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MTU 12 V 4000 M93 x, Operating Instructions Manual

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MTU 12 V 4000 M93 x Operating Instructions Manual Download Page 217

Diesel fuel

Part No.:
Qty.:

Used in:

 

7.6.1 Fuel filter – Replacement (→ Page 147)

Qty.:

Used in:

 

7.6.3 Fuel prefilter – Draining (→ Page 150)

Qty.:

Used in:

 

7.6.5 Fuel prefilter – Filter element replacement (→ Page 153)

Qty.:

Used in:

 

7.19.5 Coalescer filter element – Replacement (→ Page 191)

Engine coolant

Part No.:
Qty.:

Used in:

 

7.14.5 Engine coolant – Filling (→ Page 179)

Engine oil

Part No.:
Qty.:

Used in:

 

7.3.1 Valve gear – Lubrication (→ Page 133)

Qty.:

Used in:

 

7.3.2 Valve clearance – Check and adjustment (→ Page 134)

Qty.:

Used in:

 

7.4.1 HP pump – Filling with engine oil (→ Page 139)

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Used in:

 

7.5.2 Injector – Removal and installation (→ Page 142)

Qty.:

Used in:

 

7.12.2 Engine oil – Change (→ Page 163)

Qty.:

Used in:

 

7.13.1 Oil indicator filter – Cleaning (→ Page 166)

Qty.:

Used in:

 

7.13.2 Automatic oil filter – Oil filter candles replacement (→ Page 168)

Qty.:

Used in:

 

7.13.3 Oil indicator filter – Cleaning and check (→ Page 171)

Qty.:

Used in:

 

7.19.5 Coalescer filter element – Replacement (→ Page 191)

Fuel

Part No.:
Qty.:

Used in:

 

7.6.4 Fuel prefilter – Flushing (→ Page 151)

Grease (Kluthe Hakuform 30-10/Emulgier)

Part No.:

X00029933

Qty.:

Used in:

1 

7.5.2 Injector – Removal and installation (→ Page 142)

Qty.:

Used in:

1 

7.13.2 Automatic oil filter – Oil filter candles replacement (→ Page 168)

MS150047/04E 2013-07 | Appendix B | 217

DCL-ID: 0000017652 - 003

Summary of Contents for 12 V 4000 M93 x

Page 1: ...Operating Instructions Diesel engine 12 V 4000 M93 x 16 V 4000 M93 x MS150047 04E ...

Page 2: ...ed 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 Friedrichshafen GmbH This restriction also applies to copyright distribution translation mi crofilming and storage or processing on electronic systems including data bases and online services This han...

Page 3: ... 72 4 4 Starting the engine 73 4 5 Operational checks 74 4 6 Fuel treatment system control cabinet Control elements 75 4 7 Tasks after extended out of service periods 3 weeks 76 4 8 Checks prior to start up 77 4 9 Fuel treatment system Putting into operation 78 4 10 Fuel treatment system Switching on 81 4 11 Stopping the engine 82 4 12 Engine emergency stop at BlueLine automation system control st...

Page 4: ...ling 179 7 14 6 Engine coolant pump Relief bore check 181 7 14 7 Engine coolant Sample extraction and analysis 182 7 15 Raw Water Pump with Connections 183 7 15 1 Raw water pump Relief bore check 183 7 16 Battery Charging Generator 184 7 16 1 Battery charging generator drive Coupling condition check 184 7 17 Engine Mounting Support 185 7 17 1 Engine mounting Check 185 7 18 Auxiliary PTO 186 7 18 1...

Page 5: ...ion 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 maintenance requirements over the entire service life of the product Main tenance Schedule In compliance with the maintenance and repair instructions contained in this manual in particular with rega...

Page 6: ...ork 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 Training Center of the manufacturer Qualified personnel specialized in mechanical and plant engineering The operator must define the responsibilities of the personnel involved in operation maintenance r...

Page 7: ...nts 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 cases of emergency in particular emergency stop must be practiced regularly The following steps must be taken if a malfunction of the system is recognized or reported by the sys tem Inform superviso...

Page 8: ...yllium 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 measure Safety regulations during maintenance and repair work Take special care when removing ventilation or plug screws from the product Cover the screw or plug with a rag to prevent fluids escapin...

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 procedures Observe the max permissible push on pressure specified for the equipment Do not attempt to bend or apply force to lines Before starting work pay attention to the following Vent the hydrau...

Page 10: ...ncy 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 for repair i e protected in particular against moisture and impact and wrapped in antistatic foil if necessary Working with laser equipment When working with laser equipment always wear special lase...

Page 11: ...tics 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 facturer Noncompliance with these guidelines will invalidate the design type approval issued by the emissions regulation authorities The manufacturer does not accept any liability for violations of th...

Page 12: ...he 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 painting in areas other than spray booths equipped with extractors ensure good ventilation Make sure that neighboring work areas are not adversely affected There must be no naked flames in the vicinity...

Page 13: ... event of a situation involving potential danger Consequences Minor or moderate injuries Remedial action NOTICE In the event of a situation involving potentially adverse effects on the product Consequences Material damage Remedial action Additional product information Safety notices u This manual with all safety instructions and safety notices must be issued to all personnel involved in operation ...

Page 14: ... 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 the engine against tilting during transport The engine must be especially secured against slip ping or tilting when going up or down inclines and ramps Setting the engine down after transport Only set...

Page 15: ... 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 12 16 Number of cylinders V Cylinder arrangement V engine 4000 Series M Application x Application segment 1 2 y Design index 3 z R reduced power speed L enhanced power speed MS150047 04E 2013 07 Gene...

Page 16: ...ghtness 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 electronically controlled hydraul ically actuated flaps Cooling system Engine cooling as split circuit cooling system with plate core heat exchanger Heating of the charge air in idle and low load operation p...

Page 17: ...lso 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 starter Terminal 45 of starter A B starter engaged Pneumatic starter Start air pressure valve Start air pressure sensor Barring gear barring gear 1 and 2 Generator with excitation control Optional shut ...

Page 18: ...larms 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 room Interface to CAN field bus for connected communicating monitoring system components SOLAS Fire safety requirements All lines with SOLAS compliant covers for pipe connections according to MTU standa...

Page 19: ...rom 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 MS150047 04E 2013 07 General Information 19 TIM ID 0000010056 005 ...

Page 20: ...1 Oil line on equipment carrier 1 Oil supply to HP pump 1 Oil supply to flap control free end 20 General Information MS150047 04E 2013 07 TIM ID 0000010056 005 ...

Page 21: ...upply 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 MS150047 04E 2013 07 General Information 21 TIM ID 0000010056 005 ...

Page 22: ...1 Oil line from main oil gallery 2 Oil line to main oil gallery 1 Flap control distributor 1 Air recirculation valve 22 General Information MS150047 04E 2013 07 TIM ID 0000010056 005 ...

Page 23: ...irst 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 pipe connection b Design precludes lateral spray as the point of separation is shielded by the sleeve 3 Only seepage along the pipeline is possible whereby the pressure is greatly reduced by a faulty ...

Page 24: ... 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 chamber Leak fuel is allowed to escape without pressure via the leakage overflow bore 7 The leakage chamber is sealed toward the outside by the O rings 3 This prevents leaking fuel from escaping The un...

Page 25: ...e 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 numbering of other engine components also starts with no 1 at the driving end 1 Left hand side of engine 2 Free end 3 Right hand side of engine 4 Driving end MS150047 04E 2013 07 General Information 25 TIM...

Page 26: ... 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 temp cyl B6 15 B4 B5 exhaust temp cyl B5 16 B4 B4 exhaust temp cyl B4 17 B4 B3 exhaust temp cyl B3 18 B4 B2 exhaust temp cyl B2 19 B4 B1 exhaust temp cyl B1 20 B4 22 exhaust tempera ture B bank 21 B4...

Page 27: ... 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 temp 12 B57 6 main bearing temp 13 B57 7 main bearing temp MS150047 04E 2013 07 General Information 27 TIM ID 0000032308 003 ...

Page 28: ...free 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 28 General Information MS150047 04E 2013 07 TIM ID 0000032308 003 ...

Page 29: ... 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 temp conrod bearing 10 B9 charge air tempera ture MS150047 04E 2013 07 General Information 29 TIM ID 0000032308 003 ...

Page 30: ...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 30 General Information MS150047 04E 2013 07 TIM ID 0000032308 003 ...

Page 31: ...f 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 temp cyl B8 18 B4 B7 exhaust temp cyl B7 19 B4 B6 exhaust temp cyl B6 20 B4 B5 exhaust temp cyl B5 21 B4 B4 exhaust temp cyl B4 22 B4 B3 exhaust temp cyl B3 23 B4 B2 exhaust temp cyl B2 24 B4 B1 exhaus...

Page 32: ...speed 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 main bearing temp 13 B57 8 main bearing temp 14 B57 9 main bearing temp 32 General Information MS150047 04E 2013 07 TIM ID 0000032308 003 ...

Page 33: ...free 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 MS150047 04E 2013 07 General Information 33 TIM ID 0000032308 003 ...

Page 34: ...oil 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 temp conrod bearing 11 B77 B1 spray oil temp conrod bearing 12 B9 charge air tempera ture 34 General Information MS150047 04E 2013 07 TIM ID 0000032308 003 ...

Page 35: ...16V 4000 M driving end 1 B13 crankshaft speed 2 S37 2 safety switch 3 S37 1 safety switch 4 B13 2 crankshaft speed MS150047 04E 2013 07 General Information 35 TIM ID 0000032308 003 ...

Page 36: ...2 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 pressure F33 Coolant level M8 Fuel pump F46 Leak fuel level S37 1 Start interlock limit switch A S37 2 Start interlock limit switch B X37 Start interlock turning Y26 Charge air recirculation Y27 Turboch...

Page 37: ...1 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 23 B16 24 B44 2 25 F33 26 B49 27 B44 1 28 Y27 29 Y26 30 B3 MS150047 04E 2013 07 General Information 37 TIM ID 0000032681 002 ...

Page 38: ... 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 38 General Information MS150047 04E 2013 07 TIM ID 0000032681 002 ...

Page 39: ...r 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 MS150047 04E 2013 07 General Information 39 TIM ID 0000032681 002 ...

Page 40: ...Y39A1 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 40 General Information MS150047 04E 2013 07 TIM ID 0000032681 002 ...

Page 41: ...Engine wiring harness for EIM 1 XD1 2 X1 3 X3 4 X52 5 XY1 6 X11 7 XB19 8 X37 MS150047 04E 2013 07 General Information 41 TIM ID 0000032681 002 ...

Page 42: ...Engine wiring harness for electric starter 1 EIM terminals 2 Fuse F1 3 Starter terminals 42 General Information MS150047 04E 2013 07 TIM ID 0000032681 002 ...

Page 43: ...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 2100 Fuel stop power ISO 3046 A kW 2340 GENERAL CONDITIONS for maximum power Number of cylinders 12 Intake depression new filter A mbar 15 Intake depression max L mbar 30 MODEL RELATED DATA basic design Number of cylind...

Page 44: ... connection min when engine is running L bar 0 3 Fuel pressure at engine supply connection max when engine is starting L bar 1 5 Fuel supply flow max R liter min 30 GENERAL OPERATING DATA Number of cylinders 12 Firing speed from R rpm 80 Firing speed to R rpm 120 STARTING electric Number of cylinders 12 Starter rated voltage standard design R V 24 STARTING with compressed air hydraulic starter Num...

Page 45: ...5 Oil pan capacity at dipstick mark min standard oil system option max op erating inclinations L Liters 160 Oil pan capacity at dipstick mark max standard oil system option max operating inclinations L Liters 200 WEIGHTS MAIN DIMENSIONS Number of cylinders 12 Engine dry weight with attached standard accessories without coupling R kg 8010 ACOUSTICS Number of cylinders 12 Exhaust noise undamped BL f...

Page 46: ...sure 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 2100 Fuel stop power ISO 3046 A kW 2340 GENERAL CONDITIONS for maximum power Number of cylinders 12 Intake depression new filter A mbar 15 Intake depression max L mbar 30 MODEL RELATED DATA basic design Number of cylinders 12 Cylind...

Page 47: ... connection min when engine is running L bar 0 3 Fuel pressure at engine supply connection max when engine is starting L bar 1 5 Fuel supply flow max R liter min 30 GENERAL OPERATING DATA Number of cylinders 12 Firing speed from R rpm 80 Firing speed to R rpm 120 STARTING electric Number of cylinders 12 Starter rated voltage standard design R V 24 STARTING with compressed air hydraulic starter Num...

Page 48: ...5 Oil pan capacity at dipstick mark min standard oil system option max op erating inclinations L Liters 160 Oil pan capacity at dipstick mark max standard oil system option max operating inclinations L Liters 200 WEIGHTS MAIN DIMENSIONS Number of cylinders 12 Engine dry weight with attached standard accessories without coupling R kg 8010 ACOUSTICS Number of cylinders 12 Exhaust noise undamped BL f...

Page 49: ... 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 2100 Fuel stop power ISO 3046 A kW 2580 GENERAL CONDITIONS for maximum power Number of cylinders 12 Intake depression new filter A mbar 15 Intake depression max L mbar 30 MODEL RELATED DATA basic design Number of cylinders 12 C...

Page 50: ... connection min when engine is running L bar 0 3 Fuel pressure at engine supply connection max when engine is starting L bar 1 5 Fuel supply flow max R liter min 30 GENERAL OPERATING DATA Number of cylinders 12 Firing speed from R rpm 80 Firing speed to R rpm 120 STARTING electric Number of cylinders 12 Starter rated voltage standard design R V 24 STARTING with compressed air hydraulic starter Num...

Page 51: ...5 Oil pan capacity at dipstick mark min standard oil system option max op erating inclinations L Liters 160 Oil pan capacity at dipstick mark max standard oil system option max operating inclinations L Liters 200 WEIGHTS MAIN DIMENSIONS Number of cylinders 12 Engine dry weight with attached standard accessories without coupling R kg 8010 ACOUSTICS Number of cylinders 12 Exhaust noise undamped BL f...

Page 52: ...ssure 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 2100 Fuel stop power ISO 3046 A kW 2580 GENERAL CONDITIONS for maximum power Number of cylinders 12 Intake depression new filter A mbar 15 Intake depression max L mbar 30 MODEL RELATED DATA basic design Number of cylinders 12 Cylin...

Page 53: ... connection min when engine is running L bar 0 3 Fuel pressure at engine supply connection max when engine is starting L bar 1 5 Fuel supply flow max R liter min 30 GENERAL OPERATING DATA Number of cylinders 12 Firing speed from R rpm 80 Firing speed to R rpm 120 STARTING electric Number of cylinders 12 Starter rated voltage standard design R V 24 STARTING with compressed air hydraulic starter Num...

Page 54: ...5 Oil pan capacity at dipstick mark min standard oil system option max op erating inclinations L Liters 160 Oil pan capacity at dipstick mark max standard oil system option max operating inclinations L Liters 200 WEIGHTS MAIN DIMENSIONS Number of cylinders 12 Engine dry weight with attached standard accessories without coupling R kg 8010 ACOUSTICS Number of cylinders 12 Exhaust noise undamped BL f...

Page 55: ...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 2100 Fuel stop power ISO 3046 A kW 3120 GENERAL CONDITIONS for maximum power Number of cylinders 16 Intake depression new filter A mbar 15 Intake depression max L mbar 30 MODEL RELATED DATA basic design Number of cylinders 16 Cy...

Page 56: ... connection min when engine is running L bar 0 3 Fuel pressure at engine supply connection max when engine is starting L bar 1 5 Fuel supply flow max R liter min 30 GENERAL OPERATING DATA Number of cylinders 16 Firing speed from R rpm 80 Firing speed to R rpm 120 STARTING electric Number of cylinders 16 Starter rated voltage standard design R V 24 STARTING with compressed air hydraulic starter Num...

Page 57: ...0 Oil pan capacity at dipstick mark min standard oil system option max op erating inclinations L Liters 215 Oil pan capacity at dipstick mark max standard oil system option max operating inclinations L Liters 260 WEIGHTS MAIN DIMENSIONS Number of cylinders 16 Engine dry weight with attached standard accessories without coupling R kg 9600 ACOUSTICS Number of cylinders 16 Exhaust noise undamped BL f...

Page 58: ...sure 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 2100 Fuel stop power ISO 3046 A kW 3120 GENERAL CONDITIONS for maximum power Number of cylinders 16 Intake depression new filter A mbar 15 Intake depression max L mbar 30 MODEL RELATED DATA basic design Number of cylinders 16 Cylind...

Page 59: ... connection min when engine is running L bar 0 3 Fuel pressure at engine supply connection max when engine is starting L bar 1 5 Fuel supply flow max R liter min 30 GENERAL OPERATING DATA Number of cylinders 16 Firing speed from R rpm 80 Firing speed to R rpm 120 STARTING electric Number of cylinders 16 Starter rated voltage standard design R V 24 STARTING with compressed air hydraulic starter Num...

Page 60: ...0 Oil pan capacity at dipstick mark min standard oil system option max op erating inclinations L Liters 215 Oil pan capacity at dipstick mark max standard oil system option max operating inclinations L Liters 260 WEIGHTS MAIN DIMENSIONS Number of cylinders 16 Engine dry weight with attached standard accessories without coupling R kg 9600 ACOUSTICS Number of cylinders 16 Exhaust noise undamped BL f...

Page 61: ... 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 2100 Fuel stop power ISO 3046 A kW 3440 GENERAL CONDITIONS for maximum power Number of cylinders 16 Intake depression new filter A mbar 15 Intake depression max L mbar 30 MODEL RELATED DATA basic design Number of cylinders 16 C...

Page 62: ... connection min when engine is running L bar 0 3 Fuel pressure at engine supply connection max when engine is starting L bar 1 5 Fuel supply flow max R liter min 30 GENERAL OPERATING DATA Number of cylinders 16 Firing speed from R rpm 80 Firing speed to R rpm 120 STARTING electric Number of cylinders 16 Starter rated voltage standard design R V 24 STARTING with compressed air hydraulic starter Num...

Page 63: ...0 Oil pan capacity at dipstick mark min standard oil system option max op erating inclinations L Liters 215 Oil pan capacity at dipstick mark max standard oil system option max operating inclinations L Liters 260 WEIGHTS MAIN DIMENSIONS Number of cylinders 16 Engine dry weight with attached standard accessories without coupling R kg 9600 ACOUSTICS Number of cylinders 16 Exhaust noise undamped BL f...

Page 64: ...ssure 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 2100 Fuel stop power ISO 3046 A kW 3440 GENERAL CONDITIONS for maximum power Number of cylinders 16 Intake depression new filter A mbar 15 Intake depression max L mbar 30 MODEL RELATED DATA basic design Number of cylinders 16 Cylin...

Page 65: ... connection min when engine is running L bar 0 3 Fuel pressure at engine supply connection max when engine is starting L bar 1 5 Fuel supply flow max R liter min 30 GENERAL OPERATING DATA Number of cylinders 16 Firing speed from R rpm 80 Firing speed to R rpm 120 STARTING electric Number of cylinders 16 Starter rated voltage standard design R V 24 STARTING with compressed air hydraulic starter Num...

Page 66: ...0 Oil pan capacity at dipstick mark min standard oil system option max op erating inclinations L Liters 215 Oil pan capacity at dipstick mark max standard oil system option max operating inclinations L Liters 260 WEIGHTS MAIN DIMENSIONS Number of cylinders 16 Engine dry weight with attached standard accessories without coupling R kg 9600 ACOUSTICS Number of cylinders 16 Exhaust noise undamped BL f...

Page 67: ...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 approx 2368 mm MS150047 04E 2013 07 Technical Data 67 TIM ID 0000010044 003 ...

Page 68: ...ing order 8V A1 B4 A4 A2 B3 A3 B2 B1 12V 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 20 V A1 B5 A8 B7 A5 B2 A7 B10 A2 B3 A10 B6 A3 B4 A6 B9 A4 B1 A9 B8 68 Technical Data MS150047 04E 2013 07 TIM ID 0000002796 003 ...

Page 69: ... 4 White F4 5 White F5 6 White ALARM ACKNOWL Pressing the button the first time stops alarm sig nalization Pressing the button a second time acknowledges an active alarm LED spot lights up when an alarm is active 7 White DIM Holding down the button increases LCD back ground illumination 8 White DIM Holding down the button decreases LCD back ground illumination MS150047 04E 2013 07 Operation 69 TIM...

Page 70: ...the button is held down 15 White ENGINE SPEED DECREASE Engine speed is decreased as long as the button is held down 16 Green READY FOR OPERATION Pressing the button switches between Not ready for operation and Ready for operation LED spot is illuminated when the button is in the Ready for operation position 17 Green LOCAL CONTROL Pressing the button switches between local opera tion and remote con...

Page 71: ...above waterline Fill with water approx 3 4 liters Coolant circuit If engine is out of service for more than one year change coolant Page 177 Coolant circuit Check coolant level Page 176 Coolant circuit Heat coolant with coolant preheating unit HP fuel pump Only for engines without oil priming pump Fill HP fuel pump with new engine oil Page 139 Engine control system Switch master switch to ON Press...

Page 72: ... required Coolant circuit Check coolant level Page 176 Coolant circuit Heat coolant with coolant preheating unit Engine control system Switch master switch to ON Press illuminated pushbutton READY FOR OPERATION Page 69 LOP Press illuminated pushbutton LAMP TEST Page 69 ECU Check plug connections Page 198 EIM Check plug connections Page 200 EMU 8 Check plug connections Page 199 72 Operation MS15004...

Page 73: ...rsons in the en gine s danger zone WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors The engine can be started from the following points Item Action Control stand Operating instructions for electronic system Local Operating Panel LOP Operating instructions for electronic system Local Operation Station LOS Operating instructions for electron...

Page 74: ...l running noises and vibration Check exhaust color Page 97 Air filter Check signal ring position of service indicator Page 160 Replace air filter Page 158 if the signal ring is completely visible in the service indicator observation window Intercooler Check condensate drain s for water discharge and obstruction Page 157 Exhaust gas system Check condensate drain for obstructions Fuel prefilter s Dr...

Page 75: ...owledge 5 Yellow Signal lamp Indicates Filter warning due to increased differential pressure 6 Red Illuminated but ton Indicates Replace filter element Press to acknowledge 7 Switch Pump operating mode Remote 0 Manual Switch position Remote Pump is controlled at LOP Switch position 0 Pump is switched OFF Switch position Manual Pump is started manually 8 White Signal lamp Indicates Control voltage ...

Page 76: ...eeks 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 78 2 Shut down fuel treatment system Page 92 76 Operation MS150047 04E 2013 07 TIM ID 0000007730 005 ...

Page 77: ...lves 4 Switch on fuel treatment system Page 81 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 Close ball valve at the inlet to the fuel treatment system Result Bypass line is vented via the overflow tank d Open ball valve at the inlet to the fuel treatment system 7 Check the fuel treatment s...

Page 78: ...tic 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 Switch on fuel treatment system Page 81 2 Check differential pressure at differential pressure gage 8 Differential pressure in a new system 0 1 bar to 0 3 bar Result If no differential pressure is measur...

Page 79: ...e 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 bypass 2 5 Open ball valve 19 Result Fuel emerges If no fuel emerges Open ball valve 5 at inlet to fuel treatment system No function of bypasses 2 and 3 carry out functional test of bypasses 2 and 3 ...

Page 80: ...ry 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 operation is satisfactory 6 Operate engine at full load and monitor suction pressure Result If the suction pressure is within the specified limits simulation was successful 80 Operation MS150047 04E 2013 07 ...

Page 81: ...fore 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 start up Page 77 2 Switch on master switch on switchgear cabinet Result Signal lamp Control voltage present lights up 3 Switch on switch for pump Result Signal lamp Pump running lights up MS150047 0...

Page 82: ...4 11 Stopping the engine Stopping the engine via the automation system Refer to automation system operating instructions 82 Operation MS150047 04E 2013 07 TIM ID 0000017528 004 ...

Page 83: ...o 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 at BlueLine automation system Operating Instructions for BlueLine MS150047 04E 2013 07 Operation 83 TIM ID 0000002704 005 ...

Page 84: ...N 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 Item Measure LOP Press COUPLING AHEAD illuminated pushbutton Page 69 COUPLING AHEAD button flashes Gearbox is engaged in AHEAD direction After receiving the feedback signal from coupling the COUPLING...

Page 85: ...COUPLING 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 Item Measure LOP Press COUPLING NEUTRAL illuminated pushbutton Page 69 COUPLING NEUTRAL button flashes Gearbox is disengaged neutral position After receiving the feedback signal from coupling the COUP...

Page 86: ...o 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 69 FLUSH pushbutton flashes Gearbox is engaged astern After receiving the feedback signal from coupling the FLUSH pushbut ton is illuminated brightly LOP Release FLUSH illuminated pushbutton FLUSH pushbutton flashes Gear...

Page 87: ...e 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 69 LOP Operate engine at idle speed Page 69 Temperature indications Wait until engine temperatures do not fall any further LOP Press STOP illuminated pushbutton Page 69 STOP button is illuminated Engine at a sta...

Page 88: ...s 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 BlueLine automation system control stand Item Measure Engine Stop the engine at the BlueLine automation system control stand Blue Line Operating Instructions 88 Operation MS150047 04E 2013 07 TIM ID 000000...

Page 89: ...onnecting 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 LOP Item Measure LOP Press ALARM ACKNOWLEDGE illuminated pushbutton Page 69 Audible and visual signalization stops LOP Press ALARM ACKNOWLEDGE button again Power supply to ECU is provided Alarm has b...

Page 90: ...e 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 instructions 90 Operation MS150047 04E 2013 07 TIM ID 0000017530 005 ...

Page 91: ...at 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 freezing temperatures are to be expected and the engine is to re main out of service for an extended period Engine control system Switch off Air intake and exhaust sys tem Out of service period 1 week Se...

Page 92: ...binet 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 system 5 Open drain valve until pressure has escaped from fuel treatment system 92 Operation MS150047 04E 2013 07 TIM ID 0000007732 005 ...

Page 93: ...aim 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 environmental protection 2 Prior to putting the cleaning unit into operation read the Operating Instructions of the water steam jet unit carefully and observe the safety precautions 3 For external cleanin...

Page 94: ...n differential pressure gauge of fuel prefilter Page 149 W1001 Replace fuel filter or fuel filter element Page 147 W1005 Replace air filter Page 158 W1006 Replace fuel injection valves injectors Page 141 W1008 Replace engine oil filter when changing en gine oil or when the interval years is reached at the latest Page 168 W1009 X Check layer thickness of oil residues clean and replace filter sleeve...

Page 95: ...ck general condition of engine mounting visual inspection Page 185 W1713 Injector Reset drift correction CDC param eters Page 194 Table 2 Maintenance schedule task reference table QL1 MS150047 04E 2013 07 Maintenance 95 TIM ID 0000035260 002 ...

Page 96: ...pped 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 Reset motor protection relay Signal lamp Warning filter is lit Cause Corrective action The differential pressure exceeded 1 3 bar u Replace coalescer filter element Page 191 Illuminated pushbutton Rep...

Page 97: ...code 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 Corrective action Poor rotation by starter Battery low or faulty u Charge or replace battery see special documentation Engine wiring defective u Check Page 193 Engine Control Unit defective u Contact S...

Page 98: ...indicator Page 160 Intercooler clogged u Contact Service Exhaust turbocharger defective u Contact Service Coolant leaks at intercooler Cause Corrective action Intercooler leaky major coolant discharge u Contact Service Black exhaust gas Cause Corrective action Air supply Air filter clogged u Check signal ring position of service indicator Page 160 Fuel injection Injector faulty u Replace Page 141 ...

Page 99: ...ust gas Cause Corrective action Engine is not at operating temperature u Run engine to reach operating temperature Intercooler leaky u Contact Service MS150047 04E 2013 07 Troubleshooting 99 TIM ID 0000044073 001 ...

Page 100: ...1 comprises 3 digits Fault messages may also be caused by faulty sensors actuators Contact Service to have sensors actuators tested and replaced as necessary if troubleshooting as described in the table Page 101 proves unsuccessful For explanations of alarm configuration parameters refer to PR 2 8008 100 Fault code list Page 101 100 Troubleshooting MS150047 04E 2013 07 TIM ID 0000016867 004 ...

Page 101: ...ailure 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 is too low during starting or too high during stopping HP system leaky or air in the system u Contact Service 102 AL Cons Counter Defect ZKP Number 18 004 624 Cause Corrective action Consumption met...

Page 102: ...place 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 cabling B33 replace as necessary 2 Error cleared after restarting the engine 203 SD T Charge Air ZKP Number 18 004 571 Cause Corrective action Charge air temperature sensor faulty Short circuit or...

Page 103: ...ing 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 necessary 2 Error cleared after restarting the engine 211 SD P Lube Oil ZKP Number 18 004 563 Cause Corrective action Lube oil pressure sensor faulty Short circuit or wire break 1 Check sensor and ca...

Page 104: ...k 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 circuit or wire break 1 Check sensor and cabling B7 replace as necessary 2 Error cleared after restarting the engine 219 SD T Intake Air ZKP Number 18 004 573 Cause Corrective action Intake air temperature...

Page 105: ...r 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 sensor and cabling B5 3 replace as necessary 2 Error cleared after restarting the engine 228 SD P Fuel before Filter ZKP Number 18 004 595 Cause Corrective action Fuel pressure sensor faulty Short c...

Page 106: ... 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 and cabling B44 2 replace as necessary 2 Error cleared after restarting the engine 239 SD P Diff Fuel ZKP Number 18 004 598 Cause Corrective action Fuel differential pressure sensor faulty occurs onl...

Page 107: ...ant 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 18 004 500 Cause Corrective action Time of flight measuring fault of injector in cylinder A1 Time of flight measured value extremely low or extremely high u If alarm occurs frequently replace solenoid valve ...

Page 108: ...ective 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 AL Timing Cylinder A6 ZKP Number 18 004 505 Cause Corrective action Time of flight measuring fault of injector in cylinder A6 Time of flight measured value extremely low or extremely high u If alarm...

Page 109: ...9 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 injector 311 AL Timing Cylinder B1 ZKP Number 18 004 510 Cause Corrective action Time of flight measuring fault of injector B1 Time of flight measured value extremely low or extremely high u If alar...

Page 110: ...e 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 Timing Cylinder B6 ZKP Number 18 004 515 Cause Corrective action Time of flight measuring fault of injector B6 Time of flight measured value extremely low or extremely high u If alarm occurs frequently...

Page 111: ...ault 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 Corrective action Short circuit in injector cabling to cylinder A1 Result Misfiring 1 Rectify short circuit in injector solenoid valve circuit positive to negative e g by injector replacement 2 Error...

Page 112: ...g 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 Misfiring 1 Rectify short circuit in injector solenoid valve circuit positive to negative e g by injector replacement 2 Error cleared after restarting the engine 327 AL Wiring Cylinder A7 ZKP Number 18 ...

Page 113: ... 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 Misfiring 1 Rectify short circuit in injector solenoid valve circuit positive to negative e g by injector replacement 2 Error cleared after restarting the engine 333 AL Wiring Cylinder B3 ZKP Number 18...

Page 114: ... 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 Misfiring 1 Rectify short circuit in injector solenoid valve circuit positive to negative e g by injector replacement 2 Error cleared after restarting the engine 339 AL Wiring Cylinder B9 ZKP Number 18 0...

Page 115: ... 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 Result Misfiring 1 Check continuity of injector cabling or exclude open load in solenoid valve circuit e g by injector replacement 2 Error clearance After each working cycle 345 AL Open Load Cylinder A5 ...

Page 116: ...g 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 Result Misfiring 1 Check continuity of injector cabling or exclude open load in solenoid valve circuit e g by injector replacement 2 Error clearance After each working cycle 351 AL Open Load Cylinder B1...

Page 117: ... 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 Result Misfiring 1 Check continuity of injector cabling or exclude open load in solenoid valve circuit e g by injector replacement 2 Error clearance After each working cycle 357 AL Open Load Cylinder B7 ...

Page 118: ...it 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 faults 362 AL Power Stage High ZKP Number 18 004 497 Cause Corrective action Internal electronic fault electronics possibly faulty If bit 1 1020 021 Power Stage Failure Stop Engine is set engine will be...

Page 119: ...on 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 transistor output 2 TO 2 1 Check air recirculation valve cabling repair as necessary 2 Replace engine governor 373 AL Wiring TO 3 ZKP Number 18 004 636 Cause Corrective action Short circuit or wire br...

Page 120: ...n 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 action Water level sensor in fuel prefilter faulty Short circuit or wire break u Check sensor and cabling replace as necessary 419 SD T Coolant b Engine ZKP Number 18 004 604 Cause Corrective action C...

Page 121: ...ty 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 wire break u Check signal transmitter and cabling replace as necessary 470 SD T ECU ZKP Number 18 004 587 Cause Corrective action Temperature sensor for ECU faulty Short circuit or wire break u Chec...

Page 122: ...ecorder 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 wire break u Check sensor and cabling B4 23 replace as necessary 483 SD T Exhaust D ZKP Number 18 004 597 Cause Corrective action Exhaust temperature sensor on A side faulty Short circuit or wire bre...

Page 123: ...ng 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 connection of the battery charging generator on the POM u Check connection between POM and starter 503 AL Battery Not Charging ZKP Number 14 500 903 Cause Corrective action The battery charging generator d...

Page 124: ...ess 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 Bit 11 1 Check sensor and cabling replace as necessary 2 Contact Service 525 SD P Lube Oil R2 ZKP Number 18 004 638 Cause Corrective action Redundant lube oil pressure sensor faulty Short circuit or wi...

Page 125: ...be 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 ZKP Number 11 005 006 Cause Corrective action This alarm occurs if the engine fails to come to a standstill within a specified by parametrization a period of time after the emergency stop signal was...

Page 126: ...heck 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 Prefilter ZKP Number 18 004 600 Cause Corrective action Analog input signal for pressure before prefilter faulty Short circuit or wire break 1 Check pressure sensor and cabling replace as necessary 2 Error ...

Page 127: ...ngine 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 Engine Barring manually 1 Remove guard plate Result Safety switch preventing engine starting is activated 2 Engage barring device 2 in ring gear 3 and install on flywheel housing 3 Apply ratchet 1 to barring device 2 4 Rotate crankshaft in engine dire...

Page 128: ...7 1 2 Engine Barring with starting system Barring using the automation system Refer to automation system operating instructions 128 Task Description MS150047 04E 2013 07 TIM ID 0000017532 003 ...

Page 129: ...ns 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 not sharply defined and do not cover the entire stroke area Dark areas in the upper section of the cooling bore remaining cir cumference without objections Piston rings without objections Further endo...

Page 130: ...Final steps 1 Install injector Page 142 2 Install cylinder head cover Page 138 130 Task Description MS150047 04E 2013 07 TIM ID 0000000015 014 ...

Page 131: ...und 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 may be interrupted Findings not critical Corrosion fields spots Corrosion fields spots result from water condensed water with the valves in the overlap open position They are clearly visible due to the...

Page 132: ...ation 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 inspection be carried out after further operation of the engine 132 Task Description MS150047 04E 2013 07 TIM ID 0000000014 015 ...

Page 133: ...are parts Designation Use Part No Qty Engine oil Valve gear Lubrication 1 Remove cylinder head covers Page 138 2 Fill oil chambers of valve bridges with oil 3 Fill oil chambers of rocker arms and adjust ing screws with oil 4 Install cylinder head covers Page 138 MS150047 04E 2013 07 Task Description 133 TIM ID 0000000921 010 ...

Page 134: ...are 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 138 2 Install barring device Page 127 3 The OT TDC marking 1 if fitted on the flywheel must not be used for reference 134 Task Description MS150047 04E 2013 07 TIM ID 0000000922 010 ...

Page 135: ...in 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 MS150047 04E 2013 07 Task Description 135 TIM ID 0000000922 010 ...

Page 136: ...DC 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 TDC of cylinder A1 as per diagram 1 Cylinder A1 is in firing TDC 2 Cylinder A1 is in overlap TDC I Inlet valve X Exhaust valve 4 Use feeler gauge to determine the distance between valve bridge and ro...

Page 137: ...t 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 90 Nm 9 Nm 6 Replace or rectify adjusting screws and or locknuts which do not move freely 7 Check valve clearance Final steps 1 Remove barring device Page 127 2 Install cylinder head cover Page 138 ...

Page 138: ...g cylinder head cover 1 Clean very dirty cylinder head covers prior to removal 2 Remove screws 3 Remove cylinder head cover with gasket from cylinder head Installing cylinder head cover 1 Clean mating face 2 Check condition of gasket replace if necessary 3 Place gasket and cylinder head cover on cylinder head 4 Install cylinder head cover 138 Task Description MS150047 04E 2013 07 TIM ID 0000000923...

Page 139: ...NG 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 components major material damage Ensure that th HP fuel pump is filled with engine oil before it is installed or put into operation Filling HP pump 1 Remove plug screw 1 2 Use pump oiler to fill HP pump ...

Page 140: ...ne s danger zone WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors HP pump Relief bore check 1 Visually inspect relief bore 1 for fuel dis charge 2 For jacketed HP lines leakage is indicated by the yellow combined alarm 3 If fuel discharge is found or indicated con tact Service 140 Task Description MS150047 04E 2013 07 TIM ID 0000012375 006...

Page 141: ...tor 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 142 MS150047 04E 2013 07 Task Description 141 TIM ID 0000000022 013 ...

Page 142: ...e 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 are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke Preparatory steps 1 Shut off fuel supply to engine 2 Remove cylinder head cover Page 138...

Page 143: ...er 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 rings 3 O ring 2 and damper ring 1 from injector 11 Clean all mating and sealing surfaces 12 Cover all connections and bores or seal with suitable plugs MS150047 04E 2013 07 Task Description 143 TIM...

Page 144: ...e 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 sealing face on cyl inder head and protective sleeve with mill ing cutter 6 Insert injector into cylinder head ensuring that the HP line adapter is correctly aligned 7 Press in injector with installa...

Page 145: ...th 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 torque Name Size Type Lubricant Value Standard Adapter Tightening torque 100 Nm 10 Nm 15 Install return line 7 Note Ensure special cleanness 16 Coat thread and sealing cone of HP line 5 with engine o...

Page 146: ... 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 If DiaSys is not available contact Service Final steps 1 Install cylinder head cover Page 138 2 Open fuel supply to engine 146 Task Description MS150047 04E 2013 07 TIM ID 0000000925 009 ...

Page 147: ...d 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 smoke WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors NOTICE Damage to component Severe material damage For filter replacement with the engin...

Page 148: ... 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 replaced 2 Unscrew switched off easy change filter with oil filter wrench 3 Clean sealing surface on filter head 4 Check seal on new easy change filter and moisten with fuel 5 Fit SOLAS shield Page 1...

Page 149: ... 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 differential pressure of fuel prefilter 1 With the engine running at full load or rated power read off pressure at gauge 1 2 If differential pressure as indicated between position of adjustable pointer 2 and p...

Page 150: ...e drained 1 Left filter cut in 2 Right filter cut in 2 Open threaded vent plug 5 of filter to be drained 3 Unlock drain valve 6 by pressing toggle and open it 4 Drain water and contaminants from filter until pure fuel emerges 5 Close drain valve 6 6 Remove screws for cover and take off cov er 2 7 Fill filter housing with clean fuel 8 Place new gasket in cover 2 9 Fit cover with gasket and secure i...

Page 151: ...e 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 of engine noise when the engine is running Risk of damage to hearing Wear ear protectors Fuel prefilter Flushing 1 Cut out the contaminated filter 1 Left filter cut in 2 Right filter cut in MS150047 ...

Page 152: ...refilter Filling with fuel 1 Stop engine Page 82 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 Fit cover with gasket and secure it with screws 6 Check differential pressure Page 149 Result If flushing did not lead to an improvement of the differential pressure replace filter element of fuel pre...

Page 153: ... 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 Replacing filter element 1 Cut out filter to be drained I Left filter cut in II Right filter cut in MS150047 04E 2013 07 Task Description 153 TIM ID 0000004944 005 ...

Page 154: ...2 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 secure it with screws 12 Cut in the cut out filter again 13 Close threaded vent plug 5 when fuel emerges 14 Adjust the differential pressure gauge Page 149 154 Task Description MS150047 04E 2013 07 TIM...

Page 155: ...allation of electric lines Damage to component Note down line assignment to connections before removal NOTICE Inappropriate cleaning tool Risk of damage to component Observe manufacturer s instructions Use appropriate cleaning tool Preparatory steps 1 Drain engine coolant Page 178 2 Remove air filter Page 159 3 Remove exhaust system after exhaust turbocharger 4 Remove exhaust flap with actuators 5...

Page 156: ... intake 2 Install exhaust flap with actuators 3 Install exhaust system after exhaust turbocharger 4 Install air filter Page 159 5 Fill with engine coolant Page 179 156 Task Description MS150047 04E 2013 07 TIM ID 0000034852 003 ...

Page 157: ...gans 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 drain bore s on the right and left of the engine for emerging air at driving end If no air emerges 2 Clean drain bore s and blow out with com pressed air 3 Significant coolant discharge indicates a leak...

Page 158: ...re parts Designation Use Part No Qty Air filter Spare Parts Catalog Replacing the air filter 1 Remove old air filter and install new air filter Page 159 2 Reset signal ring of contamination indicator Page 160 158 Task Description MS150047 04E 2013 07 TIM ID 0000005447 009 ...

Page 159: ... 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 with clamp 2 onto intake housing 3 5 Tighten screw on clamp 2 with torque wrench to the specified tightening torque Name Size Type Lubricant Value Standard Screw Tightening torque 5 Nm MS150047 04E 2...

Page 160: ...disabled Checking signal ring position 1 If the signal ring is completely visible in the control window 2 replace air filter Page 158 2 After installation of new filter press reset button 1 Result Engaged piston with signal ring moves back to initial position 160 Task Description MS150047 04E 2013 07 TIM ID 0000005484 008 ...

Page 161: ...heck 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 193 MS150047 04E 2013 07 Task Description 161 TIM ID 0000000905 017 ...

Page 162: ...r 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 163 5 Insert dipstick into guide tube up to the stop Oil level check after the engine is stopped 1 5 minutes after stopping the engine remove oil dipstick from the guide tube and wipe it 2 Insert dipstick into guide tube to stop withdraw after appro...

Page 163: ...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 plug s and drain oil 3 Install drain plug s with new sealing ring Oil change using semirotary hand pump Oil extraction 1 Provide a suitable container to collect the oil 2 Extract all oil from oil pan using the semirotary hand pump Dr...

Page 164: ... 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 Page 162 5 After oil change bar engine with starting system Page 128 164 Task Description MS150047 04E 2013 07 TIM ID 0000014100 003 ...

Page 165: ...oning 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 Wear ear protectors Engine oil sample extraction and analysis 1 With the engine running at operating tem perature open screw on automatic oil filter by 1 to 2 turns 2 Drain approx 2 liters engine oil to...

Page 166: ...ain combustion residues which are harmful to health Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor WARNING Compressed air gun ejects a jet of pressurized air Risk of injury to eyes and damage to hearing risk of rupturing internal organs Never direct air jet at people Always wear safety goggles face mask and ear d...

Page 167: ... required Ensure that the mesh is not damaged 4 Carefully blow out strainer with compressed air from outside to inside Checking strainer 1 Check strainer for damage 2 Fit new strainer if damaged or severely contaminated Installing strainer 1 Insert strainer with new O ring into housing 2 Fill housing with new engine oil 3 Install cover 1 with new O ring MS150047 04E 2013 07 Task Description 167 TI...

Page 168: ...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 Do not inhale oil vapor NOTICE Contamination of components Damage to component Observe manufacturer s instructions Check components for special cleanliness Removing oil filter candles 1 Remove nuts 2 from oil fi...

Page 169: ...ff 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 180 and insert new fil ter candles 1 with chamfer facing down wards MS150047 04E 2013 07 Task Description 169 TIM ID 0000006401 006 ...

Page 170: ...orking 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 hole on shaft 170 Task Description MS150047 04E 2013 07 TIM ID 0000006401 006 ...

Page 171: ...hing 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 rupturing internal organs Never direct air jet at people Always wear safety goggles face mask and ear defenders NOTICE Inappropriate cleaning tool Risk of damage to component Observe manufacturer s instru...

Page 172: ...ew part Cleaning strainer 1 Wash strainer 5 with cleaner 2 Remove stubborn deposits with soft brush 3 Blow out strainer 5 with compressed air from inside Installing strainer 1 Coat square section ring 4 on strainer 5 with engine oil and install strainer 5 2 Coat O ring 3 with engine oil and fit in filter housing 3 Fit cover 2 and secure with screws 1 and washers 172 Task Description MS150047 04E 2...

Page 173: ...rts 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 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 rupturing internal organs Never direct air jet at people Always...

Page 174: ...isk 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 cover 4 with sealing ring 5 16 Tighten rotor cover nut 3 with torque wrench to the specified torque Name Size Type Lubricant Value Standard Nut Tightening torque 35 Nm to 45 Nm 17 Place rotor 11 in h...

Page 175: ...it 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 MS150047 04E 2013 07 Task Description 175 TIM ID 0000006694 002 ...

Page 176: ...sure 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 coolant level at remote cooler 1 Check engine coolant level coolant must be visible at marker plate 2 Top up engine coolant if necessary Page 179 3 Check and clean breather valve 4 Place breather valve on ...

Page 177: ...ge Special tools Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 178 2 Fill with engine coolant Page 179 MS150047 04E 2013 07 Task Description 177 TIM ID 0000000036 031 ...

Page 178: ...on 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 expansion tank through filler neck 4 Open drain valves and drain plugs and drain coolant at the following points Preheating unit Elbow of HT coolant pump 2 Crankcase left and right side 3 T piece 5 on ...

Page 179: ...lding Let the engine cool down Wear protective clothing gloves and goggles safety mask NOTICE Cold coolant in hot engine can cause thermal stress Possible formation of cracks in the engine Fill top up coolant only into cold engine Preparatory steps 1 Turn breather valve on filler neck of expan sion tank counterclockwise to first stop and allow pressure to escape 2 Continue to turn breather valve c...

Page 180: ...neck and close until it engages first lock 6 Start engine Page 73 7 After 10 seconds of engine operation with out load shut down the engine Page 82 8 Turn breather valve counterclockwise and remove 9 Check coolant level Page 176 and top up engine coolant as required a Repeat the steps from Start engine Step 6 until coolant no longer needs topping up b Check satisfactory condition of breath er valv...

Page 181: ...to hearing Wear ear protectors Engine coolant pump Relief bore check 1 Check relief bore for oil and coolant dis charge 2 Stop engine Page 73 and disable en gine start observe general safety instruc tions on maintenance and repair 3 Clean the relief bore with a wire if it is dirty Permissible coolant discharge up to 10 drops per hour Permissible oil discharge up to 5 drops per hour 4 If discharge ...

Page 182: ...ool 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 tion and analysis 1 With the engine running open drain valve 1 2 Flush sampling point by draining approx 1 liter coolant 3 Drain approx 1 liter of engine coolant into a clean container 4 Close drain...

Page 183: ... 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 73 and disable en gine start observe general safety instruc tions on maintenance and repair 3 Clean the relief bore with a wire if it is dirty Permissible raw water discharge up to 10 drops per hour Permissible oil discharge up to 5 drops per hour ...

Page 184: ...ed 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 deformation or cracking Contact Service 4 Install protective cover 184 Task Description MS150047 04E 2013 07 TIM ID 0000007390 007 ...

Page 185: ...ngine mounting Check Engine mounting Check Item Findings Action Visually inspect mounts Damage Brittleness Deformation Crack formation Swelling visible Replace contact Service MS150047 04E 2013 07 Task Description 185 TIM ID 0000015370 004 ...

Page 186: ...oise 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 82 and disable en gine start 3 Clean relief bores with a wire if dirty Permissible water discharge up to 10 drops per hour Permissible oil discharge up to 5 drops per hour 4 If discharge exceeds the specified limits Contact ...

Page 187: ...y 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 MS150047 04E 2013 07 Task Description 187 TIM ID 0000007733 007 ...

Page 188: ...ces Do not smoke Checking differential pressure gauge 1 Switch on fuel treatment system Page 81 2 Set the alarm points at the differential pressure gauge to zero Result Alarm is initiated with preset delay 3 Reset the alarm points at the differential pressure gauge to the specified values 188 Task Description MS150047 04E 2013 07 TIM ID 0000007737 005 ...

Page 189: ...nect 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 level probe in tank Result Alarm must be triggered with the preset delay 7 Switch off the system 8 Disconnect connector from water level probe 9 Remove water level probe from tank 10 Screw in water level...

Page 190: ...ck 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 at the pump intake side b Check pressure at the pressure gauge in the inlet to the fuel treatment system and note down c Open ball valve at inlet and outlet of fuel treatment system 4 Calculate wear ...

Page 191: ...omponents 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 element Re placement 1 Close ball valve at the inlet and outlet of the fuel treatment system 2 Open drain valve 3 Drain fuel 4 Close drain valve 5 Remove nuts 9 and washers 2 6 Remove screws 1 7 Remove ...

Page 192: ...ghtening 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 system Result The fuel treatment system is ready for operation 192 Task Description MS150047 04E 2013 07 TIM ID 0000007735 009 ...

Page 193: ...t 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 Contacts Sockets Cables and terminals Plug in contacts Result Contact Service if cable conductors are damaged Note Close male connectors that are not plugged in with the protective cap supplied 6 Clean di...

Page 194: ...C 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 DiaSys is not available Note The CDC parameters must be reset otherwise the emission certification of the engine is no longer ap plicable u Contact Service 194 Task Description MS150047 04E 2013 07 TIM ID...

Page 195: ...l alcohol 2 Remove dirt from the connector and cable surfaces with isopropyl alcohol 3 Check legibility of cable labels Clean or replace illegible labels Cleaning severely contaminated connectors on EMU 1 Release the latch and pull off connector 2 Clean connector housings connector socket housings and all contacts with isopropyl alcohol 3 When connectors sockets and all contacts are dry Fit connec...

Page 196: ...ing 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 ensuring that the switch 3 is actuated by the guard plate 1 4 If switch 3 and guard plate 1 are instal led but switch 3 is in the OFF position Make certain that the guard plate 1 at the side of the sw...

Page 197: ...rom housing surface with isopropyl alcohol 2 Remove dirt from connector and cable surfaces with isopropyl alcohol 3 Check legibility of cable labels Clean or replace illegible labels Cleaning severely contaminated connectors on the engine governor Note Seal unused connectors with the supplied protective cap 1 Release the latch and pull off connectors 2 Clean connector housings connector socket hou...

Page 198: ...nd 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 cable clamps are not faulty 198 Task Description MS150047 04E 2013 07 TIM ID 0000016847 005 ...

Page 199: ...rting 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 that cable clamps are not defective MS150047 04E 2013 07 Task Description 199 TIM ID 0000044016 001 ...

Page 200: ...isabled 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 that cable clamps are not faulty 200 Task Description MS150047 04E 2013 07 TIM ID 0000017034 003 ...

Page 201: ...governor 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 Installing engine governor on engine 1 Install in reverse order Ensure correct assignment of connectors and sockets in so doing 2 Check resilient mount before installing Result Replace resilient mou...

Page 202: ...all 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 Place EMU 4 on ECU 1 2 Screw in and tighten screws on base of EMU 4 Installing ECU with EMU on engine 1 Install in reverse order Ensure correct assignment of plugs and sockets 2 Check resilient mo...

Page 203: ...r 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 appropriate FSW and parameter descriptor module the diagnostic lamp DILA indicates flashing code 4 when the power supply is connected Page 204 2 The FSW and the parameter descriptor module must first be ...

Page 204: ...for 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 the housing of the Engine Interface Module It indicates the status of the fuses An orange LED is provided to allow diagnosis of a tripped fuse fault directly at the unit as it is often difficult to ...

Page 205: ...toring 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 failed S12 14 PIM current path failed S13 15 Spare current path failed S14 The failed current paths are signaled consecutively following the preamble LED on for 4 seconds 1 There is a pause lasting 4...

Page 206: ... 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 power supply 206 Task Description MS150047 04E 2013 07 TIM ID 0000038009 002 ...

Page 207: ... 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 Cleaning connectors on LOP 1 Remove dirt from connector and socket surfaces using isopropyl alcohol 2 Check legibility of cable labels Clean or replace illegible labels MS150047 04E 2013 07 Task Desc...

Page 208: ...ne 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 GMU Gear Monitoring Unit Gear monitoring unit HAT Harbour Acceptance Test HI High Alarm Measured value exceeds 1st maximum limit HIHI High High Alarm Measured value exceeds 2nd maximum limit HT High ...

Page 209: ... 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 Down Air Flaps Emergency air shutoff flap s SILA Sicherungslampe Fuse lamp on EIM SOLAS International Convention for the Safety of Life at Sea SS Safety System Safety system alarm SSK Schnellschlusskl...

Page 210: ...ve 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 9077778 Asia Pacific 65 6100 2688 North and Latin America 1 248 560 8000 Spare parts service Fast simple and correct identification of spare parts for your drive system or vehicle fleet The right sp...

Page 211: ... gauge Check 188 Disengaging from LOP 85 E ECU 7 Installation 201 Removal 201 ECU 7 engine governor Installation 201 Removal 201 Emergency stop From LOP 89 EMU Cleaning 195 EMU 8 Installation 202 Removal 202 Engine Barring with starting system 128 Emergency stop 90 Start 73 Stopping 82 At the BlueLine automation system control stand 88 From LOP 87 Wiring check 193 Engine Control Unit ECU 7 Checkin...

Page 212: ...al pressure gauge check 149 Draining 150 Filter element Replacement 153 Flushing 151 Fuel treatment system Putting into operation 78 Shutdown 92 Switching on 81 Fuel treatment system control cabinet Control elements 75 H Hotline 210 HP pump Filling with engine oil 139 Relief bore check 140 I Injector Removal and installation 142 Replacement 141 Intercooler Check water drain for coolant discharge a...

Page 213: ...g position check 160 Service partners 210 Spare parts service 210 Starter Condition check 161 T Tasks After extended out of service periods 76 Tasks after extended out of service periods 3 weeks 76 transport 14 Troubleshooting 97 Fuel treatment system 96 V Valve clearance Adjustment 134 Check 134 Valve gear Lubrication 133 Venting points 175 W Water drain valve Check 187 Water level probe 3 in 1 r...

Page 214: ...nt replacement Page 153 Filter sleeve Part No Qty Used in 7 13 4 Centrifugal oil filter Cleaning and filter sleeve replacement Page 173 Gasket Part No Qty Used in 7 3 3 Cylinder head cover Removal and installation Page 138 Qty Used in 7 6 3 Fuel prefilter Draining Page 150 Qty Used in 7 6 5 Fuel prefilter Filter element replacement Page 153 Qty Used in 7 19 5 Coalescer filter element Replacement P...

Page 215: ... candles replacement Page 168 Seal Part No Qty Used in 7 6 4 Fuel prefilter Flushing Page 151 Sealing ring Part No Qty Used in 7 12 2 Engine oil Change Page 163 Qty Used in 7 13 4 Centrifugal oil filter Cleaning and filter sleeve replacement Page 173 Square section ring Part No Qty Used in 7 13 3 Oil indicator filter Cleaning and check Page 171 Strainer Part No Qty Used in 1 7 13 1 Oil indicator f...

Page 216: ... Snow White 11 0 Part No X00054118 Qty Used in 1 7 13 1 Oil indicator filter Cleaning Page 166 Cleaner Snow White 11 0 Part No 40460 Qty Used in 1 7 13 3 Oil indicator filter Cleaning and check Page 171 Cold cleaner Part No X00056750 Qty Used in 1 7 7 1 Compressor wheel Cleaning Page 155 Cold cleaner Hakutex 60 Part No X00056750 Qty Used in 1 7 13 4 Centrifugal oil filter Cleaning and filter sleev...

Page 217: ...il Page 139 Qty Used in 7 5 2 Injector Removal and installation Page 142 Qty Used in 7 12 2 Engine oil Change Page 163 Qty Used in 7 13 1 Oil indicator filter Cleaning Page 166 Qty Used in 7 13 2 Automatic oil filter Oil filter candles replacement Page 168 Qty Used in 7 13 3 Oil indicator filter Cleaning and check Page 171 Qty Used in 7 19 5 Coalescer filter element Replacement Page 191 Fuel Part ...

Page 218: ...0 1 Engine wiring Check Page 193 Qty Used in 1 7 21 4 Engine governor and connectors Cleaning Page 197 Isopropyl alcohol Part No X00058037 Qty Used in 1 7 22 1 LOP and connectors Cleaning Page 207 218 Appendix B MS150047 04E 2013 07 DCL ID 0000017652 003 ...

Page 219: ...F30039526 Qty Used in 1 7 3 2 Valve clearance Check and adjustment Page 134 Feeler gauge Part No Y20098771 Qty Used in 1 7 3 2 Valve clearance Check and adjustment Page 134 Installation removal tool Part No F6789889 Qty Used in 1 7 5 2 Injector Removal and installation Page 142 MS150047 04E 2013 07 Appendix B 219 DCL ID 0000017652 003 ...

Page 220: ...ne oil Sample extraction and analysis Page 165 Qty Used in 1 7 14 7 Engine coolant Sample extraction and analysis Page 182 Oil filter wrench Part No F30379104 Qty Used in 1 7 6 1 Fuel filter Replacement Page 147 Ratchet Part No F30027340 Qty Used in 1 7 5 2 Injector Removal and installation Page 142 220 Appendix B MS150047 04E 2013 07 DCL ID 0000017652 003 ...

Page 221: ...t Part No F30027339 Qty Used in 1 7 19 5 Coalescer filter element Replacement Page 191 Ratchet head with extension Part No F30006212 Qty Used in 1 7 1 1 Engine Barring manually Page 127 Rigid endoscope Part No Y20097353 Qty Used in 1 7 2 1 Cylinder liner Endoscopic examination Page 129 MS150047 04E 2013 07 Appendix B 221 DCL ID 0000017652 003 ...

Page 222: ...ed in 1 7 12 2 Engine oil Change Page 163 Torque wrench 0 5 5 Nm Part No 0015384230 Qty Used in 1 7 5 2 Injector Removal and installation Page 142 Torque wrench 10 60 Nm Part No F30452769 Qty Used in 1 7 5 2 Injector Removal and installation Page 142 222 Appendix B MS150047 04E 2013 07 DCL ID 0000017652 003 ...

Page 223: ... Centrifugal oil filter Cleaning and filter sleeve replacement Page 173 Qty Used in 1 7 19 5 Coalescer filter element Replacement Page 191 Torque wrench 60 320 Nm Part No F30452768 Qty Used in 1 7 3 2 Valve clearance Check and adjustment Page 134 Qty Used in 1 7 5 2 Injector Removal and installation Page 142 MS150047 04E 2013 07 Appendix B 223 DCL ID 0000017652 003 ...

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