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MTU 12 V 4000 M63, Operating Instructions Manual

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MTU 12 V 4000 M63 Operating Instructions Manual Download Page 4

7.8.1 Intercooler – Checking condensate drain for

water discharge and obstruction

173

7.9 Air Filter

174

7.9.1 Air filter – Replacement

174

7.9.2 Air filter – Removal and installation

175

7.10 Air Intake

176

7.10.1 Service indicator – Signal ring position check

(optional)

176

7.11 Starting Equipment

177

7.11.1 Starter – Condition check

177

7.12 Lube Oil System, Lube Oil Circuit

178

7.12.1 Engine oil – Level check

178

7.12.2 Engine oil – Change

179

7.12.3 Engine oil – Sample extraction and analysis

181

7.13 Oil Filtration / Cooling

183

7.13.1 Engine oil filter – Replacement

183

7.13.2 Oil indicator filter – Check

185

7.13.3 Centrifugal oil filter – Cleaning and filter

sleeve replacement

187

7.14 Coolant Circuit, General, High-Temperature

Circuit

190

7.14.1 Drain and vent points

190

7.14.2 Engine coolant level – Check

194

7.14.3 Engine coolant – Change

195

7.14.4 Engine coolant – Draining

196

7.14.5 Engine coolant – Filling

199

7.14.6 HT coolant pump — Relief bore check

201

7.14.7 Engine coolant – Sample extraction and

analysis

202

7.14.8 Engine coolant filter – Replacement

203

7.14.9 Preheating unit

204

7.15 Raw Water Pump with Connections

207

7.15.1 Raw water pump – Relief bore check

207

7.16 Battery-Charging Generator

208

7.16.1 Battery-charging generator drive – Coupling

condition check

208

7.17 Auxiliary PTO

209

7.17.1 Bilge pump – Relief bore check

209

7.18 Fuel Supply System

210

7.18.1 Water drain valve – Check

210

7.18.2 Differential pressure gauge – Check

211

7.18.3 Water level probe (3-in-1 rod electrode) –

Check

212

7.18.4 Pump capacity – Check

213

7.18.5 Coalescer filter element – Replacement

214

7.19 Wiring (General) for Engine/Gearbox/Unit

216

7.19.1 Engine wiring – Check

216

7.20 Accessories for (Electronic) Engine

Governor / Control System

217

7.20.1 CDC parameters – Reset with DiaSys®

217

7.20.2 Limit switch for start interlock ‒ Check

218

7.20.3 Engine Control Unit ECU 7 – Checking plug

connections

219

7.20.4 Engine monitoring unit EMU – Plug

connection check

220

7.20.5 Interface module plug connections – Check

221

7.20.6 ECU 7 engine governor – Removal and

installation

222

7.20.7 EMU 7 – Removal and installation

223

7.20.8 Engine Interface Module EIM – Removal and

installation

224

7.20.9 Diagnostic features of EIM

225

8 Appendix A

8.1 Abbreviations

228

8.2 MTU contact persons/service partners

230

9 Appendix B

9.1 Special Tools

231

9.2 Index

237

4 | Table of Contents | MS150066/02E 2013-02

DCL-ID: 0000005757 - 002

Summary of Contents for 12 V 4000 M63

Page 1: ...Operating Instructions Diesel engine 12 V 4000 M63 16 V 4000 M63 16 V 4000 M63R MS150066 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: ...ne stop 97 4 13 After stopping the engine 98 4 14 Plant cleaning 99 5 Maintenance 5 1 Maintenance task reference table QL1 100 6 Troubleshooting 6 1 Troubleshooting 102 6 2 Fuel treatment system Troub...

Page 4: ...r Pump with Connections 207 7 15 1 Raw water pump Relief bore check 207 7 16 Battery Charging Generator 208 7 16 1 Battery charging generator drive Coupling condition check 208 7 17 Auxiliary PTO 209...

Page 5: ...on approved by the manufacturer in writ ing including engine control parameters In compliance with all safety instructions and in adherence to all warning notices in this manual In accordance with the...

Page 6: ...lar must be read and understood This is particularly important in the case of personnel who only occasionally perform work on or around the product This personnel must be instructed repeatedly Personn...

Page 7: ...ts and monitoring units must be permanently observed with re gard to present operating status violation of limit values and warning or alarm messages Malfunctions and emergency stop The procedures for...

Page 8: ...llium containing pinion Do not blow out the interior of the flywheel housing or the starter with compressed air Clean the flywheel housing inside with a class H dust extraction device as an additional...

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

Page 10: ...cy 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...

Page 11: ...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 Noncompliance with these guid...

Page 12: ...ne or before the equipment or tool is to be replaced Carry out leak test in accordance with the specifications Paints and lacquers Observe the relevant safety data sheet for all materials When carryin...

Page 13: ...UTION In the event of possible danger Consequences Minor or moderate injuries Remedial action NOTICE In the event of a situation involving potentially adverse effects on the product Consequences Mater...

Page 14: ...ort 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 Secur...

Page 15: ...designated A and those of the right side B as per DIN ISO 1204 The cylinders of each bank are numbered consecutively starting with No 1 at the driving end Other components are numbered in the same way...

Page 16: ...t on 12V and 16V engines with electronically controlled hydraul ically actuated flaps Cooling system Split circuit engine cooling system with remote or engine mounted heat exchanger Heating of the cha...

Page 17: ...ce for diagnosis The engine interface comprises two parts The first part of signals is integrated in the engine wiring har ness with a 62 pole Tyco connector X52 The second part refers to signals asso...

Page 18: ...led exhaust lines Common Rail fuel injection and cylinder cutout allow engine operation at low load Nevertheless low load operation at engine load below 15 of the nominal rating is permitted for max 1...

Page 19: ...ox 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 do...

Page 20: ...1 Fuel line after LP pump 1 Fuel line to fuel filter head retainer 20 General Information MS150066 02E 2013 02 TIM ID 0000010054 008...

Page 21: ...1 Fuel line from fuel filter head 1 Fuel line on HP pump MS150066 02E 2013 02 General Information 21 TIM ID 0000010054 008...

Page 22: ...1 Fuel line on fuel filter head 1 Fuel line on fuel filter head 22 General Information MS150066 02E 2013 02 TIM ID 0000010054 008...

Page 23: ...h 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 MS150066 02E 2013 02 General Informat...

Page 24: ...1 Oil supply line on HP pump 1 Oil supply line of HP pump on equipment carrier 24 General Information MS150066 02E 2013 02 TIM ID 0000010054 008...

Page 25: ...1 Oil supply for actuating cylinder of turbocharger B1 exhaust flap 1 Oil supply on equipment carrier MS150066 02E 2013 02 General Information 25 TIM ID 0000010054 008...

Page 26: ...ines with horizontal air intake 1 Oil supply for actuating cylinder of turbocharger B1 air flap 2 Oil supply for T piece of flap control 26 General Information MS150066 02E 2013 02 TIM ID 0000010054 0...

Page 27: ...1 Oil supply to distributor 2 Oil return 1 Oil return MS150066 02E 2013 02 General Information 27 TIM ID 0000010054 008...

Page 28: ...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 28 General Information MS150066 02E 2013 02 TIM ID 00000100...

Page 29: ...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 MS150066 02E 2013 02 General Inf...

Page 30: ...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 30 General Information MS150066 02E 2013 02 TIM ID...

Page 31: ...1 Oil supply for flap control to main oil gallery in en gine Vee engine free end MS150066 02E 2013 02 General Information 31 TIM ID 0000010054 008...

Page 32: ...1 Turbocharger oil supply connection to main oil gal lery in engine Vee 32 General Information MS150066 02E 2013 02 TIM ID 0000010054 008...

Page 33: ...1 Oil supply on distribution point of turbocharger oil supply on engine free end 1 Cover on oil filter cartridge MS150066 02E 2013 02 General Information 33 TIM ID 0000010054 008...

Page 34: ...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 coppe...

Page 35: ...e 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 c...

Page 36: ...unts 9 Oil pan 10 Oil filler neck 11 Crankcase 12 Fuel filter 13 Cylinder head 14 Exhaust manifold 15 Centrifugal oil filter 16 Oil filter 17 HP fuel pump 18 Battery charging generator 19 Bilge pump o...

Page 37: ...il pan 10 Oil filler neck 11 Crankcase 12 Fuel filter 13 Cylinder head 14 Exhaust manifold 15 Centrifugal oil filter 16 Oil filter 17 HP fuel pump 18 Battery charging generator 19 Bilge pump option 20...

Page 38: ...iller neck 11 Crankcase 12 Fuel filter 13 Cylinder head 14 Exhaust manifold 15 Centrifugal oil filter 16 Oil filter 17 HP fuel pump 18 Battery charging generator 19 Bilge pump option 20 Coolant outlet...

Page 39: ...ing generator 19 Bilge pump option 20 Raw water inlet 21 Raw water outlet 22 Engine management and monitoring 23 Plate core heat exchanger 24 Oil cooler 25 Coolant expansion tank 26 Crankcase breather...

Page 40: ...fore 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 fuel filt...

Page 41: ...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 op...

Page 42: ...0 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 42 General Information MS150066 02E 2013 02 TIM ID 000001...

Page 43: ...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 MS150066 02E 2013 02 General In...

Page 44: ...ngine 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 44 General Information MS150066 02E 2013 02 TIM ID 0...

Page 45: ...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 B34...

Page 46: ...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 op...

Page 47: ...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 MS150066 02E 2013 02 General Information...

Page 48: ...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 48 General Information MS150066...

Page 49: ...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 MS150066 02E 2013 02 General Information 4...

Page 50: ...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 2 fuel...

Page 51: ...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 optio...

Page 52: ...4000 M right engine side 1 B44 2 turbocharger B speed 2 Y27 turbocharger control valve 3 B16 coolant pressure 4 B9 charge air tempera ture 52 General Information MS150066 02E 2013 02 TIM ID 0000018445...

Page 53: ...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 MS150066 02E 2013 02 General Infor...

Page 54: ...ir 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 54 General Information MS1...

Page 55: ...rcula 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 is fit...

Page 56: ...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 optio...

Page 57: ...ne 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 MS150066 02E 2013 02 General Information 57...

Page 58: ...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 58 General Information MS150066 02...

Page 59: ...0 M plan view 1 B4 cylinder exhaust tem perature A1 A6 B1 B8 optional 2 B33 alternatively fuel temperature in common rail 3 F33 coolant level MS150066 02E 2013 02 General Information 59 TIM ID 0000018...

Page 60: ...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 fitted 7...

Page 61: ...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 optio...

Page 62: ...4000 M right engine side 1 B44 2 turbocharger B speed 2 Y27 turbocharger control valve 3 B16 coolant pressure 4 B9 charge air tempera ture 62 General Information MS150066 02E 2013 02 TIM ID 0000018445...

Page 63: ...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 MS150066 02E 2013 02 General Infor...

Page 64: ...16 V 4000 M plan view 1 B4 cylinder exhaust tem perature A1 A6 B1 B8 optional 2 B33 alternatively fuel temperature in common rail 64 General Information MS150066 02E 2013 02 TIM ID 0000018445 002...

Page 65: ...cula 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 fitt...

Page 66: ...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 optio...

Page 67: ...ngine 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 MS150066 02E 2013 02 General Information...

Page 68: ...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 68 General Information MS150066 02...

Page 69: ...0 M plan view 1 B4 cylinder exhaust tem perature A1 A6 B1 B8 optional 2 B33 alternatively fuel temperature in common rail 3 F33 coolant level MS150066 02E 2013 02 General Information 69 TIM ID 0000018...

Page 70: ...mbar 1000 1000 1000 1000 Site altitude above sea level m 100 100 100 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Heat exchanger engine mounted Heat exchanger remote Rated...

Page 71: ...4 95 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 low idle meas point before engi...

Page 72: ...linations L Degrees 10 10 10 10 Longitudinal inclination temporary max driving end up Option max operating in clinations L Degrees Transverse inclination continuous max Option max operating inclinatio...

Page 73: ...exchanger engine mounted Heat exchanger remote Exhaust noise unsilenced BL free field sound pressure level Lp 1m distance ISO 6798 3dB A tolerance R dB A 107 107 107 107 Engine surface noise with att...

Page 74: ...00 100 POWER RELATED DATA 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 Fuel stop power ISO 3046 A...

Page 75: ...oil operating pressure low idle meas point before engine R bar 2 5 2 5 2 5 2 5 FUEL SYSTEM Heat exchanger engine mounted Heat exchanger remote Fuel pressure at engine inlet connection min when engine...

Page 76: ...nation continuous max Option max operating inclinations L Degrees 22 5 22 5 22 5 22 5 Transverse inclination temporary max Option max operating inclinations L Degrees CAPACITIES Heat exchanger engine...

Page 77: ...ee field sound pressure level Lp 1m distance ISO 6798 3dB A tolerance R dB A 110 110 110 110 Engine surface noise with attenuated in take noise filter BL free field sound power level Lp 1 m distance I...

Page 78: ...RELATED DATA power ratings are net brake power as per ISO 3046 Heat exchanger engine mounted Heat exchanger remote Rated engine speed A rpm 1600 1600 1600 1600 Fuel stop power ISO 3046 A kW 1920 1920...

Page 79: ...oil operating pressure low idle meas point before engine R bar 2 5 2 5 2 5 2 5 FUEL SYSTEM Heat exchanger engine mounted Heat exchanger remote Fuel pressure at engine inlet connection min when engine...

Page 80: ...nation continuous max Option max operating inclinations L Degrees 22 5 22 5 22 5 22 5 Transverse inclination temporary max Option max operating inclinations L Degrees CAPACITIES Heat exchanger engine...

Page 81: ...ee field sound pressure level Lp 1m distance ISO 6798 3dB A tolerance R dB A 109 109 109 109 Engine surface noise with attenuated in take noise filter BL free field sound power level Lp 1 m distance I...

Page 82: ...3 4 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 82 Technical Data MS150066 02E 2013 02 TIM ID 0000010713 002...

Page 83: ...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 silencer Width B with si lence...

Page 84: ...00 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 Height C without silencer Height C with si lencer 12V...

Page 85: ...4 Operation 4 1 Controls Automation system controls Refer to automation system operating instructions MS150066 02E 2013 02 Operation 85 TIM ID 0000016959 003...

Page 86: ...th position of pressure indicator Page 156 HP fuel pump Only for engines without oil priming pump Fill HP fuel pump with new engine oil Page 144 Raw water pump if located above waterline only appli ca...

Page 87: ...oil if required Coolant system Check coolant level Page 194 Coolant system Heat engine coolant with coolant preheating unit Fuel prefilter Drain Page 157 Check that suction side pressure indicated at...

Page 88: ...4 4 Starting the engine Start the engine via the automation system Refer to automation system operating instructions 88 Operation MS150066 02E 2013 02 TIM ID 0000017525 003...

Page 89: ...ain Page 173 Air filter Check signal ring position of service indicator Page 176 Replace air filter Page 174 if the signal ring is completely visible in the service indicator control window HP fuel pu...

Page 90: ...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 92 2 Shut down fuel treatment system Page 95 90...

Page 91: ...ves 4 Switch on fuel treatment system Page 94 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 92: ...coalescer filter element and in the pressure tank Initial operation HAT 1 Replace fuel filter on engine Page 154 Note Determine the suction pressure upstream of the engine mounted fuel delivery pump...

Page 93: ...on fuel treatment system Page 94 2 Start engine Page 88 3 Run engine at idling speed 4 Switch off pump 21 on switchgear cabinet 20 Result The engine mounted fuel delivery pump draws fuel via bypass 2...

Page 94: ...hing on ensure that all housings are closed Before switching on ensure that no work is in progress anywhere on the entire system Switching on fuel treatment system 1 Carry out checks prior to start up...

Page 95: ...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 96: ...4 11 Stopping the engine Stopping the engine via the automation system Refer to automation system operating instructions 96 Operation MS150066 02E 2013 02 TIM ID 0000017528 004...

Page 97: ...eme stress to the engine Risk of overheating damage to components Initiate emergency stop only in emergency situations Emergency stop 1 Refer to automation system operating instructions 2 Follow instr...

Page 98: ...rature the antifreeze concentration is insufficient for the engine room tempera ture antifreeze concentration is 50 and engine room temperature is below 40 C Raw water only on engines with engine moun...

Page 99: ...cleaning 1 Carry out plant cleaning only in areas where an appropriate oil separator is provided environmental protection 2 Prior to putting the cleaning unit into operation read the Operating Instru...

Page 100: ...age 174 W1006 Replace fuel injectors Page 146 W1008 Replace engine oil filter when changing engine oil or when the interval years is reached at the latest Page 183 W1009 X Check layer thickness of the...

Page 101: ...filter element of supple mentary fuel filter Page 153 W1713 Injector Reset drift compensation CDC parameters Page 217 W1714 X Check and clean oil indicator filter Page 185 Table 1 Maintenance task ref...

Page 102: ...ace if required and re start the system by actuating the key switch Engine turns on starting but does not fire Cause Corrective action Poor rotation by starter Battery low or faulty u Charge or replac...

Page 103: ...icator Page 176 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 104: ...t gas Cause Corrective action Engine is not at operating temperature u Run engine to reach operating temperature Intercooler leaky u Contact Service 104 Troubleshooting MS150066 02E 2013 02 TIM ID 000...

Page 105: ...n 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 motor...

Page 106: ...mprises 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 in the table b...

Page 107: ...lure 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 108: ...ce 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 and...

Page 109: ...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 110: ...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 111: ...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 112: ...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 113: ...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 114: ...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 115: ...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 116: ...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 117: ...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 118: ...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 119: ...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 120: ...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 121: ...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 122: ...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 123: ...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 124: ...t 1 1020 021 Power Stage Failure Stop engine is set engine is additionally stopped in this case u Start ITS If the ITS diagnosis result is electronics OK note further fault messages e g cabling faults...

Page 125: ...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 tr...

Page 126: ...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 127: ...y 1 Check signal transmitter and wiring 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 128: ...error of crash recorder 1 Check settings 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 wi...

Page 129: ...o a missing consumer 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 th...

Page 130: ...19 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 Bit 11...

Page 131: ...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 132: ...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 133: ...y Danger to life Before barring the engine ensure that nobody is in the danger zone Engine Barring manually 1 Remove guard plate 2 Engage barring device 2 with ring gear 3 and install on flywheel hous...

Page 134: ...7 1 2 Engine Barring with starting system Barring using the automation system Refer to automation system operating instructions 134 Task Description MS150066 02E 2013 02 TIM ID 0000017532 003...

Page 135: ...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 no...

Page 136: ...Final steps 1 Install injector Page 147 2 Install cylinder head cover Page 143 136 Task Description MS150066 02E 2013 02 TIM ID 0000000015 014...

Page 137: ...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 may be i...

Page 138: ...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 139: ...re parts Designation Use Part No Qty Engine oil Valve gear Lubrication 1 Remove cylinder head covers Page 143 2 Fill oil chambers of valve bridges with oil 3 Fill oil chambers of rocker arms and adjus...

Page 140: ...ools Material Spare parts Designation Use Part No Qty Feeler gage Y20010128 1 Torque wrench 60 320 Nm F30047446 1 Socket wrench 24 mm F30039526 1 Engine oil Preparatory steps 1 Remove cylinder head co...

Page 141: ...d Two crankshaft positions 12V 1 Cylinder A1 is in firing TDC 2 Cylinder A1 is in overlap TDC I Inlet valve X Exhaust valve Two crankshaft positions 16V 1 Cylinder A1 is in firing TDC 2 Cylinder A1 is...

Page 142: ...feeler gage 5 Adjust valve clearance if the deviation from the desired value exceeds 0 1 mm Adjusting valve clearance 1 Release locknut 1 2 Insert feeler gage between valve bridge and rocker arm 3 Tur...

Page 143: ...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 144: ...rs are combustible explosive Risk of fire and explosion Avoid open flames electric sparks and ignition sources Do not smoke CAUTION Fuel system high pressure pump not filled with engine oil Damage to...

Page 145: ...engine WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors Checking HP pump relief bore 1 Visually inspect relief bore 1 for fuel dis charge 2 For jacketed HP lines leaka...

Page 146: ...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 147 146 Task Description M...

Page 147: ...rench 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 are...

Page 148: ...cylinder 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 R...

Page 149: ...nstallation 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 se...

Page 150: ...h torque 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...

Page 151: ...ew Tightening torque 40 Nm 5 Nm 19 Fit cable connector onto injector Note Failure to reset drift compensation CDC will void the emissions certification 20 Reset drift compensation CDC with Dia Sys E53...

Page 152: ...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 152 Task Description MS150066 02E 20...

Page 153: ...NING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protec...

Page 154: ...els are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors CA...

Page 155: ...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 156: ...n installing the new filter element align adjustable pointer 2 with pressure indicating pointer 3 of pressure gauge 1 2 Check differential pressure Checking differential pressure of fuel prefilter 1 W...

Page 157: ...al sparks and ignition sources Do not smoke Draining fuel prefilter 1 Filter A cut out 2 Filter B cut out 1 Cut out the filter to be drained 2 Open threaded vent plug 1 of filter to be drained 3 Open...

Page 158: ...fuel emerges from the vent pipe 7 or 5 8 Close vent valve 2 or 4 9 Open rotary slide valve 6 a little by ap prox 30 and open vent valve s 2 or 4 until fuel emerges from the vent pipe 7 or 5 10 Close v...

Page 159: ...ial care when working on a running engine WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke WARNING Engine noise above 85 d...

Page 160: ...ction 1 or 3 on the intake side of the filter 3 Open vent valve 2 or 4 and fill with fuel until fuel emerges from the vent pipe 7 or 5 4 Close vent valve 2 or 4 5 Open rotary slide valve 6 a little by...

Page 161: ...Parts Catalog WARNING Tank is pressurized Risk of injury Allow pressure to escape slowly Wear goggles or facial protection WARNING Fuels are combustible Risk of fire and explosion Avoid open flames el...

Page 162: ...filter element 7 6 Insert new filter element in filter housing 7 Fit O ring 8 Reinstall filter housing A or B with filter el ement 7 9 Tighten screws 6 or 3 to specified torque max half a turn per sc...

Page 163: ...fuel emerges from the vent pipe 7 or 5 12 Close vent valve 2 or 4 13 Open rotary slide valve 6 a little by ap prox 30 and open vent valve s 2 or 4 until fuel emerges from the vent pipe 7 or 5 14 Close...

Page 164: ...s 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 slide valve 1 Open...

Page 165: ...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 166: ...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 167: ...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 168: ...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 169: ...filter Page 175 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 170: ...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 171: ...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 172: ...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 173: ...rs Intercooler Checking conden sate drain for water discharge and obstruction 1 With the engine running check if air emerges from drain bore s on the left and right sides on engine driving end If no a...

Page 174: ...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 175 2 Reset signal ring of contamination indicator P...

Page 175: ...the flange of the intake housing 1 and clean it 4 Attach air filter 3 with clamp 2 onto in take housing 1 5 Tighten clamp 2 Air filter with intake silencer 1 Release clamp 2 2 Remove air filter 3 and...

Page 176: ...isabled Checking signal ring position 1 If the signal ring is completely visible in the control window 2 replace air filter Page 174 2 After installation of new filter press reset button 1 Result Enga...

Page 177: ...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 216 MS150066 02E...

Page 178: ...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 179 5 Insert oil dipstick into guide tube up to the...

Page 179: ...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 180: ...ening torque 100 Nm 10Nm 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 Page 178 5 Turn...

Page 181: ...rotective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors Engine oil Sample ext...

Page 182: ...il 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...

Page 183: ...ety mask Avoid contact with skin Do not inhale oil vapor CAUTION Damage to component Serious damage to plant For filter replacement with the engine running operate the engine at low engine load The fi...

Page 184: ...4 9 Check oil level Page 178 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 185: ...ning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor WARNING Compressed air Risk of injury Do not direct compressed air jet at persons Wear prot...

Page 186: ...ings Action Strainer Metallic residues Clean Monitor engine operation Check strainer daily Contact Service Strainer Damaged Fit new part Square section ring Damaged Fit new part O ring Damaged Fit new...

Page 187: ...are Parts Catalog Sealing ring Spare Parts Catalog Sealing ring Spare Parts Catalog Sealing ring Spare Parts Catalog WARNING Hot oil Oil can contain combustion residues which are harmful to health Ris...

Page 188: ...ith sealing ring 13 14 Insert new filter sleeve 10 in rotor tube 11 with the smooth paper surface facing the wall 15 Check sealing ring 9 fit new one if neces sary 16 Install rotor cover 8 with sealin...

Page 189: ...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 190: ...ircuit General High Temperature Circuit 7 14 1 Drain and vent points Coolant lines on ETC 1 Vent point Coolant line to charge air cooler 1 Vent point 190 Task Description MS150066 02E 2013 02 TIM ID 0...

Page 191: ...1 Vent point Coolant line to raw water cooler 1 Vent point MS150066 02E 2013 02 Task Description 191 TIM ID 0000014545 002...

Page 192: ...Vent line Distribution cross 1 Vent point Coolant drain point engine driving end 1 Drain points 192 Task Description MS150066 02E 2013 02 TIM ID 0000014545 002...

Page 193: ...Coolant drain point engine free end 1 Drain point MS150066 02E 2013 02 Task Description 193 TIM ID 0000014545 002...

Page 194: ...ise 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...

Page 195: ...e Special tools Material Spare parts Designation Use Part No Qty Coolant Engine coolant Change 1 Drain engine coolant Page 196 2 Fill with engine coolant Page 199 MS150066 02E 2013 02 Task Description...

Page 196: ...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 counterclock...

Page 197: ...pipework driv ing end 1 6 Open vent valve on seawater cooler 1 or remote heat exchanger 7 Open drain plugs and drain coolant from crankcase left and right sides 1 MS150066 02E 2013 02 Task Descriptio...

Page 198: ...plug and drain coolant on cool ant pump elbow 1 Final steps 1 Seal all open vent and drain points 2 Set breather valve onto filler neck and close it 198 Task Description MS150066 02E 2013 02 TIM ID 00...

Page 199: ...ctive clothing gloves and goggles safety mask CAUTION Cold coolant in hot engine can cause thermal stress Formation of cracks in components Fill top up coolant only into cold engine Preparatory steps...

Page 200: ...faces if required 5 Set breather valve onto filler neck and turn until the first stop 6 Start engine Page 88 7 After 10 seconds of running the engine without load shut down the engine Page 96 8 Turn b...

Page 201: ...tectors 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 start 3 Clean the relief bore wi...

Page 202: ...Wear protective clothing gloves and goggles safety mask WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors Engine coolant Sample extrac tion and analysis 1 With the engi...

Page 203: ...e Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Engine coolant filter Replace ment 1 Close shut off cock 1 2 Remove engine coolant filter...

Page 204: ...he engine coolant The circulating pump 8 ensures the circulation of the preheated engine coolant through the engine The flow heater 5 comprises a heating element The thermostat 7 switches off the preh...

Page 205: ...reheating unit 1 On Off switch Cylinders Rated voltage frequency Heat output kW 12V and 16V 230 V 50 Hz 9 400 V 50 Hz 9 230 V 60 Hz 9 440 V 60 Hz 9 MS150066 02E 2013 02 Task Description 205 TIM ID 000...

Page 206: ...lap 3 prevents engine coolant from flowing through the preheating unit when the engine is running The thermostat 5 switches off the preheating unit via contactors when the engine coolant temperature h...

Page 207: ...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 96 and disable en gine start 3 Clean the relief bor...

Page 208: ...d and starting disabled Battery charging generator drive Coupling condition check 1 Remove protective cover 2 Check resilient coupling for cracks arrow and plastic deformation 3 In case of severe defo...

Page 209: ...of damage to hearing Wear ear protectors Checking bilge pump relief bore 1 Check relief bores for oil and water dis charge 2 Stop engine Page 209 and disable en gine start 3 Clean relief bores with a...

Page 210: ...System 7 18 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 210 Task Description MS150066 02E 2013 02 TIM ID...

Page 211: ...es Do not smoke Checking differential pressure gauge 1 Switch on fuel treatment system Page 94 2 Set the alarm points at the differential pressure gauge to zero Result Alarm is initiated with preset d...

Page 212: ...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 213: ...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 214: ...on of components 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 Replacing co...

Page 215: ...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 216: ...nnot swing freely 3 Check that cable ties are firm tighten loose cable ties 4 Replace faulty cable ties 5 Visually inspect the following electrical line components for damage connector housings contac...

Page 217: ...parameters must be reset otherwise the emission certification of the engine is no longer ap plicable u Reset the CDC parameters with DiaSys Manufacturer s documentation Resetting CDC parameters DiaSy...

Page 218: ...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 219: ...d starting disabled Check plug connections on ECU 7 1 Check all connectors on ECU for firm seat ing Ensure that clips 3 are engaged 2 Check screws 2 of cable clamps on ECU for firm seating Ensure that...

Page 220: ...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 221: ...sabled Checking EIM plug connections 1 Check both Tyco plugs 62 pole 1 on EIM for firm seating Make sure that the clips 2 are engaged 2 Check screws 3 of cable clamps on EIM for firm seating Ensure th...

Page 222: ...t from engine 1 Note or mark assignment of cables and connectors 2 Remove all screws 2 3 Undo latches 3 of the connectors 4 Remove all connectors 5 Remove screws 1 6 Take off Engine Control Unit Insta...

Page 223: ...screws 2 3 Undo clips 3 on connectors 4 Disconnect all connectors 5 Remove screws 1 6 Remove ECU 1 with EMU 4 Removing EMU 1 Unscrew screws on base of EMU 4 2 Remove EMU 4 from ECU 1 Installing EMU 1...

Page 224: ...erve 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 appropriate FSW and pa...

Page 225: ...2 Timing 1 8 s 3 Ready for operation 4 Application loader active 5 External RAM faulty 6 External FLASH faulty 7 No firmware 8 Application crashed Fuse lamp A second indicator is the fuse lamp SILA Th...

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: ...MU Engine Monitoring Unit Engine monitoring unit SPC Spare Parts Catalog FPP Fixed Pitch Propeller Fixed pitch propeller GCU Gear Control Unit Gear control unit GMU Gear Monitoring Unit Gear monitorin...

Page 229: ...dule Peripheral interface module RCS Remote Control System Remote Control System RL Redundancy Lost Alarm Redundant CAN bus failure SAE Society of Automotive Engineers U S standardization organization...

Page 230: ...u either during operation for preventive maintenance corrective work in case of malfunction or changed operating conditions or for spare parts supply Your contact at Headquarters Service support mtu o...

Page 231: ...wrench Part No F30379104 Qty Used in 1 7 6 2 Supplementary fuel filter Replacement Page 153 Qty Used in 1 7 6 3 Fuel filter Replacement Page 154 Qty Used in 7 13 1 Engine oil filter Replacement Page...

Page 232: ...it Part No 5605892099 00 Qty Used in 1 7 12 3 Engine oil Sample extraction and analysis Page 181 Qty Used in 1 7 14 7 Engine coolant Sample extraction and analysis Page 202 Ratchet Part No F30027340 Q...

Page 233: ...0027340 Qty Used in 1 7 7 1 Compressor wheel Cleaning Page 165 Ratchet adapter Part No F30027339 Qty Used in 1 7 18 5 Coalescer filter element Replacement Page 214 Ratchet with extension Part No F3000...

Page 234: ...mm Part No F30039526 Qty Used in 1 7 3 2 Valve clearance Check and adjustment Page 140 Steam jet cleaner Part No Qty Used in 1 4 14 Plant cleaning Page 99 Torque wrench 0 5 5 Nm Part No 0015384230 Qty...

Page 235: ...2 Injector Removal and installation Page 147 Torque wrench 40 200 Nm Part No F30027337 Qty Used in 1 7 12 2 Engine oil Change Page 179 Torque wrench 6 50 Nm Part No F30027336 Qty Used in 1 7 13 3 Cen...

Page 236: ...047446 Qty Used in 1 7 3 2 Valve clearance Check and adjustment Page 140 Torque wrench 60 320 Nm Part No F30452768 Qty Used in 1 7 5 2 Injector Removal and installation Page 147 236 Appendix B MS15006...

Page 237: ...val and installation 223 Engine Barring manually 133 Barring with starting system 134 Emergency stop 97 Main dimensions 83 Start 88 Stopping 96 Wiring check 216 Engine Control Unit ECU 7 Checking plug...

Page 238: ...lug connections Check 221 Preheating unit 204 Product description 16 Pump capacity Check 213 Putting the engine into operation after extended out of service periods 3 months 86 Putting the engine into...

Page 239: ...ar Lubrication 139 W Warning notices standards 13 Water drain valve Check 210 Water level probe 3 in 1 rod electrode Check 212 Wiring engine Check 216 MS150066 02E 2013 02 Appendix B 239 DCL ID 000000...

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