POS. FAIL Incorrect injection amount. 1. Check wiring


Governor test fault: (→ Page 167);
2. Contact Service.
The actuator has not reached
the intended position during
the "start fuel test".

25 Not used

26 AL ETC SPEED A1 Speed signal from active 1. Check wiring


ETC A1 missing. (→ Page 167);
2. Contact Service.

27 AL ETC SPEED A2 Speed signal from active 1. Check wiring


ETC A2 missing. (→ Page 167);
2. Contact Service.

28 AL ETC SPEED B1 Speed signal from active 1. Check wiring


ETC B1 missing. (→ Page 167);
2. Contact Service.

29 AL ETC SPEED B2 Speed signal from active 1. Check wiring


ETC B2 missing. (→ Page 167);
2. Contact Service.

30 AL ETC SPEED B3 Speed signal from active 1. Check wiring


ETC B3 missing. (→ Page 167);
2. Contact Service.

31 Not used

MS15017/00E 06-11 © MTU


Troubleshooting 65

Fault code Alarm text Cause of fault Task

32 SD P-GEAR CONTR. Gear control pressure sensor 1. Check wiring


OIL fault: (→ Page 167);
No signal or signal 2. Contact Service.
implausibe.

33 SD P-GEAR LUBE OIL Gear lube oil pressure sensor 1. Check wiring
fault: (→ Page 167);
No signal or signal 2. Contact Service.
implausibe.

34 SD P-PISTON COOL. Piston-cooling oil pressure 1. Check wiring


OIL sensor fault: (→ Page 167);
No signal or signal 2. Contact Service.
implausibe.

35 SD P-CHARGE AIR Charge-air pressure sensor 1. Check wiring


fault: (→ Page 167);
No signal or signal 2. Contact Service.
implausibe.

36 SD P-LUBE OIL ETC ETC lube oil pressure sensor 1. Check wiring
fault: (→ Page 167);
No signal or signal 2. Contact Service.
implausible.

37 SD P-LUBE OIL Lube oil pressure sensor 1. Check wiring


fault: (→ Page 167);
No signal or signal 2. Contact Service.
implausibe.

38 SD P-STAR AIR Start air pressure sensor 1. Check wiring


fault: (→ Page 167);
No signal or signal 2. Contact Service.
implausibe.

39 SD P-CONTROL AIR Control air pressure sensor 1. Check wiring


fault: (→ Page 167);
No signal or signal 2. Contact Service.
implausibe.

40 SD FUEL RACK 1 Control rack travel sensor 1. Check wiring


(Main ECS) fault: (→ Page 167);
No signal or signal 2. Contact Service.
implausibe.

41 SD T-INTAKE AIR Intake air temperature sensor Check wiring (→ Page 167).
fault:
No signal or signal
implausibe.

42 SD T-FUEL Fuel temperature sensor 1. Check wiring


fault: (→ Page 167);
No signal or signal 2. Contact Service.
implausibe.

MS15017/00E 06-11 © MTU


66 Troubleshooting

Fault code Alarm text Cause of fault Task

43 SD T-COOLANT Coolant temperature sensor 1. Check wiring


fault: (→ Page 167);
No signal or signal 2. Contact Service.
implausibe.

44 SD T-LUBE OIL Lube oil temperature sensor 1. Check wiring


fault: (→ Page 167);
No signal or signal 2. Contact Service.
implausibe.

45 SD T-RAW WATER Raw water temperature 1. Check wiring


INLET sensor fault: (→ Page 167);
No signal or signal 2. Contact Service.
implausibe.

46 SD ENGINE SPEED Engine speed sensor failure 1. Check wiring


Loss of redundancy, (→ Page 167);
change-over to ECS 2. Contact Service.

47 HI T-FUEL Fuel temperature too high 1. Reduce power;


Warning 2. Contact Service.

48 SS EMERGENCY Engine shut down by Note further alarms.


STOP emergency air shut-off flaps.
Emergency stop by
engine overspeeding or
"EMERGENCY STOP"
button pressed on LOP or
on Monitoring and Control
System or fuel rack jamming

49 AL ECS-SS TRANS. Internal data transfer Contact Service.


DEF between Main and Backup
ECS faulty

50 LO P-GEAR CONTR. Gear control oil pressure too Contact Service.


OIL low
Warning and disengagement

51 LO P-GEAR LUBE OIL Gear lube oil pressure too Contact Service.
low
Warning at p < plimit curve 1
Shutdown at p < plimit curve
2

52 LO P-PISTON COOL. Piston cooling oil pressure 1. Check oil level;


OIL too low (→ Page 132);
2. Replace piston cooling-oil
filter (→ Page 142);
3. Contact Service.

53 LO P-CHARGE AIR Charge air pressure too low Contact Service.

54 LO P-LUBE OIL ETC ETC lube oil pressure too low Contact Service.

55 LO P-LUBE OIL Oil pressure before last Contact Service.


L.BEAR. bearing too low
Warning at p < plimit curve 1

MS15017/00E 06-11 © MTU


Troubleshooting 67

Fault code Alarm text Cause of fault Task

56 LO P-STAR AIR Starting-air pressure too low 1. Check compressed-air


Warning at p < pLimit 1 supply;
2. Check pressure-reducing
No start possible if p < pLimit
station (→ Page 125);
2
Contact Service.

57 HI T-COOLANT Engine coolant temperature 1. Reduce power;


too high 2. Check coolant level
Warning at T > TLimit 1 (→ Page 156);
3. Contact Service.
Shutdown at T > TLimit 2

58 HI T-LUBE OIL Engine oil temperature too 1. Reduce power;


high 2. Check oil level;
Warning at T > TLimit 1 (→ Page 132);
3. Contact Service.
Shutdown at T > TLimit 2
(configurable)

59 LO POWER SUPPLY Supply voltage too low Check supply voltage.


Warning at U < ULimit 1

60 HI POWER SUPPLY Supply voltage too high Check supply voltage.


Warning at U ULimit 2

61 HI T-ECS Temperature in ECS too high Note temperature readings.


ELECTRONIC Warning at T > TLimit 1

62 Not used

63 Internal message (not visible) -

64 AL SECOND ECS One ECS is faulty If alarm comes from Main


FAILED Failure of one ECS or faulty ECS: Check Backup ECS,
communication between the if alarm comes from Backup
ECS assemblies ECS: Check Main ECS.

65 MG BU-ECS IN Backup ECS in operation Note further alarms.


OPERAT. Causes: Try to switch over to Main ECS
• Manual change-over manually.
• Faulty communication
Main - Backup ECS
• Speed sensor Sys. I
and Sys. II (Main) faulty
• Fuel rack position
sensor Sys. I defective

66 SS SECURITY Safety shutdown of the Note further alarms on LOP.


C.ACTIVE engine
Inadmissible engine
operating values have
led to shutdown

MS15017/00E 06-11 © MTU


68 Troubleshooting

Fault code Alarm text Cause of fault Task

67 AL OVERRIDE Safety system switched off -


ACTIVE Override function activated
• Engine can be operated
with critical operating
values.
• Possible shutdown
causes are suppressed,
fault messages,
however, are displayed.

68 AL TC CONTROL Fault in charge-air preheater Contact Service.


DEFECT control

69 HI T-INTAKE AIR Intake air temperature too Contact Service.


high

70 AL MEMORY DEFECT Fault in ECS memory 1. Contact Service.


• If alarm comes from
Main ECS, fit new
Main ECS.

71 AL A/D CONVERTER A/D converter fault 1. Contact Service.


DEF • If alarm comes from
Main ECS, fit new
Main ECS.

72 AL SUBPROCESSOR I/O processor fault 1. Contact Service.


DEF. System reset • If alarm comes from
Main ECS, fit new
Main ECS.

73 AL CTRL. ETC A1 ETC control A1 faulty Contact Service.


DEF.

74 AL CTRL. ETC A2 ETC control A2 faulty Contact Service.


DEF.

75 AL CTRL. ETC B1 ETC control B1 faulty Contact Service.


DEF.

76 AL CTRL. ETC B2 ETC control B2 faulty Contact Service.


DEF.

77 AL BINARY OUT Binary output channel faulty Note further alarms.


DEFECT

78 AL EDM FAILURE Engine data not available or 1. Contact Service.


invalid • If alarm comes from
Main ECS, fit new
Main ECS.

79 AL ECS System error 1. Switch ECS off and on;


PROC.OVERLOAD 2. Contact Service.
• If alarm comes from
Main ECS, fit new
Main ECS.

80 AL PROC. FORK Number of processes Contact Service.


ERROR running deviates from
the configured number of
processes

MS15017/00E 06-11 © MTU


Troubleshooting 69

Fault code Alarm text Cause of fault Task

81 SD T-CHARGE AIR Charge-air temperature 1. Check wiring


sensor fault: (→ Page 167);
No signal or signal 2. Contact Service.
implausibe.

82 HI T-CHARGE AIR Charge-air temperature too 1. Check engine-room


high temperature;
Warning at T > TLimit 1 2. Check raw-water circuit;
3. Contact Service.

83 SD P-COOLANT Coolant temperature sensor 1. Check wiring


fault: (→ Page 167);
No signal or signal 2. Contact Service.
implausibe.

84 LO P-COOLANT Low coolant pressure Contact Service.


Warning at p < pLimit 1
Shutdown at p < pLimit 2

85 MG COLD START Request to carry out cold Carry out cold start.
REQUIRED start to start the engine

86 MG PUSH START Engine start enabled -


AGAIN

87 MG ENGAGE TEMP. Temperature too low for 1. Reduce power;


LOW engagement 2. Contact Service.

88 MG MR2 ILLEGAL Inadmissible data request by 1. Contact Service.


REQU. operational data recorder • Check operational
data recorder.

89 MG BDR NOT No data received from the 1. Contact Service.


AVAILABLE operational data recorder • Check transmission
path and operational
data recorder.

90 AL SDAF ACTUAT. Emergency air shut-down Contact Service.


FAIL flaps have been activated but
do not close within a defined
time period

91 MD COLDST. Cold start has been initiated -


ACTIVATED automatically, TK (coolant
temperature) < TK_Limit 1

92 MG INJECTION LIMIT Fuel limitation is active, -


speed is below the limit

93 Not used

94 Not used

95 Not used

96 Not used

97 Not used

98 Not used

MS15017/00E 06-11 © MTU


70 Troubleshooting

Fault code Alarm text Cause of fault Task

99 SD P-RAW WATER Raw-water pressure sensor 1. Check wiring


fault: (→ Page 167);
No signal or signal 2. Contact Service.
implausibe.

100 LO P-RAW WATER Raw water pressure too low Contact Service.
Warning

101 SD P-LUBE OIL B.FILT Lube oil pressure before 1. Check wiring
filter, sensor fault. (→ Page 167);
2. Contact Service.

102 LO P-LUBE OIL B.FILT Lube oil pressure before filter 1. Check wiring
too low (→ Page 167);
2. Contact Service.

103 SD P-FUEL A. FILTER Fuel pressure after filter, 1. Check wiring


sensor fault: (→ Page 167);
No signal or signal 2. Contact Service.
implausibe.

104 LO P-FUEL A. FILTER Fuel pressure after filter too Contact Service.
low
Warning

105 HI P-FUEL F. DIFF. Fuel filter differential Contact Service.


pressure too high

106 HI P-LUBE OIL F. DIFF Oil filter differential pressure Contact Service.
too high

107 SD P-LUBE OIL A.FILT Lube oil pressure after filter, 1. Check wiring
sensor fault: (→ Page 167);
No signal or signal 2. Contact Service.
implausibe.

108 LO P-LUBE OIL A.FILT Lube oil pressure after filter 1. Check wiring
too low (→ Page 167);
Warning at p < pLimit 1 2. Contact Service.

109 LO COOLANT LEVEL Engine coolant level too low Contact Service.
1 Safety shutdown can be
initiated (configurable)

110 TD P-LUBE OIL Deviation between values Contact Service.


from first and second lube oil
pressure sensors

111 TD T-COOLANT Deviation between values Contact Service.


from first and second coolant
temperature sensors

112 TD P-PISTON Deviation between values Contact Service.


COOL.OIL from first and second piston
cooling oil pressure sensors

113 TD P-COOLANT Deviation between values Contact Service.


from first and second coolant
pressure sensors

MS15017/00E 06-11 © MTU


Troubleshooting 71

Fault code Alarm text Cause of fault Task

114 AL ACTUATOR Governor actuator function 1. Check wiring


DEFECT impaired. (→ Page 167);
Overcurrent detection. 2. Contact Service.

115 AL CTRL. ETC ETC lubrication control faulty Contact Service.


LUB.DEF.

116 SD SPEED DEMAND No external speed setpoint 1. Check wiring


input or (→ Page 167);
signal implausible. 2. Contact Service.

117 LO P-CONTROL AIR Control air pressure too low. Contact Service.
Warning if a limit value is
undershot.

118 AL PRIMING Oil priming control faulty 1. Check wiring


CTRL.FAIL (→ Page 167);
2. Contact Service.

119 AL START VALVE Start air valve or control 1. Check wiring


DEF. faulty (→ Page 167).;
2. Contact Service.

120 Not used

121 Not used

122 AL EEPROM EEPROM write error (dialog Contact Service.


FAIL.DIAL. mode)

123 AL EEPROM EEPROM write error (fault Contact Service.


FAIL.ERREC recorder)

124 AL EEPROM EEPROM write error (ECS) Leak-off-fuel tank


FAIL.STORE

125 HI T-RAW WATER Raw water temperature too 1. Reduce power;


INLET high 2. Check vent line
Warning at T > TLimit 1 (→ Page 154).

126 Not used

127 Not used

128 Not used

129 HI LEAK. FUEL LEVEL Level in leak fuel tank too Empty leak fuel tank
high (→ Page 103).

130 LO LUB.OIL TANK Oil level in tank of oil Contact Service.


LEV. replenishment unit too low

131 SD T- EXHAUST BULK Exhaust bulk temperature 1. Check wiring


T1 sensor 1 faulty: (→ Page 167);
No signal or signal 2. Contact Service.
implausibe.

132 HI T-EXHAUST BULK Exhaust bulk temperature Contact Service.


T1 too high

MS15017/00E 06-11 © MTU


72 Troubleshooting

Fault code Alarm text Cause of fault Task

133 AL EMERG. POWER Power supply failure Contact Service.


FAIL.

134 AL OVERSPEED ETC ETC speed too high Contact Service.


A1 ETC speed nETC > nLimit 1
Reduction of fuel injection;
ETC speed nETC > nLimit 2
Rapid retraction of fuel
control rack

135 AL OVERSPEED ETC ETC speed too high Contact Service.


A2 ETC speed nETC > nLimit 1
Reduction of fuel injection;
ETC speed nETC > nLimit 2
Rapid retraction of fuel
control rack

136 AL OVERSPEED ETC ETC speed too high Contact Service.


B1 ETC speed nETC > nLimit 1
Reduction of fuel injection;
ETC speed nETC > nLimit 2
Rapid retraction of fuel
control rack

137 AL OVERSPEED ETC ETC speed too high Contact Service.


B2 ETC speed nETC > nLimit 1
Reduction of fuel injection;
ETC speed nETC > nLimit 2
Rapid retraction of fuel
control rack

138 AL OVERSPEED ETC ETC speed too high, ETC Contact Service.
B3 speed nETC > nLimit 1,
reduction of fuel injection,
ETC speed nETC > nLimit 2,
rapid retraction of fuel control
rack

139 Not used

140 AL SPEED DEV.ETC ETC running too fast or too Contact Service.
A1 slow, ETC speed deviation

141 AL SPEED DEV.ETC ETC running too fast or too Contact Service.
A2 slow, ETC speed deviation

142 AL SPEED DEV.ETC ETC running too fast or too Contact Service.
B1 slow, ETC speed deviation

143 AL SPEED DEV.ETC ETC running too fast or too Contact Service.
B2 slow, ETC speed deviation

144 AL SPEED DEV.ETC ETC running too fast or too Contact Service.
B3 slow, ETC speed deviation

145 Not used

MS15017/00E 06-11 © MTU


Troubleshooting 73

Fault code Alarm text Cause of fault Task

146 HI IDLE SPEED ETC Cut-out ETC A1 running at Contact Service.


A1 excessive idle speed, the
ETC is cut in

147 HI IDLE SPEED ETC Cut-out ETC A2 running at Contact Service.


A2 excessive idle speed, the
ETC is cut in

148 HI IDLE SPEED ETC Cut-out ETC B1 running at Contact Service.


B1 excessive idle speed, the
ETC is cut in

149 HI IDLE SPEED ETC Cut-out ETC B2 running at Contact Service.


B2 excessive idle speed, the
ETC is cut in

150 HI IDLE SPEED ETC Cut-out ETC B3 running at Contact Service.


B3 excessive idle speed, the
ETC is cut in

151 Not used

152 SD FUEL RACK POS.2 Fuel rack position sensor of 1. Check wiring
system 2 faulty: No signal or (→ Page 167);
signal implausibe. 2. Contact Service.

153 TD FUEL RACK POS. Different measured values Contact Service.


from the two fuel rack
position sensors

154 AL REVERSE POWER Engine driven externally

155 AL COLD START Cold start equipment faulty 1. Check wiring


DEFECT (→ Page 167);
2. Contact Service.

156 AL ETC CONTROL ETC control faulty 1. Check wiring


DEF. (→ Page 167);
2. Contact Service.

157 AL ETC JOB ETC configuration changed


ROTATION due to fault

158 AL MCS-4 DATA MCS faulty Contact Service.


FAULTY

159 SD T-GEAR OIL Gear lube oil temperature 1. Check wiring


sensor fault: No signal or (→ Page 167);
signal implausible 2. Contact Service.

160 AL MCS NOT READY Data transmission to MCS 1. Switch ECS off and on;
faulty 2. Contact Service.

161 SD T-EXHAUST A1 Exhaust temperature sensor 1. Check wiring


faulty (→ Page 167);
2. Contact Service.

162 SD T-EXHAUST A2 Contact Service.

MS15017/00E 06-11 © MTU


74 Troubleshooting

Fault code Alarm text Cause of fault Task

163 SD T-EXHAUST A3 The exhaust gas temperature 1. Reduce power;


of the cylinder is out of the 2. Contact Service.
164 SD T-EXHAUST A4 admissible range
165 SD T-EXHAUST A5

166 SD T-EXHAUST A6

167 SD T-EXHAUST A7

168 SD T-EXHAUST A8

169 SD T-EXHAUST A9

170 SD T-EXHAUST A10

171 SD T-EXHAUST B1

172 SD T-EXHAUST B2

173 SD T-EXHAUST B3

174 SD T-EXHAUST B4

175 SD T-EXHAUST B5

176 SD T-EXHAUST B6

177 SD T-EXHAUST B7

178 SD T-EXHAUST B8

179 SD T-EXHAUST B9

180 SD T-EXHAUST B10

181 AL MCS-ECS NOT ECS receiving no data from 1. Check wiring


READY MCS/ECS (→ Page 167);
2. Contact Service.

182 SD SHAFT SPEED No signal from shaft speed 1. Check wiring


SYS.1 sensor, system 1 (→ Page 167);
2. Contact Service.

183 SD SHAFT SPEED No signal from shaft speed 1. Check wiring


SYS.2 sensor, system 2 (→ Page 167);
2. Contact Service.

184 Not used

185 Not used

186 SD P-OIL A.NIV.PUMP Oil pressure sensor after 1. Check wiring


oil-level regulating pump (→ Page 167);
faulty: No signal or signal 2. Contact Service.
implausibe.

187 LO P-OIL A.NIV.PUMP Oil pressure after oil-level 1. Check oil level;
regulating pump too low, (→ Page 132);
warning at p < pLimit 1 2. Contact Service.

188 SD LOAD PULSE, Load pulse sensor faulty: No 1. Check wiring


(only for rail signal or signal implausibe. (→ Page 167);
application) 2. Contact Service.

MS15017/00E 06-11 © MTU


Troubleshooting 75

Fault code Alarm text Cause of fault Task

189 AL MWA NOT READY No data from MWA (ETB 2) 1. Check wiring
(→ Page 167);
2. Contact Service.

190 AL CTRL. ETC B3 ETC B3 control faulty 1. Check wiring


DEF. (→ Page 167);
2. Contact Service.

191 AL START Start sequence aborted Cause displayed in additional


TERMINATION message.

192 MG T-OPER. TOO Operating temperature too Run engine to reach operating
LOW low temperature.

193 AL WATER Water level in fuel prefilter Drain fuel prefilter


FUELPREFILT too high (→ Page 108).

194 Not used

195 SD P-FUEL B. FILTER Fuel pressure before filter 1. Check wiring


sensor fault, measured value (→ Page 167);
out of plausible range 2. Contact Service.

196 LO P-FUEL B. FILTER Fuel pressure before filter Contact Service.


too low

197 SD FAST SPEED - -


REDUC. (only for rail
application)

198 AL PDM FAILURE Plant data not available or Fit PDM with valid plant data.
invalid

199 AL TESTBENCH DATA Test bench data invalid or Fit EDM with valid data.
NV not available

200 MG REM.SPEED Setpoint speed of Remote Correct control lever position


DEM. HI Control System on switching of Remote Control System.
from Local to Remote Mode
too high

201 MG REM.ENGAGE Engagement request from Correct control lever position


DEMAND Remote Control System of Remote Control System,
applied on switching from cancel engagement request.
Local to Remote Mode

202 MG DEV.REMOTE When trying to switch over Bring clutch position request
CLUTCH from Local to remote Mode, of Remote Control System in
the clutch position requested accordance with the actual
by the Remote Control clutch position in Local Mode.
System deviates from the
present clutch position in
Local Mode

203 HI T-GEAR OIL Gear oil temperature too Contact Service.


high.

MS15017/00E 06-11 © MTU


76 Troubleshooting

Fault code Alarm text Cause of fault Task

204 MG REM.SPEED When trying to switch over Reduce present speed in Local
DEM. LO from Local to remote Mode, Mode or increase requested
the speed demand form speed in Remote Mode.
the Remote Control System
deviates too much from the
present speed setting in
Local Mode; Change-over to
remote Mode is therefore not
admissible.

205 Not used

206 Not used

207 Not used

208 HI P-GEAR OIL Differential pressure at gear (→Gearbox documentation)


FILTER oil filter too high

209 LO GEAR OIL LEVEL Gear oil level too low Check gear-oil level.
(→Gearbox documentation ).

210 LO COOLANT LEVEL Engine coolant level too low Fill with engine coolant
2 (→ Page 159).

211 SD T-EXHAUST BULK Exhaust bulk temperature 1. Check wiring


T2 sensor 2 faulty: No signal or (→ Page 167);
signal implausibe. 2. Contact Service.

212 SD T-EXHAUST BULK Exhaust bulk temperature 1. Check wiring


T3 sensor 3 faulty: No signal or (→ Page 167);
signal implausibe. 2. Contact Service.

213 HI T-EXHAUST BULK Exhaust temperature T2 too Reduce power.


T2 high

214 HI T-EXHAUST BULK Exhaust temperature T3 too Reduce power.


T3 high

215 TD P-GEAR CONTR. Deviation between values Contact Service.


OIL from first and second gear
control oil pressure sensors

216 TD P-GEAR LUBE OIL Deviation between values Contact Service.


from first and second gear oil
pressure sensors

217 TD REM. SPEED Deviation between speed Contact Service.


DEMAND demand values from first and
second sensors

218 TD T-LUBE OIL Deviation between values Contact Service.


from first and second lube oil
temperature sensors

219 TD FAST SPEED - -


REDUC. (only for rail
application)

220 TD T-GEAR OIL Deviation between values Contact Service.


from first and second gear
lube oil temperature sensors

MS15017/00E 06-11 © MTU


Troubleshooting 77

Fault code Alarm text Cause of fault Task

221 Not used

222 TD LOAD PULSE, -


(only for rail
application)

223 AL EEPROM DATA EEPROM data not available Fit PDM and EDM, if the
FAIL. or invalid data are available and valid,
exchange MERC

224 AL ECS-DATATRANS- Plant Data Module Fit new Plant Data Module in
MOD incomplete active ECS

225 AL MCS-DATATRANS- Plant Data Module (Backup Contact Service.


MOD ECS) incomplete

226 AL SECURITY Sensor failure of a safety Note further alarms.


CHN.DEF system channel

227 AL SECURITY Limit value violation of a Reduce power.


CHANNEL channel with impending
safety shutdown on reaching
a second limit

228 MG CLUTCH Clutch is engaged on 1. Check wiring


ENGAGED command transfer to another (→ Page 167);
control stand 2. Contact Service.

MS15017/00E 06-11 © MTU


78 Troubleshooting

Fault code Alarm text Cause of fault Task

229 HI T-EXHAUST A1 Exhaust gas temperature 1. Reduce power;


fault, the exhaust 2. Check wiring
230 HI T-EXHAUST A2 temperature of the cylinder is (→ Page 167);
above the admissible range 3. Check injectors
231 HI T-EXHAUST A3 (→ Page 93);
4. Contact Service.
232 HI T-EXHAUST A4
• Engine oil in
233 HI T-EXHAUST A5 combustion air.

234 HI T-EXHAUST A6

235 HI T-EXHAUST A7

236 HI T-EXHAUST A8

237 HI T-EXHAUST A9

238 HI T-EXHAUST A10

239 HI T-EXHAUST B1

240 HI T-EXHAUST B2

241 HI T-EXHAUST B3

242 HI T-EXHAUST B4

243 HI T-EXHAUST B5

244 HI T-EXHAUST B6

245 HI T-EXHAUST B7

246 HI T-EXHAUST B8

247 HI T-EXHAUST B9

248 HI T-EXHAUST B10

MS15017/00E 06-11 © MTU


Troubleshooting 79

Fault code Alarm text Cause of fault Task

249 LO T-EXHAUST A1 Exhaust gas temperature 1. Run engine to reach


fault, the exhaust operating temperature;
250 LO T-EXHAUST A2 temperature of the cylinder is 2. Check wiring
below the admissible range (→ Page 167);
251 LO T-EXHAUST A3 3. Check cooling;
4. Contact Service.
252 LO T-EXHAUST A4

253 LO T-EXHAUST A5

254 LO T-EXHAUST A6

255 LO T-EXHAUST A7

256 LO T-EXHAUST A8

257 LO T-EXHAUST A9

258 LO T-EXHAUST A10

259 LO T-EXHAUST B1

260 LO T-EXHAUST B2

261 LO T-EXHAUST B3

262 LO T-EXHAUST B4

263 LO T-EXHAUST B5

264 LO T-EXHAUST B6

265 LO T-EXHAUST B7

266 LO T-EXHAUST B8

267 LO T-EXHAUST B9

268 LO T-EXHAUST B10

269 MG MR ILLEGAL Inadmissible request Check monitoring computer.


REQU. from monitoring computer
(external)

270 Not used

271 SS P-COOLANT Engine shutdown by 1. Check coolant level


coolant pressure limit value (→ Page 156);
monitoring (safety system) 2. Contact Service.

272 SS P-GEAR LUBE OIL Engine shutdown by gear 1. Check gear-oil


lube oil pressure limit value level (→Gearbox
monitoring (safety system) documentation )
;
2. Contact Service.

273 SS P-GEAR CTRL.OIL Engine shutdown and 1. Check gear-oil


automatic disengagement level. (→Gearbox
by gear oil control pressure documentation )
limit value monitoring (safety ;
system) 2. Contact Service.

MS15017/00E 06-11 © MTU


80 Troubleshooting

Fault code Alarm text Cause of fault Task

274 SS T-COOLANT Engine shutdown by coolant 1. Check coolant level


temperature limit value (→ Page 156);
monitoring (safety system) 2. Contact Service.

275 SS SPEED SENSOR Engine shutdown caused by 1. Check wiring


DEF. total failure of speed sensors (→ Page 167);
2. Contact Service.

276 SS FUEL RACK Engine shutdown caused by 1. Check wiring


BINDING jammed control rack (→ Page 167);
2. Contact Service.

277 SS F.RACK SENSOR Engine shutdown caused 1. Check wiring


DEF by total failure of fuel rack (→ Page 167)
sensors 2. Contact Service.

278 SS COOLANT LEVEL Engine shutdown by coolant 1. Check coolant level


level limit value monitoring (→ Page 156);
(safety system) 2. Contact Service.

279 Not used

280 SS T-LUBE OIL Engine shutdown by lube 1. Check oil level;


oil temperature limit value (→ Page 132);
monitoring (safety system) 2. Contact Service.

281 SS P-PISTON COOL. Engine shutdown by piston 1. Check oil level;


OIL cooling oil pressure limit (→ Page 132);
value monitoring (safety 2. Replace piston cooling-oil
system) filter (→ Page 142);
3. Contact Service.

282 SS P-LUBE OIL Engine shutdown by lube 1. Check oil level;


oil pressure limit value (→ Page 132);
monitoring (safety system) 2. Contact Service.

283 MG TEST BENCH Test bench mode is active -


MODE

284 AL EXT.SAFETY External monitoring system -


SYSTEM initiated alarm

285 MG ACKNOWL. TOO Maintenance acknowledge- Press key MI ACKNOWL.


EARLY ment too early (→ Page 23), acknowledge-
ment will be accepted.

286 MG ACKNOWL. TOO Maintenance acknowledge- Press key MI ACKNOWL.


LATE ment too late (→ Page 23), acknowledge-
ment will be accepted.

287 AL MIM Fault in maintenance Contact Service.


PROJ.MOD.MISS indicator

288 AL MIM Fault in maintenance Contact Service.


CAL.MOD.MISS indicator

289 AL LP Fault in maintenance If fault message cannot


MOD.REDUN.LOST indicator, (loss of be deleted by pressing
redundancy) keys ACKNOWL. and
STORED ALARM RESET
(→ Page 23)Contact Service.

MS15017/00E 06-11 © MTU


Troubleshooting 81

Fault code Alarm text Cause of fault Task

290 AL MIM LP MOD MISS. Fault in maintenance If fault message cannot


indicator be deleted by pressing
keys ACKNOWL. and
STORED ALARM RESET
(→ Page 23)Contact Service.

291 AL MIM Fault in maintenance If fault message cannot


PROJ.MOD.MISS indicator be deleted by pressing
keys ACKNOWL. and
STORED ALARM RESET
(→ Page 23)Contact Service.

292 AL LD Fault in maintenance If fault message cannot


MOD.REDUN.LOST indicator, (loss of be deleted by pressing
redundancy) keys ACKNOWL. and
STORED ALARM RESET
(→ Page 23)Contact Service.

293 AL MIM LD MOD. Fault in maintenance If fault message cannot


MISS. indicator be deleted by pressing
keys ACKNOWL. and
STORED ALARM RESET
(→ Page 23)Contact Service.

294 AL MERC LD Fault in maintenance If fault message cannot


MOD.MISS. indicator be deleted by pressing
keys ACKNOWL. and
STORED ALARM RESET
(→ Page 23)Contact Service.

295 AL MIM WRITE LIMIT Fault in maintenance Contact Service.


indicator (EEPROM
write limit in maintenance
indicator)

296 AL MIM WRITE Fault in maintenance Contact Service.


ERROR indicator

297 AL MIM ERROR 13 Fault in maintenance Contact Service.


indicator

298 AL MIM ERROR 14 Fault in maintenance Contact Service.


indicator

299 MG T-COOLANT Coolant temperature too 1. Reduce power;


POW.RED high, system reduced engine 2. Check coolant level
power (→ Page 156).

300 AL VALVE LUB. Valve seat lubrication faulty Contact Service.


DEFECT

301 LO T-EXHAUST Exhaust gas temperature Contact Service.


MEAN mean value too low

302 HI T-EXHAUST MEAN Exhaust gas temperature Contact Service.


mean value too high

303 TD T-INTAKE AIR Deviation between intake air 1. Check wiring


temperature values from first (→ Page 167);
and second sensors 2. Contact Service.

MS15017/00E 06-11 © MTU


82 Troubleshooting

Fault code Alarm text Cause of fault Task

304 TD P-CHARGE AIR Deviation between charge-air 1. Check wiring


temperature values from first (→ Page 167);
and second sensors 2. Contact Service.

305 TD T-RAW WATER Deviation between raw water 1. Check wiring


temperature values from first (→ Page 167);
and second sensors 2. Contact Service.

306 SD P-LUBE OIL F. Oil pressure sensor before 1. Check wiring


DIFF or after filter faulty (→ Page 167);
2. Contact Service.

307 MG T-OIL POWER Oil temperature too high, Reduce power further.
RED. system reduced engine
power

308 MG T-CH. AIR Charge-air temperature too Reduce power further.


REDUC. high, system reduced engine
power

MS15017/00E 06-11 © MTU


Troubleshooting 83

6.3 Oil priming pump, oil refill pump – Troubleshooting


Oil priming pump (PPC) does not run in automatic mode

Component Probable Cause Task

PPC, LPU (green indicator Contactor K001 defective. Contact Service.


lamp is illuminated).

PPC, LPU (green indicator Excessive temperature of pump Contact Service.


lamp does not light). motor.

Wrong setting of motor protection Contact Service:


relay. • Adjust motor protection relay Q001.

Motor protection relay defective. Contact Service:


• Replace motor protection relay Q001.

Wiring defective. Contact Service:


• Check wiring (→ Page 167).

Selector switch is not in AUTO Turn selector switch to AUTO (→ Page 30).
position.

Switch S001 defective. Contact Service:


• Replace switch S001.

No control signal from LOP 1. Check wiring (→ Page 167);


2. Contact Service.

Oil priming pump (PPC) does not run in manual mode

Component Probable Cause Task

PPC, LPU (green indicator Fault in load circuit: No external Contact Service.
lamp is illuminated). mains voltage supply.

Wiring defective. Check wiring (→ Page 167).

Contacts or coil of contactor K001 Contact Service.


defective.

Oil priming pump defective. Contact Service.

PPC, LPU (green indicator Fault in control circuit: No 24VDC Contact Service.
lamp does not light). supply at terminal X001–1.

Switch S001 defective. Contact Service.

Motor protection relay Q001 has 1. Check wiring (→ Page 167);


tripped. 2. Contact Service:
• Check priming pump.

MS15017/00E 06-11 © MTU


84 Troubleshooting

Oil priming pump (PPC) runs normally

Component Probable Cause Task

PPC, LPU (no or weak LED of indicator lamp defective. Replace LED (→ Page 178).
illumination of green indicator
lamp).

Oil refill pump (LPU) does not run in automatic mode

Component Probable Cause Task

LPU (green indicator lamp is Contactor K003 defective. Contact Service.


illuminated)

LPU (green indicator lamp Selector switch is not in AUTO Turn selector switch to AUTO position
does not light) position. (→ Page 30).

Overcurrent breaker Q002 has Contact Service:


tripped. • Check refill pump.

Fault in control or load circuit: Contact Service.


Switch S002 defective, no control
signal from LOP.

Oil refill pump (LPU) does not run in manual mode

Component Probable Cause Task

LPU (green indicator lamp is Fault in load circuit: No external 1. Check wiring (→ Page 167);
illuminated) mains voltage supply. 2. Contact Service.

Fault in control circuit: Contacts or Contact Service.


coil of contactor K003 defective

Refill pump defective. Contact Service:


• Check refill pump.

LPU (green indicator lamp Selector switch is not in AUTO Turn selector switch to AUTO position
does not light) position. (→ Page 30).

Fault in control circuit: No 24VDC Contact Service.


supply at terminal X001–1.
Switch S002 defective, no control
signal from LOP.

Motor protection relay has tripped. 1. Check wiring (→ Page 167);


2. Contact Service:
• Check refill pump.

Oil refill pump (LPU) runs normally

Component Probable Cause Task

LPU (no or weak illumination LED of indicator lamp defective. Replace LED (→ Page 178).
of green indicator lamp)

MS15017/00E 06-11 © MTU


Task Description 85

7 Task Description

7.1 Engine

7.1.1 Engine – Barring manually

Preconditions
• Engine is stopped and starting disabled.

Special tools
Designation / Use Part No. Qty.
Power amplifier F30030459 1
Ratchet F30006211 1

Unguarded rotating and moving engine components.


Risk of serious injury - danger to life!
DANGER • Before barring or starting the engine, ensure that nobody is in the danger zone.
• After working on the engine, check that all protective devices have been reinstalled
and all tools removed from the engine.

MS15017/00E 06-11 © MTU


86 Task Description

Engine – Barring manually


1. Remove cover (1).
Result: Limit switch (2) is in rest position. Start
interlock is active.

2. Fit power amplifier (2) in the recessed square


of flange (1).
Result: The extension is located between the
stops (4).
3. Fit ratchet (3).
4. Rotate crankshaft in engine direction of rotation.
Result: If, in addition to compression resistance,
further resistance should occur, contact Service.
5. Continue to move ratchet (3) in the same
direction until the change-over lever at the power
amplifier (2), can be switched over to the opposite
direction of rotation.
Result: Ratchet (3) and power amplifier (2) can
be removed.
6. For barring-tool removal follow reverse sequence
of working steps.

MS15017/00E 06-11 © MTU


Task Description 87

7.1.2 Engine – Barring with starting system

Preconditions
• No load connected to PTO.
• External start interlock is not activated.
• Emergency air shutoff flaps (if provided) are open.

Unguarded rotating and moving engine components.


Risk of serious injury - danger to life!
DANGER • Before barring or starting the engine, ensure that nobody is in the danger zone.
• After working on the engine, check that all protective devices have been reinstalled
and all tools removed from the engine.

Engine noise above 85 dB (A).


Risk of damage to hearing!
WARNING • Wear ear protectors.

Engine – Barring with starting system


1. Switch on engine control system (ECS) and activate LOCAL CONTROL.
2. Press TURN ENGINE button on control panel (LOP) until spot flashes and release button.
3. Repeat starting process without start fuel and bar engine until oil pressure is displayed.

MS15017/00E 06-11 © MTU


88 Task Description

7.2 Cylinder Liner

7.2.1 Combustion chambers – Blowing out condensate

Preconditions
• Engine is stopped and starting disabled.
Combustion chambers – Blowing out condensate
1. Back-off decompression valve stem (arrow) by
three turns on all cylinders.
2. Press TURN ENGINE key on the ECS-UNI
(→ Page 23).
Result: Crankshaft rotates for approx. 10 second
with zero fuel injection.
3. Check whether fluid emerges.
• If the quantity of emerging fluid is abnormally
high, contact Service.
4. Disable engine start.
5. Use torque wrench to tighten decompression valve
stem (arrow) of all cylinders to specified tightening
torque 20 Nm +2 Nm.

MS15017/00E 06-11 © MTU


Task Description 89

7.3 Valve Drive

7.3.1 Valve clearance – Check and adjustment

Preconditions
• Engine is stopped and starting disabled.
• Engine coolant temperature is max. 40 °C.

Special tools
Designation / Use Part No. Qty.
Feeler gauge Y4099505 1
Wrench F30371153 1
Torque wrench 40-200 Nm F30027337 1

Material
Designation / Use Part No. Qty.
Engine oil

Unguarded rotating and moving engine components.


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

Preparatory steps
1. Install barring tool (→ Page 87).
2. Remove cylinder-head cover (→ Page 91).
3. Open decompression valves (→ Page 88).

Checking valve clearance in two crankshaft positions


1. Rotate crankshaft in the normal direction of rotation until the A1 piston is at firing TDC.
2. Check firing TDC position.
Result: A1 rocker arms are free to move.
3. Using a feeler gauge, check the clearance between valve stem and adjusting screw.
• Inlet = 0.30 mm
• Exhaust = 0.50 mm
4. If the deviation from the reference value exceeds 0.1 mm, adjust valve clearance.
5. Set the remaining pistons one by one to firing TDC and check valve clearance in the same way.

MS15017/00E 06-11 © MTU


90 Task Description

Adjusting valve clearance


1. Release lock nut (2) and unscrew the adjusting
screw (3) slightly using wrench (4).
2. Insert feeler gauge between valve stem and
adjusting screw.
3. Use wrench (4) to readjust adjusting screw so that
the feeler gauge just passes through the gap.
4. Coat lock nut with engine oil.
5. Tighten lock nut to specified torque 90 Nm using
torque wrench.
6. Check whether the feeler gauge just passes
through between valve stem and adjusting screw.
Result: If not, adjust valve clearance.

Final steps
1. Remove barring tool (→ Page 87).
2. Install cylinder head cover (→ Page 91).
3. Close decompression valves (→ Page 88).

MS15017/00E 06-11 © MTU


Task Description 91

7.3.2 Cylinder head cover – Removal and installation

Preconditions
• Engine is stopped and starting disabled.

Special tools
Designation / Use Part No. Qty.
Torque wrench

Material
Designation / Use Part No. Qty.
Engine oil
Terrokal 2192 Super 40151 1

Spare parts
Designation / Use Part No. Qty.
Sealing ring
Sealing ring

Cylinder head cover – Removal and installation


1. Remove screws (arrow).
2. Take off cylinder head cover with sealing ring.
3. Clean sealing face.
4. Check condition of sealing ring.
5. If sealing ring is damaged, fit new one.
5.1. Clean groove in cylinder head cover.
5.2. Coat groove with Terrokal 292 Super.
5.3. Insert sealing ring.
6. Fit cylinder head cover and tighten screws (arrow)
to specified tightening torque 30 Nm using torque
wrench.

MS15017/00E 06-11 © MTU


92 Task Description

7.4 Injector

7.4.1 Injector – Cleaning

Preconditions
• Engine is stopped and starting disabled.

Special tools
Designation / Use Part No. Qty.
Ultrasonic cleaning unit F30378615 1
Reamer F30372284 1

Material
Designation / Use Part No. Qty.
Grease 40388 1
Cleaning liquid 40495/5 1
Test oil 50743 1

Fuels are combustible.


Risk of fire and explosion!
WARNING • Avoid naked flames, electrical sparks and ignition sources.
• Do not smoke.
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

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

Preparatory steps

Remove injector (→ Page 100).

Injector – Cleaning
1. Fill ultrasonic cleaning unit with cleaning liquid.
2. Place injector or individual components (→ Page 95) in ultrasonic cleaning unit.
3. Operate ultrasonic cleaning unit for approx. 15 minutes.
4. Rinse injector or individual components with filtered fuel and blow out with compressed air.
5. Check individual components for wear, renew components if defective.
6. Place injector or individual part in clean test oil until installation.

Cleaning injector port in cylinder head


1. Coat reamer with grease.
Note: Recondition only to the extent required for proper seating of the injector.

2. Insert reamer in injector port and clean.

MS15017/00E 06-11 © MTU


Task Description 93

7.4.2 Injector – Tests

Special tools
Designation / Use Part No. Qty.
Nozzle tester 8205892521/00 1

Material
Designation / Use Part No. Qty.
Test oil 50743 1

High-pressure jet.
Risk of injury and fire!
WARNING • For testing the fuel injectors, do not use gasoline, only test oil.
• Avoid naked flames, electrical sparks and ignition sources.
• Do not smoke.
• Do not allow oil mist to enter work area.
• Use ventilation equipment.

Preparatory steps
1. Remove injector (→ Page 100)
2. Clean injector (→ Page 92)

Injector – Tests
1. Connect pressure line (6) to injector (5).
2. Fill test oil tank (7) with test oil.

Pre-Test
1. Close shut-off valve (2) for pressure gauge (1).
2. Operate pump lever (4) vigorously several times.
Result: This will rectify slight malfunctions as, for instance, a sticking nozzle needle and flush nozzle holder
and nozzle with test oil.

MS15017/00E 06-11 © MTU


94 Task Description

Opening pressure test


1. Open shut-off valve (2).
2. Operate pump lever (4) slowly.
3. Record the gauge pressure indicated when the nozzle opens.
Result: Opening pressure:

Preset pressure with new spring 400 bar +12 bar

Specified value with used spring 380 bar

Minimum pressure for trouble-free operation 320 bar

Leak test with nozzle needle closed


1. Operate pump lever (4) slowly.
2. The pressure gauge (1) must indicate a pressure which is approx. 20 bar below the preset nozzle opening
pressure
Result: No droplets of fuel should form at the nozzle holes within 10 seconds.

Visual inspection for clogged nozzle holes: Spray test


1. Switch off the pressure gauge (1).
2. Move the pump lever (4) up and down as rapidly as possible, at least 2 downward strokes per second.
Result:
• The number of spray jets must correspond with number of nozzle holes.
• If required, clean injection nozzle once again.
• Replace injection nozzles if defective.

MS15017/00E 06-11 © MTU


Task Description 95

7.4.3 Injector – Disassembly

Preconditions
• Engine is stopped and starting disabled.

Special tools
Designation / Use Part No. Qty.
Mandrel F30378334 1

Material
Designation / Use Part No. Qty.
Engine oil

Fuels are combustible.


Risk of fire and explosion!
WARNING • Avoid naked flames, electrical sparks and ignition sources.
• Do not smoke.
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.

Preparatory steps
1. Remove injector (→ Page 100).
2. Clean injector externally.

Injector – Disassembly
1. Clamp the injector vertically into a vice by the
spanner flats.
2. Back-off nozzle retaining cap (4) by two to three
turns.
3. Use mandrel (1) to detach nozzle body (3).
4. Remove nozzle retaining cap (4).
5. Remove all components and protect against
damage.

MS15017/00E 06-11 © MTU


96 Task Description

7.4.4 Injector – Assembly

Special tools
Designation / Use Part No. Qty.
Torque wrench

Material
Designation / Use Part No. Qty.
Engine oil

Spare parts
Designation / Use Part No. Qty.
Compensating washer
Compression spring
Thrust pin

Fuels are combustible.


Risk of fire and explosion!
WARNING • Avoid naked flames, electrical sparks and ignition sources.
• Do not smoke.
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.

Preparatory steps
1. Disassemble injector (→ Page 95).
2. Clean injector (→ Page 92).

Injector – Assembly
1. Check compression spring (7) for cracks.
Result: If cracks are found: Fit new compression
spring.
2. Check thrust pin (6) for wear traces.
Result: If wear traces are found: Fit new thrust pin.
3. Clamp the injector holder (10) vertically into a vice
by the spanner flats.
4. Insert compensation washer (9), spring plate (8),
compression spring (7) and thrust pin (6) into
nozzle holder (10).
5. Fit spacer block (4), nozzle body (2) with
needle (1) onto nozzle holder (10), ensuring that
the pins (5) are seated correctly.
6. Screw nozzle retaining cap (3) onto nozzle
holder (10) and use torque wrench to tighten to
specified torque 200 Nm + 20 Nm.

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Task Description 97

Final steps
1. Test injector (→ Page 93).
2. Install injector (→ Page 100).

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98 Task Description

7.4.5 Injector – Replacement

Spare parts
Designation / Use Part No. Qty.
Fuel injector

Remove injector and install new one (→ Page 100).

MS15017/00E 06-11 © MTU


Task Description 99

7.4.6 Injector – Nozzle replacement

Preconditions
• Engine is stopped and starting disabled.

Spare parts
Designation / Use Part No. Qty.
Hole-type nozzle

Fuels are combustible.


Risk of fire and explosion!
WARNING • Avoid naked flames, electrical sparks and ignition sources.
• Do not smoke.
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.

Injector – Nozzle replacement


1. Remove injector (→ Page 100).
2. Disassemble injector (→ Page 95).
3. Fit new nozzle.
4. Assemble injector (→ Page 95).
5. Install injector (→ Page 100).

MS15017/00E 06-11 © MTU


100 Task Description

7.4.7 Injector – Removal and installation

Preconditions
• Engine is stopped and starting disabled.

Special tools
Designation / Use Part No. Qty.
Puller F30371763 1

Material
Designation / Use Part No. Qty.
Petroleum jelly, white
Molykote G-n plus
Engine oil
Fuel

Spare parts
Designation / Use Part No. Qty.
O-ring
Sealing ring

Fuels are combustible.


Risk of fire and explosion!
WARNING • Avoid naked flames, electrical sparks and ignition sources.
• Do not smoke.
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

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

Unsuitable cleaning tools.


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

Remove cylinder head cover (→ Page 91).

MS15017/00E 06-11 © MTU


Task Description 101

Injector removal
1. Remove nuts (4) and screws (5) from connecting
flanges (6).
2. Remove screws (3).
3. Remove fuel line (8), pipe (7) with connecting
flanges and thrust sleeve (2).
4. Remove sleeve nut (9).
5. Remove feed pipe (10) from cylinder head (11).

6. Remove screw from hold-down clamp (arrow).


7. Remove cylinder head cover (→ Page 91).
8. Remove hold-down clamp (arrow).
9. Use puller to remove injector from cylinder head.
10. Remove sealing ring.
11. Clean injector:
11.1. Clean injector externally.
11.2. Remove deposits at the nozzle holes with
a wooden stick and fuel.
11.3. Clean injectors showing heavy carbon
deposits in the ultrasonic cleaning unit
(→ Page 92).
11.4. Clean injector port in cylinder head
(→ Page 92).
12. Seal openings with suitable covers.

Clean injector (→ Page 92).

Test injector (→ Page 93).

Injector installation
1. Fit new sealing rings on nozzle holder.
2. Place new sealing ring on bottom of injector and
hold in place with petroleum jelly.
3. Insert injector into cylinder head with the alignment
mark facing the feed pipe bore.

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102 Task Description

4. Blow out the feed pipe (1) with compressed air.


5. Fit new sealing ring (2) on HP fuel pipe (1) and
coat with petroleum jelly.
6. Coat thread and front face of the feed pipe (1) with
Molykote G-n plus.
7. Insert HP fuel pipe (1) into cylinder head and
tighten to specified torque 140 Nm +14 using
torque wrench.
8. Fit new sealing rings (4) on sleeve nut (3) and coat
with petroleum jelly.
9. Install sleeve nut (3) to within a half-turn of seating.
10. Place hold-down clamp on nozzle holder.
11. Coat threads and screw head mating face of stress
bolt with Molykote G-n plus.
12. Tighten stress bolt to specified torque 110 Nm +10
Nm using torque wrench.
13. Release stress bolt.
14. Tighten stress bolt to specified torque 25 Nm +3
Nm using torque wrench.
15. Additional angle of rotation 90° +5°.
16. Tighten stress bolt to specified check torque 120
Nm using torque wrench.
17. Install cylinder head cover (→ Page 91).
18. Use torque wrench to tighten sleeve nut (9) to
specified torque: 5 Nm .
19. Insert fuel line (8), pipe (7) with connecting flanges
and thrust sleeves (2).
20. Back-off thrust screws (5).
21. Install screws (3) in thrust sleeve (2) at cylinder
head (11) and injection pump (1) and tighten.
22. Hand-tighten lower thrust screw (5).
Result: Lower spherical seal is in positioned in
seating.
23. Hand-tighten upper thrust screw (5).
Result: Upper spherical seal is in positioned in
seating.
24. Tighten lower thrust screw (5) to specified torque
50 Nm +5 Nm using torque wrench.
25. Tighten upper thrust screw (5) to specified torque
50 Nm +5 Nm using torque wrench.
26. Secure both thrust screws (5) with nut (4).
27. Use torque wrench to tighten nut (4) to specified
torque: 5 +0.5 Nm .

MS15017/00E 06-11 © MTU


Task Description 103

7.5 Fuel System

7.5.1 Leak-fuel tank – Draining

Preconditions
• Engine is stopped and starting disabled.

Spare parts
Designation / Use Part No. Qty.
Sealing ring

Fuels are combustible.


Risk of fire and explosion!
WARNING • Avoid naked flames, electrical sparks and ignition sources.
• Do not smoke.

Leak fuel tank – Draining


1. Screw out drain plug on leak fuel tank.
2. Catch leak fuel in suitable container.
3. Screw in drain plug with new sealing ring and tighten.
4. Eliminate any leaks in fuel system, contact Service.

MS15017/00E 06-11 © MTU


104 Task Description

7.5.2 Fuel system – Venting

Preconditions
• Engine is stopped and starting disabled.

Fuels are combustible.


Risk of fire and explosion!
WARNING • Avoid naked flames, electrical sparks and ignition sources.
• Do not smoke.

Fuel system – Venting


1. Release the fuel priming pump lever (arrow).
2. Operate priming pump until fuel system is fully
primed.
3. Turn valve stems of vent valves by two turns to
open them (→ Page 150).
4. Operate fuel priming pump until bubble-free fuel
emerges from the vent valves.
5. Turn in valve stems and tighten with torque wrench
to specified torque 15 Nm + 5 Nm.
6. Operate fuel priming pump with approx. 50
strokes.
Result: Fuel filters are vented.
7. Secure the fuel priming pump lever (arrow).

MS15017/00E 06-11 © MTU


Task Description 105

7.6 Fuel Filter

7.6.1 Fuel filter – Replacement

Preconditions
• Engine is stopped and starting disabled.

Material
Designation / Use Part No. Qty.
Diesel fuel

Spare parts
Designation / Use Part No. Qty.
Easy-change filter
O-ring

Unguarded rotating and moving engine components.


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

Fuels are combustible.


Risk of fire and explosion!
WARNING • Avoid naked flames, electrical sparks and ignition sources.
• Do not smoke.
Engine noise above 85 dB (A).
Risk of damage to hearing!
WARNING • Wear ear protectors.

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

Three-way cock – Switching positions


a) Series 396, Series 595, Series 1163
1 Both filters cut in (normal operating position)
2 Right filter cut out
3 Left filter cut out
b) Series 396, Series 595, Series 1163
1 Both filters cut in (normal operating position)
2 Right filter cut out
3 Left filter cut out
4 Both filters cut out (for draining off fuel from filter)

MS15017/00E 06-11 © MTU


106 Task Description

Fuel filter replacement with the engine stopped


1. Cut out the easy-change filter to be replaced.
2. Release wing nut (3) and take off cover (1).
3. Remove screw (4) and take off cover (2).
4. Take off O-ring (5).
5. Remove easy-change filter (6).
6. Clean filter housing (7).
7. Place new easy-change filter (6) in filter housing
(7).
8. Place new O-ring (5) into the groove of cover (2).
9. Mount cover (2) with screw (4) on filter housing (7).
10. Set the three-way cock to operating position.
11. Replace further fuel filters in the same way.→ 1.
12. Mount cover (1) with wing nut on filter housing (7).
13. Vent fuel system (→ Page 104).

Fuel filter replacement with the engine running


1. Cut out the easy-change filter to be replaced.
2. Release wing nut (3) and take off cover (1).
3. Remove screw (4) and take off cover (2).
4. Take off O-ring (5).
5. Remove easy-change filter (6).
6. Clean filter housing (7).
7. Place new easy-change filter (6) in filter housing
(7).
8. Place new O-ring (5) into the groove of cover (2).
9. Mount cover (2) with screw (4) on filter housing (7).
10. Set the three-way cock to operating position.
11. Replace further fuel filters in the same way.→ 1.
12. Mount cover (1) with wing nut on filter housing (7).

MS15017/00E 06-11 © MTU


Task Description 107

7.6.2 Fuel prefilter – Differential pressure check and adjustment of gauge


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

Engine noise above 85 dB (A).


Risk of damage to hearing!
WARNING • Wear ear protectors.

Setting adjustable pointer of differential pressure


gauge
1. After installation of a new filter element, align
adjustable pointer (2) with pressure-indicating
pointer (3) of pressure gauge (1).
2. Verify that differential pressure is within the limit.

Fuel prefilter – Checking differential pressure


1. With the engine running at full load or rated power, read off pressure at gauge (1).
2. If differential pressure as indicated between position of adjustable pointer (2) and pressure-indicating pointer
(3) of pressure gauge is ≥ 0.3 bar, flush filter element of the cut-in filter (→ Page 110).

MS15017/00E 06-11 © MTU


108 Task Description

7.6.3 Fuel prefilter – draining

Preconditions
• Engine is stopped and starting disabled.

Material
Designation / Use Part No. Qty.
Diesel fuel

Spare parts
Designation / Use Part No. Qty.
Gasket

Fuels are combustible.


Risk of fire and explosion!
WARNING • Avoid naked flames, electrical sparks and ignition sources.
• Do not smoke.

MS15017/00E 06-11 © MTU


Task Description 109

Fuel prefilter – draining


1. Cut out the filter to be drained.

I Left filter cut in


II Right filter cut in

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


3. Unlock drain cock (6) by pressing toggle and
open it.
4. Drain water and contaminants from the filter until
pure fuel emerges.
5. Close drain cock (6).
6. Remove screws securing the cover and take
off cover (2).
7. Fill filter housing with clean fuel.
8. Place new gasket in cover (2).
9. Fit cover with gasket and secure it with screws.
10. Cut the cut-out filter in again.
11. When fuel emerges from system, close vent
plug (5).

MS15017/00E 06-11 © MTU


110 Task Description

7.6.4 Fuel prefilter – flushing

Material
Designation / Use Part No. Qty.
Diesel fuel

Spare parts
Designation / Use Part No. Qty.
Gasket

Unguarded rotating and moving engine components.


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

Fuels are combustible.


Risk of fire and explosion!
WARNING • Avoid naked flames, electrical sparks and ignition sources.
• Do not smoke.
Engine noise above 85 dB (A).
Risk of damage to hearing!
WARNING • Wear ear protectors.

MS15017/00E 06-11 © MTU


Task Description 111

Fuel prefilter – flushing


1. Cut out the contaminated filter.

I Left filter cut in


II Right filter cut in

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


3. Unlock drain cock (6) by pressing toggle, open it
and drain fuel.
Result: Fuel flows from filtered side back to
the unfiltered side, flushing the filter deposits
downwards out of the filter.
4. Close vent plug (5) and drain cock (6).

Fuel prefilter – filling fuel


1. Stop engine (→ Page 35)and disable engine start.
2. Remove screws securing the cover and take off cover (2).
3. Fill filter housing with clean fuel.
4. Place new gasket in cover (2).
5. Fit cover with gasket and secure it with screws.
6. Check differential pressure (→ Page 107).
Result: If flushing did not lead to an improvement of the differential pressure, replace filter element
(→ Page 112).

MS15017/00E 06-11 © MTU


112 Task Description

7.6.5 Fuel prefilter – Filter element replacement

Preconditions
• Engine is stopped and starting disabled.

Material
Designation / Use Part No. Qty.
Diesel fuel

Spare parts
Designation / Use Part No. Qty.
Filter element
Gasket

Fuels are combustible.


Risk of fire and explosion!
WARNING • Avoid naked flames, electrical sparks and ignition sources.
• Do not smoke.

MS15017/00E 06-11 © MTU


Task Description 113

Draining fuel prefilter


1. Cut out the contaminated filter.

I Left filter cut in


II Right filter cut in

2. Open vent cock (1).


3. Unlock drain cock (2) by pressing toggle and
open it.
4. Drain fuel into a suitable container.
5. Close drain cock (2).

6. Remove nuts (5) and take off cover (1).


7. Remove spring housing (2) and filter element (3).
8. Insert new filter element (3) and spring housing (2).
9. Insert new seal (4).
10. Fir cover and tighten nuts (5).

MS15017/00E 06-11 © MTU


114 Task Description

Fuel prefilter – Filling with fuel


1. Open filler cock (2).
2. Fill with fuel using hand pump or static supply
pressure.
3. Close vent cock (1).
4. Close filler cock (2).

Final steps
1. Check for leaks.
2. Adjust pointer of differential pressure gauge (→ Page 107).

MS15017/00E 06-11 © MTU


Task Description 115

7.7 Charge-air Cooling, General, Left Side

7.7.1 Intercooler – Checking condensate drain line for coolant


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

Engine noise above 85 dB (A).


Risk of damage to hearing!
WARNING • Wear ear protectors.

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

Intercooler – Checking condensate drain line


1. With the engine running, verify that air emerges
from the condensate drain lines on left and right
engine side. If no air emerges:
2. Remove condensate drain line(s) and blow out
with compressed air.
3. Replace obstructed drain line(s) with new one(s).
4. Install drain line(s).
5. If a large amount of coolant is discharged, the
intercooler is leaking. Contact Service.

Emergency measures prior to engine start with a leaking intercooler


1. Blow out combustion chambers (→ Page 88).
2. If the quantity of emerging fluid is abnormally high, do not operate engine any longer and contact Service.

MS15017/00E 06-11 © MTU


116 Task Description

7.8 Air Filter

7.8.1 Air filter and dust bowl – Cleaning

Preconditions
• Engine is stopped and starting disabled.

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

Air filter element – Cleaning


Note: Clean paper filter element dry only.

1. Remove air filter (→ Page 118).


2. Blow out filter element with compressed air (max.
3 bar) from inside until all dust has been removed.

Visual inspection
1. Use inspection lamp to check cleaned filter
element for damage.
2. Fit new filter insert if damaged (→ Page 117).

MS15017/00E 06-11 © MTU


Task Description 117

7.8.2 Air filter replacement

Spare parts
Designation / Use Part No. Qty.
Air filter

Remove air filter and install new one (→ Page 118).

Reset signal ring of service indicator (→ Page 119).

MS15017/00E 06-11 © MTU


118 Task Description

7.8.3 Air filter removal and installation

Preconditions
• Engine is stopped and starting disabled.
Air filter removal and installation
1. Loosen clamp (2).
2. Remove air filter (3) and clamp (2) from flange of
intake housing (1).
3. Verify that there are no objects in the flange of the
intake housing (1) and clean it.
4. Place new air filter (3) with clamp (2) onto intake
housing (1).
5. Tighten clamp (2).

MS15017/00E 06-11 © MTU


Task Description 119

7.9 Air Intake

7.9.1 Service indicator – Signal ring position check

Preconditions
• Engine is stopped and starting disabled.
Signal ring position check
1. If the signal ring is completely visible in the control
window (2), replace air filter (→ Page 117).
2. After installation of new filter, press reset button (1).
Result: Engaged piston with signal ring moves
back to initial position.

MS15017/00E 06-11 © MTU


120 Task Description

7.9.2 Emergency air shut-off flaps – Lubrication

Preconditions
• Engine is stopped and starting disabled.

Special tools
Designation / Use Part No. Qty.
Grease gun F30006433 1

Material
Designation / Use Part No. Qty.
Grease 40388 1
Engine oil - -

Emergency air shut-off flaps – Lubrication


1. Clean grease nipples.
2. Press in grease.
3. Remove cover plate.
4. Lubricate joints, levers and rollers with engine oil.
5. Install cover plate.

MS15017/00E 06-11 © MTU


Task Description 121

7.9.3 Emergency air shut-off flaps – Electric control check

Preconditions
• Engine is stopped.
• ECS is switched on.
Emergency air shut-off flaps – Electric control check
1. Press EMERGENCY STOP button on LOP (→ Page 23).
Result:
• Emergency air shut-off flaps close.
• Fault messages AL SDAF CLOSED and SS EMERGENCY STOP WITH SDAF are displayed on the LOP.
• On the first graphics screen page, fuel rack travel is indicated as 0 mm, and the marked SDAF CLOSED box
indicates that the emergency shut-off air flaps are closed. .
2. After testing, reopen the emergency air shut-off flaps manually.

MS15017/00E 06-11 © MTU


122 Task Description

7.9.4 Emergency air shut-off flaps – Opening/closing manually

Preconditions
• Engine is stopped and starting disabled.

Emergency air shut-off flaps close abruptly.


Risk of crushing!
WARNING • Before starting work, remove tripping lever with screwdriver.

Opening/closing emergency air shut-off flap


1. Open emergency air shut-off flap with hand
lever (1).
Result: Hand lever in operating position A
2. Actuate lever (2) when engine is stopped.
Emergency air shut-off flap closes.
Result: Hand lever in position B

A Emergency air shut-off flap open


B Emergency air shut-off flap closed
1 Hand lever
2 Actuating lever

MS15017/00E 06-11 © MTU


Task Description 123

7.10 Exhaust Flap with Actuators

7.10.1 Exhaust turbocharger control – Control linkage lubrication

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

Special tools
Designation / Use Part No. Qty.
Grease gun F30006433 1

Material
Designation / Use Part No. Qty.
Grease 40388 1

Unguarded rotating and moving engine components.


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

Lubricating control linkage


1. Clean all grease nipples.
2. Press in grease.
3. Clean and oil joints.

1 Piston rod
2 Actuating cylinder of air-flow control flap
3 Actuating cylinder of exhaust-flow control flap

MS15017/00E 06-11 © MTU


124 Task Description

7.10.2 Air-flow and exhaust flow control flaps – Functional test

Preconditions
• Engine is stopped and starting disabled.
• Minimum compressed air pressure of 6 bar available at the valve block.

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

Air-flow and exhaust-flow control flaps – Checking


function of actuating cylinders
1. Set 5/2-way solenoid valve (arrow) to position 1.
Result: Air-flow and exhaust-flow control flaps
open.
2. Check position of flaps.
3. Set 5/2-way solenoid valve (arrow) to position 0.
Result: Air-flow and exhaust-flow control flaps
close.
4. Check position of flaps.
5. Set all 5/2-way solenoid valves (arrow) to initial
position 0.

Air-flow and exhaust-flow control flaps – Checking


position of actuating cylinders
1. Check position of actuating cylinder for air-flow
control flap (2):
• Piston rod (1) retracted - air flap (2) open
• Piston rod (1) extended - air flap (2) closed
2. Check position of actuating cylinder for
exhaust-flow control flap (3):
• Piston rod (1) retracted - exhaust flap (3) closed
• Piston rod (1) extended - exhaust flap (3) open

MS15017/00E 06-11 © MTU


Task Description 125

7.11 Starting Equipment

7.11.1 Pressure reducing station – Putting into operation


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

Cutting in pressure reducing station


1. Set lever to position 3.
Result: Both air filters and both pressure reducing
valves are cut in.
2. Check pressure at pressure gauge.

1 Pressure line is shut off and working-air line vented


2 Right-hand air filter and right-hand pressure
reducing valve are cut in
3 Operating position: Both air filters and both pressure
reducing valves are cut in
4 Left-hand air filter and left-hand pressure reducing
valve are cut in

Pressure reducing station - Adjusting output pressure


1. Make sure that the main valve of the compressed-air supply is open.
2. Cut out left-hand pressure reducing valve.
3. Adjust output pressure at adjusting screws of right-hand pressure reducing valve.
4. Cut in left-hand pressure reducing valve.
5. Cut out right-hand pressure reducing valve.
6. Adjust output pressure at adjusting screws of left-hand pressure reducing valve.
7. Cut in right-hand pressure reducing valve.

MS15017/00E 06-11 © MTU


126 Task Description

Pressure reducing station – Checking safety valve


1. Press manual control (arrow).
Result: Safety valve (located below safety valve
on the right) is raised.
2. If safety valve does not trip, contact Service.

MS15017/00E 06-11 © MTU


Task Description 127

7.11.2 Pressure reducing station – Venting and putting out of operation


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

Pressure reducing station – Venting and putting


out of operation
1. Close main valve of compressed-air supply.
2. Set lever to position 1.
Result: Pressure line is shut off and working-air
line vented.

1 Pressure line is shut off and working-air line vented


2 Right-hand air filter and right-hand pressure
reducing valve are cut in
3 Operating position: Both air filters and both pressure
reducing valves are cut in
4 Left-hand air filter and left-hand pressure reducing
valve are cut in

MS15017/00E 06-11 © MTU


128 Task Description

7.11.3 Pressure reducing station – Filter cleaning

Material
Designation / Use Part No. Qty.
Cleaner

Spare parts
Designation / Use Part No. Qty.
O-ring
Filter element

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

Cleaning filter
1. Vent pressure reducing station and put out of
operation (→ Page 127).
2. Remove filter elements from housing and take
off (arrowed).
3. Check filter elements.
Result: Fit new filter elements if damaged.
4. Clean filter elements with cleaner and blow out
with compressed air.
5. Install filter elements with new O-rings in housing.
6. Put pressure reducing station into operation
(→ Page 125).

MS15017/00E 06-11 © MTU


Task Description 129

7.11.4 Starter – Condition check

Preconditions
• Engine is stopped and starting disabled.
Starter – Condition check
1. Check starter securing screws for secure seating.
2. Tighten loose screw connections.
3. Check wiring (→ Page 167).

MS15017/00E 06-11 © MTU


130 Task Description

7.11.5 Start pilot – Start fuel replenishment

Spare parts
Designation / Use Part No. Qty.
Start fuel 1
Sealing ring 1

Fuels are combustible.


Risk of fire and explosion!
WARNING • Avoid naked flames, electrical sparks and ignition sources.
• Do not smoke.

Replenishing start fuel


1. Loosen handle (1).
2. Turn cover (2) to the left, unlock and take off.
3. Open fuel bottle with piercer (4) and drain fuel
into container.
4. Fit cover (2) with new sealing ring (3), turn to the
right and lock.
5. Tighten handle (1).

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Task Description 131

7.11.6 Start pilot – Fluid level check


Start pilot – Fluid level check
1. Wipe container.
2. Fluid level must be up to the level mark.
3. Top up with start fuel if necessary (→ Page 130).

MS15017/00E 06-11 © MTU


132 Task Description

7.12 Lube-oil System, Lube-oil Circuit

7.12.1 Engine oil – Level check

Preconditions
• Engine is stopped and starting disabled.

Material
Designation / Use Part No. Qty.
Engine oil

Engine noise above 85 dB (A).


Risk of damage to hearing!
WARNING • Wear ear protectors.

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

Rotating, moving parts.


Risk of injury!
CAUTION • Wear protective clothing, gloves, and goggles / safety mask.
• Wear hairnet.
• Vacuum dust from grinding.

Checking engine oil level on initial oil filling


Note: The oil dipstick is marked as follows on the
front respectively on the rear side:
• 0 rpm
• 1000 rpm

1. Fill engine with oil until oil level reaches the


“max” mark on the "0 rpm" side of the dipstick
(→ Page 134).
2. Switch on oil priming pump and operate for at
least 10 minutes (→ Page 30).
3. Check oil level and top up to “max” mark
(→ Page 134).
4. Run the engine for some minutes at idling speed.
5. Stop the engine.
6. Check oil level after approx. 5 minutes of standstill
and top up to “max” mark (→ Page 134).
7. Top up oil replenishment tank to “max” mark.

Checking oil level prior to engine start


1. Withdraw dipstick from guide tube and wipe it.
2. Insert dipstick into guide tube up to the stop, withdraw after approx. 10 seconds and check oil level.
3. Oil level must reach the “max” mark on the "0 rpm" side of the oil dipstick.
4. If necessary, top up to "max" mark (→ Page 134).

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Task Description 133

5. Insert dipstick into guide tube up to the stop.


6. Top up oil replenishment tank to “max” mark.

Checking oil level after the engine is stopped


1. 5 minutes after stopping the engine, remove oil dipstick from the guide tube and wipe it.
2. Insert dipstick into guide tube up to the stop, withdraw after approx. 10 seconds and check oil level.
3. Oil level must reach the “max” mark on the "0 rpm" side of the oil dipstick.
4. If necessary, top up to "max" mark (→ Page 134).
5. Insert dipstick into guide tube up to the stop.

Checking engine oil level with the engine running


1. Run the engine at constant speed of 1000 rpm for 10 minutes.
2. Withdraw dipstick from guide tube and wipe it.
3. Insert dipstick into guide tube up to the stop, withdraw after approx. 10 seconds and check oil level.
4. Oil level must not be below the "min" mark on the "1000 rpm" side of the oil dipstick.
5. Check oil replenishment system if required.

Oil replenishment system – Oil level check


1. Check oil level at sight glass of oil storage tank, tank must be filled to minimum 2/3 of tank capacity.
2. Top up if required.

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134 Task Description

7.12.2 Engine oil – Change

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

Material
Designation / Use Part No. Qty.
Engine oil

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

Oil change without semirotary hand pump: Draining oil at drain plug on oil pan
1. Provide a suitable container in which to collect the oil.
2. Remove drain plug and drain oil.
3. Install drain plug with new sealing ring.
4. Replace engine oil filter (→ Page 140).

Oil change with semirotary hand pump: Oil extraction


1. Provide a suitable container in which to collect the oil.
2. Extract all oil from oil pan using the semirotary hand pump.
3. Replace engine oil filter (→ Page 140).

Engine oil system filling


1. Determine amount of engine oil required for oil
change (Product Summary - Technical Data).
2. Open cover of filler neck.
3. Pour oil in at filler neck up to "max." mark at oil
dipstick.
4. Close cover of filler neck.
5. Check oil level (→ Page 132).

MS15017/00E 06-11 © MTU


Task Description 135

7.12.3 Engine oil – Sample extraction and analysis

Preconditions
• MTU Fluids and Lubricants Specification (A001061/..) is available.
• Engine is at operating temperature.

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

Unguarded rotating and moving engine components.


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

Engine noise above 85 dB (A).


Risk of damage to hearing!
WARNING • Wear ear protectors.

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

Engine-oil – Sample extraction and analysis


1. Drain approx. 2 l of engine oil from the drain cock of the engine oil filter.
Result: Oil sludge in the drain cock is flushed out.
2. Drain approx. 1 liter engine oil into a clean container.
3. Using the equipment and chemicals of the MTU test kit, examine the engine oil for:
• Dispersion capability (spot test);
• Water content;
• Dilution by fuel.

MS15017/00E 06-11 © MTU


136 Task Description

7.12.4 Oil sludge inspection for metallic residues

Material
Designation / Use Part No. Qty.
Grease solvent or diesel fuel
Filter paper
Filtering funnel 1
Collection container 1

Oils are combustible.


Risk of fire!
WARNING • No naked flames, no electric sparks. Do not smoke. Avoid ignition sources.

Oil sludge inspection


1. Dilute oil sludge with grease solvent or fuel.
2. Place filter paper into filter funnel. Filter out solid oil sludge constituents, collecting the solvent in a container.
3. If the filter paper shows metallic residues, monitor engine carefully during further engine operation and inspect
oil sludge daily.
4. If metallic residues are still disclosed, check the engine.

MS15017/00E 06-11 © MTU


Task Description 137

7.12.5 Lube oil priming pump – Checking direction of rotation

Preconditions
• Engine is stopped.

Electrical voltage.
Risk of serious injury - danger to life!
DANGER • Make certain that the power supply to the engine is switched off before starting to work.
Ensure that the power supply cannot be switched on unintentionally!

Lube oil priming pump – Checking direction of rotation


1. Switch on oil priming pump (→ Page 30)and operate it briefly to check the direction of rotation.
Result: Pump rotor rotates in accordance with the arrow on the pump housing. If not:
2. Change polarity of electric leads.
3. Check direction of rotation.

MS15017/00E 06-11 © MTU


138 Task Description

7.13 Oil Filtration/Cooling

7.13.1 Disk-pack filter – Cleaning

Preconditions
• Engine is stopped and starting disabled.

Material
Designation / Use Part No. Qty.
Cleaner 50602 1

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

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

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

Disk-pack filter – Cleaning


1. Remove screw (6).
2. Remove cover (5) and sealing ring (4).
3. Remove nut (3).
4. Remove disk pack (2).
5. Plug both ends of the clean oil side of the disc
pack.
6. Wash disk pack (2) with degreasing detergent.
7. Blow out disk pack (2) from inside to outside
with compressed air.
8. Clean filter bowl (1).
9. Assemble disk pack filter in the reverse sequence,
observing the following instructions:
9.1. Use new sealing ring (4).
9.2. Use torque wrench to tighten screw (6) to
specified torque: 10 Nm +15 Nm.

MS15017/00E 06-11 © MTU


Task Description 139

7.13.2 Engine oil filter – Cleaning filter element

Preconditions
• Engine is stopped and starting disabled.
Cleaning filter element
1. Rotate the handle on the engine oil filter through one or two turns.
2. Repeat this procedure on each engine oil filter.

MS15017/00E 06-11 © MTU


140 Task Description

7.13.3 Engine oil filter – Replacement

Preconditions
• Engine is stopped and starting disabled.

Material
Designation / Use Part No. Qty.
Engine oil

Spare parts
Designation / Use Part No. Qty.
Filter element
O-ring
O-ring

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

MS15017/00E 06-11 © MTU


Task Description 141

Replacing filter elements


1. Drain oil at oil drain valve (7) and oil drain cock (8)
and collect in suitable container.
2. Remove nuts (1) with washers (2).
3. Take off filter cover (3).
4. Remove filter elements (5).
5. Insert new filter elements (5).
6. Coat O-rings (4) and (9) with engine oil and insert.
7. Fit filter cover (3).
8. Install nuts (1) with washers (2) and tighten
crosswise.
9. Check oil level (→ Page 132).

MS15017/00E 06-11 © MTU


142 Task Description

7.13.4 Piston cooling-oil filter – Replacement

Special tools
Designation / Use Part No. Qty.
Oil filter wrench F30379104 1

Material
Designation / Use Part No. Qty.
Engine oil

Spare parts
Designation / Use Part No. Qty.
Oil filter

Unguarded rotating and moving engine components.


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

Engine noise above 85 dB (A).


Risk of damage to hearing!
WARNING • Wear ear protectors.

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

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

Replacing oil filters on a shut-down engine


1. Stop engine (→ Page 35)and disable engine start.
2. Cut-out the filter to be replaced at diverter valve (1).
3. Remove the cut-out filter using the oil-filter wrench.
4. Clean sealing face on filter head.
5. Check sealing ring of new oil filter and coat with
engine oil.
6. Fit new oil filter and tighten by hand.
7. Replace further oil filters in the same manner.
8. Bar engine with starting system after each oil
change and filter replacement (→ Page 87).
9. Check oil level (→ Page 132).

MS15017/00E 06-11 © MTU


Task Description 143

Replacing oil filters on a running engine


1. Cut-out the filter to be replaced at diverter valve (1).
2. Remove the cut-out filter using the oil-filter wrench.
3. Clean sealing face on filter head.
4. Check sealing ring of new oil filter and coat with engine oil.
5. Fit new oil filter and tighten by hand.
6. Replace further oil filters in the same manner.

MS15017/00E 06-11 © MTU


144 Task Description

7.13.5 Centrifugal oil filter – Cleaning and filter-sleeve replacement

Preconditions
• Engine is stopped and starting disabled.

Special tools
Designation / Use Part No. Qty.
Strap wrench

Material
Designation / Use Part No. Qty.
Cleaner Hakutex 60

Spare parts
Designation / Use Part No. Qty.
Filter sleeve
O-ring
O-ring

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

Remove centrifugal oil filter (→ Page 147).

Removing rotor and taking off rotor cap


1. Take off cover (1).
2. Take off O-ring (2).
3. Carefully remove rotor (3) from lower part of
housing (4).

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Task Description 145

4. Secure lower part of rotor lightly in a vise.


5. Mark position of rotor cap with respect to lower
part of rotor.
6. Remove nut (arrow).
Result: Rotor cap is detached from lower part
of rotor.
7. Remove rotor cap carefully.

8. Remove filter sleeve (2) from rotor cap (1).


9. Measure thickness of oil residues on filter sleeve
(2).
10. If maximum layer thickness (25 mm) is exceeded,
shorten maintenance interval.
11. Wash rotor parts with cleaner and blow out with
compressed air, ensuring that the nozzles are
not obstructed.
12. Fit new O-ring (6) on lower part of rotor (4).
13. Place the oil guide tube onto the lower part of the
rotor housing, ensuring that it is seated with the
guide pin (5) engaged.
14. Insert new filter sleeve (2) in rotor cap (1).
15. Place rotor cap (1) carefully onto lower part
of rotor, ensuring alignment according to the
markings made before disassembly.
16. Screw in nut.
Result: Rotor cap is pressed down onto metallic
stop.
17. Tighten nut to specified torque 50 Nm using
torque wrench.

MS15017/00E 06-11 © MTU


146 Task Description

18. Wipe cover (1) and lower part of housing (4) with
a clean cloth.
19. Insert new O-ring in groove in lower part of
housing.
20. Insert rotor (3) carefully into lower part of housing.
21. Make sure that the rotor (3) moves easily.
22. Put cover (1) into place.

Install centrifugal oil filter bracket (→ Page 147).

MS15017/00E 06-11 © MTU


Task Description 147

7.13.6 Centrifugal oil filter bracket – Removal and installation

Preconditions
• Engine is stopped and starting disabled.
Centrifugal oil filter bracket – Removal
1. Release screws (1) and (3).
2. Swing bracket (2) up.
3. Release nut (5) on cover (4).
4. Swing screws outwards.

Centrifugal oil filter bracket – Installation


1. Swing screws up to place them in the grooves.
2. Tighten nuts (5) crosswise.
3. Swing bracket (2) down to place it in the grooves
of the cover (4).
4. Tighten screws (3).
5. Tighten screws (1).
6. Check centrifugal oil filter for leaks during engine
operation.

MS15017/00E 06-11 © MTU


148 Task Description

7.13.7 Engine oil bypass filter – Replacement

Preconditions
• Engine is stopped and starting disabled.

Material
Designation / Use Part No. Qty.
Engine oil

Spare parts
Designation / Use Part No. Qty.
Filter element
Filter element
Sealing ring
Sealing ring
Sealing ring

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

Replacing filter elements


1. Close shut-off valve of engine oil bypass filter.
2. Counterholding screw (3), remove screw (1).
3. Remove drain screw from lower part of housing.
4. Drain oil sludge.
Note: Filter cover (5) is spring-loaded.

5. Remove screw (3).


6. Remove filter cover with sealing ring (4), spring (7)
and washer (8).
7. Clean components.

MS15017/00E 06-11 © MTU


Task Description 149

8. Lift up grip (arrow).


9. Rotate filter element backward and forward to
withdraw it at the grip (arrow).
10. Rotate lower filter element backward and forward
and withdraw it using the hook.
11. Clean filter housing.
12. Insert the new filter elements using the hook.

13. Place washer (8) onto upper filter element.


14. Fit spring (7).
15. Fit cover (5) with new sealing ring (6).
16. Compress cover (5) to install screw (3) with
new sealing ring (4).
17. Tighten screw (3).
18. Install screw (1) with sealing ring (2) and tighten.
19. Install drain screw with new sealing ring in lower
part of housing and tighten.
20. Replace further filter elements in the same way.
21. Open shut-off valve of engine oil bypass filter.

MS15017/00E 06-11 © MTU


150 Task Description

7.14 Cooling Circuit, General, HT Circuit

7.14.1 Drain and venting points

1 Vent line, raw water circuit 4 Piston cooling-oil filter 7 Oil filler neck
2 Connection, engine coolant 5 Connection, engine coolant
vent line sample extraction
3 Fuel filter 6 Centrifugal oil filter

MS15017/00E 06-11 © MTU


Task Description 151

Free end

1 Fuel filter 5 Connection: Engine coolant 8 Connection for automatic


2 Connection: Oil sample extraction vent line seawater inductor
3 Piston cooling-oil filter 6 Connection: Engine coolant 9 Centrifugal oil filter
4 Connection: Engine coolant drain point
sample extraction 7 Engine coolant thermostat

MS15017/00E 06-11 © MTU


152 Task Description

Side view

1 Vent line, raw water circuit 8 Fuel priming pump


2 Connection: Coolant vent line 9 Centrifugal oil filter
3 Fuel filter 10 Connection for barring device
4 Fuel vent valve 11 Oil filler neck
5 Three-way cock, fuel filter 12 Oil dipstick
6 Oil filter 13 Crankcase safety valve
7 Edge-type filter, drain point 14 Connection: Engine coolant
for contaminants drain point

MS15017/00E 06-11 © MTU


Task Description 153

Driving end

1 Engine oil system vent valve 2 Oil filler neck

MS15017/00E 06-11 © MTU


154 Task Description

7.14.2 Vent line – Checking for obstructions

Preconditions
• Engine is stopped and starting disabled.

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

Vent line – Checking for obstructions


1. Remove vent line (→ Page 150).
2. Blow out vent line with compressed air. If vent line is blocked, fit new one.
3. Install vent line.
4. Repeat this procedure for all vent lines (→ Page 150).

MS15017/00E 06-11 © MTU


Task Description 155

7.14.3 Heat exchanger – Venting


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

Heat exchanger – Venting


1. Open shut-off valves in fuel venting line upstream and downstream of heat exchanger.
2. Vent until bubble-free fuel emerges.
3. Close shut-off valves.

MS15017/00E 06-11 © MTU


156 Task Description

7.14.4 Engine coolant – Level check

Preconditions
• Engine is stopped and starting disabled.
• Engine coolant temperature is under 40 °C.
• MTU Fluids and Lubricants Specification (A001061/..) is available.

Coolant is hot and under pressure.


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

Checking engine coolant level on coolant expansion


tank
1. Coolant level must be between "min." and
"max." marks.
2. If required, top up to “max.” mark with treated
coolant (→ Page 159).

MS15017/00E 06-11 © MTU


Task Description 157

7.14.5 Engine coolant – Change

Material
Designation / Use Part No. Qty.
Engine coolant

Drain engine coolant (→ Page 158).

Fill engine coolant system (→ Page 159).

MS15017/00E 06-11 © MTU


158 Task Description

7.14.6 Engine coolant – Draining

Preconditions
• Engine is stopped and starting disabled.
• Coolant temperature is max. 40 °C

Coolant is hot and under pressure.


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

Preparatory steps
1. Make sure that all drain lines are connected to the drain points (→ Page 150).
2. Switch off preheating unit.

Engine coolant – Draining


1. Turn breather valve of filler neck on coolant expansion tank counterclockwise 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. Draw off engine coolant into wastewater tank (→Shipside draining/filling equipment).
5. Set breather valve onto filler neck and close it.

MS15017/00E 06-11 © MTU


Task Description 159

7.14.7 Engine coolant system – Filling

Preconditions
• Engine is stopped and starting disabled.
• Engine coolant temperature is below 40 °C.
• MTU Fluids and Lubricants Specification (A001061/..) is available.

Material
Designation / Use Part No. Qty.
Engine coolant

Coolant is hot and under pressure.


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

Cold coolant in hot engine can cause thermal stress.


Formation of cracks in components!
CAUTION • Fill / top up coolant only into cold engine.

Preparatory steps
1. Turn breather valve (arrow) of filler neck on coolant
expansion tank counterclockwise to the first stop
and allow pressure to escape.
2. Continue to turn breather valve (arrow)
counterclockwise and remove.

Filling coolant with pump


1. Make sure that the filling line is connected (→shipside draining/filling equipment).
2. Operate pump to fill engine with treated coolant until the required coolant level is reached at the coolant
expansion tank (→ Page 156).

Final steps
1. Start the engine and operate it at idle speed for some minutes.
2. Vent coolant system.
2.1. Open vent (→ Page 150).
2.2. Close vent when bubble-free coolant emerges.
2.3. Repeat this procedure for all vents.
2.4. Close breather valve (arrow) on coolant expansion tank.
3. Check coolant level (→ Page 156).

MS15017/00E 06-11 © MTU


160 Task Description

7.14.8 Engine coolant pump – Relief bore check


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

Engine noise above 85 dB (A).


Risk of damage to hearing!
WARNING • Wear ear protectors.

Engine coolant pump – Relief bore check


1. Check relief bore for oil and water discharge.
2. Stop engine (→ Page 35) and disable engine start.
3. Clean the relief bore with a wire if it is 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.

MS15017/00E 06-11 © MTU


Task Description 161

7.14.9 Engine coolant – Sample extraction and analysis

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

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

Unguarded rotating and moving engine components.


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

Coolant is hot and under pressure.


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

Engine noise above 85 dB (A).


Risk of damage to hearing!
WARNING • Wear ear protectors.

Engine coolant – Sample extraction and analysis


1. Draw off approx. 1 liter of coolant from expansion tank.
2. Using the equipment and chemicals of the MTU test kit, examine coolant for:
• antifreeze concentration;
• corrosion inhibitor concentration;
• pH value.

MS15017/00E 06-11 © MTU


162 Task Description

7.14.10 Coolant system – Strainer removal

Preconditions
• Engine is stopped and starting disabled.
• Coolant temperature is below 40 °C

Material
Designation / Use Part No. Qty.
Petroleum jelly, white

Spare parts
Designation / Use Part No. Qty.
O-ring
Seal

Strainer removal
1. Drain coolant (→ Page 158).
2. Remove screws from elbow (1).
3. Remove elbow (1) from sleeve (5).
Note: Store the strainer for future use after
component maintenance or extended
component maintenance.

4. Remove strainer (7).


5. Coat O-ring (6) with petroleum jelly and insert.
6. Slide elbow (1) onto sleeve (5).
7. Mount elbow (1) with seal (2) with screws on
holder (3) and coolant line (4).
8. Tighten screws.
9. Fill in coolant (→ Page 159).

MS15017/00E 06-11 © MTU


Task Description 163

7.15 Raw Water Pump with Connections

7.15.1 Raw water pump – Relief bore check


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

Engine noise above 85 dB (A).


Risk of damage to hearing!
WARNING • Wear ear protectors.

Raw water pump – Relief bore check


1. Check relief bore for oil and raw water discharge.
2. Stop the engine (→ Page 35) and disable engine
start, observe general "Service and Maintenance"
safety instructions.
3. Clean the relief bore with a wire if it is dirty.
• Permissible raw water discharge: up to 10
drops per hour.
• Permissible oil discharge: up to 5 drops per
hour.
4. If discharge quantity exceeds the specified limits:
Contact Service.

MS15017/00E 06-11 © MTU


164 Task Description

7.15.2 Automatic seawater inductor – Functional test

Preconditions
• Engine is stopped.
Note: During engine operation, the automatic
seawater inductor is controlled and monitored
by the electronic engine control and monitoring
system.

Automatic seawater inductor – Functional test


Note: The automatic seawater inductor is
supplied with compressed air from the
starting air system. Carry out functional
test only once.

1. Operate pushbutton (1) on the solenoid valve of


the automatic seawater inductor (→ Page 150).
Result:
• Seawater pump is vented.
• Seawater emerges from the opening (arrow).
.
2. Release pushbutton (1).
3. Remove contaminants.

MS15017/00E 06-11 © MTU


Task Description 165

7.16 Engine Mounting

7.16.1 Engine mounts – Cleaning


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

Engine mounts – Cleaning


Note: Protect rubber elements from coming into contact with oil and fuel.

1. Wipe rubber surfaces with dry cloth, do not use organic detergents.
2. Thoroughly blow all components clean with compressed air.

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166 Task Description

7.16.2 Engine mounts – securing screws check

Preconditions
• Engine is stopped and starting disabled.
Engine mounts – securing screws check
1. Check securing screws for secure seating.
2. Tighten loose screw connections.

MS15017/00E 06-11 © MTU


Task Description 167

7.17 General Cabling for Engine / Gearbox / Genset

7.17.1 Engine wiring check

Preconditions
• Engine is stopped and starting disabled.

Material
Designation / Use Part No. Qty.
Isopropyl alcohol

Engine wiring check


1. Check securing screws of cable clamps on the engine and tighten loose screw connections.
2. Make certain that cables are securely seated in clamps and cannot move freely.
3. Check cable binders for secure seating, tighten loose cable binders.
4. Replace defective cable binders.
5. Inspect electrical components visually for damage:
• connector housings;
• contacts;
• connector sockets;
• cables and terminals;
• plug-in contacts.
6. If conductors are damaged, contact Service.
7. Clean dirty connector housings, sockets and contacts with isopropyl alcohol.

MS15017/00E 06-11 © MTU


168 Task Description

7.17.2 Sensors and actuators

Item Designation Meaning

1 Y12/1 Solenoid valve A:


Emergency air shut-off flap

2 S12/1 Limit switch A:


Emergency air shut-off flap

MS15017/00E 06-11 © MTU


Task Description 169

Item Designation Meaning

1 Y12/2 Solenoid valve B:


Emergency air shut-off flap

2 S12/2 Limit switch B:


Emergency air shut-off flap

MS15017/00E 06-11 © MTU


170 Task Description

Item Designation Meaning

1 B5/1 Pressure sensor 16 bar:


Lube oil pressure before last bearing (Main
ECS).

1 B5/2 Pressure sensor 16 bar:


Lube oil pressure before last bearing (Backup
ECS).

1 B5/3 Pressure sensor 16 bar:


Lube oil pressure before filter.

1 B5/4 Pressure sensor 16 bar:


Lube oil differential pressure

1 B16 Pressure sensor 4 bar:


Engine coolant pressure

1 B10 Pressure sensor 4 bar:


Charge-air pressure

1 B17 Pressure sensor 8 bar:


Control air pressure

MS15017/00E 06-11 © MTU


Task Description 171

Item Designation Meaning

1 B19 Pressure sensor 50 bar:


Starting-air pressure

1 B20.1 Pressure sensor 4 bar:


Fuel pressure before filter.

1 B20.2 Pressure sensor 4 bar:


Fuel pressure after filter.

1 B21 Pressure sensor 4 bar:


Raw water pressure

1 B30.1 Pressure sensor 16 bar:


Piston cooling oil pressure (Main ECS).

1 B30.2 Pressure sensor 16 bar:


Piston cooling oil pressure (Backup ECS).

1 B36 Pressure sensor 8 bar:


ETC lube oil pressure.

1 B42 Pressure sensor 8 bar:


Oil pressure after oil level regulating pump.

1 B46.1 Pressure sensor 100 mbar:


Crankcase pressure (Main ECS)

1 B46.2 Pressure sensor 100 mbar:


Crankcase pressure (Backup ECS)

2 ECS Main ECS and Backup ECS

3 Y35 Air preheater

4 X10 Terminal box governor sensor

5 B11 Fuel rack travel

6 A12 Actuator

7 B7 Lube-oil temperature

8 B28/1, B28/2 Speed sensors

9 B1/1–B1/5 Speed sensors

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172 Task Description

Item Designation Meaning

1 V1 - V4 Control block

2 B12/2 ETC A1 speed

3 B12/5 ETC A2 speed

4 B4/1 - B410 Exhaust temperature of cylinders A1 to A10

5 B6/1 - B6/5 Coolant temperature


B26/1 - B26/3

6 B4/11 - B4/20 Exhaust temperature of cylinders B1 to B10

7 B12/4 ETC B3 speed

8 B12/1 ETC B2 speed

9 B12/3 ETC B1 speed

MS15017/00E 06-11 © MTU


Task Description 173

7.18 Accessories for Engine Governor (Electronic) / Control


System

7.18.1 ECS – Connectors and housing cleaning

Preconditions
• Engine is stopped and starting disabled.

Special tools
Designation / Use Part No. Qty.
Connector pliers 0135315483 1

Material
Designation / Use Part No. Qty.
Isopropyl alcohol

Cleaning ECS housing and connectors


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

Cleaning severely contaminated ECS connectors


1. Use connector pliers to unlock bayonet union nut and withdraw connector.
2. Clean connector housings, connector socket housings and all contacts with isopropyl alcohol.
3. When connectors, sockets and all contacts are dry: Install connectors and check plug-in connections
(→ Page 174).

MS15017/00E 06-11 © MTU


174 Task Description

7.18.2 Plug-in connections – Check

Preconditions
• Engine is stopped and starting disabled.

Special tools
Designation / Use Part No. Qty.
Connector pliers 0135315483 1

Checking plug-in connections


1. Use connector pliers to make certain that all plug-in connections are securely seated
2. Tighten loose bayonet union nuts with connector pliers by turning them clockwise until they lock into place.
3. Ensure that unassigned connector sockets are protected with covering caps.
4. Contact Service if bayonet union nut is defective.

MS15017/00E 06-11 © MTU


Task Description 175

7.18.3 ECS – Removal and installation

Preconditions
• Engine is stopped and starting disabled.

Special tools
Designation / Use Part No. Qty.
Connector pliers 0135315483 1

Incorrect installation can lead to destruction of the device.


Damage to component!
CAUTION • Ensure correct connector alignment.

Removing ECS from engine


1. Note or mark assignment of cables to connector
sockets.
2. Use connector pliers to unlock bayonet union nuts
of the connectors of Main ECS (4) and Backup
ECS (5) by turning them counterclockwise.
3. Withdraw all connectors.
4. Close connector sockets with appropriate covering
caps (1).
5. Secure Main ECS (4) and Backup ECS (5) against
falling down.

1 Mounting rack
2 Engine terminal box ETB
3 Engine terminal box ETB 2 F
4 Main ECS
5 Backup ECS
6 Rubber metal

6. Remove screws (1) between Main ECS (2) and


mounting plate (3) using wrench (4).
7. Take off Main ECS (2) and Backup ECS.

MS15017/00E 06-11 © MTU


176 Task Description

Installing ECS on engine


1. For installation follow reverse sequence of working steps. Ensure that connectors are plugged in the correct
socket.
2. Use connector pliers to turn the bayonet union nuts of the connectors clockwise until they lock into place.

MS15017/00E 06-11 © MTU


Task Description 177

7.19 Displays and Controls, General

7.19.1 Limit switch – Check

Preconditions
• Engine is stopped and starting disabled.
Limit switch – Check
1. Verify that cover (1) is fitted.
2. Verify that limit switch (2) is activated.

MS15017/00E 06-11 © MTU


178 Task Description

7.19.2 Indicator lamp - LED replacement

Special tools
Designation / Use Part No. Qty.
Cap puller 0015383730 1

Spare parts
Designation / Use Part No. Qty.
LED, yellow
LED, red
LED, green

Faulty LED installation can destroy contacts.


Damage to component!
CAUTION • Fit LED with correct polarity.

Removing LED
1. Insert small screwdriver (1) between glass
cover (2) and lamp housing (3).
2. Pry out glass cover together with inscription
label (6). Take care not to break lugs (4).
3. Insert screwdriver between lamp housing and
edge of lens (5).
4. Carefully withdraw lens from lamp housing.
Result: The LED is visible.

MS15017/00E 06-11 © MTU


Task Description 179

5. Apply cap puller (1) to LED and pull out LED.


Record the direction the contact surface marked
“+24V” (2) faces.

Installing LED
1. Insert new LED with correct polarization (note
orientation of the contact surface marked “+24V”).
2. Ensure LED latches in position.
3. Insert lens (1) into lamp housing. Recesses
(2) must be positioned horizontally opposite
one another.
4. Press inscription label onto lower side of glass
cover (5) and set on both together, ensuring that
lugs (3) engage in recesses (4) of the lens.
5. Press glass cover slightly to latch into position.

MS15017/00E 06-11 © MTU


180 Task Description

7.19.3 Fluid level monitor – Check

Preconditions
• Monitoring system is switched on.
• MTU Fluids and Lubricants Specification (A001061/..) is available.

Coolant is hot and under pressure.


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

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

Oils are combustible.


Risk of fire!
WARNING • No naked flames, no electric sparks. Do not smoke. Avoid ignition sources.

Checking function
1. Open cap from the tank.
2. Drain or extract fluid until monitoring system responds.
Result: Fit new fluid level monitor if monitoring system does not respond.
3. Top up with fluid.
4. Close the tank.

MS15017/00E 06-11 © MTU


Task Description 181

7.20 Emergency Instrumentation (LOP)

7.20.1 Engine control system – Operational tests

Preconditions
• Engine is stopped.
Screen test
1. Press key NEXT PAGE.
Result: The next page is displayed.
2. Press key PREVIOUS PAGE.
Result: The previous page is displayed.

Lamp test
1. Press key LAMP TEST and hold.
Result: All spots and illuminated keys light up, if not:
2. Replace defective lamps.

Turn test
1. Press LOCAL CONTROL key.
2. Press TURN ENGINE key.
Result:
• Spot of the key flashes.
• Key is not lit.
• All components involved in the engine start procedure are checked without starting the engine.

Governor test
1. Press LOCAL CONTROL key.
2. Press TEST GOVERNOR key and hold for approx. 8 seconds.
Result: Actuator magnet is retracted to start fuel injection within one second, if not:
3. Note fault messages.
4. Release TEST GOVERNOR key.
Result: Governor test is completed.

Emergency stop test


1. Press EMERGENCY STOP button.
Result:
• Emergency air-shutoff flaps closed.
• Fault messages AL SDAF CLOSED and SS EMERGENCY STOP WITH SDAF are displayed on the LOP.
• On the first graphic screen page, fuel rack travel is indicated as 0 mm, and the marked SDAF CLOSED box
indicates that the emergency shut-off air flaps are closed. .
2. Open emergency air-shutoff flaps manually.

Overspeed test
1. Start engine (→ Page 33).
Result:
• Engine runs at idling speed.
• Clutch is disengaged.
2. Press TEST OVERSPEED key and hold for approx. 5 seconds.
Result:
• Spot of the key flashes.
• Key illumination goes out.
• Test is started.

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182 Task Description

3. Increase engine speed to test speed (admissible speed minus 100 rpm.).
Result:
• Emergency air shut-off flaps close.
• Fault messages
• AL SDAF CLOSED
• SS OVERSPEED
• SS EMERGENCY STOP
are displayed in the display window.
• Test is automatically terminated after 300 seconds.
• Spot flashes no longer.
• Key lights up.
4. Stop the engine.

Checking oil priming pump operation


1. Turn selector switch of oil priming pump to position MAN and hold.
Result:
• Indicator lamp is lit.
• Oil priming pump is running.
2. Turn selector switch of oil priming pump to position AUTO.

Checking preheating unit operation


1. Turn selector switch of oil preheater unit to position MANUAL and hold.
Result:
• Indicator lamp is lit.
• Preheating unit is in operation.
2. Turn selector switch of preheating unit to position AUTOMATIC.

MS15017/00E 06-11 © MTU


Special Tools 183

8 Special Tools

8.1 Special tools

Part No. Designation / Use Qty.

F30030459 Power amplifier 1

F30006211 Ratchet 1

MS15017/00E 06-11 © MTU


184 Special Tools

Part No. Designation / Use Qty.

Y4099505 Feeler gauge 1

F30371153 Wrench 1

MS15017/00E 06-11 © MTU


Special Tools 185

Part No. Designation / Use Qty.

F30027337 Torque wrench 40-200 Nm 1

Torque wrench

F30378615 Ultrasonic cleaning unit 1

MS15017/00E 06-11 © MTU


186 Special Tools

Part No. Designation / Use Qty.

F30372284 Reamer 1

8205892521/00 Nozzle tester 1

MS15017/00E 06-11 © MTU


Special Tools 187

Part No. Designation / Use Qty.

F30378334 Mandrel 1

F30371763 Puller 1

MS15017/00E 06-11 © MTU


188 Special Tools

Part No. Designation / Use Qty.

F30006433 Grease gun 1

5605892099/00 MTU test kit 1

MS15017/00E 06-11 © MTU


Special Tools 189

Part No. Designation / Use Qty.

F30379104 Oil filter wrench 1

Strap wrench

MS15017/00E 06-11 © MTU


190 Special Tools

Part No. Designation / Use Qty.

0015383730 Cap puller 1

0135315483 Connector pliers 1

MS15017/00E 06-11 © MTU


Special Tools 191

8.2 Standard tools – Overview

Part No. Designation Qty.


Use

8205891159/00 General tools kit 1

MS15017/00E 06-11 © MTU


192 Special Tools

MS15017/00E 06-11 © MTU


Annex 193

9 Annex

9.1 Manufacturer’s documentation


See Manufacturer’s documentation.

MS15017/00E 06-11 © MTU


194 Annex

9.2 MTU contact person/service partner


You will find the MTU contact person/service partner for your region at www.mtu-online.com,
worldwide, in the left-hand navigation margin.

MS15017/00E 06-11 © MTU


Annex 195

9.3 Index
16V 1163TB73L engine data . . . . . . . . . . . . . . 20 Engine coolant – Sample extraction and
50-hours service . . . . . . . . . . . . . . . . . . . . . . . 43 analysis . . . . . . . . . . . . . . . . . . . . . . . . . 161
Engine coolant pump – Relief bore
check . . . . . . . . . . . . . . . . . . . . . . . . . . 160
A Engine coolant system – Filling . . . . . . 159
Accessories for Engine Governor (Electronic) / Heat exchanger – Venting . . . . . . . . . . 155
Control System . . . . . . . . . . . . . . . . . . . . . . . . 173 Vent line – Checking for
ECS – Connectors and housing obstructions . . . . . . . . . . . . . . . . . . . . . 154
cleaning . . . . . . . . . . . . . . . . . . . . . . . . 173 Cylinder head cover – Removal and
ECS – Removal and installation . . . . . . 175 installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Plug-in connections – Check . . . . . . . . 174 Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . 88
After stopping the engine . . . . . . . . . . . . . . . . 37 Combustion chambers – Blowing out
Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 condensate . . . . . . . . . . . . . . . . . . . . . . 88
Air filter and dust bowl – Cleaning . . . . 116
Air filter removal and installation . . . . . . 118
Air filter replacement . . . . . . . . . . . . . . . 117
D
Disk-pack filter – Cleaning . . . . . . . . . . . . . . . 138
Air filter and dust bowl – Cleaning . . . . . . . . . . 116
Displays and Controls, General . . . . . . . . . . . 177
Air filter removal and installation . . . . . . . . . . . 118
Fluid level monitor – Check . . . . . . . . . . 180
Air filter replacement . . . . . . . . . . . . . . . . . . . . 117 Indicator lamp - LED replacement . . . . 178
Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Limit switch – Check . . . . . . . . . . . . . . . 177
Emergency air shut-off flaps – Electric Drain and venting points . . . . . . . . . . . . . . . . . 150
control check . . . . . . . . . . . . . . . . . . . . 121
Emergency air shut-off flaps –
Lubrication . . . . . . . . . . . . . . . . . . . . . . 120 E
Emergency air shut-off flaps – ECS – Connectors and housing cleaning . . . . 173
Opening/closing manually . . . . . . . . . . . 122 ECS – Removal and installation . . . . . . . . . . . 175
Service indicator – Signal ring position
check . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Emergency air shut-off flaps – Electric control
check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Air-flow and exhaust flow control flaps –
Functional test . . . . . . . . . . . . . . . . . . . . . . . . 124 Emergency air shut-off flaps – Lubrication . . . 120
Automatic seawater inductor – Functional Emergency air shut-off flaps – Opening/closing
test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Auxiliary materials, fire prevention and Emergency Instrumentation (LOP) . . . . . . . . . 181
environmental protection . . . . . . . . . . . . . . . . . 11 Engine control system – Operational
tests . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Emergency stop from LOP . . . . . . . . . . . . . . . 36
C Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Centrifugal oil filter – Cleaning and filter-sleeve Engine – Barring manually . . . . . . . . . . 85
replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Engine – Barring with starting
Centrifugal oil filter bracket – Removal and system . . . . . . . . . . . . . . . . . . . . . . . . . 87
installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Engine – Barring manually . . . . . . . . . . . . . . . 85
Charge-air Cooling, General, Left Side . . . . . . 115 Engine – Barring with starting system . . . . . . . 87
Intercooler – Checking condensate
Engine control system – Operational tests . . . 181
drain line for coolant discharge and
obstruction . . . . . . . . . . . . . . . . . . . . . . 115 Engine coolant – Change . . . . . . . . . . . . . . . . 157
Combustion chambers – Blowing out Engine coolant – Draining . . . . . . . . . . . . . . . . 158
condensate . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Engine coolant – Level check . . . . . . . . . . . . . 156
Coolant system – Strainer removal . . . . . . . . . 162 Engine coolant – Sample extraction and
Cooling Circuit, General, HT Circuit . . . . . . . . 150 analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Coolant system – Strainer removal . . . . 162 Engine coolant pump – Relief bore check . . . . 160
Drain and venting points . . . . . . . . . . . . 150 Engine coolant system – Filling . . . . . . . . . . . . 159
Engine coolant – Change . . . . . . . . . . . 157
Engine layout . . . . . . . . . . . . . . . . . . . . . . . . . 15
Engine coolant – Draining . . . . . . . . . . . 158
Engine coolant – Level check . . . . . . . . 156

MS15017/00E 06-11 © MTU


196 Annex

Engine Mounting . . . . . . . . . . . . . . . . . . . . . . . 165 G


Engine mounts – Cleaning . . . . . . . . . . 165 General Cabling for Engine / Gearbox /
Engine mounts – securing screws Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
check . . . . . . . . . . . . . . . . . . . . . . . . . . 166 Engine wiring check . . . . . . . . . . . . . . . 167
Engine mounts – Cleaning . . . . . . . . . . . . . . . 165 Sensors and actuators . . . . . . . . . . . . . 168
Engine mounts – securing screws check . . . . 166 General conditions . . . . . . . . . . . . . . . . . . . . . 05
Engine oil – Change . . . . . . . . . . . . . . . . . . . . 134
Engine oil – Level check . . . . . . . . . . . . . . . . . 132 H
Engine oil – Sample extraction and Heat exchanger – Venting . . . . . . . . . . . . . . . . 155
analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Engine oil bypass filter – Replacement . . . . . . 148
I
Engine oil filter – Cleaning filter element . . . . . 139
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Engine oil filter – Replacement . . . . . . . . . . . . 140
Indicator lamp - LED replacement . . . . . . . . . . 178
Engine Overview . . . . . . . . . . . . . . . . . . . . . . . 15
Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Engine layout . . . . . . . . . . . . . . . . . . . . 15
Injector – Assembly . . . . . . . . . . . . . . . 96
Engine side and cylinder designations . . . . . . 17 Injector – Cleaning . . . . . . . . . . . . . . . . 92
Engine Side and Cylinder Designations . . . . . 17 Injector – Disassembly . . . . . . . . . . . . . 95
Engine side and cylinder Injector – Nozzle replacement . . . . . . . 99
designations . . . . . . . . . . . . . . . . . . . . . 17 Injector – Removal and installation . . . . 100
Engine wiring check . . . . . . . . . . . . . . . . . . . . 167 Injector – Replacement . . . . . . . . . . . . . 98
Injector – Tests . . . . . . . . . . . . . . . . . . . 93
Exhaust Flap with Actuators . . . . . . . . . . . . . . 123
Air-flow and exhaust flow control flaps – Injector – Assembly . . . . . . . . . . . . . . . . . . . . 96
Functional test . . . . . . . . . . . . . . . . . . . 124 Injector – Cleaning . . . . . . . . . . . . . . . . . . . . . 92
Exhaust turbocharger control – Control Injector – Disassembly . . . . . . . . . . . . . . . . . . 95
linkage lubrication . . . . . . . . . . . . . . . . . 123
Injector – Nozzle replacement . . . . . . . . . . . . 99
Exhaust turbocharger control – Control linkage
Injector – Removal and installation . . . . . . . . . 100
lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Injector – Replacement . . . . . . . . . . . . . . . . . . 98
Injector – Tests . . . . . . . . . . . . . . . . . . . . . . . . 93
F
Intercooler – Checking condensate drain line for
Fault indication and fault messages . . . . . . . . 60 coolant discharge and obstruction . . . . . . . . . 115
Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Firing Order . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Firing order . . . . . . . . . . . . . . . . . . . . . . 19
L
Leak-fuel tank – Draining . . . . . . . . . . . . . . . . 103
Fluid level monitor – Check . . . . . . . . . . . . . . . 180
Limit switch – Check . . . . . . . . . . . . . . . . . . . . 177
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Fuel filter – Replacement . . . . . . . . . . . 105 Local control mode – Changing engine
Fuel prefilter – Differential pressure check speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
and adjustment of gauge . . . . . . . . . . . 107 Local control mode – Engaging/disengaging the
Fuel prefilter – draining . . . . . . . . . . . . . 108 gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Fuel prefilter – Filter element LOP – Overview . . . . . . . . . . . . . . . . . . . . . . . 23
replacement . . . . . . . . . . . . . . . . . . . . . 112
Lube oil priming pump – Checking direction of
Fuel prefilter – flushing . . . . . . . . . . . . . 110
rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Fuel filter – Replacement . . . . . . . . . . . . . . . . 105
Lube-oil System, Lube-oil Circuit . . . . . . . . . . 132
Fuel prefilter – Differential pressure check and Engine oil – Change . . . . . . . . . . . . . . . 134
adjustment of gauge . . . . . . . . . . . . . . . . . . . . 107 Engine oil – Level check . . . . . . . . . . . . 132
Fuel prefilter – draining . . . . . . . . . . . . . . . . . . 108 Engine oil – Sample extraction and
Fuel prefilter – Filter element replacement . . . 112 analysis . . . . . . . . . . . . . . . . . . . . . . . . . 135
Lube oil priming pump – Checking
Fuel prefilter – flushing . . . . . . . . . . . . . . . . . . 110
direction of rotation . . . . . . . . . . . . . . . . 137
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Oil sludge inspection for metallic
Fuel system – Venting . . . . . . . . . . . . . 104 residues . . . . . . . . . . . . . . . . . . . . . . . . 136
Leak-fuel tank – Draining . . . . . . . . . . . 103
Fuel system – Venting . . . . . . . . . . . . . . . . . . . 104

MS15017/00E 06-11 © MTU


Annex 197

M Putting the engine into operation after scheduled


Main engine dimensions . . . . . . . . . . . . . . . . . 18 out-of-service period . . . . . . . . . . . . . . . . . . . . 32
Main Engine Dimensions . . . . . . . . . . . . . . . . 18
Main engine dimensions . . . . . . . . . . . . 18 R
Maintenance schedule matrix . . . . . . . . . . . . . 44 Raw water pump – Relief bore check . . . . . . . 163
Maintenance tasks . . . . . . . . . . . . . . . . . . . . . 48 Raw Water Pump with Connections . . . . . . . . 163
Manufacturer’s documentation . . . . . . . . . . . . 193 Automatic seawater inductor – Functional
MTU contact person/service partner . . . . . . . . 194 test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Raw water pump – Relief bore
check . . . . . . . . . . . . . . . . . . . . . . . . . . 163
N
Normal Operation: LOS or LOP with S
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Local control mode – Changing engine Safety precautions when working on the
speed . . . . . . . . . . . . . . . . . . . . . . . . . . 40 engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08
Local control mode – Engaging/disengag- Sensors and actuators . . . . . . . . . . . . . . . . . . 168
ing the gearbox . . . . . . . . . . . . . . . . . . . 39 Service indicator – Signal ring position
check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
O Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Oil Filtration/Cooling . . . . . . . . . . . . . . . . . . . . 138 Standard tools – Overview . . . . . . . . . . . . . . . 191
Centrifugal oil filter – Cleaning and Standards for warning notices in the
filter-sleeve replacement . . . . . . . . . . . . 144 publication . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Centrifugal oil filter bracket – Removal Start pilot – Fluid level check . . . . . . . . . . . . . 131
and installation . . . . . . . . . . . . . . . . . . . 147
Start pilot – Start fuel replenishment . . . . . . . . 130
Disk-pack filter – Cleaning . . . . . . . . . . 138
Engine oil bypass filter – Starter – Condition check . . . . . . . . . . . . . . . . 129
Replacement . . . . . . . . . . . . . . . . . . . . 148 Starting Equipment . . . . . . . . . . . . . . . . . . . . . 125
Engine oil filter – Cleaning filter Pressure reducing station – Filter
element . . . . . . . . . . . . . . . . . . . . . . . . . 139 cleaning . . . . . . . . . . . . . . . . . . . . . . . . 128
Engine oil filter – Replacement . . . . . . . 140 Pressure reducing station – Putting into
Piston cooling-oil filter – operation . . . . . . . . . . . . . . . . . . . . . . . . 125
Replacement . . . . . . . . . . . . . . . . . . . . 142 Pressure reducing station – Venting and
Oil priming pump, oil refill pump – putting out of operation . . . . . . . . . . . . . 127
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 83 Start pilot – Fluid level check . . . . . . . . 131
Start pilot – Start fuel replenishment . . . 130
Oil sludge inspection for metallic residues . . . 136
Starter – Condition check . . . . . . . . . . . 129
Operational checks . . . . . . . . . . . . . . . . . . . . . 34
Starting the engine from LOP . . . . . . . . . . . . . 33
Stopping the engine from LOP . . . . . . . . . . . . 35
P
Personnel and organizational require-
ments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 06
T
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . 20
Piston cooling-oil filter – Replacement . . . . . . 142
16V 1163TB73L engine data . . . . . . . . 20
Plug-in connections – Check . . . . . . . . . . . . . 174
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07
PPC, LPU – Functional check . . . . . . . . . . . . . 38
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 51
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Pressure reducing station – Filter cleaning . . . 128
V
Pressure reducing station – Putting into
operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Valve clearance – Check and adjustment . . . . 89
Pressure reducing station – Venting and putting Valve Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
out of operation . . . . . . . . . . . . . . . . . . . . . . . . 127 Cylinder head cover – Removal and
installation . . . . . . . . . . . . . . . . . . . . . . . 91
Pump control – Control and display Valve clearance – Check and
elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 adjustment . . . . . . . . . . . . . . . . . . . . . . 89
Putting the engine into operation after extended Vent line – Checking for obstructions . . . . . . . 154
out-of-service periods (>3 months) . . . . . . . . . 31

MS15017/00E 06-11 © MTU