MTU 12 V 4000 M33F Operating Instructions Manual Download Page 1

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Operating Instructions

Diesel Engine

12 V 4000 M33F
12 V 4000 M33S
16 V 4000 M33F
16 V 4000 M33S
16 V 4000 M43S

MS150069/02E

Summary of Contents for 12 V 4000 M33F

Page 1: ...Operating Instructions Diesel Engine 12 V 4000 M33F 12 V 4000 M33S 16 V 4000 M33F 16 V 4000 M33S 16 V 4000 M43S MS150069 02E...

Page 2: ...ten 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 on...

Page 3: ...ter scheduled out of service period 78 3 4 Starting the engine 79 3 5 Operational checks 80 3 6 Tasks after extended out of service periods 3 weeks 81 3 7 Checks prior to start up 82 3 8 Fuel treatmen...

Page 4: ...lling 234 6 15 6 HT coolant pump Relief bore check 236 6 15 7 Engine coolant Sample extraction and analysis 237 6 15 8 Engine coolant filter Replacement 238 6 15 9 Preheating unit 239 6 15 10 Preheate...

Page 5: ...nfiguration 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 accordanc...

Page 6: ...rk 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 Tra...

Page 7: ...t 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...

Page 8: ...s and displays The operator must be familiar with the consequences of any operations performed During operation the display instruments and monitoring units must be permanently observed with re gard t...

Page 9: ...nce 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 S...

Page 10: ...pipes which are to be welded from the product beforehand Hydraulic installation and removal Check satisfactory function and safe operating condition of tools jigs and fixtures to be used Use only the...

Page 11: ...stop feature Store spare parts properly prior to replacement i e protect them against moisture in particular Pack defective electronic components and assemblies in a suitable manner when dispatched f...

Page 12: ...are prohibited by emission regulations Emission control units systems may only be maintained exchanged or repaired if the components used for this purpose are approved by the manu facturer Noncomplian...

Page 13: ...be replaced Carry out leak test in accordance with the specifications Paints and varnishes Observe the relevant safety data sheet for all materials When painting in areas other than spray booths equi...

Page 14: ...event of a situation involving potential danger Consequences Minor or moderate injuries Remedial action NOTICE In the event of a situation involving potentially adverse effects on the product Conseque...

Page 15: ...nt 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...

Page 16: ...charging generator Open bus interface to the plant SAE J1939 Emergency stop function with line break monitoring Redundant supply voltage input Emergency air shutoff flap control option Key switch logi...

Page 17: ...marine engine Series 4000M53R to M93L may be operated in low load operation State of the art design and equipment features e g TE coolant circuit sequential turbocharging jacketed coolant cooled exha...

Page 18: ...of rated power takes place in single ETC mode with only one exhaust turbocharger running To ensure the functionality of the control mechanism and of the exhaust flap of the turbocharger which does not...

Page 19: ...after LP pump 1 SOLAS clip on the fuel line on fuel filter head retainer 1 SOLAS clip on the fuel line on HP pump 2 SOLAS clip on the fuel line after fuel filter head MS150069 02E 2014 03 Product Sum...

Page 20: ...LAS clips on the fuel line on fuel filter head Lube oil system oil lines with oil pressure 1 8 bar All lines with SOLAS compliant covers for pipe connections according to MTU standard MTN5233 are show...

Page 21: ...ylinder ETC B1 1 SOLAS clips on air flap switching cylinder ETC B1 2 SOLAS clips on flap control T adapt er ETC B1 1 SOLAS clips on distributor element 2 SOLAS clips on oil return MS150069 02E 2014 03...

Page 22: ...line to ETC 2 SOLAS clip on oil line to flap control 3 SOLAS clip on oil line to recircula tion valve 4 SOLAS clips on oil line from main gallery 1 SOLAS clips on recirculation valve 22 Product Summa...

Page 23: ...on HP pump oil supply on HP pump 1 SOLAS clip on HP pump oil supply on equipment carrier 1 SOLAS clip on ETC oil supply 2 SOLAS clip on ETC oil supply MS150069 02E 2014 03 Product Summary 23 TIM ID 00...

Page 24: ...on oil filter cartridge Special connections The following types of union are spray proof in case of leakage even without covers and have been con firmed as being SOLAS compliant by GL and DNV 24 Prod...

Page 25: ...hread The pressure is so greatly reduced by this and the faulty sealing ring 1 that any leakage is not under pressure Plug in pipe union b The sleeve 3 covers the joint to prevent lateral spray Only l...

Page 26: ...ll type seal area 20 Leak fuel connection The HP fuel line is sealed by the thrust ring 8 If leakage in the area of the thrust ring 8 or the HP line 2 occurs the emerging fuel is routed to the leakage...

Page 27: ...8 Air pipe to intercooler 9 Intercooler 10 Recirculation line 11 Exhaust manifold 12 Engine mounts 13 Charge air line 14 Oil pan 15 Oil filler neck 16 Crankcase 17 Cylinder head 18 Fuel filter 19 Bat...

Page 28: ...8 Dry type air filter 9 Exhaust turbocharger 10 Exhaust outlet 11 Air pipe to intercooler 12 Recirculation line 13 Exhaust manifold 14 Intercooler 15 Charge air line 16 Engine mounts 17 Oil pan 18 Oi...

Page 29: ...air filter 8 Exhaust manifold 9 Recirculation line 10 Exhaust turbocharger 11 Exhaust outlet 12 Air pipe to intercooler 13 Intercooler 14 Engine mounts 15 Charge air line 16 Oil pan 17 Oil filler neck...

Page 30: ...ne mounts 17 Oil pan 18 Oil filler neck 19 Crankcase 20 Cylinder head 21 Fuel filter 22 Oil filter 23 HP fuel pump 24 Battery charging generator 25 Bilge pump option 26 Raw water inlet KGS Free end Ov...

Page 31: ...V 4000 M with external cooling 1 B49 charge air temp air recirculation valve Y26 air recirculation valve A 2 B4 A1 B4 B6 single ex haust temp A1 A6 B1 B6 3 B33 fuel temperature in common rail MS150069...

Page 32: ...f filter 3 B5 1 oil pressure down stream of filter 4 B33 fuel temperature in common rail 5 B48 fuel pressure in com mon rail 6 B1 camshaft speed 7 B54 oil refill pump pres sure 8 B6 2 coolant tempera...

Page 33: ...cooling 1 B4 21 exhaust tempera ture A bank 2 B4 22 exhaust tempera ture B bank 3 B13 crankshaft speed 4 S37 2 safety switch 5 S37 1 safety switch 6 B13 2 crankshaft speed MS150069 02E 2014 03 Product...

Page 34: ...ir temperature 3 B44 1 turbocharger A speed 4 B10 charge air pressure 5 B34 3 fuel pressure up stream of filter 6 B34 2 fuel pressure up stream of filter 7 B34 1 fuel pressure down stream of filter 8...

Page 35: ...f engine 12V 4000 M external cooling 1 B44 2 turbocharger B speed 2 Y27 turbocharger control valve 3 B16 coolant pressure 4 B9 charge air tempera ture MS150069 02E 2014 03 Product Summary 35 TIM ID 00...

Page 36: ...p view 12V 4000 M integral cooling 1 B4 A1 B4 B6 single ex haust temp A1 A6 B1 B6 2 B33 fuel temperature in common rail 3 F33 coolant level 36 Product Summary MS150069 02E 2014 03 TIM ID 0000038758 00...

Page 37: ...f filter 3 B5 1 oil pressure down stream of filter 4 B33 fuel temperature in common rail 5 B48 fuel pressure in com mon rail 6 B1 camshaft speed 7 B54 oil refill pump pres sure 8 B6 2 coolant tempera...

Page 38: ...cooling 1 B4 21 exhaust tempera ture A bank 2 B4 22 exhaust tempera ture B bank 3 B13 crankshaft speed 4 S37 2 safety switch 5 S37 1 safety switch 6 B13 2 crankshaft speed 38 Product Summary MS150069...

Page 39: ...ir recirculation valve A 3 B3 intake air temperature 4 B44 1 turbocharger A speed 5 B10 charge air pressure 6 B34 3 fuel pressure up stream of filter 7 B34 2 fuel pressure up stream of filter 8 B34 1...

Page 40: ...4000 M integral cooling 1 B44 2 turbocharger B speed 2 Y27 turbocharger control valve 3 B16 coolant pressure 4 B21 raw water pressure 5 B9 charge air tempera ture 40 Product Summary MS150069 02E 2014...

Page 41: ...al cooling 1 B49 charge air temp air recirculation valve Y26 air recirculation valve A 2 B4 A1 B4 B8 single ex haust temp A1 A8 B1 B8 3 B33 fuel temperature in common rail MS150069 02E 2014 03 Product...

Page 42: ...f filter 3 B5 1 oil pressure down stream of filter 4 B33 fuel temperature in common rail 5 B48 fuel pressure in com mon rail 6 B1 camshaft speed 7 B54 oil refill pump pres sure 8 B6 2 coolant tempera...

Page 43: ...cooling 1 B4 21 exhaust tempera ture A bank 2 B4 22 exhaust tempera ture B bank 3 B13 crankshaft speed 4 S37 2 safety switch 5 S37 1 safety switch 6 B13 2 crankshaft speed MS150069 02E 2014 03 Product...

Page 44: ...ir temperature 3 B44 1 turbocharger A speed 4 B10 charge air pressure 5 B34 3 fuel pressure up stream of filter 6 B34 2 fuel pressure up stream of filter 7 B34 1 fuel pressure down stream of filter 8...

Page 45: ...f engine 16V 4000 M external cooling 1 B44 2 turbocharger B speed 2 Y27 turbocharger control valve 3 B16 coolant pressure 4 B9 charge air tempera ture MS150069 02E 2014 03 Product Summary 45 TIM ID 00...

Page 46: ...p view 16V 4000 M integral cooling 1 B4 A1 B4 B8 single ex haust temp A1 A8 B1 B8 2 B33 fuel temperature in common rail 3 F33 coolant level 46 Product Summary MS150069 02E 2014 03 TIM ID 0000038758 00...

Page 47: ...f filter 3 B5 1 oil pressure down stream of filter 4 B33 fuel temperature in common rail 5 B48 fuel pressure in com mon rail 6 B1 camshaft speed 7 B54 oil refill pump pres sure 8 B6 2 coolant tempera...

Page 48: ...cooling 1 B4 21 exhaust tempera ture A bank 2 B4 22 exhaust tempera ture B bank 3 B13 crankshaft speed 4 S37 2 safety switch 5 S37 1 safety switch 6 B13 2 crankshaft speed 48 Product Summary MS150069...

Page 49: ...ir recirculation valve A 3 B3 intake air temperature 4 B44 1 turbocharger A speed 5 B10 charge air pressure 6 B34 3 fuel pressure up stream of filter 7 B34 2 fuel pressure up stream of filter 8 B34 1...

Page 50: ...4000 M integral cooling 1 B44 2 turbocharger B speed 2 Y27 turbocharger control valve 3 B16 coolant pressure 4 B21 raw water pressure 5 B9 charge air tempera ture 50 Product Summary MS150069 02E 2014...

Page 51: ...The cylinders of each bank are numbered consecutively starting with No 1 at the driving end The numbering of other engine components is also from the driving end starting with no 1 1 Left hand side o...

Page 52: ...ight C 16V 4000 M23S 23F 33S 33F 43S 16V 4000 M53R 53 63R 63 63L approx 3108 mm approx 1690 mm approx 1850 mm approx 2064 mm With engine mounted heat exchanger Engine model Length A Width B without si...

Page 53: ...m approx 2448 mm 16V 4000 M23S 23F 33S 33F 43S 16V 4000 M53R 53 63R 63 63L approx 3108 mm approx 1602 mm approx 2361 mm approx 2441 mm With engine mounted heat exchanger Engine model Length A Width B...

Page 54: ...Sequence 2 4 1 Firing order 8V A1 B4 A4 A2 B3 A3 B2 B1 12 V A1 B5 A5 B3 A3 B6 A6 B2 A2 B4 A4 B1 16 V A1 A7 B4 B6 A4 B8 A2 A8 B3 B5 A3 A5 B2 A6 B1 B7 54 Product Summary MS150069 02E 2014 03 TIM ID 0000...

Page 55: ...level m 100 100 100 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Heat exchanger installed Heat exchanger separate Rated engine speed A rpm 1500 1500 1500 1500 Continuous p...

Page 56: ...pressure upstream of engine from R bar 5 0 5 0 5 0 5 0 Lube oil operating pressure before engine to R bar 6 0 6 0 6 0 6 0 Lube oil operating pressure low idle meas point before engine R bar FUEL SYSTE...

Page 57: ...ters N N N N Oil change quantity max standard oil system option max operating inclina tions R Liters 265 265 265 265 Oil pan capacity at dipstick mark min standard oil system option max operat ing inc...

Page 58: ...power ratings are net brake power as per ISO 3046 Heat exchanger installed Heat exchanger separate Rated engine speed A rpm 1800 1800 1800 1800 Continuous power ISO 3046 10 over load capability design...

Page 59: ...Lube oil operating pressure low idle meas point before engine R bar FUEL SYSTEM Heat exchanger installed Heat exchanger separate Fuel pressure at engine inlet connection min when engine is starting L...

Page 60: ...ion max operating inclina tions R Liters 265 265 265 265 Oil pan capacity at dipstick mark min standard oil system option max operat ing inclinations L Liters 195 195 195 195 Oil pan capacity at dipst...

Page 61: ...ratings are net brake power as per ISO 3046 Heat exchanger installed Heat exchanger separate Rated engine speed A rpm 1800 1800 1800 1800 Continuous power ISO 3046 10 over load capability design powe...

Page 62: ...Lube oil operating pressure low idle meas point before engine R bar FUEL SYSTEM Heat exchanger installed Heat exchanger separate Fuel pressure at engine inlet connection min when engine is starting L...

Page 63: ...ion max operating inclina tions R Liters 265 265 265 265 Oil pan capacity at dipstick mark min standard oil system option max operat ing inclinations L Liters 195 195 195 195 Oil pan capacity at dipst...

Page 64: ...power ratings are net brake power as per ISO 3046 Heat exchanger installed Heat exchanger separate Rated engine speed A rpm 1500 1500 1500 1500 Continuous power ISO 3046 10 over load capability design...

Page 65: ...0 Lube oil operating pressure low idle meas point before engine R bar FUEL SYSTEM Heat exchanger installed Heat exchanger separate Fuel pressure at engine inlet connection min when engine is starting...

Page 66: ...n max operating inclina tions R Liters 280 280 280 280 Oil pan capacity at dipstick mark min standard oil system option max operat ing inclinations L Liters 210 210 210 210 Oil pan capacity at dipstic...

Page 67: ...power ratings are net brake power as per ISO 3046 Heat exchanger installed Heat exchanger separate Rated engine speed A rpm 1800 1800 1800 1800 Continuous power ISO 3046 10 over load capability design...

Page 68: ...3 Lube oil operating pressure low idle meas point before engine R bar FUEL SYSTEM Heat exchanger installed Heat exchanger separate Fuel pressure at engine inlet connection min when engine is starting...

Page 69: ...n max operating inclina tions R Liters 280 280 280 280 Oil pan capacity at dipstick mark min standard oil system option max operat ing inclinations L Liters 210 210 210 210 Oil pan capacity at dipstic...

Page 70: ...ratings are net brake power as per ISO 3046 Heat exchanger installed Heat exchanger separate Rated engine speed A rpm 1800 1800 1800 1800 Continuous power ISO 3046 10 over load capability design powe...

Page 71: ...3 Lube oil operating pressure low idle meas point before engine R bar FUEL SYSTEM Heat exchanger installed Heat exchanger separate Fuel pressure at engine inlet connection min when engine is starting...

Page 72: ...n max operating inclina tions R Liters 280 280 280 280 Oil pan capacity at dipstick mark min standard oil system option max operat ing inclinations L Liters 210 210 210 210 Oil pan capacity at dipstic...

Page 73: ...A power ratings are net brake power as per ISO 3046 Heat exchanger engine mounted Heat exchanger remote Rated engine speed A rpm 1800 1800 1800 1800 Continuous power ISO 3046 10 over load capability d...

Page 74: ...sure before engine to R bar 6 5 6 5 6 5 6 5 Lube oil operating pressure low idle meas point before engine R bar FUEL SYSTEM Heat exchanger engine mounted Heat exchanger remote Fuel pressure at supply...

Page 75: ...stem option max operating inclina tions R Liters Oil pan capacity at dipstick mark min standard oil system option max operat ing inclinations L Liters 210 210 210 210 Oil pan capacity at dipstick mark...

Page 76: ...3 Operation 3 1 Controls Automation system controls Refer to automation system operating instructions 76 Operation MS150069 02E 2014 03 TIM ID 0000016959 003...

Page 77: ...th position of pressure indicator Page 192 HP fuel pump Only for engines without oil priming pump Fill HP fuel pump with new engine oil Page 179 Raw water pump if located above waterline only appli ca...

Page 78: ...Check coolant level Page 229 Coolant system Preheat coolant with preheating unit Fuel prefilter Drain Page 193 Check that suction side pressure indicated at the fuel prefilter pressure gauge is withi...

Page 79: ...3 4 Starting the engine Start the engine via the automation system Refer to automation system operating instructions MS150069 02E 2014 03 Operation 79 TIM ID 0000017525 003...

Page 80: ...rge air cooler Check condensate drain Page 208 Air filter Check signal ring position of service indicator Page 211 Replace air filter Page 209 if the signal ring is completely visible in the service i...

Page 81: ...eks Tasks after extended out of service periods 3 weeks Note Operate fuel treatment system for at least 5 minutes 1 Start up fuel treatment system Page 83 2 Shut down fuel treatment system Page 87 MS1...

Page 82: ...ves 4 Switch on fuel treatment system Page 86 5 Check direction of rotation of pump 6 Vent bypass and fuel lines of the system a Open ball valve for pressure tank b Open ball valve for overflow tank c...

Page 83: ...ic water drain 18 Water level electrode 19 Ball valve sample extrac tion inlet 20 Switchgear cabinet 21 Pump 22 Coarse filter 23 Fuel supply from tank 24 Tank Switching on fuel treatment system 1 Swit...

Page 84: ...ball valve 5 at inlet to fuel treatment system Result The pressure upstream of the fuel treatment system increases until the overflow valve at the pump unit opens and fuel flows through bypass 3 and...

Page 85: ...y pump draws fuel via bypass 2 directly from tank 24 5 Check suction pressure at the engine mounted fuel delivery pump Note If the suction pressure is within the permissible limits and engine operatio...

Page 86: ...re switching on ensure that all housings are closed Before switching on ensure that no work is in progress anywhere on the entire system Fuel treatment system Switching on 1 Carry out checks prior to...

Page 87: ...inet until water discharge from the outlet stops 2 Switch off fuel treatment system 3 Close ball valve at the inlet to the fuel treatment system 4 Close ball valve at the outlet of the fuel treatment...

Page 88: ...3 11 Stopping the engine Stopping the engine via the automation system Refer to automation system operating instructions 88 Operation MS150069 02E 2014 03 TIM ID 0000017528 004...

Page 89: ...stress to the engine plant Risk of overheating damage to components Initiate emergency stop only in emergency situations Emergency stop 1 Refer to automation system operating instructions 2 Follow in...

Page 90: ...ature the antifreeze concentration is insufficient for the engine room tem perature antifreeze concentration is 50 and engine room temperature is below 40 C Raw water only on engines with engine mount...

Page 91: ...ressed air gun directly at seals or electronic components such as connectors or ECUs Plant Cleaning 1 Carry out plant cleaning only in areas where an appropriate oil separator is provided environmenta...

Page 92: ...005 X Replace air filter Page 209 W1006 Replace fuel injectors Page 181 W1008 X Replace engine oil filter when changing engine oil or when the interval years is reached at the latest Page 218 W1009 Ch...

Page 93: ...W1675 X Replace fuel prefilter or fuel prefilter element Page 197 W1713 Injector Reset drift correction parameter CDC Page 261 Table 1 Maintenance task reference table QL1 MS150069 02E 2014 03 Mainten...

Page 94: ...rt the system by actuating the key switch Running gear blocked engine cannot be barred manually u Contact Service Engine turns on starting but does not fire Cause Corrective action Poor rotation by st...

Page 95: ...icator Page 211 Intercooler dirty u Contact Service Exhaust turbocharger defective u Contact Service Coolant leaks at intercooler Cause Corrective action Intercooler leaky major coolant discharge u Co...

Page 96: ...st gas Cause Corrective action Engine is not at operating temperature u Run engine to reach operating temperature Intercooler leaky u Contact Service 96 Troubleshooting MS150069 02E 2014 03 TIM ID 000...

Page 97: ...h an overload protection If the maximum permissible current consumption is exceeded e g in case of a blockage or dry running the motor protection relay triggers and the pump is switched off u Reset mo...

Page 98: ...ault code 1 comprises 3 digits Fault messages may also be caused by faulty sensors actuators Contact Service to have sensors actuators tested and replaced as necessary if troubleshooting as described...

Page 99: ...may be exposed to heat u Contact Service 5 HI T Charge Air ZKP Number 2 0121 931 Charge air temperature too high limit value 1 Yellow alarm warning Cause Corrective action Charge air cooler not funct...

Page 100: ...tive action Coolant circuit for charge air defective 1 Check charge air cooler and coolant cooler 2 Contact Service 15 LO P Lube Oil ZKP Number 2 0100 921 Lube oil pressure too low limit value 1 Yello...

Page 101: ...2 0127 931 Exhaust temperature too high B side limit value 1 Yellow alarm warning Cause Corrective action Wiring damage 1 Check air filter and wiring Page 260 2 Contact Service 22 SS T Exhaust B ZKP N...

Page 102: ...HI Level Leakage Fuel ZKP Number 2 0151 931 Leak off fuel level too high limit value 1 Yellow alarm warning Cause Corrective action Fuel lines leaking 1 Check fuel system 2 Contact Service 29 HI ETC...

Page 103: ...l filter differential oil pressure too high limit value 1 Yellow alarm warning Cause Corrective action Fuel filter not functioning correctly 1 Replace fuel filter Page 189 2 Contact Service 34 SS P Di...

Page 104: ...204 Yellow alarm warning Cause Corrective action ETC2 failed to cut in u Contact Service 44 LO Coolant Level Charge Air Cooler ZKP Number 2 0153 921 Coolant level of charge air cooler too low limit va...

Page 105: ...ant pressure too low limit value 2 Red alarm engine stop or reduced injection quantity Cause Corrective action Leak in coolant circuit 1 Check coolant level Page 229 2 Check coolant circuit 59 SS T Co...

Page 106: ...ive action Crankcase exhaust system clogged or leaking 1 Reduce power 2 Replace oil mist fine separator element 3 Contact Service 64 SS P Crankcase ZKP Number 2 0106 932 Crankcase pressure too high li...

Page 107: ...age leaks low coolant level 1 Reduce power 2 Check coolant circuit 68 SS T Coolant ZKP Number 2 0120 932 Coolant temperature too high limit value 2 Red alarm engine shutdown Cause Corrective action Co...

Page 108: ...ervice 085 HI T Recirculation ZKP Number 2 0128 931 Recirculation temperature too high limit value 1 Cause Corrective action Charge air temperature before recirculation valve too high u Reduce power 0...

Page 109: ...Red alarm warning Cause Corrective action Starter rotates too slowly or does not rotate at all 1 Check for additional messages 2 Contact Service 93 SS T Preheat ZKP Number 2 1090 922 Preheating tempe...

Page 110: ...g system faulty Yellow alarm warning Cause Corrective action Hour meter faulty u Contact Service 118 LO ECU Power Supply Voltage ZKP Number 2 0140 921 Supply voltage too low limit value 1 Yellow alarm...

Page 111: ...ltage 2 Contact Service 122 HI T ECU ZKP Number 2 0132 921 Electronics temperature too high limit value 1 Yellow alarm warning Cause Corrective action Electronics overheated 1 Reduce power 2 Improve e...

Page 112: ...engine governor indicated for each indiv module u Contact Service 180 AL CAN1 Node Lost ZKP Number 2 0500 680 Connection to a node on CAN bus 1 failed Yellow alarm warning Cause Corrective action Conn...

Page 113: ...governor 1 Check devices connected to CAN 2 Contact Service 184 AL CAN PU Data Flash Error ZKP Number 2 0500 684 CAN PU data flash error Cause Corrective action A program fault occurred while trying t...

Page 114: ...rate incompatibility 1 Check CAN bus for short circuit rectify short circuit as necessary 2 Check shielding improve shielding as necessary 3 Contact Service 189 AL CAN2 Error Passive ZKP Number 2 050...

Page 115: ...is rectified when engine is restarted Page 79 3 Contact Service 203 SD T Charge Air ZKP Number 1 8004 571 Signal error charge air temperature sensor Yellow alarm warning Cause Corrective action Charge...

Page 116: ...ary Page 260 2 Fault is rectified when engine is restarted Page 79 3 Contact Service 207 SD T Exhaust B ZKP Number 1 8004 577 Signal error exhaust temperature sensor on B side Yellow alarm warning Cau...

Page 117: ...ine is restarted Page 79 3 Contact Service 213 SD P Coolant Charge Air Cooler ZKP Number 1 8004 569 Charge air cooler coolant pressure sensor faulty Yellow alarm warning Cause Corrective action Charge...

Page 118: ...ce as necessary Page 260 2 Fault is rectified when engine is restarted Page 79 3 Contact Service 219 SD T Intake Air ZKP Number 1 8004 573 Signal error intake air temperature sensor Yellow alarm warni...

Page 119: ...engine is restarted Page 79 3 Contact Service 223 SD Level Coolant Charge Air Cooler ZKP Number 1 8004 583 Charge air cooler coolant level sensor faulty Yellow alarm warning Cause Corrective action C...

Page 120: ...ring to connector B1 replace as necessary Page 260 2 Fault is rectified when engine is restarted Page 79 3 Contact Service 230 SD Crankshaft Speed ZKP Number 1 8004 498 Signal error crankshaft sensor...

Page 121: ...sensor and wiring B44 2 replace as necessary Page 260 2 Fault is rectified when engine is restarted Page 79 3 Contact Service 239 SD P Diff Fuel ZKP Number 1 8004 598 Differential pressure sensor for...

Page 122: ...nsor faulty Short circuit or wire break u Check sensor and wiring replace as necessary Fault is rectified following engine restart 245 SD ECU Power Supply Voltage ZKP Number 2 8006 589 Signal error en...

Page 123: ...e 79 3 Contact Service 270 SD Frequency Input ZKP Number 2 8006 590 Signal error frequency input Red alarm forced idle Cause Corrective action Frequency input faulty Short circuit or wire break 1 Chec...

Page 124: ...u Replace injector if the fault message appears frequently Page 181 306 AL Timing Cylinder A6 ZKP Number 1 8004 505 Time of flight measuring fault of injector Cause Corrective action Flight time valu...

Page 125: ...u Replace injector if the fault message appears frequently Page 181 312 AL Timing Cylinder B2 ZKP Number 1 8004 511 Time of flight measuring fault of injector Cause Corrective action Flight time valu...

Page 126: ...u Replace injector if the fault message appears frequently Page 181 318 AL Timing Cylinder B8 ZKP Number 1 8004 517 Time of flight measuring fault of injector Cause Corrective action Flight time value...

Page 127: ...ault is rectified when engine is restarted Page 79 3 Contact Service 323 AL Wiring Cylinder A3 ZKP Number 1 8004 522 Wiring fault cylinder A3 Yellow alarm misfire Cause Corrective action Short circuit...

Page 128: ...ault is rectified when engine is restarted Page 79 3 Contact Service 327 AL Wiring Cylinder A7 ZKP Number 1 8004 526 Wiring fault cylinder A7 Yellow alarm misfire Cause Corrective action Short circuit...

Page 129: ...Fault is rectified when engine is restarted Page 79 3 Contact Service 331 AL Wiring Cylinder B1 ZKP Number 1 8004 530 Wiring fault cylinder B1 Yellow alarm misfire Cause Corrective action Short circui...

Page 130: ...ault is rectified when engine is restarted Page 79 3 Contact Service 335 AL Wiring Cylinder B5 ZKP Number 1 8004 534 Wiring fault cylinder B5 Yellow alarm misfire Cause Corrective action Short circuit...

Page 131: ...lt is rectified when engine is restarted Page 79 3 Contact Service 339 AL Wiring Cylinder B9 ZKP Number 1 8004 538 Wiring fault cylinder B9 Yellow alarm misfire Cause Corrective action Short circuit f...

Page 132: ...age 181 3 Fault rectified after each working cycle 4 Contact Service 343 AL Open Load Cylinder A3 ZKP Number 1 8004 542 Injector wiring fault cylinder A3 Yellow alarm misfire Cause Corrective action D...

Page 133: ...age 181 3 Fault rectified after each working cycle 4 Contact Service 347 AL Open Load Cylinder A7 ZKP Number 1 8004 546 Injector wiring fault cylinder A7 Yellow alarm misfire Cause Corrective action D...

Page 134: ...Page 181 3 Fault rectified after each working cycle 4 Contact Service 351 AL Open Load Cylinder B1 ZKP Number 1 8004 550 Injector wiring fault cylinder B1 Yellow alarm misfire Cause Corrective action...

Page 135: ...age 181 3 Fault rectified after each working cycle 4 Contact Service 355 AL Open Load Cylinder B5 ZKP Number 1 8004 554 Injector wiring fault cylinder B5 Yellow alarm misfire Cause Corrective action D...

Page 136: ...e 181 3 Fault rectified after each working cycle 4 Contact Service 359 AL Open Load Cylinder B9 ZKP Number 1 8004 558 Injector wiring fault cylinder B9 Yellow alarm misfire Cause Corrective action Dis...

Page 137: ...shutdown possible Cause Corrective action Electronics faulty 1 Start ITS 2 Replace engine governor if required 3 Check additional messages if ITS indicates diagnosis Electronics OK e g wiring faulty 4...

Page 138: ...e action Short circuit or wire break on transistor output 1 TO 1 1 Check charger valve wiring repair as necessary 2 Replace engine governor 372 AL Wiring TO 2 ZKP Number 1 8004 635 Line disruption Cau...

Page 139: ...reak on transistor output plant side 2 TOP 2 u Check wiring to plant 383 AL Wiring TOP 3 ZKP Number 2 8006 640 Line disruption on digital input 3 Yellow alarm warning Cause Corrective action Short cir...

Page 140: ...2 Cause Corrective action Redundant coolant temperature reading too high engine stop 1 Check wiring and sensor 2 Contact Service 394 LO P Lube Oil Red ZKP Number 2 0112 921 Limit value 1 Cause Correct...

Page 141: ...larm warning Cause Corrective action Wiring faulty No resistance over switch 1 Check wiring Page 260 2 Check target device input 3 Contact Service 402 AL Open Load Digital Input 3 ZKP Number 2 8006 62...

Page 142: ...Check wiring Page 260 2 Check target device input 3 Contact Service 406 AL Open Load Digital Input 7 ZKP Number 2 8006 631 Line disruption on digital input 7 Yellow alarm warning Cause Corrective act...

Page 143: ...aulty current supply 1 Check wiring Page 260 2 Check supply 3 Contact Service 411 LOLO U PDU ZKP Number 2 0141 922 Injector voltage too low limit value 2 Red alarm engine shutdown Cause Corrective act...

Page 144: ...P Number 2 0107 921 Coolant pressure in charge air cooler too low limit 1 Yellow alarm warning Cause Corrective action Leak in coolant circuit u Top up coolant 416 SS P Coolant Charge Air Cooler ZKP N...

Page 145: ...Number 2 0160 922 Limit value 2 Cause Corrective action Input signal of Aux 1 has exceeded not attained limit value 2 depending on configuration u Determine cause of limit value violation and rectify...

Page 146: ...depending on configuration u Determine cause of limit value violation and rectify fault 444 SD U PDU ZKP Number 1 8004 578 Injector power stage supply voltage fault Yellow alarm warning Cause Correct...

Page 147: ...at turbine bypass flap u Contact Service 449 SS P Charge Air ZKP Number 2 0103 932 Charge air pressure too high limit value 2 Red alarm engine shutdown Cause Corrective action Fault at turbine bypass...

Page 148: ...use Corrective action Input signal of Aux 1 plant side has exceeded not attained limit value 1 depending on configuration u Determine cause of limit value violation and rectify fault 456 AL L2 Aux1 Pl...

Page 149: ...pressure faulty short circuit or wire break u Check pressure transmitter and wiring replace as necessary Fault is rectified following engine restart 467 AL L2 T Aux 1 ZKP Number 2 0130 922 Limit valu...

Page 150: ...79 3 Contact Service 471 SD Coil Current ZKP Number 1 8004 592 Signal error HP fuel control block Yellow alarm warning Cause Corrective action Actuation of HP fuel control block faulty Short circuit o...

Page 151: ...t Service 476 AL Crash Rec Init Error ZKP Number 1 8010 007 Initialization error of crash recorder Cause Corrective action Initialization error of crash recorder u Contact Service 478 AL Comb Alarm Ye...

Page 152: ...eak u Check sensor and wiring B4 23 replace as necessary 483 SD T Exhaust D ZKP Number 18 004 597 Cause Corrective action Exhaust temperature sensor on A side faulty Short circuit or wire break u Chec...

Page 153: ...low alarm warning Cause Corrective action Clogged charge air circuit or fault in turbocharger u Reduce power 489 SS ETC3 Overspeed ZKP Number 2 3014 932 Speed of 2nd secondary turbocharger too high li...

Page 154: ...3 Yellow alarm warning Cause Corrective action ETC3 failed to cut in u Check control valve at turbocharger 3 500 AL Wiring POM Starter 1 ZKP Number 1 4500 900 Wiring fault connection of starter 1 at P...

Page 155: ...erator and wiring Page 260 504 AL CAN POM Node Failure ZKP Number 1 4500 904 POM missing on CAN bus Yellow alarm warning Cause Corrective action If alarm 508 occurs in addition the resistor in the POM...

Page 156: ...ssible start cancelation Cause Corrective action Starter on POM could not be engaged 1 Repeat start 2 Check POM starter and wiring Page 260 3 Contact Service 519 Oil Level Calibration Error ZKP Number...

Page 157: ...ed as backup medium for FDH u Contact Service configuration fault 544 AL Configuration Changed ZKP Number 2 0555 003 Yellow alarm Cause Corrective action This alarm is activated when the system config...

Page 158: ...valid enabling code is entered via the SAM display and key controls This enabling code can be requested via the Internet using a special procedure u Request activation code via Internet 576 AL ESCM Ov...

Page 159: ...is too low limit value 1 Yellow alarm warning Cause Corrective action Oil level in oil refill tank too low 1 Check oil level top up as necessary Page 213 2 Contact Service 588 SD P Oil Refill Pump ZK...

Page 160: ...sensor and wiring replace as necessary Page 260 2 Contact Service 601 SD ETC1 ETC2 ZKP Number 1 3011 227 Signal error ETC speed sensor 1 and 2 Yellow alarm warning Cause Corrective action ETC speed se...

Page 161: ...ressure sensor before supplementary filter Yellow alarm warning Cause Corrective action Analog input signal for fuel pressure before supplementary filter faulty Short circuit or wire break 1 Check pre...

Page 162: ...too high u 761 SD T Fuel b Engine ZKP Number 1 0080 900 Cause Corrective action Oil pan temperature sensor faulty Short circuit or wire break 1 Check sensor and wiring B24 replace as necessary Page 2...

Page 163: ...lue 1 Cause Corrective action Lube oil pressure too low u Check ETC oil lubrication 867 AL L1 P Lube Oil ETC A ZKP Number 1 0222 923 Limit value 1 Cause Corrective action Lube oil pressure too low u C...

Page 164: ...ng engine parts Risk of crushing danger of parts of the body being caught or pulled in Before barring the engine make sure that there are no persons in the engine s danger zone After finishing work on...

Page 165: ...o resistance other than compression re sistance must be encountered 4 Rotate crankshaft in engine direction of ro tation Result If the resistance exceeds the normal com pression resistance contact Ser...

Page 166: ...6 1 2 Engine Barring with starting system Barring using the automation system Refer to automation system operating instructions 166 Task Description MS150069 02E 2014 03 TIM ID 0000017532 003...

Page 167: ...attern First signs of marks left by lower cooling bores Running pattern seems darker No action required Darker areas of even or varying color intensity Beginning and end of the discoloration are not s...

Page 168: ...Final steps 1 Install injector Page 182 2 Install cylinder head cover Page 178 168 Task Description MS150069 02E 2014 03 TIM ID 0000000015 016...

Page 169: ...nd the liner It appears rather darker within the honed struc ture in contrast to the bright metallic running surface The honing pattern is undis turbed Discolorations extend in stroke direction and ma...

Page 170: ...tion are similar A thorough investigation and compliance with the above evaluation criteria allow an unambiguous evaluation To avoid unnecessary disassembly work it is recommended that another inspect...

Page 171: ...Overview For 12V engines 1 Vent pipe 2 Plug 3 Oil separator 4 Impactor carrier 5 Bracket 6 Oil line 7 Service block 8 Vent housing 9 Spigot pipe 10 Drain pipe 11 Bracket 12 Connection MS150069 02E 201...

Page 172: ...nes 1 Vent pipe 2 Impactor carrier 3 Bracket 4 Oil line 5 Service block 6 Vent housing 7 Spigot pipe 8 Drain pipe 9 Bracket 10 Plug 11 Oil separator 172 Task Description MS150069 02E 2014 03 TIM ID 00...

Page 173: ...Oil can contain combustion residues which are harmful to health Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Rep...

Page 174: ...re parts Designation Use Part No Qty Engine oil Valve gear Lubrication 1 Remove cylinder head covers Page 178 2 Fill oil chambers of valve bridges with oil 3 Fill oil chambers of rocker arms and adjus...

Page 175: ...l Spare parts Designation Use Part No Qty Feeler gage Y20010128 1 Torque wrench 60 320 Nm F30452768 1 Socket wrench 24 mm F30039526 1 Engine oil Preparatory steps 1 Remove cylinder head cover Page 178...

Page 176: ...engines two crankshaft positions 1 Cylinder A1 is in firing TDC 2 Cylinder A1 is in overlap TDC I Inlet valve X Exhaust valve Diagram for 16V engines two crankshaft positions 1 Cylinder A1 is in firin...

Page 177: ...value exceeds 0 1 mm adjust valve clearance Adjusting valve clearance 1 Release locknut 1 2 Insert feeler gage 3 between valve bridge and rocker arm 3 Using Allen key set adjusting screw 2 so that th...

Page 178: ...r head covers 1 prior to removal 2 Remove screws 3 4 with washers 2 5 3 Take off cylinder head cover 1 with O ring 6 from cylinder head 7 Installing cylinder head cover 1 Clean mounting surface 2 Chec...

Page 179: ...G Oils oil vapors are combustible explosive Risk of fire and explosion Avoid open flames electric sparks and ignition sources Do not smoke NOTICE HP fuel pump not filled with engine oil Damage to comp...

Page 180: ...e s danger zone WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors HP pump Relief bore check 1 Visually inspect relief bore 1 for fuel dis char...

Page 181: ...acement Special tools Material Spare parts Designation Use Part No Qty Injector Spare Parts Catalog Injector Replacement u Remove injector and install new one Page 182 MS150069 02E 2014 03 Task Descri...

Page 182: ...h 60 320 Nm F30452768 1 Ratchet adapter F30027341 1 Assembly paste Optimoly Paste White T 40477 1 Assembly compound Kluthe Hakuform 30 11C Emulgier X00059351 1 Engine oil O ring Spare Parts Catalog WA...

Page 183: ...emove injector with installation removal jig 7 Remove installation removal jig 8 Remove sealing ring 4 from injector or use a self made hook to take it out of the cylinder head 9 Remove O rings 3 O ri...

Page 184: ...osition of sealing ring 4 Fit new O rings 3 included in the scope of delivery of the injector O ring 2 and damping ring 1 onto the injector and coat with assembly compound Kluthe Hakuform 30 11C Emulg...

Page 185: ...reload torque Engine oil 5 Nm to 10 Nm 13 Tighten screw 2 with torque wrench to the specified tightening torque Name Size Type Lubricant Value Standard Screw M12 Tightening torque 100 Nm 10 Nm 14 Tigh...

Page 186: ...ill void the emissions certification 18 Reset drift compensation CDC with Dia Sys E531920 If DiaSys is not available contact Service Final steps 1 Install cylinder head cover Page 178 2 Open fuel supp...

Page 187: ...mentary fuel filter Overview 1 Storage tank 2 Day tank 3 Passive standard prefilter with water separator 4 LP pump 5 Supplementary fuel filter 6 Main engine filter MS150069 02E 2014 03 Task Descriptio...

Page 188: ...ls are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke WARNING High level of engine noise when the engine is running Risk of damage to hear...

Page 189: ...engine is running Risk of damage to hearing Wear ear protectors NOTICE Damage to component Severe material damage For filter replacement with the engine running operate the engine at low engine load T...

Page 190: ...filter 1 using an oil filter wrench 3 Clean sealing surface on filter head 4 Check sealing ring of new filter 1 and coat with fuel 5 Screw on filter 1 and tighten manually 6 Turn three way cock into...

Page 191: ...lters are operational 2 Open threaded vent plugs 1 3 Unlock fuel priming pump 2 screw out handle by turning it counterclockwise 4 Operate fuel priming pump 2 until bubble free fuel emerges from the th...

Page 192: ...f ferential pressure gauge 1 After installation of a new filter element align adjustable pointer 2 with pressure indicating pointer 3 of pressure gauge 1 2 Verify that differential pressure is within...

Page 193: ...cal sparks and ignition sources Do not smoke Draining fuel prefilter 1 Cut out the filter to be replaced A or B 1 Filter A cut out 2 Filter B cut out 2 Open vent plug 1 of filter to be drained 3 Open...

Page 194: ...l until fuel emerges from the vent pipe 3 8 Close vent valve 2 9 Open rotary slide valve 4 a little by ap prox 30 and open vent valve s 2 until fuel emerges from the vent pipe 3 10 Close vent valve s...

Page 195: ...at low power Keep away from the engine s danger zone WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke WARNING High level o...

Page 196: ...ng connection 1 on the suction side of the filter 3 Open vent valve 2 and fill with fuel until fuel emerges from the vent pipe 3 4 Close vent valve 2 5 Open rotary slide valve 4 a little by ap prox 30...

Page 197: ...WARNING Tank is pressurized Risk of eye injuries resulting from fluid escaping under high pressure Open tank slowly Wear goggles or safety mask WARNING Fuels are combustible Risk of fire and explosio...

Page 198: ...ng torque maximum half a turn per screw Name Size Type Lubricant Value Standard Screw Tightening torque 40 Nm 10 Connect filling pump to filling connection 1 on the suction side of the filter 11 Open...

Page 199: ...mask WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke Fuel prefilter with water separa tor O ring replacement in rota ry...

Page 200: ...rns Observe the instructions of the cleaning agent manufacturer NOTICE Inappropriate cleaning tool Risk of damage to component Observe manufacturer s instructions Use appropriate cleaning tool NOTICE...

Page 201: ...er 5 Remove oil lines 2 6 Loosen clamp 1 7 Remove intake housing 3 with actuating cylinder 2 8 Remove coolant lines 1 from compressor housing 3 9 Remove coolant ventilation line 2 from compressor hous...

Page 202: ...ing with a smooth paint brush or brush 2 Clean compressor wheel 2 and bearing housing 1 3 Thoroughly remove cleaner from all compo nents 4 Fit new sealing rings between bearing housing compressor hous...

Page 203: ...e using a torque wrench Name Size Type Lubricant Value Standard Clamp Tightening torque 15 Nm 2 Nm 6 Install oil lines 2 Tighten threaded adapter at actuating cylinder to specified torque using a torq...

Page 204: ...filter Page 210 3 Seal all openings with suitable covers 4 Remove charge air pipework 1 from ex haust turbocharger to intercooler 5 Remove oil lines 2 6 Loosen clamp 1 7 Remove intake housing 3 with a...

Page 205: ...e Do not use wire brushes scrapers or simi lar tools for cleaning 1 Clean compressor housing with a smooth paint brush or brush 2 Clean compressor wheel 2 and bearing housing 1 3 Thoroughly remove cle...

Page 206: ...ening torque Engine oil 20 Nm 2 5 Nm 3 Install coolant ventilation line and coolant lines on compressor housing 4 Install intake housing 3 with actuating cyl inder 2 5 Align clamp 1 and tighten to spe...

Page 207: ...me Size Type Lubricant Value Standard Threaded adapter 10 G 1 4 A Tightening torque Engine oil 40 Nm 4 Nm 7 Install charge air pipework 1 between exhaust turbocharger and intercooler 8 Install air fil...

Page 208: ...air jet at people Always wear safety goggles face mask and ear defenders Intercooler Checking conden sate drain for water discharge and obstruction 1 With the engine running check if air emerges from...

Page 209: ...re parts Designation Use Part No Qty Air filter Spare Parts Catalog Replacing the air filter 1 Remove old air filter and install new air filter Page 210 2 Reset signal ring of contamination indicator...

Page 210: ...in the flange of the intake housing 3 and clean it 4 Attach air filter 1 with clamp 2 onto in take housing 3 5 Tighten clamp 2 Air filter with intake silencer 1 Loosen clamp 2 2 Remove air filter 1 a...

Page 211: ...isabled Checking signal ring position 1 If the signal ring is completely visible in the control window 2 replace air filter Page 209 2 After installation of new filter press reset button 1 Result Enga...

Page 212: ...eck Preconditions Engine is stopped and starting disabled Checking starter condition 1 Check securing screws of starter for secure seating and tighten if required 2 Check wiring Page 260 212 Task Desc...

Page 213: ...xchanger flowing back into the oil pan 3 The oil level must reach mark 1 or exceed mark 1 by up to 2 cm 4 Top up with oil to mark 1 as necessary Page 214 5 Insert dipstick into guide tube up to the st...

Page 214: ...y mask Avoid contact with skin Do not inhale oil vapor Oil change without semirotary hand pump Draining oil via drain plug s on oil pan 1 Provide a suitable container to collect the oil 2 Remove drain...

Page 215: ...tening torque Engine oil 100 Nm 10 Nm Filling with new oil 1 Open cap on filler neck 2 Pour oil in at filler neck up to max mark at oil dipstick 3 Close cap on filler neck 4 Check engine oil level Pag...

Page 216: ...ar protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear p...

Page 217: ...filter by 1 to 2 rotations 2 Drain approx 2 liters engine oil to flush out the oil sludge 3 Drain approx 1 liter engine oil into a clean container 4 Close screw 5 Using the equipment and chemicals in...

Page 218: ...ve clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor NOTICE Damage to component Severe material damage For filter replacement with the engine running operate the...

Page 219: ...6 9 Check oil level Page 213 Oil filter with diverter option Oil filter replacement with the engine running 1 To cut out the filter to be replaced set the three way cock to the corresponding posi tion...

Page 220: ...e clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor WARNING Compressed air gun ejects a jet of pressurized air Risk of injury to eyes and damage to hearing risk o...

Page 221: ...part Cleaning strainer 1 Wash strainer 5 with cleaner 2 Remove stubborn deposits with soft brush 3 Blow out strainer 5 with compressed air from inside Installing strainer 1 Coat square section ring 4...

Page 222: ...Catalog Sealing ring Spare Parts Catalog Sealing ring Spare Parts Catalog WARNING Hot oil Oil can contain combustion residues which are harmful to health Risk of injury and poisoning Wear protective...

Page 223: ...and rotor base 10 with sealing ring 9 13 Insert new filter sleeve 6 in rotor tube 7 with the smooth paper surface facing the outer wall 14 Check sealing ring 5 fit new one if neces sary 15 Mount rotor...

Page 224: ...Push standpipe 12 onto rotor lower sec tion 13 13 Insert new filter sleeve 9 with stiffener plate 10 into rotor cap 8 ensuring that the smooth surface of the filter sleeve 9 faces the rotor cap 8 14...

Page 225: ...t Circuit General High Temperature Circuit 6 15 1 Drain and vent points Coolant lines on ETC 1 Vent point Coolant line to intercooler 1 Vent point MS150069 02E 2014 03 Task Description 225 TIM ID 0000...

Page 226: ...1 Vent point Coolant line to raw water cooler 1 Vent point 226 Task Description MS150069 02E 2014 03 TIM ID 0000014545 004...

Page 227: ...Vent line Distribution cross 1 Vent point Coolant drain point engine driving end 1 Drain point MS150069 02E 2014 03 Task Description 227 TIM ID 0000014545 004...

Page 228: ...Coolant drain point engine free end 1 Drain point 228 Task Description MS150069 02E 2014 03 TIM ID 0000014545 004...

Page 229: ...se up to the first stop and allow pressure to escape 2 Continue to turn breather valve counterclockwise and remove 3 Check coolant level coolant must be visible at the bottom edge of the cast in eye i...

Page 230: ...e Special tools Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 231 2 Fill with engine coolant Page 234 230 Task Description MS150069 02E 201...

Page 231: ...2 Switch off preheating unit Engine coolant Draining 1 Turn breather valve on expansion tank for engines with remote heat exchanger the expansion tank is part of the remote cooling system countercloc...

Page 232: ...e on exhaust pipework driv ing end 1 6 Open vent valve on seawater cooler 1 or remote heat exchanger 7 Open drain plug 1 and drain coolant at crankcase 232 Task Description MS150069 02E 2014 03 TIM ID...

Page 233: ...screw 1 and drain coolant on coolant pump elbow Final steps 1 Seal all open vent and drain points 2 Set breather valve onto filler neck and close it MS150069 02E 2014 03 Task Description 233 TIM ID 00...

Page 234: ...e clothing gloves and goggles safety mask NOTICE Cold coolant in hot engine can cause thermal stress Possible formation of cracks in the engine Fill top up coolant only into cold engine Preparatory st...

Page 235: ...faces if required 5 Set breather valve onto filler neck and turn until the first stop 6 Start engine Page 79 7 After 10 seconds of running the engine without load shut down the engine Page 88 8 Turn b...

Page 236: ...of damage to hearing Wear ear protectors HT coolant pump Relief bore check 1 Check relief bore for oil and coolant dis charge 2 Stop engine Operating instructions elec tronic system and disable engine...

Page 237: ...own Wear protective clothing gloves and goggles safety mask WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors Engine coolant Sample extrac tio...

Page 238: ...alding Let the engine cool down Wear protective clothing gloves and goggles safety mask Engine coolant filter Replace ment 1 Remove locking device 1 2 Close shut off cock 3 3 Remove engine coolant fil...

Page 239: ...d to warm up the engine coolant The circulating pump 8 ensures the circulation of the preheated engine coolant through the engine The continuous flow heater 5 comprises a heating element The thermosta...

Page 240: ...eating unit 1 On Off switch Cylinders Nominal voltage frequency Heating power kW 12 V and 16 V 230 V 50 Hz 9 400 V 50 Hz 9 230 V 60 Hz 9 440 V 60 Hz 9 240 Task Description MS150069 02E 2014 03 TIM ID...

Page 241: ...prises a heating element A non return flap 3 prevents coolant from flowing through the preheating unit when the engine is running When the coolant temperature has reached the value of the thermostat s...

Page 242: ...y to heating element 2 Close shut off valve in coolant line before and after preheater 3 Drain coolant at drain valve into a clean container 4 Clean and flush coolant circuit 5 Check hoses for cracks...

Page 243: ...asses facial protection Checking operation Note The coolant temperature must correlate to the control range of the thermostat when the preheater is ready for operation 1 Check coolant preheating tempe...

Page 244: ...se when the engine is running Risk of damage to hearing Wear ear protectors Raw water pump Relief bore check 1 Check relief bore for oil and coolant dis charge 2 Stop engine Page 88 and disable en gin...

Page 245: ...gine mounting Check Engine mounting Check Item Findings Action Visually inspect mounts Damage Brittleness Deformation Crack formation Swelling visible Replace contact Service MS150069 02E 2014 03 Task...

Page 246: ...ed Battery charging generator drive Coupling condition check 1 Remove screws 1 2 Remove protective cover 2 3 Check resilient coupling 3 for cracks and plastic deformation 4 If there is serious deforma...

Page 247: ...ise when the engine is running Risk of damage to hearing Wear ear protectors Bilge pump Relief bore check 1 Check relief bores for oil and water dis charge 2 Stop engine Page 88 and disable en gine st...

Page 248: ...System 6 20 1 Water drain valve Check Water drain valve Check 1 Open water drain valve 2 Check water outlet for obstructions 3 Close water drain valve 248 Task Description MS150069 02E 2014 03 TIM ID...

Page 249: ...es Do not smoke Checking differential pressure gauge 1 Switch on fuel treatment system Page 86 2 Set the alarm points at the differential pressure gauge to zero Result Alarm is initiated with preset d...

Page 250: ...ect connector from water level probe 4 Immerse water level probe into a tank filled with water until water level reaches the thread 5 Switch system on Result Water drain valve opens 6 Leave water leve...

Page 251: ...k pressure at the pressure gauge in the inlet to the fuel treatment system and note down 3 Check pump pressure with reduced suction a Reduce suction pressure of pump to 0 8 bar with the shutoff valve...

Page 252: ...mponents and lines Damage to component Ensure that components lines are installed so that they are never under tension or strain Ensure correct installation position of components Coalescer filter ele...

Page 253: ...htening torque Engine oil 30 Nm 3 Nm 17 Fit gasket 10 18 Install cover 19 Install screws 1 washers 2 and nuts 9 20 Tighten nuts 9 21 Open ball valve at the inlet and outlet of the fuel treatment syste...

Page 254: ...filter B34 2 Fuel pressure upstream of filter B34 3 Fuel pressure upstream of external filter B44 1 Rotation speed exhaust turbocharger A B44 2 Rotation speed exhaust turbocharger B B48 HP fuel press...

Page 255: ...ensors 12V engine 1 M8 2 B1 3 B6 4 X2 5 X37 6 XXF33 7 F33 8 B16 9 XF33 10 B54 11 B44 2 12 Y27 13 B4 22 14 B9 15 S37 1 16 B34 3 17 B34 2 18 B34 1 19 B50 20 B49 21 B44 1 22 Y26 23 B5 3 24 B3 25 B4 21 26...

Page 256: ...2 7 X37 8 XF33 9 B54 10 B16 11 XXF33 12 F33 13 B4 22 14 B9 15 S37 1 16 B34 3 17 B34 2 18 B34 1 19 B50 20 B49 21 B44 1 22 Y26 23 B5 3 24 B3 25 B4 21 26 B10 27 B13 28 S37 2 29 B7 30 B5 1 31 B48 32 B33 3...

Page 257: ...iring harness for injectors 12V engine 1 Y39A1 2 Y39A2 3 Y39A3 4 Y39A4 5 Y39A5 6 Y39A6 7 X4 8 Y39B6 9 Y39B5 10 Y39B4 11 Y39B3 12 Y39B2 13 Y39B1 MS150069 02E 2014 03 Task Description 257 TIM ID 0000038...

Page 258: ...injectors 16V engine 1 Y39A1 2 Y39A2 3 Y39A3 4 Y39A4 5 Y39A5 6 Y39A6 7 Y39A7 8 Y39A8 9 X4 10 Y39B8 11 Y39B7 12 Y39B6 13 Y39B5 14 Y39B4 15 Y39B3 16 Y39B2 17 Y39B1 258 Task Description MS150069 02E 2014...

Page 259: ...Engine wiring harness for electric starter 1 Connection terminals EIM 2 Fuse F1 3 Connection terminals starter MS150069 02E 2014 03 Task Description 259 TIM ID 0000038739 002...

Page 260: ...tion 4 Replace cable clips if defective 5 Check that cable clamps are firm tighten loose cable clamps 6 Replace faulty cable clamps 7 Visually inspect the following electrical line components for dama...

Page 261: ...starting disabled Note Failure to reset drift compensation CDC parameters will void the emissions certification Resetting CDC parameters with DiaSys u Dialog system DiaSys E531920 Resetting CDC parame...

Page 262: ...ng 2 2 Check whether both switches 3 are actu ated 3 If switches 3 and or guard plate 1 with engine support 4 is are not installed Screw on guard plate 1 with engine support 4 Then screw on switch 3 e...

Page 263: ...starting disabled Check plug connections on ECU 7 1 Check all connectors on ECU for firm seat ing Ensure that the clips 1 are engaged 2 Check screws 2 of cable clamps on ECU for firm seating Ensure th...

Page 264: ...ing disabled Checking EMU plug connections 1 Check both connectors on EMU 2 for firm seating Make sure that frames 3 are en gaged 2 Check screws 1 of cable clamps on EMU 2 for firm seating Make sure t...

Page 265: ...ng disabled Checking EIM plug connections 1 Check both Tyco plugs 62 pole 2 on EIM for firm seating Ensure that clips 3 are engaged 2 Check screws 1 of cable clamps on EIM for firm seating Ensure that...

Page 266: ...ntrol Unit from engine 1 Note or mark assignment of cables and connectors 2 Remove all screws 3 3 Undo clips 2 on connectors 4 Remove all male connectors 5 Remove screws 1 6 Take off Engine Control Un...

Page 267: ...rews 2 3 Undo latches 3 of the connectors 4 Disconnect all connectors 5 Remove screws 1 6 Remove ECU 5 with EMU 4 Removing EMU 1 Unscrew screws on base of EMU 4 2 Remove EMU 4 from ECU 5 Installing EM...

Page 268: ...When doing so observe correct assignment between cables and plugs 2 Check seal before installing Result Replace seal if porous or defective Downloading software 1 The new EIM still does not have appro...

Page 269: ...r operation 4 Application loader active 5 External RAM faulty 6 External FLASH faulty 7 No firmware 8 Application crashed Fuse lamp SILA A second indicator is the fuse lamp This is also integrated in...

Page 270: ...oring current path failed S8 10 Emergency stop current path failed 24V internal S9 11 ES pushbutton current path failed 24V external S10 12 Key switch current path failed S11 13 SDAF 1 2 current path...

Page 271: ...fuse S4 fail ure 1 2 second steps Note These bit sequences are transmitted constantly Information about the status of the current paths of the EIM is also provided in the CAN message Sta tus internal...

Page 272: ...Engine management system ECU Engine Control Unit Engine governor EDM Engine Data Module Memory module for engine data EIM Engine Interface Module Interface to engine monitoring system EMU Engine Moni...

Page 273: ...nel PCU Propeller Control Unit PIM Peripheral Interface Module RCS Remote Control System RL Redundancy Lost Alarm Redundant CAN bus failure SAE Society of Automotive Engineers U S standardization orga...

Page 274: ...e work in case of malfunction or changed operating conditions or for spare parts supply Your contact person in our Customer Assistance Center E mail info mtu online com Tel 49 7541 9077777 Fax 49 7541...

Page 275: ...er wrench Part No F30379104 Qty Used in 1 6 7 2 Additional fuel filter Replacement Page 188 Qty Used in 1 6 7 3 Fuel filter Replacement Page 189 Qty Used in 6 14 1 Engine oil filter Replacement Page 2...

Page 276: ...Removal and installation Page 182 MTU test kit Part No 5605892099 00 Qty Used in 1 6 13 3 Engine oil Sample extraction and analysis Page 216 Qty Used in 1 6 15 7 Engine coolant Sample extraction and a...

Page 277: ...wheel Cleaning Page 200 Ratchet adapter Part No F30027341 Qty Used in 1 6 6 2 Injector Removal and installation Page 182 Qty Used in 1 6 13 2 Engine oil Change Page 214 Ratchet with extension Part No...

Page 278: ...m Part No 0015384230 Qty Used in 1 6 6 2 Injector Removal and installation Page 182 Torque wrench 10 60 Nm Part No F30452769 Qty Used in 1 6 6 2 Injector Removal and installation Page 182 Qty Used in...

Page 279: ...ing and filter sleeve replacement Page 222 Torque wrench 6 50 Nm Part No F30027336 Qty Used in 1 6 20 5 Coalescer filter element Replacement Page 252 Torque wrench 60 320 Nm Part No F30452768 Qty Used...

Page 280: ...Differential pressure gauge Check 249 Drain and vent points 225 Drift compensation Reset 261 E ECU 7 Installation 266 Removal 266 EMU 7 Installation 267 Removal 267 Engine Barring manually 164 Barring...

Page 281: ...sure gauge Adjustment 192 Check 192 Fuel system Venting 191 Fuel treatment system Putting into operation 83 Shutdown 87 Switching on 86 H Hotline 274 HP pump Filling with engine oil 179 Relief bore ch...

Page 282: ...r Signal ring position check 211 Service partners 274 Spare parts service 274 Starter Condition check 212 Supplementary fuel filter Overview 187 T Tasks After extended out of service periods 81 Tasks...

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MTU 12 V 4000 M33F, Operating Instructions Manual

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Summary of Contents for 12 V 4000 M33F

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