MTU 12 V 4000 M53 Operating Instructions Manual Download Page 213

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6.20 Wiring (General) for Engine/Gearbox/Unit

6.20.1 Overview of engine wiring harness

Engine wiring harnesses – Terminal assignment

Description

Terminal assignment

Sensors

Camshaft speed

Intake air temperature

B4.21

Exhaust temperature, A side

B4.22

Exhaust temperature, B-side

B5.1

Oil pressure downstream of filter

B5.3

Oil pressure upstream of filter

Coolant temperature

Oil temperature

Charge-air temperature

B10

Charge-air pressure

B13

Crankshaft speed

B16

Coolant pressure

B33

Fuel temperature

B34.1

Fuel pressure downstream of filter

B34.2

Fuel pressure upstream of filter

B34.3

Fuel pressure upstream of external filter

B44.1

Rotation speed, turbocharger A

B44.2

Rotation speed, turbocharger B

B48

HP fuel pressure

B49

Charge air before recirculation

B50

Crankcase pressure

B54

Replenishment pump pressure

Level monitor

F33

Coolant level

XF33

Coolant level adaptation

XXF33

Coolant level, outer skin cooling

F46

Fuel overflow level

Pump

Fuel pump

Limit switch

S37.1

Start lockout A

S37.2

Start lockout B

Adaptation

ECU-7 module

X37

Cranking start lockout

XG03

Alternator

Valves

Y26

Charge-air recirculation

Y27

Turbocharger

MS150035/01E 2013-11 | Task Description | 213

TIM-ID: 0000038739 - 001

Summary of Contents for 12 V 4000 M53

Page 1: ...Operating Instructions Diesel engine 12 V 4000 M53 16 V 4000 M53 MS150035 01E...

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: ...op 93 3 13 After stopping the engine 94 3 14 Plant Cleaning 95 4 Maintenance 4 1 Maintenance task reference table QL1 96 5 Troubleshooting 5 1 Troubleshooting 98 5 2 Fuel treatment system Troubleshoot...

Page 4: ...aw water pump Relief bore check 203 6 16 Battery Charging Generator 204 6 16 1 Battery charging generator drive Coupling condition check 204 6 17 Auxiliary PTO 205 6 17 1 Bilge pump Relief bore check...

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: ...trans port pallet or transport with equipment for heavy loads forklift truck Install the crankshaft locking device and the locking screws for the engine mounts prior to engine trans portation Secure t...

Page 8: ...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 Safe...

Page 9: ...uct beforehand Hydraulic installation and removal Check satisfactory function and safe operating condition of tools jigs and fixtures to be used Use only the specified jigs and fixtures for hydraulic...

Page 10: ...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 11: ...roduct 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 Nonc...

Page 12: ...y line or before device or tool is to 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...

Page 13: ...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 14: ...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 i...

Page 15: ...Open bus interface to the plant SAE J1939 Emergency stop function with line break monitoring Redundant power supply Optional control of emergency air shutoff flaps Key switch logic Interface to ECU a...

Page 16: ...marine engine models 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 17: ...prox 20 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...

Page 18: ...1 Fuel line after LP pump 1 Fuel line to fuel filter head retainer 18 Product Summary MS150035 01E 2013 11 TIM ID 0000010054 008...

Page 19: ...1 Fuel line from fuel filter head 1 Fuel line on HP pump MS150035 01E 2013 11 Product Summary 19 TIM ID 0000010054 008...

Page 20: ...1 Fuel line on fuel filter head 1 Fuel line on fuel filter head 20 Product Summary MS150035 01E 2013 11 TIM ID 0000010054 008...

Page 21: ...ith oil pressure 1 8 bar All lines with SOLAS compliant covers for pipe connections according to MTU standard MTN5233 are shown 1 Oil supply for recirculation valve MS150035 01E 2013 11 Product Summar...

Page 22: ...1 Oil supply line on HP pump 1 Oil supply line of HP pump on equipment carrier 22 Product Summary MS150035 01E 2013 11 TIM ID 0000010054 008...

Page 23: ...1 Oil supply for actuating cylinder of turbocharger B1 exhaust flap 1 Oil supply on equipment carrier MS150035 01E 2013 11 Product Summary 23 TIM ID 0000010054 008...

Page 24: ...ngines with horizontal air intake 1 Oil supply for actuating cylinder of turbocharger B1 air flap 2 Oil supply for T piece of flap control 24 Product Summary MS150035 01E 2013 11 TIM ID 0000010054 008...

Page 25: ...1 Oil supply to distributor 2 Oil return 1 Oil return MS150035 01E 2013 11 Product Summary 25 TIM ID 0000010054 008...

Page 26: ...l line to flap control 2 Oil line to recirculation valve 3 Oil line from main oil gal lery 4 Oil line to ETC 1 ETC oil supply 2 ETC oil supply 26 Product Summary MS150035 01E 2013 11 TIM ID 0000010054...

Page 27: ...1 Oil supply for actuating cylinder of turbocharger B1 air flap 2 Oil supply for T piece of flap control 3 Oil supply for actuating cylinder of turbocharger B1 air flap MS150035 01E 2013 11 Product S...

Page 28: ...o distributor of flap control B side 1 Oil lines for B side flap control from main oil gal lery 2 Oil lines for B side flap control to main oil gallery 28 Product Summary MS150035 01E 2013 11 TIM ID 0...

Page 29: ...1 Oil supply for flap control to main oil gallery in en gine Vee engine free end MS150035 01E 2013 11 Product Summary 29 TIM ID 0000010054 008...

Page 30: ...1 Turbocharger oil supply connection to main oil gal lery in engine Vee 30 Product Summary MS150035 01E 2013 11 TIM ID 0000010054 008...

Page 31: ...1 Oil supply on distribution point of turbocharger oil supply on engine free end 1 Cover on oil filter cartridge MS150035 01E 2013 11 Product Summary 31 TIM ID 0000010054 008...

Page 32: ...is decreased significantly if an O ring 3 defect occurs The union is confirmed as being SOLAS compliant by DNV and GL Plugs and sensors Screw in plugs 2 are sealed toward the outside either with a cop...

Page 33: ...ipe of HP line 19 Ball type seal area 20 Leak fuel connection The HP fuel line is sealed by the thrust ring 8 In case of leakage around the thrust ring 8 or the HP line 5 fuel escapes into the leakage...

Page 34: ...pipe to charge air cool er 9 Charge air cooler 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...

Page 35: ...type air filter 9 Exhaust turbocharger 10 Exhaust outlet 11 Air pipe to charge air cool er 12 Recirculation line 13 Exhaust manifold 14 Charge air cooler 15 Charge air line 16 Engine mounts 17 Oil pa...

Page 36: ...filter 8 Exhaust manifold 9 Recirculation line 10 Exhaust turbocharger 11 Exhaust outlet 12 Air pipe to charge air cool er 13 Charge air cooler 14 Engine mounts 15 Charge air line 16 Oil pan 17 Oil fi...

Page 37: ...16 Engine 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 Fre...

Page 38: ...erature before recircula tion valve recirculation valve A 2 B3 intake air temperature 3 B44 1 turbocharger A speed 4 B10 charge air pressure 5 B34 3 fuel pressure be fore filter only if supple mentary...

Page 39: ...B5 1 lube oil pressure af ter 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 optional 8 B6 2 coolant tempera ture...

Page 40: ...000 M engine right engine side 1 B44 2 turbocharger B speed 2 Y27 turbocharger control valve 3 B16 coolant pressure 4 B9 charge air tempera ture 40 Product Summary MS150035 01E 2013 11 TIM ID 00000129...

Page 41: ...B4 22 exhaust tempera ture B bank 2 B13 crankshaft speed 3 S37 2 safety switch 4 S37 1 safety switch 5 B13 2 crankshaft speed optional 6 B4 21 exhaust tempera ture a bank MS150035 01E 2013 11 Product...

Page 42: ...engine top view 1 B4 cylinder exhaust tem perature A1 A6 B1 B6 optional 2 B50 crankcase pressure 3 B33 alternatively fuel temperature in common rail 42 Product Summary MS150035 01E 2013 11 TIM ID 000...

Page 43: ...on valve recirculation valve A 2 B3 intake air temperature 3 B44 1 turbocharger A speed 4 B10 charge air pressure 5 B34 3 fuel pressure be fore filter only if supple mentary fuel filter is fitted 6 B3...

Page 44: ...B5 1 lube oil pressure af ter 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 optional 8 B6 2 coolant tempera ture...

Page 45: ...t engine side 1 B44 2 turbocharger B speed 2 Y27 turbocharger control valve 3 B16 coolant pressure 4 B21 raw water pressure optional 5 B9 charge air tempera ture MS150035 01E 2013 11 Product Summary 4...

Page 46: ...B4 22 exhaust tempera ture B bank 2 B13 crankshaft speed 3 S37 2 safety switch 4 S37 1 safety switch 5 B13 2 crankshaft speed optional 6 B4 21 exhaust tempera ture a bank 46 Product Summary MS150035 0...

Page 47: ...p view 1 B4 cylinder exhaust tem perature A1 A6 B1 B6 optional 2 B50 crankcase pressure 3 B33 alternatively fuel temperature in common rail 4 F33 coolant level MS150035 01E 2013 11 Product Summary 47...

Page 48: ...ide 1 B50 crankcase pressure 2 B3 intake air temperature 3 B44 1 turbocharger A speed 4 B10 charge air pressure 5 B34 3 fuel pressure be fore filter only if supple mentary fuel filter is fitted 6 B34...

Page 49: ...B5 1 lube oil pressure af ter 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 optional 8 B6 2 coolant tempera ture...

Page 50: ...00 M engine right engine side 1 B44 2 turbocharger B speed 2 Y27 turbocharger control valve 3 B16 coolant pressure 4 B9 charge air tempera ture 50 Product Summary MS150035 01E 2013 11 TIM ID 000001844...

Page 51: ...B4 22 exhaust tempera ture B bank 2 B13 crankshaft speed 3 S37 2 safety switch 4 S37 1 safety switch 5 B13 2 crankshaft speed optional 6 B4 21 exhaust tempera ture a bank MS150035 01E 2013 11 Product...

Page 52: ...arge air tem perature before recircula tion valve recirculation valve A 2 B4 cylinder exhaust tem perature A1 A6 B1 B8 optional 3 B33 alternatively fuel temperature in common rail 52 Product Summary M...

Page 53: ...recircula tion valve recirculation valve A 3 B44 1 turbocharger A speed 4 B3 intake air temperature 5 B10 charge air pressure 6 B34 3 fuel pressure be fore filter only if supple mentary fuel filter i...

Page 54: ...B5 1 lube oil pressure af ter 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 optional 8 B6 2 coolant tempera ture...

Page 55: ...engine side 1 B44 2 turbocharger B speed 2 Y27 turbocharger control valve 3 B16 coolant pressure 4 B21 raw water pressure optional 5 B9 charge air tempera ture MS150035 01E 2013 11 Product Summary 55...

Page 56: ...B4 22 exhaust tempera ture B bank 2 B13 crankshaft speed 3 S37 2 safety switch 4 S37 1 safety switch 5 B13 2 crankshaft speed optional 6 B4 21 exhaust tempera ture a bank 56 Product Summary MS150035 0...

Page 57: ...M engine engine top 1 B4 cylinder exhaust tem perature A1 A6 B1 B8 optional 2 B33 alternatively fuel temperature in common rail 3 F33 coolant level MS150035 01E 2013 11 Product Summary 57 TIM ID 00000...

Page 58: ...rcula tion valve recirculation valve A 3 B3 intake air temperature 4 B44 1 turbocharger A speed 5 B10 charge air pressure 6 B34 3 fuel pressure be fore filter only if supple mentary fuel filter is fit...

Page 59: ...B5 1 lube oil pressure af ter 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 optional 8 B6 2 coolant tempera ture...

Page 60: ...00 M engine right engine side 1 B44 2 turbocharger B speed 2 Y27 turbocharger control valve 3 B16 coolant pressure 4 B9 charge air tempera ture 60 Product Summary MS150035 01E 2013 11 TIM ID 000001844...

Page 61: ...B4 22 exhaust tempera ture B bank 2 B13 crankshaft speed 3 S37 2 safety switch 4 S37 1 safety switch 5 B13 2 crankshaft speed optional 6 B4 21 exhaust tempera ture a bank MS150035 01E 2013 11 Product...

Page 62: ...16V 4000 M engine engine top 1 B4 cylinder exhaust tem perature A1 A6 B1 B8 optional 2 B33 alternatively fuel temperature in common rail 62 Product Summary MS150035 01E 2013 11 TIM ID 0000018445 003...

Page 63: ...recircula tion valve recirculation valve A 3 B3 intake air temperature 4 B44 1 turbocharger A speed 5 B10 charge air pressure 6 B34 3 fuel pressure be fore filter only if supple mentary fuel filter is...

Page 64: ...B5 1 lube oil pressure af ter 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 optional 8 B6 2 coolant tempera ture...

Page 65: ...engine side 1 B44 2 turbocharger B speed 2 Y27 turbocharger control valve 3 B16 coolant pressure 4 B21 raw water pressure optional 5 B9 charge air tempera ture MS150035 01E 2013 11 Product Summary 65...

Page 66: ...B4 22 exhaust tempera ture B bank 2 B13 crankshaft speed 3 S37 2 safety switch 4 S37 1 safety switch 5 B13 2 crankshaft speed optional 6 B4 21 exhaust tempera ture a bank 66 Product Summary MS150035 0...

Page 67: ...M engine engine top 1 B4 cylinder exhaust tem perature A1 A6 B1 B8 optional 2 B33 alternatively fuel temperature in common rail 3 F33 coolant level MS150035 01E 2013 11 Product Summary 67 TIM ID 00000...

Page 68: ...to the cylinders on the left hand side of the engine and the letter B 3 to refer to the cylinders on the right hand side The cylinders of each bank are numbered consecutively starting with No 1 at th...

Page 69: ...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 70: ...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 71: ...g Sequence 2 4 1 Firing order Cylinders Firing order 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 MS150035 01E 2013 11 Product Summary 71 TIM ID 000002...

Page 72: ...tude above sea level m 100 100 100 100 POWER DATA power is net power to ISO 3046 Engine mounted heat exchanger Remote heat ex changer Rated engine speed A rpm 1800 1800 1800 1800 Fuel stop power to IS...

Page 73: ...94 93 94 Lube oil operating pressure before engine from R bar 5 3 5 3 5 3 5 3 Lube oil operating pressure before engine to R bar 6 3 6 3 6 3 6 3 Lube oil operating pressure lower idle speed measuring...

Page 74: ...erating inclinations L degrees 10 10 10 10 Longitudinal inclination temporary max drive end higher Design max operating inclinations L degrees Transverse inclination continuous max Design max operatin...

Page 75: ...ine mounted heat exchanger Remote heat ex changer Exhaust noise unsilenced BL free field sound level Lp 1m distance ISO 6798 3dB A tolerance R dB A 112 112 112 112 Engine surface noise with attenuated...

Page 76: ...is net power to ISO 3046 Engine mounted heat exchanger Remote heat ex changer Rated engine speed A rpm 1800 1800 1800 1800 Fuel stop power to ISO 3046 A kW 1840 1840 1840 1840 PERIPHERAL CONDITIONS f...

Page 77: ...6 3 6 3 Lube oil operating pressure lower idle speed measuring point before engine R bar 2 5 2 5 2 5 2 5 FUEL SYSTEM Engine mounted heat exchanger Remote heat ex changer Fuel pressure on engine inlet...

Page 78: ...verse inclination continuous max Design max operating inclinations L degrees 22 5 22 5 22 5 22 5 Transverse inclination temporary max Design max operating inclinations L degrees CAPACITIES Engine moun...

Page 79: ...BL free field sound level Lp 1m distance ISO 6798 3dB A tolerance R dB A 111 111 111 111 Engine surface noise with attenuated in take noise filter BL free field sound level Lp 1m distance ISO 6798 2d...

Page 80: ...3 Operation 3 1 Controls Automation system controls Refer to automation system operating instructions 80 Operation MS150035 01E 2013 11 TIM ID 0000016959 003...

Page 81: ...th position of pressure indicator Page 153 HP fuel pump Only for engines without oil priming pump Fill HP fuel pump with new engine oil Page 141 Raw water pump if located above waterline only appli ca...

Page 82: ...Check coolant level Page 190 Coolant system Preheat coolant with preheating unit Fuel prefilter Drain Page 154 Check that suction side pressure indicated at the fuel prefilter pressure gauge is withi...

Page 83: ...3 4 Starting the engine Start the engine via the automation system Refer to automation system operating instructions MS150035 01E 2013 11 Operation 83 TIM ID 0000017525 003...

Page 84: ...rge air cooler Check condensate drain Page 169 Air filter Check signal ring position of service indicator Page 172 Replace air filter Page 170 if the signal ring is completely visible in the service i...

Page 85: ...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 87 2 Shut down fuel treatment system Page 91 MS1...

Page 86: ...ves 4 Switch on fuel treatment system Page 90 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 87: ...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 88: ...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 89: ...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 90: ...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 91: ...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 92: ...3 11 Stopping the engine Stopping the engine via the automation system Refer to automation system operating instructions 92 Operation MS150035 01E 2013 11 TIM ID 0000017528 004...

Page 93: ...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 94: ...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 95: ...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 96: ...e engine oil filter at each oil change or when the time limit years is reached at the latest Page 181 W1009 Check layer thickness of oil residue clean and replace filter sleeve during every oil change...

Page 97: ...njector reset drift compensation parameters CDC Page 229 W1714 Check and clean oil indicator filter if fitted Page 179 Table 1 Maintenance task reference table QL1 MS150035 01E 2013 11 Maintenance 97...

Page 98: ...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 99: ...icator Page 172 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 100: ...t gas Cause Corrective action Engine is not at operating temperature u Run engine to reach operating temperature Intercooler leaky u Contact Service 100 Troubleshooting MS150035 01E 2013 11 TIM ID 000...

Page 101: ...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 102: ...ult 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 i...

Page 103: ...ilure ZKP Number 18 004 204 Cause Corrective action ETC2 could not be cut in 1 Reduce power 2 Contact Service 81 AL Rail Leakage ZKP Number 18 004 046 Cause Corrective action Pressure gradient in rail...

Page 104: ...lace as necessary 2 Error cleared after restarting the engine 202 SD T Fuel ZKP Number 18 004 572 Cause Corrective action Coolant temperature sensor faulty Short circuit or wire break 1 Check sensor a...

Page 105: ...ng B4 22 replace as necessary 208 SD P Charge Air ZKP Number 18 004 566 Cause Corrective action Charge air pressure sensor faulty Short circuit or wire break 1 Check sensor and cabling B10 replace as...

Page 106: ...sensor and cabling B48 replace as necessary 2 Error cleared after restarting the engine 216 SD T Lube Oil ZKP Number 18 004 575 Cause Corrective action Lube oil temperature sensor faulty Short circui...

Page 107: ...cleared after restarting the engine 227 SD P Lube Oil before Filter ZKP Number 18 004 620 Cause Corrective action Sensor for lube oil pressure before filter faulty Short circuit or wire break 1 Check...

Page 108: ...Error cleared after restarting the engine 233 SD Charger 2 Speed ZKP Number 13 011 129 Cause Corrective action Speed sensor of secondary turbocharger faulty Short circuit or wire break 1 Check sensor...

Page 109: ...nt lube oil pressure sensor faulty Short circuit or wire break 1 Check sensor and cabling replace as necessary 2 Error cleared after restarting the engine 301 AL Timing Cylinder A1 ZKP Number 18 004 5...

Page 110: ...ctive action Time of flight measuring fault of injector in cylinder A5 Time of flight measured value extremely low or extremely high u If alarm occurs frequently replace solenoid valve of injector 306...

Page 111: ...Cause Corrective action Time of flight measuring fault of injector in cylinder A10 Time of flight measured value extremely low or extremely high u If alarm occurs frequently replace solenoid valve of...

Page 112: ...Corrective action Time of flight measuring fault of injector B5 Time of flight measured value extremely low or extremely high u If alarm occurs frequently replace solenoid valve of injector 316 AL Ti...

Page 113: ...ult of injector B10 Time of flight measured value extremely low or extremely high u If alarm occurs frequently replace solenoid valve of injector 321 AL Wiring Cylinder A1 ZKP Number 18 004 520 Cause...

Page 114: ...by injector replacement 2 Error cleared after restarting the engine 326 AL Wiring Cylinder A6 ZKP Number 18 004 525 Cause Corrective action Short circuit in injector cabling to cylinder A6 Result Mis...

Page 115: ...g by injector replacement 2 Error cleared after restarting the engine 332 AL Wiring Cylinder B2 ZKP Number 18 004 531 Cause Corrective action Cabling fault in injector cabling to cylinder B2 Result Mi...

Page 116: ...by injector replacement 2 Error cleared after restarting the engine 338 AL Wiring Cylinder B8 ZKP Number 18 004 537 Cause Corrective action Cabling fault in injector cabling to cylinder B8 Result Misf...

Page 117: ...g by injector replacement 2 Error clearance After each working cycle 344 AL Open Load Cylinder A4 ZKP Number 18 004 543 Cause Corrective action Disruption fault in injector cabling to cylinder A4 Resu...

Page 118: ...by injector replacement 2 Error clearance After each working cycle 350 AL Open Load Cylinder A10 ZKP Number 18 004 549 Cause Corrective action Disruption fault in injector cabling to cylinder A10 Res...

Page 119: ...g by injector replacement 2 Error clearance After each working cycle 356 AL Open Load Cylinder B6 ZKP Number 18 004 555 Cause Corrective action Disruption fault in injector cabling to cylinder B6 Resu...

Page 120: ...t 1 1020 021 Power Stage Failure Stop Engine is set engine will be shut down as additional measure u Start ITS If the ITS diagnosis result is electronics OK note further fault messages e g cabling fau...

Page 121: ...n transistor output 1 TO 1 1 Check charger valve cabling repair as necessary 2 Replace engine governor 372 AL Wiring TO 2 ZKP Number 18 004 635 Cause Corrective action Short circuit or wire break on t...

Page 122: ...Maximum deviation of lube oil pressure values from sensors 1 Check sensor and cabling replace as necessary 2 Contact Service 417 SD Level Water Fuel Prefilter ZKP Number 18 004 594 Cause Corrective a...

Page 123: ...y 1 Check signal transmitter and cabling replace as necessary 2 Replace engine governor 469 SD AUX 1 ZKP Number 18 004 590 Cause Corrective action Analog input signal for Aux 1 faulty Short circuit or...

Page 124: ...corder initialization error 1 Check setting with DiaSys 2 Contact Service 482 SD T Exhaust C ZKP Number 18 004 596 Cause Corrective action Exhaust temperature sensor on A side faulty Short circuit or...

Page 125: ...g consumer a wire break or a short circuit u Check connection between POM and starter 502 AL Open Load POM Alternator ZKP Number 14 500 902 Cause Corrective action Open load was detected at the connec...

Page 126: ...ss 519 Oillevel Calibration Error ZKP Number 10 158 921 Cause Corrective action Error when writing the calibration value into the Flash or SD memory of the level sensor associated PV AL Group 6 Mot Bi...

Page 127: ...e Oil Pan ZKP Number 10 137 900 Cause Corrective action Temperature sensor in oil pan defective Short circuit or wire break u Check sensor and cabling replace as necessary 582 AL Emergency Stop Failed...

Page 128: ...eck sensor and cabling replace as necessary 601 SD ETC1 ETC2 ZKP Number 13 011 227 Cause Corrective action SD ETC1 and ETC2 u Check sensor and cabling replace as necessary 625 SD P Fuel before Prefilt...

Page 129: ...ing engine parts Risk of crushing danger of parts of the body being caught or pulled in Before cranking the engine make sure that there are no persons in the engine s danger zone After finishing work...

Page 130: ...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 131: ...6 1 2 Engine Barring with starting system Barring using the automation system Refer to automation system operating instructions MS150035 01E 2013 11 Task Description 131 TIM ID 0000017532 003...

Page 132: ...s First signs of marks left by lower cooling bores Running pattern seems darker No action required Dark areas with even or varying degrees of discoloration Beginning and end of the discoloration are n...

Page 133: ...Final steps 1 Install injector Page 144 2 Install cylinder head cover Page 140 MS150035 01E 2013 11 Task Description 133 TIM ID 0000000015 014...

Page 134: ...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 135: ...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 136: ...re parts Designation Use Part No Qty Engine oil Valve gear Lubrication 1 Remove cylinder head covers Page 140 2 Fill oil chambers of valve bridges with oil 3 Fill oil chambers of rocker arms and adjus...

Page 137: ...ial Spare parts Designation Use Part No Qty Feeler gauge Y20010128 1 Torque wrench 60 320 Nm F30047446 1 Socket wrench 24 mm F30039526 1 Engine oil Preparatory steps 1 Remove cylinder head cover Page...

Page 138: ...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 139: ...exceeds 0 1 mm adjust valve clearance Valve clearance adjustment 1 Release locknut 1 2 Insert feeler gauge 3 between valve bridge and rocker arm 3 Using Allen key set adjusting screw 2 so that the spe...

Page 140: ...cylinder head cover 1 Clean very dirty cylinder head covers prior to removal 2 Remove screws 3 Remove cylinder head cover with gasket from cylinder head Installing cylinder head cover 1 Clean mating...

Page 141: ...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 142: ...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 143: ...or Replacement Special tools Material Spare parts Designation Use Part No Qty Injector Spare Parts Catalog Replacing injector u Remove injector and install new injector Page 144 MS150035 01E 2013 11 T...

Page 144: ...wrench 60 320 Nm F30452768 1 Ratchet F30027341 1 Assembly paste Optimoly Paste White T 40477 1 Grease Kluthe Hakuform 30 10 Emulgier X00029933 1 Engine oil O ring Spare Parts Catalog WARNING Fuels ar...

Page 145: ...r head 7 Remove injector with installation removal tool 8 Remove installation removal tool 9 Remove sealing ring 4 from injector or use a self made hook to take it out of the cylinder head 10 Remove O...

Page 146: ...installation position of seal ing ring 4 Fit new O rings 3 included in the scope of supply of the injector O ring 2 and damping ring 1 onto the injector and coat with grease 5 Remove oil carbon from...

Page 147: ...orque wrench to the specified tightening torque Name Size Type Lubricant Value Standard Screw M12 Tightening torque 100 Nm 10 Nm 14 Tighten adapter 3 with torque wrench to the specified tightening tor...

Page 148: ...screw Tightening torque 40 Nm 5 Nm 19 Fit connectors on injector Note Failure to reset drift compensation CDC will void the emissions certification 20 Reset drift compensation CDC with Dia Sys E531920...

Page 149: ...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 MS150035 01E 2013 11 Task Descriptio...

Page 150: ...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 151: ...RNING Fuels 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 damag...

Page 152: ...her fuel filters in the same way 9 Vent fuel system 1 Replacing fuel filter with the en gine running 1 Cut out the filter to be replaced 2 Unscrew cut out easy change filter with fil ter wrench 3 Clea...

Page 153: ...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 154: ...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 155: ...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 156: ...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 157: ...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 158: ...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 159: ...per screw using a torque wrench 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 vent val...

Page 160: ...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 161: ...nd chemical burns Always obey manufacturer s instructions for use CAUTION Incorrect installation of components and lines Damage to component Ensure that components lines are installed so that they are...

Page 162: ...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 163: ...g 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 housin...

Page 164: ...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 165: ...filter Page 171 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 166: ...ote Do not use wire brush scraper or similar 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 clean...

Page 167: ...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 168: ...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 169: ...jet at people Always wear safety goggles face mask and ear defenders Charge air cooler Checking condensate drain for water dis charge and obstruction 1 With the engine running check if air emerges fro...

Page 170: ...e 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 171 2 Reset signal ring of contamination indicator P...

Page 171: ...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 an...

Page 172: ...isabled Checking signal ring position 1 If the signal ring is completely visible in the control window 2 replace air filter Page 170 2 After installation of new filter press reset button 1 Result Enga...

Page 173: ...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 218 MS150035 01E...

Page 174: ...or heat exchanger back to 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 175 5 Insert dipstick into guide tube up to the st...

Page 175: ...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 176: ...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 177: ...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 178: ...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 179: ...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 of...

Page 180: ...m Findings Action Strainer Metallic residues Clean Monitor engine operation Check strainer daily Notify Service Strainer Damaged Fit new part Square section ring Damaged Fit new part O ring Damaged Fi...

Page 181: ...loves 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 engine at low...

Page 182: ...1 9 Check oil level Page 174 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 183: ...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 184: ...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 185: ...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 186: ...nt Circuit General High Temperature Circuit 6 14 1 Drain and vent points Coolant line on ETC 1 Vent point Coolant line to intercooler 1 Vent point 186 Task Description MS150035 01E 2013 11 TIM ID 0000...

Page 187: ...1 Vent point Coolant line to raw water cooler 1 Vent point MS150035 01E 2013 11 Task Description 187 TIM ID 0000014545 003...

Page 188: ...Vent line Distribution cross 1 Vent point Coolant drain point engine driving end 1 Drain point 188 Task Description MS150035 01E 2013 11 TIM ID 0000014545 003...

Page 189: ...Coolant drain point engine free end 1 Drain point MS150035 01E 2013 11 Task Description 189 TIM ID 0000014545 003...

Page 190: ...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 191: ...e Special tools Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 192 2 Fill with engine coolant Page 195 MS150035 01E 2013 11 Task Description...

Page 192: ...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 193: ...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 MS150035 01E 2013 11 Task Description 193 TIM ID...

Page 194: ...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 194 Task Description MS150035 01E 2013 11 TIM ID 00...

Page 195: ...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 196: ...faces if required 5 Set breather valve onto filler neck and turn until the first stop 6 Start engine Page 83 7 After 10 seconds of running the engine without load shut down the engine Page 92 8 Turn b...

Page 197: ...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 198: ...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 199: ...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 200: ...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 201: ...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 MS150035 01E 2013 11 Task Description 201 TIM ID...

Page 202: ...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 203: ...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 92 and disable en gin...

Page 204: ...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 205: ...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 92 and disable en gine st...

Page 206: ...gine mounting Check Engine mounting Check Item Findings Action Visually inspect mounts Damage Brittleness Deformation Crack formation Swelling visible Replace contact Service 206 Task Description MS15...

Page 207: ...System 6 19 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 MS150035 01E 2013 11 Task Description 207 TIM ID...

Page 208: ...es Do not smoke Checking differential pressure gauge 1 Switch on fuel treatment system Page 90 2 Set the alarm points at the differential pressure gauge to zero Result Alarm is initiated with preset d...

Page 209: ...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 210: ...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 211: ...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 212: ...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 213: ...4 1 Fuel pressure downstream of filter B34 2 Fuel pressure upstream of filter B34 3 Fuel pressure upstream of external filter B44 1 Rotation speed turbocharger A B44 2 Rotation speed turbocharger B B4...

Page 214: ...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 215: ...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 216: ...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 216 Task Description MS150035 01E 2013 11 TIM ID 0000038...

Page 217: ...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 MS150035 01E 2013 11 Task Description...

Page 218: ...that cable clamps are firm tighten loose cable clamps 4 Replace faulty cable clamps 5 Visually inspect the following electrical line components for damage Connector housing Contacts Sockets Cables and...

Page 219: ...on both sides of flywheel housing 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 su...

Page 220: ...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 221: ...ng 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 th...

Page 222: ...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 223: ...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 224: ...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 225: ...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 226: ...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 227: ...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 228: ...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 229: ...o reset drift compensation CDC parameters will void the emissions certification Resetting CDC parameters with DiaSys u Dialog system DiaSys E531920 Resetting CDC parameters without DiaSys u If no DiaS...

Page 230: ...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 231: ...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 232: ...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 233: ...er wrench Part No F30379104 Qty Used in 1 6 6 2 Additional fuel filter Replacement Page 150 Qty Used in 1 6 6 3 Fuel filter Replacement Page 151 Qty Used in 6 13 2 Engine oil filter Replacement Page 1...

Page 234: ...r Removal and installation Page 144 MTU test kit Part No 5605892099 00 Qty Used in 1 6 12 3 Engine oil Sample extraction and analysis Page 177 Qty Used in 1 6 14 7 Engine coolant Sample extraction and...

Page 235: ...element Replacement Page 211 Ratchet adapter Part No F30027340 Qty Used in 1 6 6 7 Fuel prefilter with water separator Filter ele ment replacement Page 158 Qty Used in 1 6 7 1 Compressor wheel Cleani...

Page 236: ...rt No Y20097353 Qty Used in 1 6 2 1 Cylinder liner Endoscopic examination Page 132 Socket wrench 24 mm Part No F30039526 Qty Used in 1 6 3 2 Valve clearance Check and adjustment Page 137 Steam jet cle...

Page 237: ...y Used in 1 6 6 7 Fuel prefilter with water separator Filter ele ment replacement Page 158 Torque wrench 10 60 Nm Part No F30452769 Qty Used in 1 6 7 1 Compressor wheel Cleaning Page 161 Torque wrench...

Page 238: ...3 3 Centrifugal oil filter Cleaning and filter sleeve replacement Page 183 Torque wrench 6 50 Nm Part No F30027336 Qty Used in 1 6 19 5 Coalescer filter element Replacement Page 211 Torque wrench 60 3...

Page 239: ...Torque wrench 60 320 Nm Part No F30452768 Qty Used in 1 6 5 2 Injector Removal and installation Page 144 MS150035 01E 2013 11 Appendix B 239 DCL ID 0000005146 003...

Page 240: ...examination 134 D Designations Engine sides and cylinders 68 Differential pressure gauge Check 208 Drain and vent points 186 Drift compensation Reset 229 E ECU 7 Installation 223 Removal 223 EMU 7 In...

Page 241: ...Check 219 M MTU contact persons 232 O Oil indicator filter Checking 179 Operational checks 84 P Plant Cleaning 95 Plug connections Check 222 Product description 14 Pump capacity Check 210 Putting the...

Page 242: ...alve clearance Adjustment 137 Check 137 Valve gear Lubrication 136 W Water drain valve Check 207 Water level probe 3 in 1 rod electrode Check 209 242 Appendix B MS150035 01E 2013 11 DCL ID 0000005146...

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MTU 12 V 4000 M53, Operating Instructions Manual

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