MTU 20 V 4000 M93 User manual

Operating Instructions
Diesel Engine
20 V 4000 M93
20 V 4000 M93L
MS150048/03E

Printed in Germany
© 2012 Copyright MTU Friedrichshafen GmbH
This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior
written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, micro‐
filming and storage or processing on electronic systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage
during operation.
Subject to alterations and amendments.

Table of Contents
1 Safety
1.1 General conditions 5
1.2 Personnel and organizational requirements 6
1.3 Transport 7
1.4 Crankshaft transport locking device 8
1.5 Safety regulations for startup and operation 11
1.6 Explosion hazard when removing
inspection port cover on engine 12
1.7 Safety regulations for maintenance and
repair work 13
1.8 Auxiliary materials, fluids and lubricants,
fire prevention and environmental
protection 16
1.9 Conventions for safety instructions in the
text 18
2 General Information
2.1 Engine side and cylinder designations 19
2.2 Product description 20
2.3 Engine overview 29
2.4 Sensors, actuators and injectors –
Overview 30
3 Technical Data
3.1 20V 4000 M93 engine data: IMO, engine-
mounted heat exchanger, intercooler made
of copper-based alloy 35
3.2 20V 4000 M93 engine data: EPA 2, engine-
mounted heat exchanger 38
3.3 20V 4000 M93L engine data: IMO, engine-
mounted heat exchanger, intercooler made
of copper-based alloy 41
3.4 20V 4000 M93L engine data: EPA 2,
engine-mounted heat exchanger 44
3.5 Firing order 47
4 Operation
4.1 Controls 48
4.2 Tasks after extended out-of-service periods
(>3 weeks) 49
4.3 Checks prior to start-up 50
4.4 Fuel treatment system – Putting into
operation 51
4.5 Starting the engine 53
4.6 Fuel treatment system – Switching on 54
4.7 Starting the engine 55
4.8 Engine emergency stop at BlueLine
automation system (control stand) 56
4.9 Operational checks 57
4.10 Coupling – Engaging from LOP 58
4.11 Coupling – Disengaging from LOP 59
4.12 Waterjet – Flushing from LOP (optional) 60
4.13 Stopping the engine from LOP 61
4.14 Stopping the engine at the BlueLine
automation system (control stand) 62
4.15 Emergency stop from LOP 63
4.16 After stopping the engine 64
4.17 Fuel treatment system – Shutdown 65
4.18 Plant cleaning 66
5 Maintenance
5.1 Maintenance schedule task reference table
[QL1] 67
6 Troubleshooting
6.1 Fuel treatment system – Troubleshooting 68
6.2 Troubleshooting 69
7 Task Description
7.1 Engine 72
7.1.1 Engine – Barring manually 72
7.1.2 Engine – Barring with starting system 73
7.2 Cylinder Liner 74
7.2.1 Cylinder liner – Endoscopic examination 74
7.2.2 Cylinder liner – Instructions and comments on
endoscopic and visual examination 76
7.3 Valve Drive 78
7.3.1 Valve gear – Lubrication 78
7.3.2 Valve clearance – Check and adjustment 79
7.3.3 Cylinder head cover – Removal and
installation 83
7.4 Injection Valve / Injector 84
7.4.1 Injector – Replacement 84
7.4.2 Injector – Removal and installation 85
7.5 Fuel Filter 90
7.5.1 Fuel filter – Replacement 90
MS150048/03E 2012-07 | Table of Contents | 3
DCL-ID: 0000015617 - 001

7.5.2 Fuel prefilter – Differential pressure gauge
check and adjustment 92
7.5.3 Fuel prefilter – Draining 93
7.5.4 Fuel prefilter ‒ Flushing 94
7.5.5 Fuel prefilter – Filter element replacement 96
7.6 Charge-Air Cooling 98
7.6.1 Compressor wheel – Cleaning 98
7.6.2 Intercooler – Check water drain for coolant
discharge and obstruction 100
7.7 Air Filter 101
7.7.1 Air filter – Replacement 101
7.7.2 Air filter – Removal and installation 102
7.8 Air Intake 103
7.8.1 Contamination indicator – Signal ring position
check (optional) 103
7.8.2 Air flap – Check for ease of movement 104
7.9 Exhaust Flap with Actuator 105
7.9.1 Exhaust flap – Check for easy movement 105
7.10 Starting Equipment 106
7.10.1 Starter – Condition check 106
7.11 Lube Oil System, Lube Oil Circuit 107
7.11.1 Engine oil level – Check 107
7.11.2 Engine oil – Change 108
7.11.3 Engine oil – Sample extraction and analysis 110
7.12 Oil Filtration / Cooling 111
7.12.1 Engine oil filter – Replacement 111
7.12.2 Automatic oil filter – Oil filter candle
replacement 113
7.12.3 Oil indicator filter – Check 116
7.12.4 Centrifugal oil filter – Cleaning and filter
sleeve replacement 118
7.13 Coolant Circuit, General, High-
Temperature Circuit 120
7.13.1 Ventilation points 120
7.13.2 Engine coolant – Level check 121
7.13.3 Engine coolant – Change 122
7.13.4 Engine coolant draining 123
7.13.5 Engine coolant – Filling 124
7.13.6 Engine coolant pump – Relief bore check 127
7.13.7 Engine coolant – Sample extraction and
analysis 128
7.13.8 Coolant filter – Replacement 129
7.14 Low-Temperature Circuit 130
7.14.1 Charge-air coolant – Draining 130
7.15 Raw Water Pump with Connections 131
7.15.1 Raw water pump – Relief bore check 131
7.16 Battery-Charging Generator 132
7.16.1 Battery-charging generator drive – Coupling
condition check 132
7.17 Engine Mounting / Support 133
7.17.1 Engine mounts – Checking securing screws
for firm seating 133
7.17.2 Engine mounts – Resilient element check 134
7.18 Drive Systems, Driving End and Free End
(Coupling) 136
7.18.1 Coupling – Condition check 136
7.19 Fuel Supply System 137
7.19.1 Water drain valve – Check 137
7.19.2 Differential pressure gauge – Check 138
7.19.3 Water level probe (3-in-1 rod electrode) –
Check 139
7.19.4 Pump capacity – Check 140
7.19.5 Coalescer filter element – Replacement 141
7.20 Wiring (General) for Engine/Gearbox/Unit 143
7.20.1 Engine wiring – Check 143
7.21 Accessories for (Electronic) Engine
Governor / Control System 144
7.21.1 CDC parameters – Reset with DiaSys® 144
7.21.2 Engine governor and connectors – Cleaning 145
7.21.3 EMU and connectors – Cleaning 146
7.21.4 Engine Monitoring Unit EMU 7 – Plug
connection check 147
7.21.5 Engine governor – Checking plug-in
connections 148
7.21.6 ECU 7 engine governor – Removal and
installation 149
7.22 Emergency Instrumentation (Local
Operating Panel) 150
7.22.1 LOP and connectors – Cleaning 150
8 Appendix A
8.1 Abbreviations 151
8.2 MTU contact persons/service partners 153
9 Appendix B
9.1 Special Tools 154
9.2 Index 161
4 | Table of Contents | MS150048/03E 2012-07
DCL-ID: 0000015617 - 001

1 Safety
1.1 General conditions
General
In addition to the instructions in this publication, the applicable country-specific legislation and other com‐
pulsory regulations regarding accident prevention and environmental protection must be observed. This
state-of-the-art engine has been designed to meet all applicable laws and regulations. The engine may
nevertheless present a risk of injury or damage in the following cases:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Modifications or conversions
• Noncompliance with the Safety Instructions
Correct use
The engine is intended solely for use in accordance with contractual agreements and the purpose envis‐
aged for it on delivery. Any other use is considered improper use. The engine manufacturer accepts no
liability whatsoever for resultant damage or injury in such case. The responsibility is borne by the user
alone.
Correct use also includes observation of and compliance with the maintenance specifications.
Modifications or conversions
Unauthorized modifications to the engine represent a safety risk.
MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or
conversions.
Spare parts
Only genuine MTU spare parts must be used to replace components or assemblies. MTU accepts no
liability whatsoever for damage or injury resulting from the use of other spare parts and the warranty shall
be voided in such case.
Reworking components
Repair or engine overhaul must be carried out in workshops authorized by MTU.
MS150048/03E 2012-07 | Safety | 5
TIM-ID: 0000000860 - 017

1.2 Personnel and organizational requirements
Personnel requirements
All work on the engine shall be carried out by trained and qualified personnel only.
The specified legal minimum age must be observed.
The operator must specify the responsibilities of the operating, maintenance and repair personnel.
Organizational measures
This publication must be issued to all personnel involved in operation, maintenance, repair or transporta‐
tion.
Keep it at hand at the operating site of the engine so that it is available to operating, maintenance, repair
and transport personnel at all times.
Use the manual as a basis for instructing personnel on engine operation and repair with an emphasis on
explaining safety-relevant instructions.
This is particularly important in the case of personnel who only occasionally perform work on or around
the engine. This personnel must be instructed repeatedly.
For the identification and layout of the spare parts during maintenance or repair work, take photos or use
the spare parts catalog.
Working clothes and protective equipment
Wear proper protective clothing for all work.
Use the necessary protective equipment for the given work to be done.
6 | Safety | MS150048/03E 2012-07
TIM-ID: 0000000874 - 018

1.3 Transport
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 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.
MS150048/03E 2012-07 | Safety | 7
TIM-ID: 0000002621 - 002

1.4 Crankshaft transport locking device
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Torque wrench, 10-60 Nm F30510423 1
Torque wrench, 60-320 Nm F30047446 1
Engine oil
Transport locking device
Note: The locking device protects the crankshaft bearings from shocks and vibration damage during engine
transport.
For installation and removal of the transport locking device, follow the instructions
below:
1. The transport locking device must remain installed as long as possible during engine installation in order
to avoid damage.
2. Prior to every engine transport, the transport locking device must be reinstalled on both sides according
to the instructions.
3. If the engine is to be moved together with the generator, the transport locking device for the generator
must also be installed.
4. Always use the screws supplied with or installed in the transport locking device to secure it on the en‐
gine.
5. Starting or barring the engine is allowed only with the transport locking device removed. If the generator
is already mounted on the engine, ensure that the transport locking device of the generator is also re‐
moved.
6. Attach these instructions, clearly visible, to the engine.
Removing guard plates and engine
mounting brackets (if applicable)
on driving end (KS)
1. Remove screws (4) om both sides and take
off with washers (3), guard plates (1) and
engine mounting brackets (2).
2. Store the removed parts of the transport
locking device carefully for possible reuse.
8 | Safety | MS150048/03E 2012-07
TIM-ID: 0000004010 - 008

Fitting the transport locking device
on driving end (KS)
Note: Attach plates (2) only to the upper part of the openings.
1. Secure the two plates (2) with screws (6) and washers (5) at the bores on both sides of the flywheel
housing and tighten to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw M16 Tightening torque (Engine oil) 250 Nm +25 Nm
2. Screw nut (3) onto screws (4) up to the end of the thread.
3. The long end of retainers (1) must face downwards. Push retainers (1) with the round front face through
the plate openings (2).
Note: The retainers (1) must lock the flywheel only, not the ring gear.
4. Install screws (4) into the bores of retainers (1) until the retainers (1) are locked in position.
5. Tighten screws (4) alternately with torque wrench to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw M10 Tightening torque (Engine oil) 30 Nm +3 Nm
6. Screw on nuts (3) of both screws (4) at plates (2) and secure.
Removing the transport locking
device from driving end (KS)
1. Release the locknuts (3) on both sides of
the flywheel housing, remove screws (4)
and take off the two locks (1).
2. Unscrew screws (6) and remove together
with washers (5) and plates (2).
3. Store the removed parts of the transport
locking device together with this documen‐
tation carefully for possible reuse.
MS150048/03E 2012-07 | Safety | 9
TIM-ID: 0000004010 - 008

Installing guard plates and engine
mounting brackets (if applicable)
on driving end (KS)
Note: Always use the screws supplied with the or
removed from the guard plates and engine
mounting brackets to secure them on the
engine.
1. Install engine mounting brackets (2) on both
sides with guard plates (1) washers (3), and
screws (4).
2. Tighten screws (4).
10 | Safety | MS150048/03E 2012-07
TIM-ID: 0000004010 - 008

1.5 Safety regulations for startup and operation
Safety precautions when putting the equipment into operation
Prior to initial operation of the assembly or plant, install the assembly or unit according to the specifica‐
tions and check the installation according to the MTU specifications.
Before putting the device or plant into operation, always ensure:
• that all maintenance and repair work is completed,
• that all loose parts have been removed from rotating machine components,
• that all persons are clear of the danger zone of moving machine components.
Immediately after putting the device or plant into operation, make sure that all control and display instru‐
ments as well as the monitoring, signaling and alarm systems are working properly.
Safety regulations for equipment operation
Emergency procedures must be practiced regularly.
The operator must be familiar with the controls and displays.
The operator must be familiar with the consequences of all operations to be performed.
During operation, the display instruments and monitoring units must be permanently observed with re‐
gard to present operating status, violation of limit values and warning or alarm messages.
The following steps must be taken if a malfunction of the system is recognized or reported by the system:
• inform supervisor(s) in charge,
• analyze the message,
• if required, carry out emergency operations e.g. emergency engine stop.
Engine operation
The following conditions must be fulfilled before starting the engine:
• Wear ear protectors.
• Ensure that the engine room is well ventilated.
• Do not inhale engine exhaust gases.
• Ensure that the exhaust system is free of leaks and that the gases are discharged to atmosphere.
• Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binding
agent.
• Protect battery terminals, battery-charger terminals and cables against accidental contact.
• When the engine is running, never release coolant, oil, fuel, compressed-air or hydraulic lines.
Operation of electrical equipment
When operating electrical equipment, certain components of this equipment are live.
Observe the safety instructions for these devices.
MS150048/03E 2012-07 | Safety | 11
TIM-ID: 0000023743 - 010

1.6 Explosion hazard when removing inspection port cover on
engine
DANGER Explosion hazard due to oil vapors.
Risk of serious injury – danger to life!
• Allow the engine to cool down before opening the crankcase!
• Avoid open flames, electrical sparks and ignition sources.
Safety instructions
uBefore starting maintenance work, allow the engine to cool down for at least 10 min. (danger of explosion
due to oil vapors).
12 | Safety | MS150048/03E 2012-07
TIM-ID: 0000022931 - 006

1.7 Safety regulations for maintenance and repair work
Safety regulations for maintenance and repair work
Have maintenance and repair work carried out by qualified and authorized personnel only.
Allow the engine to cool down before starting maintenance work (risk of explosion of oil vapors).
Before starting work, relieve pressure in systems and compressed-air lines which are to be opened.
Take special care when removing ventilation or plug screws from the engine. Cover the screw or plug
with a rag to prevent fluids escaping under pressure.
Take special care when draining hot fluids ⇒ Risk of injury.
When changing the engine oil or working on the fuel system, ensure that the engine room is adequately
ventilated.
Allow the engine / system to cool down before starting to work.
Observe the maintenance and repair instructions.
Never carry out maintenance and repair work with the engine running unless expressly instructed to do
so.
Secure the engine against accidental starting.
Disconnect the battery when electrical starters are fitted.
Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic
starters are fitted.
Disconnect the control equipment from the assembly or system.
Use only proper, calibrated tools. Observe the specified tightening torques during assembly/disassembly.
Carry out work only on assembles and/or units which are properly secured.
Never use lines for climbing.
Keep fuel injection lines and connections clean.
Always seal connections with caps or covers if a line is removed or opened.
Take care not to damage lines, in particular fuel lines, during maintenance and repair work.
Ensure that all retainers and dampers are installed correctly.
Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent con‐
tact with other components. Do not place fuel or oil lines near hot components.
Do not touch elastomeric seals if they have carbonized or resinous appearance unless hands are proper‐
ly protected.
Note cooling time for components which are heated for installation or removal ⇒ Risk of burning.
When working high on the engine, always use suitable ladders and work platforms. Make sure compo‐
nents are placed on stable surfaces.
Observe special cleanness when conducting maintenance and repair work on the assembly or system.
After completion of maintenance and repair work, make sure that no loose objects are in/on the assem‐
bly or system.
Before barring the engine, make sure that nobody is standing in the danger zone. Check that all guards
have been reinstalled and that all tools and loose parts have been removed after working on the engine.
The following additional instructions apply to starters with beryllium copper pinion:
• Breathing protection of filter class P2 must be applied during maintenance work to avoid health haz‐
ards caused by the beryllium-containing pinion. Do not blow out the interior of the flywheel housing or
the starter with compressed air. Clean the flywheel housing inside with a class H dust extraction de‐
vice as an additional measure.
MS150048/03E 2012-07 | Safety | 13
TIM-ID: 0000000879 - 023

Welding work
Never carry out welding work on the assembly, system, or engine-mounted units. Cover the engine when
welding in its vicinity.
Do not use the assembly or system as ground terminal.
Do not route the welding lead over or near the wiring harnesses of MTU systems. The welding current
may otherwise induce an interference voltage in the wiring harnesses which could conceivably damage
the electrical system.
Remove parts (e.g. exhaust pipes) which are to be welded from the engine beforehand.
Hydraulic installation and removal
Check the function and safe operating condition of tools and fixtures to be used. Use only the specified
devices for hydraulic removal/installation procedures.
Observe the max. permissible push-on pressure specified for the equipment.
Do not attempt to bend or apply force to lines.
Before starting work, pay attention to the following:
• Vent the hydraulic installation/removal tool, the pumps and the lines at the relevant points for the
equipment to be used (e.g. open vent plugs, pump until bubble-free air emerges, close vent plugs).
• For hydraulic installation, screw on the tool with the piston retracted.
• For hydraulic removal, screw on the tool with the piston extended.
For a hydraulic installation/removal tool with central expansion pressure supply, screw spindle into shaft
end until correct sealing is established.
During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of the
component to be installed/removed.
Working on electrical/electronic assemblies
Always obtain the permission of the person in charge before commencing maintenance and repair work
or switching off any part of the electronic system required to do so.
De-energize the appropriate areas prior to working on assemblies.
Do not damage cabling during removal work. When reinstalling ensure that wiring is not damaged during
operation by contact with sharp objects, by rubbing against other components or by a hot surface.
Do not secure cables on lines carrying fluids.
Do not use cable binders to secure cables.
Always use connector pliers to tighten connectors.
Subject the device or system to a function check on completion of all repair work.
Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Pack de‐
fective electronic components and assemblies in a suitable manner when dispatched for repair, i.e. par‐
ticularly protected against moisture and impact and wrapped in antistatic foil if necessary.
Working with laser equipment
When working with laser equipment, always wear special laser-protection goggles ⇒ Heavily focused ra‐
diation.
Laser equipment must be fitted with the protective devices necessary for safe operation according to
type and application.
14 | Safety | MS150048/03E 2012-07
TIM-ID: 0000000879 - 023

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.
MS150048/03E 2012-07 | Safety | 15
TIM-ID: 0000000879 - 023

1.8 Auxiliary materials, fluids and lubricants, fire prevention and
environmental protection
Fire prevention
Rectify any fuel or oil leaks immediately; even splashes of oil or fuel on hot components can cause fires –
therefore always keep the engine in a clean condition. Do not leave cloths soaked with fluids and lubri‐
cants lying on or near the assembly or unit. Do not store inflammable material near the assembly or unit.
Do not weld pipes and components carrying oil or fuel! Before welding, clean with a nonflammable fluid.
When starting the engine with an external power source, connect the ground lead last and remove it first.
To avoid sparks in the vicinity of the battery, connect the ground lead from the external power source to
the ground lead of the engine or to the ground terminal of the starter.
Always keep suitable firefighting 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 noises indicating
danger are drowned.
Wear ear protectors in work areas with a sound pressure level in excess of 85 dB (A).
Environmental protection and disposal
Modification or removal of mechanical or electronic components or the installation of additional compo‐
nents as well as the execution of calibration processes that might affect the emission characteristics of
the engine are prohibited by emission regulations. Emission control units/systems may only be main‐
tained, exchanged or repaired if the components used for this purpose are approved by MTU or equiva‐
lent components. Noncompliance with these guidelines might represent a violation of the Clean Air Act
and involves the termination of the operating license by the emission authorities. MTU does not accept
any liability for violations of the emission regulations. MTU will provide assistance and advice if emission-
relevant components are intended to be modified. The MTU Maintenance Schedules ensure the reliabili‐
ty and performance of MTU engines and must be complied with over the entire life cycle of the engine.
Use only fuel of prescribed quality to comply with emission limit values.
Dispose of used fluids, lubricants and filters in accordance with local regulations.
Within the EU, batteries can be returned free of charge to MTU FN / MTU Onsite Energy where they are
subjected to proper recycling procedures.
Auxiliary materials, fluids and lubricants
Use only fluids and lubricants that have been tested and approved by MTU.
The Fluids and Lubricants Specifications will be amended or supplemented as necessary. Before using
them, make sure you have the latest version. The latest version is also available at: http://www.mtu-on‐
line.com/mtu/mtu-valuecare/mtu-valueservice-Technische-Dokumentation.
Keep fluids and lubricants in suitable, properly designated containers. When using fluids, lubricants and
other chemical substances, follow the safety instructions that apply to the product. Take special care
when using hot, chilled or caustic materials. When using flammable materials, avoid all sparks and do
not smoke.
Used oil
Used oil contains harmful combustion residues.
Rub barrier cream into hands.
Wash hands after contact with used oil.
16 | Safety | MS150048/03E 2012-07
TIM-ID: 0000000880 - 016

Lead
• When working with lead or lead-containing compounds, avoid direct contact to the skin and do not
inhale lead vapors.
• Adopt suitable measures to avoid the formation of lead dust.
• Switch on extraction system.
• Wash hands after contact with lead or lead-containing substances.
Compressed air
Observe special safety precautions when working with compressed air:
• Pay special attention to the pressure level in the compressed air network and pressure vessel.
• Assemblies and equipment to be connected must either be designed for this pressure, or, if the per‐
mitted 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 couplings and connections must be securely attached.
• Wear goggles when blowing off components or blowing away chips.
• Provide the snout of the air nozzle with a protective disk (e.g. rubber disk).
• 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 bursting.
• Carry out leak test in accordance with the specifications.
Paints and lacquers
• When carrying out painting work outside the spray stands provided with fume extraction systems, en‐
sure that the area is well ventilated. Make sure that neighboring work areas are not impaired.
• No open flames.
• No smoking.
• Observe fire prevention regulations.
• Always wear a mask providing protection against paint and solvent vapors.
Liquid nitrogen
• Store liquid nitrogen only in small quantities and always in regulation containers without fixed covers.
• Avoid body contact (eyes, hands).
• Wear protective clothing, protective gloves, closed shoes and protective goggles / safety mask.
• Make sure that working area is well ventilated.
• Avoid all knocks and jars to the containers, fixtures or workpieces.
Acids and alkaline solutions
• When working with acids and alkaline solutions, wear protective goggles or face mask, gloves and
protective clothing.
• If such solutions are spilled onto clothing, remove the affected clothing immediately.
• Rinse injured parts of the body thoroughly with clean water.
• Rinse eyes immediately with eyedrops or clean tap water.
MS150048/03E 2012-07 | Safety | 17
TIM-ID: 0000000880 - 016

1.9 Conventions for safety instructions in the text
DANGER In the event of immediate danger.
Consequences: Death or serious injury
• Remedial action
WARNING In the event of potentially dangerous situations.
Consequences: Death or serious injury
• Remedial action
CAUTION In the event of dangerous situations.
Consequences: Minor injury or material damage
• Remedial action
NOTICE In the event of a situation involving potentially adverse effects on the product.
Consequences: Material damage.
• Remedial action
• Additional product information
Note: This manual contains highlighted safety warnings in accordance with the US ANSI Z535 standard which
begin with one of the signal words listed above depending on the severity of the hazard.
Safety instructions
1. Read and familiarize yourself with all safety notices before starting up or repairing the product.
2. Pass on all safety instructions to your operating, maintenance, repair and transport personnel.
18 | Safety | MS150048/03E 2012-07
TIM-ID: 0000000881 - 018

2 General Information
2.1 Engine side and cylinder designations
Engine sides are always designated as viewed from the driving end (KS).
The cylinders of the left engine side are designated "A" and those of the right side "B" (as per DIN ISO
1204). The cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end.
Other components are numbered in the same way, i.e. starting with No. 1 on driving end.
1 Left engine side
2 KGS = Free end
3 Right engine side
4 KS = Driving end
MS150048/03E 2012-07 | General Information | 19
TIM-ID: 0000002185 - 010

2.2 Product description
Description of the engine
Engine
The engine is a liquid-cooled four-stroke cycle diesel engine, rotating counterclockwise (seen from driv‐
ing end), with direct injection, sequential exhaust turbocharging and charge-air cooling.
The engine is monitored by an engine control and monitoring system (ADEC).
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 HP pump, pressure accumulator (rail) and
single injectors with integrated individual store.
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 ex‐
haust turbocharger is cut-in and cut-out on 12V and 16V engines with electronically-controlled, hydrauli‐
cally-actuated flaps. ETC B1 A2 and B2 on 20V engines.
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 flows through engine coolant and fuel heat exchanger as well as the raw water 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
• Automatic oil filter
• Centrifugal lube oil filter
• Coolant expansion tank (20V 4000 M03 only, not installed on engine).
Electronic system
Electronic control and monitoring system with integrated security and test system with interfaces to re‐
mote control system (RCS) and to monitoring system (MCS).
20 | General Information | MS150048/03E 2012-07
TIM-ID: 0000010057 - 001