MTU 12 V 4000 M23F User manual

Operating Instructions
Diesel engine
12 V 4000 M23F
12 V 4000 M23S
16 V 4000 M23F
16 V 4000 M23S
MS150068/01E

Printed in Germany
© 2014 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, mi-
crofilming 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.

Commissioning Note

Table of Contents
1 Safety
1.1 Important provisions for all products 7
1.2 Personnel and organizational requirements 8
1.3 Transport 9
1.4 Safety regulations for maintenance and
repair work 10
1.5 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials 13
1.6 Standards for safety notices in the text 15
2 Product Summary
2.1 Engine Layout 16
2.1.1 Product description 16
2.1.2 Engine layout 28
2.1.3 Overview of sensors and actuators 32
2.2 Engine Side and Cylinder Designations 52
2.2.1 Engine side and cylinder designations 52
2.3 Main Engine Dimensions 53
2.3.1 Engine – Main dimensions 53
2.4 Firing Sequence 55
2.4.1 Firing order 55
2.5 Technical Data 56
2.5.1 12V 4000 M23F engine data, RheinSchUO,
stage II, IMO Tier II 56
2.5.2 12V 4000 M23S engine data, RheinSchUO,
stage II, IMO Tier II 59
2.5.3 12V 4000 M23S engine data, IMO Tier II, EPA
Tier 2 62
2.5.4 16V 4000 M23F engine data, RheinSchUO,
stage II, IMO Tier II 65
2.5.5 16V 4000 M23S engine data, RheinSchUO,
stage II, IMO Tier II 68
2.5.6 16V 4000 M23S engine data, IMO Tier II, EPA
Tier 2 71
3 Operation
3.1 Controls 74
3.2 Putting the engine into operation after
extended out-of-service periods (>3 months) 75
3.3 Putting the engine into operation after
scheduled out-of-service-period 76
3.4 Starting the engine 77
3.5 Operational checks 78
3.6 Tasks after extended out-of-service periods
(>3 weeks) 79
3.7 Checks prior to start-up 80
3.8 Fuel treatment system – Putting into
operation 81
3.9 Fuel treatment system – Switching on 84
3.10 Fuel treatment system – Shutdown 85
3.11 Stopping the engine 86
3.12 Emergency engine stop 87
3.13 After stopping the engine 88
3.14 Plant – Cleaning 89
4 Maintenance
4.1 Maintenance task reference table [QL1] 90
5 Troubleshooting
5.1 Troubleshooting 92
5.2 Fuel treatment system – Troubleshooting 95
5.3 Engine governor ADEC (ECU 7) fault
messages for Series 4000 engines, marine
application 96
5.4 Engine governor ADEC (ECU 7) – Fault
codes 97
6 Task Description
6.1 Engine 162
6.1.1 Engine – Barring manually 162
6.1.2 Engine – Barring with starting system 164
6.2 Cylinder Liner 165
6.2.1 Cylinder liner – Endoscopic examination 165
6.2.2 Instructions and comments on endoscopic and
visual examination of cylinder liners 167
6.3 Crankcase Breather 169
6.3.1 Crankcase breather – Overview 169
6.3.2 Crankcase breather – Oil mist fine separator
replacement 171
6.4 Valve Drive 172
6.4.1 Valve gear – Lubrication 172
6.4.2 Valve clearance – Check and adjustment 173
6.4.3 Cylinder head cover – Removal and
installation 176
6.5 Injection Pump / HP Pump 177
6.5.1 HP pump – Filling with engine oil 177
6.5.2 HP pump – Relief bore check 178
6.6 Injection Valve / Injector 179
6.6.1 Injector – Replacement 179
6.6.2 Injector – Removal and installation 180
6.7 Fuel Filter 185
6.7.1 Supplementary fuel filter – Overview 185
6.7.2 Additional fuel filter – Replacement 186
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6.7.3 Fuel filter – Replacement 187
6.7.4 Fuel system – Venting 189
6.7.5 Fuel prefilter – Differential pressure check
and adjustment of gauge 190
6.7.6 Fuel prefilter – Draining 191
6.7.7 Fuel prefilter – Flushing 193
6.7.8 Fuel prefilter with water separator – Filter
element replacement 195
6.7.9 Fuel prefilter with water separator – O-ring
replacement in rotary slide valve 197
6.8 Exhaust Turbocharger 198
6.8.1 Overview of turbocharger 198
6.8.2 Compressor wheel – Cleaning 205
6.9 Charge-Air Cooling 213
6.9.1 Intercooler – Checking condensate drain for
water discharge and obstruction 213
6.10 Air Filter 214
6.10.1 Air filter – Replacement 214
6.10.2 Air filter – Removal and installation 215
6.11 Air Intake 216
6.11.1 Service indicator – Signal ring position check
(optional) 216
6.12 Starting Equipment 217
6.12.1 Starter – Condition check 217
6.13 Lube Oil System, Lube Oil Circuit 218
6.13.1 Engine oil – Level check 218
6.13.2 Engine oil – Change 219
6.13.3 Engine oil – Sample extraction and analysis 221
6.14 Oil Filtration / Cooling 223
6.14.1 Engine oil filter ‒ Replacement 223
6.14.2 Oil indicator filter – Cleaning and check 225
6.14.3 Centrifugal oil filter – Cleaning and filter
sleeve replacement 227
6.15 Coolant Circuit, General, High-Temperature
Circuit 230
6.15.1 Drain and vent points 230
6.15.2 Engine coolant level – Check 234
6.15.3 Engine coolant – Change 235
6.15.4 Engine coolant – Draining 236
6.15.5 Engine coolant – Filling 239
6.15.6 HT coolant pump – Relief bore check 241
6.15.7 Engine coolant – Sample extraction and
analysis 242
6.15.8 Engine coolant filter – Replacement 243
6.15.9 Preheating unit 244
6.15.10 Preheater – Overhaul 247
6.15.11 Preheater – Function and leak-tightness check 248
6.16 Raw Water Pump with Connections 249
6.16.1 Raw water pump – Relief bore check 249
6.17 Engine Mounting / Support 250
6.17.1 Engine mounting – Check 250
6.18 Battery-Charging Generator 251
6.18.1 Battery-charging generator drive – Coupling
condition check 251
6.19 Auxiliary PTO 252
6.19.1 Bilge pump – Relief bore check 252
6.20 Fuel Supply System 253
6.20.1 Water drain valve – Check 253
6.20.2 Differential pressure gauge – Check 254
6.20.3 Water level probe (3-in-1 rod electrode) –
Check 255
6.20.4 Pump capacity – Check 256
6.20.5 Coalescer filter element – Replacement 257
6.21 Wiring (General) for Engine/Gearbox/Unit 259
6.21.1 Engine wiring harness – Overview 259
6.21.2 Engine wiring – Check 265
6.22 Accessories for (Electronic) Engine
Governor / Control System 266
6.22.1 CDC parameters – Reset 266
6.22.2 Limit switch for start interlock ‒ Check 267
6.22.3 Engine Control Unit ECU 7 – Checking plug
connections 268
6.22.4 Engine Monitoring Unit EMU 7 – Plug
connection check 269
6.22.5 Interface module EIM plug connections –
Check 270
6.22.6 Engine Control Unit ECU 7 – Removal and
installation 271
6.22.7 EMU 7 – Removal and installation 272
6.22.8 Engine Interface Module EIM – Removal and
installation 273
6.22.9 Diagnostic features of EIM 274
7 Appendix A
7.1 Abbreviations 277
7.2 MTU contact persons/service partners 279
8 Appendix B
8.1 Special Tools 280
8.2 Index 285
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1 Safety
1.1 Important provisions for all products
Nameplate
The product is identified by nameplate, model designation or serial number and must match with the
information on the title page of this manual.
Nameplate, model designation or serial number can be found on the product.
General information
This product may pose a risk of injury or damage in the following cases:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Modifications or conversions
• Noncompliance with the safety instructions and warning notices
Correct use
The product is intended exclusively for the application specified in the contract or defined at the time of
delivery.
This means that the equipment must be operated:
• Within the permissible operating parameters in accordance with the (→ Technical data)
• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubri-
cants Specifications of the manufacturer)
• With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU
contact/Service partner)
• In the original as-delivered configuration or in a configuration approved by the manufacturer in writ-
ing (including engine control/parameters)
• In compliance with all safety regulations and in adherence with all warning notices in this manual
• In accordance with the maintenance requirements over the entire service life of the product (→ Main-
tenance Schedule)
• In compliance with the maintenance and repair instructions contained in this manual, in particular
with regard to the specified tightening torques
• With the exclusive use of technical personnel trained in commissioning, operation, maintenance and
repair
• By contracting only workshops authorized by the manufacturer to carry out repair and overhaul
Any other use is considered improper use and increases the risk of personnel injury or material damage
in product operation. The manufacturer will accept no liability for such damage.
Modifications or conversions
Unauthorized modifications to the product compromise safety.
The manufacturer will accept no liability or warranty claims for any damage caused by unauthorized
modifications or conversions.
Spare parts
Only genuine spare parts must be used to replace components or assemblies.
The manufacturer will accept no liability or warranty claims for any damage caused by the use of other
spare parts.
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1.2 Personnel and organizational requirements
Organizational measures of the operator
This manual must be issued to all personnel involved in operation, maintenance, repair or transporta-
tion.
Keep this manual handy in the vicinity of the product such that it is accessible to operating, mainte-
nance, repair and transport personnel at all times.
Use this manual as a basis for instructing personnel on product operation and repair, whereby the safe-
ty-relevant instructions, in particular, must be read and understood.
This is particularly important in the case of personnel who only occasionally perform work on or around
the product. This personnel must be instructed repeatedly.
Personnel requirements
All work on the product shall be carried out by trained and qualified personnel only.
• Training at the Training Center of the manufacturer
• Qualified personnel specialized in mechanical and plant engineering
The operator must define the responsibilities of the personnel involved in operation, maintenance, re-
pair and transport.
Working clothes and personal protective equipment
Wear proper protective clothing for all work.
When working, always wear the necessary personal protective equipment (e.g. ear protectors, protec-
tive gloves, goggles, breathing protection). Observe the information on personal protective equipment
in the respective activity description.
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1.3 Transport
Transport
Attach the engine at the lifting eyes provided only.
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 gear 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 trans-
port 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.
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1.4 Safety regulations for maintenance and repair work
Safety regulations prior to maintenance and repair work
Have maintenance or repair work carried out by qualified and authorized personnel only.
Allow the product to cool down to below 50°C before starting maintenance work (risk of explosion of oil
vapors, fluids and lubricants, risk of burning).
Before starting work, relieve pressure in systems and compressed-air lines which are to be opened. Use
suitable containers of adequate capacity to catch fluids and lubricants.
When changing the oil or working on the fuel system, ensure that the service room is adequately venti-
lated.
Never carry out maintenance and repair work with the product in operation, unless:
• It is expressly permitted to do so following a written procedure.
• The product is running in the low load range and only for as long as absolutely necessary.
Secure the product against unintentional starting, e.g. with start interlock.
Attach “Do not operate” sign in the operating area or to control equipment.
Disconnect the battery. Lock contactors.
Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic
starters are fitted.
Disconnect the control equipment from the product.
The following applies to starters with copper-beryllium alloy pinions:
• Wear breathing protection of filter class P3 during maintenance work. Do not blow out the interior of
the flywheel housing or the starter with compressed air. Clean the flywheel housing inside with a
class H dust extraction device.
• Observe the safety data sheet.
Safety regulations during maintenance and repair work
Take special care when removing ventilation or plug screws from the product. Cover the screw or plug
with a rag to prevent fluids escaping under pressure.
Take care when draining hot fluids and lubricants (risk of burning).
Use only proper and calibrated tools. Observe the specified tightening torques during assembly or dis-
assembly.
Carry out work only on assemblies or plants which are properly secured.
Never use lines for climbing.
Keep fuel injection lines and connections clean.
Always seal connections with caps or covers if a line is removed or opened.
Take care not to damage lines, in particular fuel lines, during maintenance and repair work.
Ensure that all retainers and dampers are installed correctly.
Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent
contact with other components. Do not place fuel or oil lines near hot components.
Do not touch elastomer seals if they have carbonized or resinous appearance unless hands are properly
protected.
Note cooling time for components which are heated for installation or removal (risk of burning).
When working high on the equipment, always use suitable ladders and work platforms. Make sure com-
ponents or assemblies are placed on stable surfaces.
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