MTU 12V4000M*3 series, Operating Instructions Manual

Page: 5 / 283

Table of Contents
1 Safety
1.1 Important provisions for all products 6
1.2 Correct use of all products 8
1.3 Personnel and organizational requirements 9
1.4 Initial start-up and operation – Safety
regulations 10
1.5 Assembly, maintenance, and repair work –
Safety regulations 12
1.6 Fire and environmental protection, fluids
and lubricants 16
1.7 Standards for warning notices in the text
and highlighted information 18
2 Transport
2.1 Transport 19
2.2 Lifting requirements 20
2.3 Crankshaft transport locking device 24
3 General Information
3.1 Tightening specifications for screws, nuts
and bolts 27
3.2 Engine side and cylinder designations 40
3.3 Product description 41
3.4 Engine – Overview 46
3.5 Sensors, actuators and injectors on 12V
engines – Overview 50
3.6 Sensors, actuators and injectors on 16V
engines – Overview 60
4 Technical Data
4.1 Product data 12V4000M53 70
4.2 Product data 12V4000M63 75
4.3 Product data 16V4000M53 80
4.4 Product data 16V4000M63 85
4.5 Firing order 90
4.6 Engine – Main dimensions 91
5 Operation
5.1 Controls 93
5.2 Putting the engine into operation after
extended out-of-service periods (>3 months) 94
5.3 Putting the engine into operation after
scheduled out-of-service-period 95
5.4 Starting the engine 96
5.5 Re-starting the engine following an
automatic safety shutdown 97
5.6 Stopping the engine 98
5.7 Operational checks 99
5.8 Emission label – Check 100
5.9 Tasks after extended out-of-service periods
(>3 weeks) 101
5.10 Checks prior to start-up 102
5.11 Fuel treatment system – Initial start-up 103
5.12 Fuel treatment system – Switching on 106
5.13 Fuel treatment system – Shutdown 107
5.14 Emergency engine stop 108
5.15 After shutdown 109
5.16 Plant – Cleaning 110
6 Maintenance
6.1 Maintenance task reference table [QL1] for
EPA regions 111
6.2 Maintenance task reference table [QL1] for
Non EPA regions 113
7 Troubleshooting
7.1 Troubleshooting 115
7.2 Control cabinet of fuel treatment system –
Troubleshooting 118
7.3 Engine governor ADEC (ECU 7) fault
messages for Series 4000 engines, marine
application
119
7.4 ADEC engine governor – Fault codes 120
8 Task Description
8.1 SOLAS 146
8.1.1 SOLAS shielding as per MTN 5233 –
Installation 146
8.1.2 SOLAS shielding – Installation 147
8.1.3 Installation locations for SOLAS shielding 148
8.1.4 Adhesive tape for SOLAS shielding –
Application 157
8.2 Engine 158
8.2.1 Engine – Barring manually 158
8.2.2 Barring engine with starting system 160
8.3 Cylinder Liner 161
8.3.1 Cylinder liner – Endoscopic examination 161
8.3.2 Cylinder liner – Instructions and comments on
endoscopic and visual examination 163
8.4 Crankcase Breather 165
8.4.1 Crankcase breather – Oil mist separator
replacement 165
8.5 Valve Drive 166
MS15035/00E 2018-08 | Table of Contents | 3
DCL-ID: 0000051760 - 001