5.6.1 Main Propulsion Engines - Service Manual_8V4000M.pdf

Technical Publication

Diesel Engine 8 V 4000 M60 R 12 V 4000 M60 R 16 V 4000 M60 R 16 V 4000 M61 R

Operating Instructions M015685/01E

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

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

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

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

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

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.

1 Safety

Safety, accident prevention and environmental protection instructions

2 Product Summary

Engine layout, technical data

3 Operation

Task descriptions

4 Mantenance and Servicing

Maintenance schedule

5 Troubleshooting

Malfunctions, causes, measures

6 Task Description

Inspection and maintenance tasks

7 Annex

Abbreviations

Index

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.:

Engine No.:

No du moteur:

No de motor:

Motore N.:

No. do motor:

Auftragsnr.:

MTU works order No.:

N° de commande:

N° de pedido:

N. commessa:

No. do pedido:

Motortyp:

Engine model:

Type du moteur:

Tipo de motor:

Motore tipo:

Tipo do motor:

Inbetriebnahmedatum:

Date put into operation:

Mise en service le:

Fecha de puesta en servicio:

Messa in servizio il:

Data da colocação em serviço:

Eingebaut in:

Installation site:

Lieu de montage:

Lugar de montaje:

Installato:

Incorporado em:

Schiffstyp / Schiffshersteller:

Vessel/type/class / Shipyard:

Type du bateau / Constructeur:

Tipo de buque / Constructor:

Tipo di barca / Costruttore Tipo de embarcação/estaleiro naval:

Endabnehmer/Anschrift:

End user`s address:

Adresse du client final:

Dirección del cliente final:

Indirizzo del cliente finale:

Usuário final/endereço:

Bemerkung:

Remarks:

Remarques:

Observaciones:

Commento:

Observações:

Inbetriebnahme-meldung

Commissioning Note

Notice de mise en service

Aviso de puesta en servicio

Avviso di messa in servizio

Participação da colocação em serviço

Table of Contents 01

1 Safety

1.1 General conditions

1.2 Personnel and organizational requirements

1.3 Transport

1.4 Safety precautions when working on the engine

1.5 Auxiliary materials, fire prevention and environmental protection

1.6 Standards for warning notices in the publication

2 Product Summary

2.1 Engine Layout

2.1.1 Product description

2.1.2 Engine layout

2.1.3 Engine layout

2.2 Engine Side and Cylinder Designations

2.2.1 Engine side and cylinder designations

2.3 Main Engine Dimensions

2.3.1 Main engine dimensions

2.4 Firing Order

2.4.1 Firing order

2.5 Technical Data

2.5.1 8V 4000 M60R engine data: IMO, engine-mounted heat exchanger

2.5.2 8V 4000 M60R engine data: IMO, separate heat exchanger

2.5.3 8V 4000M 60R engine data: Engine-mounted heat exchanger, IMO - 40%

2.5.4 8V 4000 M60R engine data: Separate heat exchanger, IMO - 40%

2.5.5 12V 4000 M60R engine data: IMO, engine-mounted heat exchanger

2.5.6 12V 4000 M60R engine data: IMO, separate heat exchanger

2.5.7 12V 4000 M60R engine data: Engine-mounted heat exchanger, IMO - 40%

2.5.8 12V 4000 M60R engine data: Separate heat exchanger, IMO - 40%

2.5.9 16V 4000 M60R engine data: Engine-mounted heat exchanger

2.5.10 16V 4000 M60R engine data: Engine-mounted heat exchanger, IMO - 40%

2.5.11 16V 4000 M60R engine data: Separate heat exchanger

2.5.12 16V 4000 M60R engine data: Separate heat exchanger, IMO - 40%

2.5.13 16V 4000 M61R engine data: IMO, Intake air temperature 45°C, separate heat exchanger

2.5.14 16V 4000 M61R engine data: IMO, mounted heat exchanger

2.5.15 16V 4000 M61R engine data: IMO, separate heat exchanger

3 Operation

3.1 LOP controls

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

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

3.4 Starting the engine from LOP

M015685/01E 05-11 © MTU

02 Table of Contents

3.5 Starting the engine at the BlueLine automation system (control stand)

3.6 Operational checks

3.7 Clutch – Engaging from LOP

3.8 Clutch – Disengaging from LOP

3.9 Waterjet – Flushing from LOP (optional)

3.10 Stopping the engine from LOP

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

3.12 Emergency stop from LOP

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

3.14 After stopping the engine

4 Maintenance

4.1 Preface

4.2 Maintenance schedule matrix

4.3 Maintenance tasks

5 Troubleshooting

5.1 Troubleshooting

5.2 LOP alarms

6 Task Descriptions

6.1 Engine

6.1.1 Engine – Barring manually

6.1.2 Engine – Barring with starting system

6.2 Cylinder Liner

6.2.1 Cylinder liner – Endoscopic examination

6.2.2 Instructions and comments on endoscopic and visual examination of cylinder liners

6.3 Crankcase Breather

6.3.1 Crankcase breather – Oil separator replacement, diaphragm check and replacement

6.3.2 Crankcase breather – Oil separator replacement, diaphragm check and replacement

6.3.3 Crankcase breather – oil separator replacement

6.4 Valve Gear

6.4.1 Valve gear – Lubrication

6.4.2 Valve clearance – Check and adjustment

6.4.3 Cylinder head cover – Remove and install

6.5 Injection Pump / HP Pump

6.5.1 HP fuel pump – Relief bore check

6.6 Fuel Injector

6.6.1 Injector replacement

6.6.2 Injector – Removal and installation

Table of Contents 03

6.7 Fuel System

6.7.1 Fuel system – Venting and filling

6.8 Fuel Filter

6.8.1 Fuel filter – Replacement

6.8.2 Fuel prefilter – differential pressure check and adjustment of gauge

6.8.3 Fuel prefilter – draining

6.8.4 Fuel prefilter – flushing

6.8.5 Fuel prefilter – filter element replacement

6.9 Charge-air Cooling, General, Left Side

6.9.1 Intercooler – Checking condensate drain line for coolant discharge and obstruction

6.10 Air Filter

6.10.1 Air filter replacement

6.10.2 Air filter removal and installation

6.11 Air Intake

6.11.1 Service indicator – Signal ring position check

6.11.2 Air-flow control flap – check for ease of movement

6.12 Exhaust-Flow Control Flap with Controls

6.12.1 Exhaust-flow control flap – check for ease of movement

6.13 Starting System

6.13.1 Starter – Condition check

6.14 Lube Oil System / Lube Oil Circuit

6.14.1 Engine oil – Change

6.14.2 Engine oil – Level check

6.14.3 Engine-oil – Sample extraction and analysis

6.15 Oil Filtration / Cooling

6.15.1 Engine oil filter – Replacement

6.15.2 Centrifugal oil filter – Cleaning and filter-sleeve replacement

6.16 Coolant Circuit, General, HT Circuit

6.16.1 Engine coolant – Change

6.16.2 Engine coolant filling

6.16.3 Engine coolant draining

6.16.4 Engine coolant – Level check

6.16.5 Engine coolant pump – Relief bore check

6.16.6 Engine coolant – Sample extraction and analysis

6.17 Raw Water Pump with Connections

6.17.1 Raw water pump – Relief bore check

6.18 Battery-charging Generator

6.18.1 Battery-charging generator drive – Coupling condition check

6.19 Engine Mounts

6.19.1 Engine mounts – securing screws check

6.19.2 Engine mounts – Resilient elements check

6.20 PTO Systems, KS and KGS (coupling)

6.20.1 Coupling condition check

04 Table of Contents

6.21 Auxiliary PTO

6.21.1 Bilge pump – Relief bore check

6.22 Wiring, General, for Engine / Gearbox / Plant

6.22.1 Engine wiring check

6.23 Accessories for (Electronic) Engine Governor / Control System

6.23.1 ECU and connectors – Cleaning

6.23.2 EMU and connectors – Cleaning

6.23.3 Start interlock limit switch check

6.23.4 ECU – Checking plug-in connections

6.23.5 EMU – Checking plug-in connections

6.23.6 ECU – Removal and installation

6.24 Emergency Instrumentation (Control Stand)

6.24.1 LOP and connectors cleaning

6.24.2 LOP – visual inspection

6.24.3 LOP test procedures

7 Annex

7.1 Manufacturer’s documentation

7.2 MTU contact person/service partner

7.3 Abbreviations

7.4 Index

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.

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.).

Safety 07

1.3 Transport

Engine transport

Lift the engine only with the lifting eyes provided.

The lifting eyes are designed for engine transport only, not for the transport of propulsion units (engine and gearbox).

Use only the transport and lifting equipment approved by MTU.

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

Take note of the engine center of gravity.

In the case of special packaging with aluminum foil, suspend the engine on the lifting eyes of the 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.

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.

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).

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.

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 fluids near the engine.

Do not weld pipes and components carrying oil or fuel. Before welding, clean with a non-combustible fluid.

When starting the engine with a foreign power source, connect the ground lead last and remove it first.

To avoid sparks in the vicinity of the battery, connect the ground lead from the foreign power source to the ground lead of the engine or to the ground terminal of the starter.

Always keep suitable fire-fighting equipment (fire extinguishers) at hand and familiarize yourself with their use.

SOLAS classification On engines/plants with SOLAS classification, operational checks must include the following tasks:

• Check all protective covers (according to SOLAS) of lube-oil and fuel connections (>1.8 bar) for damage, replace if necessary (→ Page 15)

Noise Noise can lead to an increased risk of accident if acoustic signals, warning shouts or noises indicating danger are drowned.

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

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

Manipulation of the injection control system can influence the engine performance and exhaust emissions.

As 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 plants that may affect water quality) is applicable, which means work must only be carried out by authorized specialist companies (MTU is an authorized specialist 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 and do not smoke.

Lead

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

• Adopt suitable measures to avoid the formation of lead dust!

• Switch on fume extraction system.

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

Acids and alkaline solutions

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

• Immediately remove clothing wetted by acids and alkalis!

• Rinse injuries with plenty of water!

• Rinse eyes immediately with eyedrops or clean tap water.

Painting

• When painting in other than spray booths equipped with extractors, ensure good ventilation.

Make sure that adjacent work areas are not affected.

• No naked flames!

• No smoking.

• Observe fire prevention regulations!

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

12 Safety

Liquid nitrogen

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

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

• Wear protective clothing, gloves, closed shoes and protective goggles!

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

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

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

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

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

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

• Connecting devices and equipment must either be designed for this pressure or, if the permitted pressure for the connecting elements is lower than the pressure required, a pressure reducing valve and safety valve (set to permitted pressure) must form an intermediate connection.

Hose coupling and connections must be securely attached!

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

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

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

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

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

• Do not blow dirty clothing with compressed air when being worn on the body.

Used oil Used oil may contain health-threatening combustion residues.

Rub barrier cream into hands!

Wash hands after contact with used oil.

Safety 13

1.6 Standards for warning notices in the publication

DANGER

In the event of immediate danger.

Consequences: Death or serious injury.

• Preventive measures

WARNING

In the event of possibly dangerous situations.

Consequences: Death or serious injury.

• Preventive measures

CAUTION

In the event of dangerous situations.

Consequences: Slight injury or material damage.

• 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!

14 Safety

Product Summary 15

2 Product Summary

2.1 Engine Layout

2.1.1 Product description

Description of the engine Engine The engine is a liquid-cooled four-stroke diesel engine, rotating counter-clockwise (seen from driving end), with direct injection, sequential turbocharging and charge air cooling.

The engine is monitored by an engine control and monitoring system (MDEC).

The monitoring in the engine room is carried out by the engine control and monitoring unit (LOP).

Fuel system Electronically controlled common-rail-injection system with H.P. pump, pressure accumulator (rail) and single injectors.

The electronic control unit controls

• Injection timing

• Injection amount

• Injection pressure

Exhaust System The exhaust system is equipped with triple-walled, water-cooled exhaust lines.

The triple-walled design permits

• low surface temperature,

• reduced amount of heat to be dissipated by the coolant,

• absolute gas-tightness.

Turbocharging Sequential turbocharging with internal, engine-coolant-controlled charge air cooling. The right-hand exhaust turbocharger is cut-in and cut-out with electronically controlled, hydraulically actuated flaps.

Cooling system Engine cooling as split-circuit cooling system with plate-core heat exchanger.

Heating of the charge-air in idle and low-load operation prevents white smoke formation.

Seawater only circulates in the engine coolant cooler and seawater pump.

Service block The service components are mounted at the auxiliary PTO end.

The layout permits easy access for maintenance.

Service components:

• Raw water pump, coolant pump

• Fuel duplex filter, switchable

• Lube-oil multiple filter, switchable

• Centrifugal lube-oil filter

• Coolant expansion tank

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

Electronic engine governor (ECU) Functions:

• Engine speed control with fuel and speed limitation dependent on engine status and operating conditions;

• Control of sequential turbocharging;

16 Product Summary

• Data processing logistics for analog and binary signals;

• Interface for data transfer to CAN field bus for remote control and ship-side monitoring;

• RS 232 Interface for connection of MTU-dialog unit.

Electronic engine monitoring unit (EMU), optional Functions:

• Data processing logistics for analog and binary signals;

• Interface for data transfer to CAN field bus for remote control and ship-side monitoring;

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

• Date processing logistics for gear coupling control;

• Input/output signals as well as data transfer to CAN field bus for remote control and ship-side monitoring.

Monitoring in engine room Engine control and monitoring unit (LOP) Functions:

• Alphanumeric, monochrome LCD display for monitoring of measured values as well as alarms when limits are exceeded;

• Pushbuttons for menu control and dimming unit;

• Combined control and display elements for local engine/gear control;

• Flashing light and horn for combined alarm in engine room;

• Interface to CAN field bus for connected, communicating monitoring system components.

SOLAS – Fire protection specifications Fuel system, fuel lines with fuel pressure >1.8 bar All lines fitted with SOLAS-compliant covers for pipe connections, according to MTU standard MTN5233, are shown.

Product Summary 17

1 Return line 2 Fuel line on fuel delivery pump

3 Non-return valve 4 Male connecting nipple

5 Fuel line on H.P. fuel pump 6 Fuel line on vent line

Lube oil system, oil lines with oil pressure >1.8 bar All lines fitted with SOLAS-compliant covers for pipe connections, according to MTU standard MTN5233, are shown.

18 Product Summary

1 Seal, oil line to ETC 2 Oil line, ETC 3 Connection, oil line to distributor 4 Oil line, ETC 5 Oil line, lube oil pump 6 Oil line on distributor 7 Connection, oil line on control block

8 Oil line on control block 9 Oil lines on T-piece

10 Oil line, valve housing 11 Oil line, actuating cylinder to control block 12 Oil line, actuating cylinder to control block

13 Connection, oil line to actuating cylinder

14 Connection, plug-in pipe to cover in V

15 O-ring, connection, plug-in pipe to distributor

Special connections In case of leakage, the following connection types are spray-protected even without a cover and have been confirmed as compliant with SOLAS by GL and DNV.

Product Summary 19

Plug-in pipe connection The sleeve (4) covers the joint to prevent lateral spray.

Only leak-off along the line is possible, the pressure decreases significantly if an O-ring (3) defect occurs.

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

Plug and sensors Screw-in plugs (2) are sealed toward the outside either with a copper sealing ring (1), according to DIN, or an O-ring (ISO).

In case of loose thread or a defective sealing ring (2), the liquid first has to pass the thread.

Because of the defective sealing ring (2), the pressure is so reduced, that the leak runs off without pressure.

20 Product Summary

H.P. connections

1 Jacketed barrel 2 H.P. fuel line 3 O-ring 4 Union nut 5 Groove for O-ring 6 Thrust ring

7 Leakage-overflow bore 8 Thrust ring 9 Union nut

10 Union nut 11 Connecting piece 12 Circlip

13 Thrust ring 14 Shims 15 Union nut 16 Thrust ring 17 O-ring

The H.P. fuel line is sealed by the thrust ring (8).

If leakage in the area of the thrust ring (8) or the H.P. line (5) occurs, the emerging fuel is routed to the leakage chamber.

The leaking is drained off without pressure via the leakage overflow-bore (7). The leakage chamber is sealed toward the outside by the O-rings (3).

This prevents the leak from escaping.

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

Product Summary 21

Protective cover of fuel filters and lube oil filters Protective cover with a plastic ring

The plastic ring (1) prevents lateral spray.

The liquid is routed into the collector bowl and the pressure is greatly reduced.

Protective cover with lip

The lip (1) prevents lateral spray.

The liquid is routed into the collector bowl and the pressure is greatly reduced.

22 Product Summary

2.1.2 Engine layout

Illustration is applicable to 8V 4000M engines

010 Crankcase and attachments 020 Gear train 030 Running gear 040 Cylinder head 050 Valve gear 070 HP fuel system 080 LP fuel system 100 Exhaust turbocharger 110 Intercooler

120 Air intake / air supply 140 Exhaust system 170 Starting equipment 180 Lube oil system 200 Cooling system 210 Electric power supply, engine-related 230 Mounting system

250 Drive systems, driving end and free end (coupling)*

360 Auxiliary systems / accessory equipment*

500 Monitoring and control system, general electric devices

* not shown

Product Summary 23

Engine model designation Key to the engine model designations 8/12/16V 4000 Mxyz

8/12/16 Number of cylinders

V Cylinder configuration: Vee engine

4000 Series m Application x Application segment (4,5, 6,7,9)

Y Design index (0, 1, 2,...)

z Special features

24 Product Summary

2.1.3 Engine layout

010 Crankcase and attachments 020 Gear train 030 Crank drive 040 Cylinder head 050 Valve gear 070 HP fuel system 080 LP fuel system 100 Exhaust turbocharger

110 Intercooler 120 Air intake / air supply 140 Exhaust system 170 Starting equipment 180 Lube oil system 200 Cooling system 210 Electric power supply, engine-related

230 Mounting / support 250 Drive systems, drive end and free end (coupling) 500 Monitoring and control system, general electric devices

Engine model designation Key to the engine model designations 12/16V 4000 Mxy

12/16 Number of cylinders

V Cylinder configuration: Vee engine

4000 Series m Application x Application segment (4, 5, 6, 7, 8, 9) y Design index (1, 2,...)

Product Summary 25

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 2 Right side

3 KS = Driving end 4 Left side

26 Product Summary

2.3 Main Engine Dimensions

2.3.1 Main engine dimensions

Main engine dimensions

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

8V 4000 M60/M60R, engine-mounted heat exchanger approx. 2339 mm approx. 1400 mm approx. 1987 mm

8V 4000 M60/M60R, separate heat exchanger approx. 1985 mm approx. 1400 mm approx. 1987 mm

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

12V 4000 M60/M60R, engine-mounted heat exchanger approx. 3203 mm approx. 1520 mm approx. 1836 mm

12V 4000 M60/M60R, separate heat exchanger approx. 2762 mm approx. 1520 mm approx. 1836 mm

Product Summary 27

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

16V 4000 M60/M60R, engine-mounted heat exchanger approx. 3692 mm approx. 1520 mm approx. 1836 mm

16V 4000 M60/M60R, separate heat exchanger approx. 3232 mm approx. 1520 mm approx. 1836 mm

16V 4000 M61/M61R, engine-mounted heat exchanger approx. 3692 mm approx. 1520 mm approx. 1836 mm

16V 4000 M61/M61R, separate heat exchanger approx. 3232 mm approx. 1520 mm approx. 1836 mm

28 Product Summary

2.4 Firing Order

2.4.1 Firing order

Firing order

8 V A1-B4-A4-A2-B3-A3-B2-B1

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

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

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

Product Summary 29

2.5 Technical Data

2.5.1 8V 4000 M60R engine data: IMO, engine-mounted heat exchanger Explanation:

DL Ref. value: Continuous power (CP) BL Ref. value: Fuel stop power (FSP)

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 setting) N Not yet defined value

- Not applicable

X Applicable

REFERENCE CONDITIONS

Engine model 8V4000M60R

Application group 1A

Intake air temperature °C 25

Raw water inlet temperature °C 25

Barometric pressure mbar 1000

Site altitude above sea level m 100

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

Number of cylinders 8

Engine rated speed A rpm 1600

Fuel stop power ISO 3046 A kW 700

GENERAL CONDITIONS (for maximum power)

Number of cylinders 8

Intake air depression (new filter) A mbar 25

Intake air depression, max. L mbar 35

30 Product Summary

MODEL-RELATED DATA (basic design)

Number of cylinders 8

Cylinder configuration: V angle degrees 90

Bore mm 165

Stroke mm 190

Cylinder displacement liter 4.06

Total displacement liter 32.5

Number of inlet valves, per cylinder 2

Number of exhaust valves, per cylinder 2

RAW WATER CIRCUIT (open circuit)

Number of cylinders 8

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

Raw water pump: inlet pressure, max. L bar +0.5

Pressure loss in the external raw water system, max. L bar 1.3

LUBE OIL SYSTEM

Number of cylinders 8

Lube oil operating temperature before engine, from R °C 85

Lube oil operating temperature before engine, to R °C 90

Lube oil operating pressure before engine, from R bar 5.3

Lube oil operating pressure before engine, to R bar 5.8

Lube oil operating pressure, low idle (meas. point: before engine) R bar 2.0

FUEL SYSTEM

Number of cylinders 8

Fuel pressure at supply connection to engine, min. (during engine starting) L bar -0.1

Fuel pressure at supply connection to engine, min. (during engine operation) L bar -0.3

Fuel pressure at supply connection to engine, max. (during engine starting) L bar 1.5

Fuel supply flow, max. R liter/min 13.0

STARTING (electric)

Number of cylinders 8

Rated starter voltage (standard design) R V= 24

Product Summary 31

STARTING (pneumatic starter)

Number of cylinders 8

Starting air pressure before starter motor, min. R bar 16

Starting air pressure before starter motor, max. R bar 30

INCLINATIONS - STANDARD OIL SYSTEM (ref.: waterline)

Number of cylinders 8

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

L degrees 15

Longitudinal inclination, temporary max. driving end down (Option: max. operating inclinations)

L degrees 22.5

Longitudinal inclination, continuous max. driving end up (Option: max. operating inclinations)

L degrees 10

Longitudinal inclination, temporary max. driving end up (Option: max. operating inclinations)

L degrees N

Transverse inclination, continuous max. (Option: max. operating inclinations) L degrees 22.5

CAPACITIES

Number of cylinders 8

Engine coolant capacity (with cooling equipment) R liter 210

Engine oil capacity, initial filling (standard oil system) (Option: max. operating inclinations)

R liter 145

Oil change quantity, max. (standard oil system) (Option: max. operating inclinations)

R liter 120

Oil pan capacity, dipstick mark min. (standard oil system) (Option: max. operating inclinations)

L liter 85

Oil pan capacity, dipstick mark max. (standard oil system) (Option: max. operating inclinations)

L liter 115

WEIGHTS / MAIN DIMENSIONS

Number of cylinders 8

Engine dry weight (with attached standard accessories, without coupling) R kg 4630

ACOUSTICS

Number of cylinders 8

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

R db(A) 108

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

R db(A) 101

32 Product Summary

2.5.2 8V 4000 M60R engine data: IMO, separate heat exchanger Explanation:

DL Ref. value: Continuous power (CP) BL Ref. value: Fuel stop power (FSP)

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 setting) N Not yet defined value

- Not applicable

X Applicable

REFERENCE CONDITIONS

Engine model 8V4000M60R

Application group 1A

Intake air temperature °C 25

Raw water inlet temperature °C 25

Barometric pressure mbar 1000

Site altitude above sea level m 100

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

Number of cylinders 8

Engine rated speed A rpm 1600

Fuel stop power ISO 3046 A kW 700

GENERAL CONDITIONS (for maximum power)

Number of cylinders 8

Intake air depression (new filter) A mbar 25

Intake air depression, max. L mbar 35

MODEL-RELATED DATA (basic design)

Number of cylinders 8

Cylinder configuration: V angle degrees 90

Bore mm 165

Stroke mm 190

Cylinder displacement liter 4.06

Total displacement liter 32.5

Number of inlet valves, per cylinder 2

Number of exhaust valves, per cylinder 2

Product Summary 33

LUBE OIL SYSTEM

Number of cylinders 8

Lube oil operating temperature before engine, from R °C 85

Lube oil operating temperature before engine, to R °C 90

Lube oil operating pressure before engine, from R bar 5.3

Lube oil operating pressure before engine, to R bar 5.8

Lube oil operating pressure, low idle (meas. point: before engine) R bar 2.0

FUEL SYSTEM

Number of cylinders 8

Fuel pressure at supply connection to engine, min. (during engine starting) L bar -0.1

Fuel pressure at supply connection to engine, min. (during engine operation) L bar -0.3

Fuel pressure at supply connection to engine, max. (during engine starting) L bar 1.5

Fuel supply flow, max. R liter/min 13.0

STARTING (electric)

Number of cylinders 8

Rated starter voltage (standard design) R V= 24

STARTING (pneumatic starter)

Number of cylinders 8

Starting air pressure before starter motor, min. R bar 16

Starting air pressure before starter motor, max. R bar 30

INCLINATIONS - STANDARD OIL SYSTEM (ref.: waterline)

Number of cylinders 8

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

L degrees 15

Longitudinal inclination, temporary max. driving end down (Option: max. operating inclinations)

L degrees 22.5

Longitudinal inclination, continuous max. driving end up (Option: max. operating inclinations)

L degrees 10

Longitudinal inclination, temporary max. driving end up (Option: max. operating inclinations)

L degrees N

Transverse inclination, continuous max. (Option: max. operating inclinations) L degrees 22.5

34 Product Summary

CAPACITIES

Number of cylinders 8

Engine oil capacity, initial filling (standard oil system)…