MTU 12 V 4000 M73 x Operating Instructions Manual Download Page 4

Page: 4 / 233

6.2 Troubleshooting

109

6.3 ADEC (ECU 7) fault codes for Series 4000

engines, marine application

112

6.4 ADEC engine governor – Fault codes

113

7 Task Description

7.1 Engine

139

7.1.1 Engine – Barring manually

139

7.1.2 Engine – Barring with starting system

140

7.2 Cylinder Liner

141

7.2.1 Cylinder liner – Endoscopic examination

141

7.2.2 Instructions and comments on endoscopic and

visual examination of cylinder liners

143

7.3 Valve Drive

145

7.3.1 Valve gear – Lubrication

145

7.3.2 Valve clearance – Check and adjustment

146

7.3.3 Cylinder head cover – Removal and

installation

150

7.4 Injection Pump / HP Pump

151

7.4.1 HP pump – Filling with engine oil

151

7.5 Injection Valve / Injector

152

7.5.1 Injector – Replacement

152

7.5.2 Injector – Removal and installation

153

7.6 Fuel Filter

158

7.6.1 Fuel filter – Replacement

158

7.6.2 Fuel prefilter – Differential pressure gauge

check and adjustment

160

7.6.3 Fuel prefilter – Draining

161

7.6.4 Fuel prefilter – Flushing

163

7.6.5 Fuel prefilter – Filter element replacement

165

7.7 Exhaust Turbocharger

167

7.7.1 Compressor wheel – Cleaning

167

7.8 Charge-Air Cooling

171

7.8.1 Intercooler – Check water drain for coolant

discharge and obstruction

171

7.9 Air Filter

172

7.9.1 Air filter – Replacement

172

7.9.2 Air filter – Removal and installation

173

7.10 Air Intake

174

7.10.1 Service indicator – Signal ring position check

(optional)

174

7.10.2 Air pipework from air filter to ETC – Check

175

7.11 Starting Equipment

176

7.11.1 Starter – Condition check

176

7.12 Lube Oil System, Lube Oil Circuit

177

7.12.1 Engine oil – Level check

177

7.12.2 Engine oil – Change

178

7.12.3 Engine oil – Sample extraction and analysis

180

7.12.4 Engine oil – Sample extraction and analysis

182

7.13 Oil Filtration / Cooling

183

7.13.1 Automatic oil filter – Oil filter candles

replacement

183

7.13.2 Oil indicator filter – Cleaning and check

186

7.13.3 Centrifugal oil filter – Cleaning and filter-

sleeve replacement

188

7.14 Coolant System, General, High-Temperature

Circuit

190

7.14.1 Venting points

190

7.14.2 Engine coolant – Level check

191

7.14.3 Engine coolant – Change

192

7.14.4 Engine coolant draining

193

7.14.5 Engine coolant– Filling up

194

7.14.6 Engine coolant pump – Relief bore check

198

7.14.7 Engine coolant – Sample extraction and

analysis

199

7.15 Raw Water Pump with Connections

200

7.15.1 Raw water pump – Relief bore check

200

7.16 Battery-Charging Generator

201

7.16.1 Battery-charging generator drive – Coupling

condition check

201

7.17 Engine Mounting / Support

202

7.17.1 Engine mounting – Check

202

7.18 Auxiliary PTO

203

7.18.1 Bilge pump – Relief bore check

203

7.19 Fuel Supply System

204

7.19.1 Water drain valve – Check

204

7.19.2 Differential pressure gauge – Check

205

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

Check

206

7.19.4 Pump capacity – Check

207

7.19.5 Coalescer filter element – Replacement

208

7.20 Wiring (General) for Engine/Gearbox/Unit

210

7.20.1 Engine wiring – Check

210

7.21 Accessories for (Electronic) Engine

Governor / Control System

211

7.21.1 Limit switch for start interlock ‒ Check

211

7.21.2 Engine Control Unit ECU 7 – Checking plug

connections

212

7.21.3 Engine Monitoring Unit EMU 8 – Plug

connections check

213

7.21.4 Interface module plug connections – Check

214

7.21.5 ECU 7 engine governor – Removal and

installation

215

7.21.6 EMU 8 – Removal and installation

216

7.21.7 Engine Interface Module EIM – Removal and

installation

217

7.21.8 Diagnostic features of EIM

218

7.22 Emergency Instrumentation (Local

Operating Panel)

221

7.22.1 LOP and connectors – Cleaning

221

4 | Table of Contents | MS150045/02E 2013-07

DCL-ID: 0000012062 - 003

Summary of Contents for 12 V 4000 M73 x

Page 1: ...Operating Instructions Diesel engine 12 V 4000 M73 x 16 V 4000 M73 x MS150045 02E...

Page 2: ...d in Germany 2013 Copyright MTU Friedrichshafen GmbH This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior written permission of MTU F...

Page 3: ...e mounted heat exchanger 68 3 10 16V 4000M73L engine data IMO Tier II engine mounted heat exchanger 71 3 11 16V 4000M73L engine data IMO engine mounted heat exchanger copper based alloy intercooler 74...

Page 4: ...and analysis 182 7 13 Oil Filtration Cooling 183 7 13 1 Automatic oil filter Oil filter candles replacement 183 7 13 2 Oil indicator filter Cleaning and check 186 7 13 3 Centrifugal oil filter Cleanin...

Page 5: ...8 Appendix A 8 1 Abbreviations 222 8 2 MTU contact persons service partners 224 9 Appendix B 9 1 Special Tools 225 9 2 Index 231 MS150045 02E 2013 07 Table of Contents 5 DCL ID 0000012062 003...

Page 6: ...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 7: ...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 8: ...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 9: ...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 10: ...roduct 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 11: ...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 12: ...ics of the product 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 f...

Page 13: ...e supply 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 pa...

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

Page 15: ...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 16: ...pan 11 Engine mounting 12 HP fuel pump 13 Automatic oil filter 14 Fuel filter 15 Centrifugal oil filter s 16 Coolant cooler Engine model designation Key to the engine model designations 16V 4000 Mxyz...

Page 17: ...htness Turbocharging Sequential turbocharging with internal engine coolant controlled charge air cooling The right hand ex haust turbocharger is cut in and cut out on 12V and 16V engines with electron...

Page 18: ...so connected to the engine wiring harness Functions ECU supply EMU supply Plant signals ECU7 connector X1 Bus interface 2x MCS5 CAN CAN dialog output 1xMCS5 CAN ECU and EMU emergency stop Electric sta...

Page 19: ...arms when limits are violated Pushbuttons for menu control and dimming unit Combined control and display elements for local engine gear control Flashing light and horn for combined alarm in engine roo...

Page 20: ...om to fuel filter head 1 Fuel line to HP pump Lube oil system oil lines with oil pressures exceeding 1 8 bar 1 Parting line ETC oil supply free end 20 General Information MS150045 02E 2013 07 TIM ID 0...

Page 21: ...1 Oil line on equipment carrier 1 Oil supply to HP pump 1 Oil supply to flap control free end MS150045 02E 2013 07 General Information 21 TIM ID 0000010056 005...

Page 22: ...pply on main oil gallery 1 Switching cylinder air flap turbo charger B1 2 T piece flap control 1 Switching cylinder exhaust flap tur bocharger B1 22 General Information MS150045 02E 2013 07 TIM ID 000...

Page 23: ...1 Oil line from main oil gallery 2 Oil line to main oil gallery 1 Flap control distributor 1 Air recirculation valve MS150045 02E 2013 07 General Information 23 TIM ID 0000010056 005...

Page 24: ...rst pass the thread in case of a loose threaded union or faulty sealing ring 1 The pressure is so greatly reduced by this and the faulty sealing ring 1 that any leakage is not under pressure Plug in p...

Page 25: ...type seal area 20 Leak fuel connection The HP fuel line is sealed by the thrust ring 8 If leakage in the area of the thrust ring 8 or the HP line 5 occurs the emerging fuel is routed to the leakage ch...

Page 26: ...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 the driving end The number...

Page 27: ...ter filter 9 B34 2 fuel pressure be fore filter 10 B34 1 fuel pressure after filter 11 B5 3 lube oil pressure be fore filter 12 B48 fuel pressure in com mon rail 13 F33 coolant level 14 B4 B6 exhaust...

Page 28: ...air temperature 5 B44 1 turbocharger A speed 6 B10 charge air pressure 7 B57 1 main bearing temp 8 B57 2 main bearing temp 9 B57 3 main bearing temp 10 B57 4 main bearing temp 11 B57 5 main bearing te...

Page 29: ...ree end 1 F46 H Fuel leakage 2 B33 T Fuel rail 3 B1 N Camshaft 4 B54 P Oil refill pump 5 B6 2 T Coolant 6 B6 T Coolant 7 Connector XD1 Dialog unit MS150045 02E 2013 07 General Information 29 TIM ID 00...

Page 30: ...oil temp conrod bearing 5 B77 B5 spray oil temp conrod bearing 6 B77 B4 spray oil temp conrod bearing 7 B77 B3 spray oil temp conrod bearing 8 B77 B2 spray oil temp conrod bearing 9 B77 B1 spray oil t...

Page 31: ...12 V 4000 M driving end 1 B13 crankshaft speed 2 S37 2 safety switch 3 S37 1 safety switch 4 B13 2 crankshaft speed MS150045 02E 2013 07 General Information 31 TIM ID 0000032308 003...

Page 32: ...filter 12 B34 2 fuel pressure be fore filter 13 B34 1 fuel pressure after filter 14 B5 3 lube oil pressure be fore filter 15 B48 fuel pressure in com mon rail 16 F33 coolant level 17 B4 B8 exhaust te...

Page 33: ...peed 5 B10 charge air pressure 6 B57 1 main bearing temp 7 B57 2 main bearing temp 8 B57 3 main bearing temp 9 B57 4 main bearing temp 10 B57 5 main bearing temp 11 B57 6 main bearing temp 12 B57 7 ma...

Page 34: ...ree end 1 F46 H Fuel leakage 2 B33 T Fuel rail 3 B1 N Camshaft 4 B54 P Oil refill pump 5 B6 2 T Coolant 6 B6 T Coolant 7 Connector XD1 Dialog unit 34 General Information MS150045 02E 2013 07 TIM ID 00...

Page 35: ...il temp conrod bearing 6 B77 B6 spray oil temp conrod bearing 7 B77 B5 spray oil temp conrod bearing 8 B77 B4 spray oil temp conrod bearing 9 B77 B3 spray oil temp conrod bearing 10 B77 B2 spray oil t...

Page 36: ...16V 4000 M driving end 1 B13 crankshaft speed 2 S37 2 safety switch 3 S37 1 safety switch 4 B13 2 crankshaft speed 36 General Information MS150045 02E 2013 07 TIM ID 0000032308 003...

Page 37: ...Fuel pressure before filter B44 1 Exhaust turbocharger A speed B44 2 Exhaust turbocharger B speed B48 High pressure fuel B49 Charge air before recirculation B50 Crankcase pressure B54 Refill pump pre...

Page 38: ...Starter Engine wiring harness for sensors 12V 1 B50 2 B7 3 B5 1 4 B5 3 5 B34 2 6 B34 1 7 F46 8 B48 9 B33 10 B1 11 XG03 12 S37 1 13 B10 14 B4 21 15 M8 16 X2 17 X37 18 B6 19 B4 22 20 B9 21 S37 2 22 B13...

Page 39: ...B5 3 5 B34 2 6 B34 1 7 F46 8 B48 9 B33 10 XG03 11 B1 12 S37 1 13 B10 14 B4 21 15 M8 16 X2 17 X37 18 B6 19 B4 22 20 B9 21 S37 2 22 B13 23 B16 24 B44 2 25 Y27 26 F33 27 B49 28 B44 1 29 B3 30 Y26 MS15004...

Page 40: ...injectors 12V 1 Y39A1 2 Y39A2 3 Y39A3 4 Y39A4 5 Y39A5 6 Y39A6 7 X4 8 E4 3 9 E4 4 10 E4 5 11 Y39B5 12 Y39B6 13 E4 2 14 E4 1 15 Y39B4 16 Y39B3 17 Y39B2 18 Y39B1 40 General Information MS150045 02E 2013...

Page 41: ...39A1 2 Y39A2 3 Y39A3 4 Y39A4 5 Y39A5 6 Y39A6 7 Y39A7 8 Y39A8 9 X4 10 E4 3 11 E4 4 12 E4 5 13 Y39B7 14 Y39B8 15 E4 2 16 E4 1 17 Y39B6 18 Y39B5 19 Y39B4 20 Y39B3 21 Y39B2 22 Y39B1 MS150045 02E 2013 07 G...

Page 42: ...Engine wiring harness for EIM 1 XD1 2 X1 3 X3 4 X52 5 XY1 6 X11 7 XB19 8 X37 42 General Information MS150045 02E 2013 07 TIM ID 0000032681 002...

Page 43: ...Engine wiring harness for electric starter 1 EIM terminals 2 Fuse F1 3 Starter terminals MS150045 02E 2013 07 General Information 43 TIM ID 0000032681 002...

Page 44: ...let temperature C 25 Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylinders 12 Rated engine speed A...

Page 45: ...inlet connection min when engine is running L bar 0 3 Fuel pressure at engine inlet connection max when engine is starting L bar 1 5 Fuel supply flow max R Liters min 28 GENERAL OPERATING DATA Number...

Page 46: ...ters 225 Oil pan capacity at dipstick mark min standard oil system Option max operating inclinations L Liters 190 Oil pan capacity at dipstick mark max standard oil system Option max operating inclina...

Page 47: ...ture C 25 Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylinders 12 Rated engine speed A rpm 1970 Fu...

Page 48: ...inlet connection min when engine is running L bar 0 3 Fuel pressure at engine inlet connection max when engine is starting L bar 1 5 Fuel supply flow max R Liters min 28 GENERAL OPERATING DATA Number...

Page 49: ...ters 225 Oil pan capacity at dipstick mark min standard oil system Option max operating inclinations L Liters 190 Oil pan capacity at dipstick mark max standard oil system Option max operating inclina...

Page 50: ...rometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylinders 12 Rated engine speed A rpm 1970 Fuel stop powe...

Page 51: ...inlet connection min when engine is running L bar 0 3 Fuel pressure at engine inlet connection max when engine is starting L bar 1 5 Fuel supply flow max R Liters min 28 GENERAL OPERATING DATA Number...

Page 52: ...ters 225 Oil pan capacity at dipstick mark min standard oil system Option max operating inclinations L Liters 190 Oil pan capacity at dipstick mark max standard oil system Option max operating inclina...

Page 53: ...arometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylinders 12 Rated engine speed A rpm 2050 Fuel stop pow...

Page 54: ...inlet connection min when engine is running L bar 0 3 Fuel pressure at engine inlet connection max when engine is starting L bar 1 5 Fuel supply flow max R Liters min 29 GENERAL OPERATING DATA Number...

Page 55: ...ters 225 Oil pan capacity at dipstick mark min standard oil system Option max operating inclinations L Liters 190 Oil pan capacity at dipstick mark max standard oil system Option max operating inclina...

Page 56: ...ture C 25 Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylinders 12 Rated engine speed A rpm 2050 Fu...

Page 57: ...inlet connection min when engine is running L bar 0 3 Fuel pressure at engine inlet connection max when engine is starting L bar 1 5 Fuel supply flow max R Liters min 29 GENERAL OPERATING DATA Number...

Page 58: ...ters 225 Oil pan capacity at dipstick mark min standard oil system Option max operating inclinations L Liters 190 Oil pan capacity at dipstick mark max standard oil system Option max operating inclina...

Page 59: ...perature C 25 Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylinders 12 Rated engine speed A rpm 205...

Page 60: ...inlet connection min when engine is running L bar 0 3 Fuel pressure at engine inlet connection max when engine is starting L bar 1 5 Fuel supply flow max R Liters min 29 GENERAL OPERATING DATA Number...

Page 61: ...ters 225 Oil pan capacity at dipstick mark min standard oil system Option max operating inclinations L Liters 190 Oil pan capacity at dipstick mark max standard oil system Option max operating inclina...

Page 62: ...erature C 25 Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylinders 16 Rated engine speed A rpm 1970...

Page 63: ...nlet connection min when engine is running L bar 0 3 Fuel pressure at engine inlet connection max when engine is starting L bar 1 5 Fuel supply flow max R Liters min 28 GENERAL OPERATING DATA Number o...

Page 64: ...Liters 270 Oil pan capacity at dipstick mark min standard oil system Option max operating inclinations L Liters 215 Oil pan capacity at dipstick mark max standard oil system Option max operating incli...

Page 65: ...ure C 25 Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylinders 16 Rated engine speed A rpm 1970 Fue...

Page 66: ...inlet connection min when engine is running L bar 0 3 Fuel pressure at engine inlet connection max when engine is starting L bar 1 5 Fuel supply flow max R Liters min 28 GENERAL OPERATING DATA Number...

Page 67: ...Liters 270 Oil pan capacity at dipstick mark min standard oil system Option max operating inclinations L Liters 215 Oil pan capacity at dipstick mark max standard oil system Option max operating incli...

Page 68: ...rometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylinders 16 Rated engine speed A rpm 1970 Fuel stop powe...

Page 69: ...inlet connection min when engine is running L bar 0 3 Fuel pressure at engine inlet connection max when engine is starting L bar 1 5 Fuel supply flow max R Liters min 28 GENERAL OPERATING DATA Number...

Page 70: ...Liters 270 Oil pan capacity at dipstick mark min standard oil system Option max operating inclinations L Liters 215 Oil pan capacity at dipstick mark max standard oil system Option max operating incli...

Page 71: ...arometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylinders 16 Rated engine speed A rpm 2050 Fuel stop pow...

Page 72: ...inlet connection min when engine is running L bar 0 3 Fuel pressure at engine inlet connection max when engine is starting L bar 1 5 Fuel supply flow max R Liters min 29 GENERAL OPERATING DATA Number...

Page 73: ...Liters 270 Oil pan capacity at dipstick mark min standard oil system Option max operating inclinations L Liters 215 Oil pan capacity at dipstick mark max standard oil system Option max operating incli...

Page 74: ...ature C 25 Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylinders 16 Rated engine speed A rpm 2050 F...

Page 75: ...inlet connection min when engine is running L bar 0 3 Fuel pressure at engine inlet connection max when engine is starting L bar 1 5 Fuel supply flow max R Liters min 29 GENERAL OPERATING DATA Number...

Page 76: ...Liters 270 Oil pan capacity at dipstick mark min standard oil system Option max operating inclinations L Liters 215 Oil pan capacity at dipstick mark max standard oil system Option max operating incli...

Page 77: ...perature C 25 Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylinders 16 Rated engine speed A rpm 205...

Page 78: ...inlet connection min when engine is running L bar 0 3 Fuel pressure at engine inlet connection max when engine is starting L bar 1 5 Fuel supply flow max R Liters min 29 GENERAL OPERATING DATA Number...

Page 79: ...Liters 270 Oil pan capacity at dipstick mark min standard oil system Option max operating inclinations L Liters 215 Oil pan capacity at dipstick mark max standard oil system Option max operating incli...

Page 80: ...A Width B Height C 12 V 4000 M73 93 L approx 2991 mm approx 1463 mm approx 2368 mm 16 V 4000 M73 93 L approx 3583 mm approx 1463 mm approx 2368 mm 20 V 4000 M73 93 L approx 4192 mm approx 1484 mm appr...

Page 81: ...rder 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 20V A1 B5 A8 B7 A5 B2 A7 B10 A2 B3 A10 B6 A3 B4 A6 B9 A4 B1 A9 B8 MS150045 02E 2013 07 Technical Data...

Page 82: ...4 Operation 4 1 Operation LOP controls Refer to automation system BlueLine BlueVision operating instructions 82 Operation MS150045 02E 2013 07 TIM ID 0000031215 001...

Page 83: ...bove waterline Fill with water approx 3 4 liters Coolant circuit If engine is out of service for more than one year change coolant Page 192 Coolant circuit Check coolant level Page 191 Coolant circuit...

Page 84: ...required Coolant circuit Check coolant level Page 191 Coolant circuit Heat coolant with coolant preheating unit Engine control system Switch master switch to ON Press illuminated pushbutton READY FOR...

Page 85: ...4 4 Starting the engine Start the engine via the automation system Refer to automation system operating instructions MS150045 02E 2013 07 Operation 85 TIM ID 0000017525 003...

Page 86: ...running noises and vibration Check exhaust color Page 109 Air filter Check signal ring position of service indicator Page 174 Replace air filter Page 172 if the signal ring is completely visible in th...

Page 87: ...ks 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 90 2 Shut down fuel treatment system Page 105 MS1...

Page 88: ...manually 4 Red Illuminated pushbutton Indicates Water alarm Press to acknowledge 5 Yellow Signal lamp Indicates Filter warning due to increased differential pressure 6 Red Illuminated pushbutton Indi...

Page 89: ...ves 4 Switch on fuel treatment system Page 93 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 90: ...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 91: ...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 92: ...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 93: ...ore 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 94: ...fter the generator breaker if provided has been opened allow the engine to cool down by running it idle for approx 5 minutes Preparing a pump drive diesel mechanical diesel electric Item Action Engine...

Page 95: ...the engine plant Risk of overheating damage to components Initiate emergency stop only in emergency situations Engine emergency stop at BlueLine automation system Item Measure Engine Emergency stop a...

Page 96: ...button flashes Coupling is engaged After receiving the feedback signal from coupling the COUPLING IN button is illuminated brightly Engaging coupling in ahead direction with reversing gearbox FPP WJ...

Page 97: ...OUPLING OUT button flashes Coupling is disengaged After receiving the feedback signal from coupling the COUPLING OUT button is illuminated brightly Disengaging coupling with reversing gearbox FPP WJ I...

Page 98: ...long Follow instructions of the waterjet manufacturer Flushing with reversing gearbox and flushing mode Item Measure LOP Press FLUSH illuminated pushbutton and keep pressed Page 82 FLUSH pushbutton f...

Page 99: ...engine at idle speed for at least 10 minutes until engine temperatures have dropped and constant values are displayed Stopping the engine from LOP Item Measure LOP Disengage gearbox Page 82 LOP Opera...

Page 100: ...Before shutting down disengage gear and run the engine at idle speed for at least 10 minutes until engine temperatures have dropped and constant values are displayed Stopping the engine at the BlueLi...

Page 101: ...nnecting the power supply to the ECU On engines with emergency air shutoff flaps flaps close EMERGENCY STOP illuminated pushbutton flashes Horn flashing lamp etc are tripped After emergency stop from...

Page 102: ...4 19 Stopping the engine Stopping the engine via the automation system Refer to automation system operating instructions 102 Operation MS150045 02E 2013 07 TIM ID 0000017528 004...

Page 103: ...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 ins...

Page 104: ...a suitable temperature the antifreeze concentration is insufficient for the engine room tem perature antifreeze concentration is 50 and engine room temperature is be low 40 C Raw water Drain If freez...

Page 105: ...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 106: ...m compressed 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 enviro...

Page 107: ...158 W1002 Check valve clearance Page 146 W1005 Replace air filter Page 172 W1006 Replace injectors Page 152 W1008 Replace engine oil filter at each oil change or when the time limit years is reached a...

Page 108: ...ed with 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 Re...

Page 109: ...de u Check fuse replace if required and re start the system by actuating the key switch Running gear blocked engine cannot be barred manually u Contact Service Engine turns but does not fire Cause Cor...

Page 110: ...ndicator Page 174 Intercooler clogged u Contact Service Exhaust turbocharger defective u Contact Service Coolant leaks at intercooler Cause Corrective action Intercooler leaky major coolant discharge...

Page 111: ...t gas Cause Corrective action Engine is not at operating temperature u Run engine to reach operating temperature Intercooler leaky u Contact Service MS150045 02E 2013 07 Troubleshooting 111 TIM ID 000...

Page 112: ...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 in the tabl...

Page 113: ...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 114: ...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 115: ...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 116: ...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 117: ...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 118: ...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 119: ...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 120: ...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 121: ...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 122: ...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 123: ...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 124: ...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 125: ...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 126: ...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 127: ...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 128: ...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 129: ...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 130: ...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 131: ...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 132: ...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 133: ...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 134: ...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 135: ...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 136: ...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 137: ...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 138: ...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 139: ...at there are no persons in the engine s danger zone After finishing work on the engine make sure that all safety devices are put back in place and all tools removed from the engine Barring engine manu...

Page 140: ...e automation system Starting barring procedure at LOP 8 BlueLine Operating Instructions BlueVision automation system Starting barring procedure at LOP 8 BlueLine Operating Instructions 140 Task Descri...

Page 141: ...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 142: ...Final steps 1 Install injector Page 153 2 Install cylinder head cover Page 150 142 Task Description MS150045 02E 2013 07 TIM ID 0000000015 014...

Page 143: ...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 144: ...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 145: ...re parts Designation Use Part No Qty Engine oil Valve gear Lubrication 1 Remove cylinder head covers Page 150 2 Fill oil chambers of valve bridges with oil 3 Fill oil chambers of rocker arms and adjus...

Page 146: ...re parts Designation Use Part No Qty Feeler gauge Y20098771 1 Torque wrench 60 320 Nm F30452768 1 Box wrench socket 24 mm F30039526 1 Engine oil Preparatory steps 1 Remove cylinder head cover Page 150...

Page 147: ...n di rection of engine rotation until the OT A1 marking and pointer are aligned Diagram for 8V engines two crankshaft positions Diagram for 12V engines two crankshaft positions MS150045 02E 2013 07 Ta...

Page 148: ...C 2 Check valve clearance with cold engine Inlet long rocker arm 0 2 mm 0 05 mm Exhaust short rocker arm 0 5 mm 0 05 mm 3 Check all valve clearances in two crankshaft positions firing TDC and overlap...

Page 149: ...1 with torque wrench to the specified tightening torque holding the adjusting screw 2 to prevent it from turning Name Size Type Lubricant Value Standard Locknut M16 x 1 5 Tightening torque Engine oil...

Page 150: ...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 151: ...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 152: ...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 153 152 Task Description M...

Page 153: ...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 154: ...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 155: ...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 156: ...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 157: ...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 158: ...in Only run the engine 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 sm...

Page 159: ...three way cock to operating position both filters cut in 8 Replace further fuel filters in the same way 9 Vent fuel system 1 Fuel filter replacement with the engine running 1 Cut out the filter to be...

Page 160: ...differential pressure gauge 1 When installing the new filter element align adjustable pointer 2 with pressure indicating pointer 3 of pressure gauge 1 2 Check differential pressure Checking differenti...

Page 161: ...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 162: ...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 163: ...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...

Page 164: ...efilter Filling with fuel 1 Stop engine Page 94 and disable engine start 2 Remove screws securing the cover and take off cover 2 3 Fill filter housing with clean fuel 4 Place new gasket in cover 2 5 F...

Page 165: ...Diesel fuel Filter element Spare Parts Catalog Gasket Spare Parts Catalog WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke...

Page 166: ...7 Remove spring housing 4 and filter ele ment 3 8 Insert new filter element 3 and spring housing 4 9 Fill filter housing with clean fuel 10 Place new gasket in cover 2 11 Fit cover with gasket and se...

Page 167: ...rve the instructions of the cleaning agent manufacturer NOTICE Incorrect installation of components and lines Damage to component Ensure that components lines are installed so that they are never unde...

Page 168: ...ooler 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 vent line 2 from com pressor housing...

Page 169: ...ssor housing 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 compre...

Page 170: ...g 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 torque wre...

Page 171: ...ans Never direct air jet at people Always wear safety goggles face mask and ear defenders Checking intercooler water drain for coolant discharge and obstruction 1 With the engine running check the dra...

Page 172: ...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 173 2 Reset signal ring of contamination indicator P...

Page 173: ...2 Remove air filter 1 and clamp 2 from connecting flange of intake housing 3 3 Verify that there are no objects in the con necting flange of the intake housing 3 and clean it 4 Place new air filter 1...

Page 174: ...isabled Checking signal ring position 1 If the signal ring is completely visible in the control window 2 replace air filter Page 172 2 After installation of new filter press reset button 1 Result Enga...

Page 175: ...Part No Qty Air hose 0229979482 2 Checking air pipework from air filter to ETC Item Findings Measure Visually check outer layer of air hose Damage Deformation Cracks Cuts Brittleness Scuffing visible...

Page 176: ...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 210 176 Task Desc...

Page 177: ...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 178 5 Insert dipstick into guide tube up to the st...

Page 178: ...ot 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 plug s and drain oil 3 Install dra...

Page 179: ...Tightening torque 100 Nm 10Nm Filling with new oil 1 Open cover 1 on filler neck 2 Pour oil in at filler neck up to max mark at oil dipstick 3 Close cover 1 on filler neck 4 Check engine oil level Pag...

Page 180: ...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 181: ...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 182: ...ning Wear 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 Wea...

Page 183: ...arts Catalog WARNING Hot oil Oil can contain combustion residues which are harmful to health Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with ski...

Page 184: ...f spring washer and washer 9 Remove screw 4 10 Remove flushing arm 5 from screen plate 6 11 Turn filter element by 180 and use appro priate tool to push out filter candles 1 12 Turn filter insert by 1...

Page 185: ...rking steps 2 Additionally the following instructions are to be observed Replace all sealing elements Coat O rings with grease Insert O rings in grooves Observe position of cylinder screw to elongated...

Page 186: ...ing 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 ruptu...

Page 187: ...w part Cleaning strainer 1 Wash strainer 5 with cleaner 2 Remove stubborn deposits with soft brush 3 Blow out strainer 5 with compressed air from inside Installing strainer 1 Coat square section ring...

Page 188: ...ts Catalog WARNING Hot oil Oil can contain combustion residues which are harmful to health Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with skin...

Page 189: ...sk 8 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 wall 14 Check sealing ring 5 fit new one if neces sary 15 Mount rotor...

Page 190: ...m General High Temperature Circuit 7 14 1 Venting points Coolant lines on ETC 1 Venting point Vent line Cross distributionn expansion tank 1 Venting point 190 Task Description MS150045 02E 2013 07 TIM...

Page 191: ...ure to escape 2 Continue to turn breather valve counterclockwise and remove 3 Check engine coolant level coolant must be visible at the bottom edge of the filler neck s cast eye Checking engine coolan...

Page 192: ...e Special tools Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 193 2 Fill with engine coolant Page 194 192 Task Description MS150045 02E 201...

Page 193: ...n expan sion tank counterclockwise to first stop and allow pressure to escape 2 Continue to turn breather valve counter clockwise and remove 3 Draw off precipitated corrosion inhibitor oil from the ex...

Page 194: ...esignation Use Part No Qty Engine coolant WARNING Coolant is hot and under pressure Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask NOTICE...

Page 195: ...until overflow edge is reached 11 When coolant temperature T Coolant of 40 C is reached increase the engine speed to 1000 rpm for approx 2 minutes 12 With the engine idling fill expansion tank until o...

Page 196: ...alve arrowed 3 Open vent points on intercooler on coolant cooler and on exhaust turbochargers Page 190 4 Ensure that the breather valve on the ex pansion tank is closed 5 Pump coolant into engine at 0...

Page 197: ...pump 13 With the expansion tank open start the en gine and run it up to nominal speed full load under load 14 Check coolant level in expansion tank If coolant level is above 50 close ex pansion tank b...

Page 198: ...hearing Wear ear protectors Engine coolant pump Relief bore check 1 Check relief bore for oil and coolant dis charge 2 Stop engine Page 102 and disable en gine start observe general safety instruc ti...

Page 199: ...ol down 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...

Page 200: ...Risk of damage to hearing Wear ear protectors Raw water pump relief bore check 1 Check relief bore for oil and raw water dis charge 2 Stop engine Page 102 and disable en gine start observe general saf...

Page 201: ...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 202: ...gine mounting Check Engine mounting Check Item Findings Action Visually inspect mounts Damage Brittleness Deformation Crack formation Swelling visible Replace contact Service 202 Task Description MS15...

Page 203: ...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 94 and disable en gine st...

Page 204: ...System 7 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 204 Task Description MS150045 02E 2013 07 TIM ID...

Page 205: ...es Do not smoke Checking differential pressure gauge 1 Switch on fuel treatment system Page 93 2 Set the alarm points at the differential pressure gauge to zero Result Alarm is initiated with preset d...

Page 206: ...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 207: ...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 208: ...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 209: ...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 210: ...swing freely 3 Check 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 Conta...

Page 211: ...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 212: ...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 213: ...ting disabled Checking EMU plug connections 1 Check both connectors on EMU 2 for firm seating Make sure that clips 3 are engag ed 2 Check screws 1 of cable clamps on EMU 2 for firm seating Make sure t...

Page 214: ...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 215: ...overnor from engine 1 Note or mark assignment of cables and connectors 2 Remove all screws 2 3 Undo latches 3 of the connectors 4 Disconnect all connectors 5 Remove screws 1 6 Take off engine governor...

Page 216: ...ll 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...

Page 217: ...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 218: ...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 219: ...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 220: ...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 221: ...1 Cleaning LOP 1 Wipe LCD display with dry cloth without applying excessive pressure 2 Remove dirt from keys using isopropyl alcohol 3 Remove heavy soiling from housing surface with isopropyl alcohol...

Page 222: ...e monitoring system EMU Engine Monitoring Unit Engine monitoring unit ETK Ersatzteilkatalog Spare Parts Catalog FPP Fixed Pitch Propeller Fixed pitch propeller GCU Gear Control Unit Gear control unit...

Page 223: ...System RL Redundancy Lost Alarm Redundant CAN bus failure SAE Society of Automotive Engineers U S standardization organization SAT Sea Acceptance Test SD Sensor Defect Alarm Sensor failure SDAF Shut D...

Page 224: ...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 225: ...Barring manually Page 139 Box wrench socket 24 mm Part No F30039526 Qty Used in 1 7 3 2 Valve clearance Check and adjustment Page 146 Feeler gauge Part No Y20098771 Qty Used in 1 7 3 2 Valve clearance...

Page 226: ...MTU test kit Part No 5605892099 00 Qty Used in 1 7 12 3 Engine oil Sample extraction and analysis Page 180 Qty Used in 1 7 12 4 Engine oil Sample extraction and analysis Page 182 Qty Used in 1 7 14 7...

Page 227: ...027341 Qty Used in 1 7 5 2 Injector Removal and installation Page 153 Qty Used in 1 7 12 2 Engine oil Change Page 178 Ratchet Part No F30027339 Qty Used in 1 7 19 5 Coalescer filter element Replacemen...

Page 228: ...jet cleaner Part No Qty Used in 1 4 23 Plant Cleaning Page 106 Torque wrench Part No F30027337 Qty Used in 1 7 12 2 Engine oil Change Page 178 Torque wrench 0 5 5 Nm Part No 0015384230 Qty Used in 1...

Page 229: ...tallation Page 153 Torque wrench 4 20 Nm Part No F30044239 Qty Used in 1 7 9 2 Air filter Removal and installation Page 173 Torque wrench 6 50 Nm Part No F30027336 Qty Used in 1 7 13 3 Centrifugal oil...

Page 230: ...60 320 Nm Part No F30452768 Qty Used in 1 7 3 2 Valve clearance Check and adjustment Page 146 Qty Used in 1 7 5 2 Injector Removal and installation Page 153 230 Appendix B MS150045 02E 2013 07 DCL ID...

Page 231: ...Cylinder head cover Removal and installation 150 Cylinder liner Endoscopic examination 141 Instructions and comments on endoscopic and visual examination 143 D Designations Engine sides and cylinders...

Page 232: ...ons check 213 Engine mounting Check 202 Engine oil Centrifugal oil filter Cleaning 188 Change 178 Filter sleeve Replacing 188 Sample analysis 182 Sample extraction 182 Sample extraction and analysis 1...

Page 233: ...n 8 Organizational requirements 7 Personnel requirements 7 Repair work 9 Safety notices standards 14 Startup 8 Sensors Overview 27 Service indicator Signal ring position check 174 Service partners 224...

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MTU 12 V 4000 M73 x, Operating Instructions Manual

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