MTU 12 V 4000 Mx4 Operating Instructions Manual Download Page 177

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Rotate crankshaft with barring tool in en-

gine direction of rotation until marking

'TDC-A1' and pointer are aligned.

Diagram for 12V engines (two

crankshaft positions)

1 Cylinder A1 is in firing TDC

2 Cylinder A1 is in overlap TDC

I Inlet valve

X Exhaust valve

Diagram for 16V engines (two

crankshaft positions)

1 Cylinder A1 is in firing TDC

2 Cylinder A1 is in overlap TDC

I Inlet valve

X Exhaust valve

MS150110/00E 2013-10 | Task Description | 177

TIM-ID: 0000012224 - 006

Summary of Contents for 12 V 4000 Mx4

Page 1: ...Operating Instructions Diesel engine 12 V 4000 Mx4 16 V 4000 Mx4 MS150110 00E...

Page 2: ...right 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 Th...

Page 3: ...ment system control cabinet Control elements 84 4 9 Fuel treatment system Putting into operation 85 4 10 Fuel treatment system Switching on 88 4 11 Emergency engine shutdown via automation system 89 4...

Page 4: ...ine coolant Draining 228 7 14 4 Engine coolant Filling 231 7 14 5 HT coolant pump Relief bore check 233 7 14 6 Engine coolant Sample extraction and analysis 234 7 14 7 Preheating unit 235 7 15 Raw Wat...

Page 5: ...nfiguration approved by the manufacturer in writ ing including engine control parameters In compliance with all safety regulations and in adherence with all warning notices in this manual In accordanc...

Page 6: ...rk on or around the product This personnel must be instructed repeatedly Personnel requirements All work on the product shall be carried out by trained and qualified personnel only Training at the Tra...

Page 7: ...th the consequences of any operations performed During operation the display instruments and monitoring units must be permanently observed with re gard to present operating status violation of limit v...

Page 8: ...work Do not blow out the interior of the flywheel housing or the starter with compressed air Clean the flywheel housing inside with a class H dust extraction device Observe the safety data sheet Safe...

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

Page 10: ...stop feature Store spare parts properly prior to replacement i e protect them against moisture in particular Pack defective electronic components and assemblies in a suitable manner when dispatched f...

Page 11: ...roduct are prohibited by emission regulations Emission control units systems may only be maintained exchanged or repaired if the components used for this purpose are approved by the manu facturer Nonc...

Page 12: ...y line or before device or tool is to be replaced Carry out leak test in accordance with the specifications Paints and varnishes Observe the relevant safety data sheet for all materials When painting...

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

Page 14: ...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 15: ...ge air cool er 9 Charge air cooler 10 Recirculation line 11 Exhaust manifold 12 Charge air line 13 Crankcase 14 Oil filler neck 15 Cylinder head 16 Oil pan 17 Fuel filter 18 Engine mounts 19 Battery c...

Page 16: ...oring 10 Oil distribution housing 11 Coolant inlet from external cooling system 12 Thermostat housing 13 Coolant pump 14 Engine mounts 15 EIM Engine Interface Module 16 Air pipe to charge air cool er...

Page 17: ...rger 9 Exhaust outlet 10 Air pipe to charge air cool er 11 Recirculation line 12 Exhaust manifold 13 Charge air cooler 14 Charge air line 15 Crankcase 16 Oil filler neck 17 Cylinder head 18 Oil pan 19...

Page 18: ...p 17 Engine mounts 18 Cylinder head 19 EIM Engine Interface Module 20 Exhaust flap 21 Air pipe to charge air cool er 22 Oil pan 23 Crankcase 24 Charge air line 25 Charge air cooler 26 Flywheel housing...

Page 19: ...h 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 C...

Page 20: ...ed out via M threaded bolts and also integrated in the engine wiring harness Functions ECU supply EMU supply Plant signals ECU7 connector X1 Bus interface 2x MCS5 CAN CAN dialog output 1xMCS5 CAN Emer...

Page 21: ...In order to avoid inadmissible oil carbon and or carbon particle deposits in the engine it is recommended to carry out a cleaning cycle for at least 20 minutes after extended low load operation period...

Page 22: ...pressure pump 1 SOLAS clip on fuel line On holder for fuel filter head 1 SOLAS clip on fuel line On high pressure pump 2 SOLAS clip on fuel line After fuel fil ter head 22 General Information MS15011...

Page 23: ...AS clip on fuel line On fuel filter head Lube oil system oil lines with oil pressure 1 8 bar All lines with SOLAS compliant covers for pipe connections according to MTU standard MTN5233 are shown MS15...

Page 24: ...exhaust flap 1 SOLAS clips on actuating cylinder of ETC B1 air flap 2 SOLAS clips on T piece of ETC B1 flap actuation 1 SOLAS clip on distributor piece 2 SOLAS clips on oil return 24 General Informati...

Page 25: ...o ETC 2 SOLAS clip on oil line to flap actua tion 3 SOLAS clip on oil line to air recircu lation valve 4 SOLAS clips on oil line from main gallery 1 SOLAS clips on air recirculation valve MS150110 00E...

Page 26: ...ly line for HP pump on HP pump 1 SOLAS clip on oil supply line for HP pump On equipment carrier 1 SOLAS clip on ETC oil supply 2 SOLAS clip on ETC oil supply 26 General Information MS150110 00E 2013 1...

Page 27: ...on oil filter cartridge Special connections The following types of union are spray proof in case of leakage even without covers and have been con firmed as being SOLAS compliant by GL and DNV MS150110...

Page 28: ...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 The sleeve 3 covers the joint to prevent lateral spray Only l...

Page 29: ...all type seal area 20 Leak fuel connection The HP fuel line is sealed by the thrust ring 8 If leakage in the area of the thrust ring 8 or the HP line 2 occurs the emerging fuel is routed to the leakag...

Page 30: ...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 31: ...2 B3 intake air temperature 3 B44 1 turbocharger A speed 4 B10 charge air pressure 5 B34 3 fuel pressure be fore filter only if supple mentary fuel filter is fitted 6 B34 2 fuel pressure be fore filt...

Page 32: ...3 lube oil pressure be fore filter 5 B5 1 lube oil pressure downstream of filter 6 B48 fuel pressure in com mon rail 7 B1 camshaft speed 8 B54 oil refill pump pres sure optional 9 B6 2 coolant temper...

Page 33: ...engine side 12V 4000 Mx4 1 B44 2 turbocharger B speed 2 Y27 turbocharger control valve 3 B16 coolant pressure 4 B9 charge air tempera ture MS150110 00E 2013 10 General Information 33 TIM ID 000004559...

Page 34: ...exhaust tempera ture A side 2 B4 22 exhaust tempera ture B side 3 B13 crankshaft speed 4 S37 2 safety switch 5 S37 1 safety switch 6 B13 2 crankshaft speed optional 34 General Information MS150110 00...

Page 35: ...er A 2 B49 Y26 charge air tem perature before air recircu lation valve A air recircu lation valve 3 B4 cylinder exhaust tem perature A1 A6 B1 B6 optional 4 B5 9 lube oil pressure be fore turbocharger...

Page 36: ...lation valve 3 B3 intake air temperature 4 B44 1 turbocharger A speed 5 B10 charge air pressure 6 B34 3 fuel pressure be fore filter only if supple mentary fuel filter is fitted 7 B34 2 fuel pressure...

Page 37: ...er filter option 4 B5 1 lube oil pressure af ter filter 5 B5 3 lube oil pressure be fore filter 6 B1 camshaft speed 7 B54 oil refill pump pres sure optional 8 B6 2 coolant tempera ture optional 9 B6 c...

Page 38: ...4000 Mx4 1 B44 2 turbocharger B speed 2 Y27 turbocharger control valve 3 B16 coolant pressure 4 B21 raw water pressure optional 5 B9 charge air tempera ture 38 General Information MS150110 00E 2013 10...

Page 39: ...exhaust tempera ture A side 2 B4 22 exhaust tempera ture B side 3 B13 crankshaft speed 4 S37 2 safety switch 5 S37 1 safety switch 6 B13 2 crankshaft speed optional MS150110 00E 2013 10 General Infor...

Page 40: ...lube oil pressure be fore turbocharger A 2 B4 cylinder exhaust tem perature A1 A6 B1 B6 optional 3 F33 coolant level 4 B5 9 lube oil pressure be fore turbocharger B 40 General Information MS150110 00E...

Page 41: ...e 2 B3 intake air temperature 3 B44 1 turbocharger A speed 4 B10 charge air pressure 5 B34 3 fuel pressure be fore filter only if supple mentary fuel filter is fitted 6 B34 2 fuel pressure be fore fil...

Page 42: ...4 B5 3 lube oil pressure be fore filter 5 B5 1 lube oil pressure af ter filter 6 B48 fuel pressure in com mon rail 7 B1 camshaft speed 8 B54 oil refill pump pres sure optional 9 B6 2 coolant tempera t...

Page 43: ...engine side 16 V 4000 Mx4 1 B44 2 turbocharger B speed 2 Y27 turbocharger control valve 3 B16 coolant pressure 4 B9 charge air tempera ture MS150110 00E 2013 10 General Information 43 TIM ID 000004560...

Page 44: ...1 exhaust tempera ture A side 2 B4 22 exhaust tempera ture B side 3 B13 crankshaft speed 4 S37 2 safety switch 5 S37 1 safety switch 6 B13 2 crankshaft speed optional 44 General Information MS150110 0...

Page 45: ...er A 2 B49 Y26 charge air tem perature before air recircu lation valve A air recircu lation valve 3 B4 cylinder exhaust tem perature A1 A6 B1 B6 optional 4 B5 9 lube oil pressure be fore turbocharger...

Page 46: ...lation valve 3 B3 intake air temperature 4 B44 1 turbocharger A speed 5 B10 charge air pressure 6 B34 3 fuel pressure be fore filter only if supple mentary fuel filter is fitted 7 B34 2 fuel pressure...

Page 47: ...er filter option 4 B5 1 lube oil pressure af ter filter 5 B5 3 lube oil pressure be fore filter 6 B1 camshaft speed 7 B54 oil refill pump pres sure optional 8 B6 2 coolant tempera ture optional 9 B6 c...

Page 48: ...4000 Mx4 1 B44 2 turbocharger B speed 2 Y27 turbocharger control valve 3 B16 coolant pressure 4 B21 raw water pressure optional 5 B9 charge air tempera ture 48 General Information MS150110 00E 2013 10...

Page 49: ...1 exhaust tempera ture a bank 2 B4 22 exhaust tempera ture B side 3 B13 crankshaft speed 4 S37 2 safety switch 5 S37 1 safety switch 6 B13 2 crankshaft speed optional MS150110 00E 2013 10 General Info...

Page 50: ...lube oil pressure be fore turbocharger A 2 B4 cylinder exhaust tem perature A1 A6 B1 B6 optional 3 F33 coolant level 4 B5 9 lube oil pressure be fore turbocharger B 50 General Information MS150110 00E...

Page 51: ...fore filter B34 3 Fuel pressure before external filter B44 1 Exhaust turbocharger A speed B44 2 Exhaust turbocharger B speed B48 High pressure fuel B49 Charge air before recirculation B50 Crankcase pr...

Page 52: ...Engine wiring harness for sensors 12V 1 XG03 2 F46 3 B48 4 B33 5 M8 6 B1 7 B6 8 X2 9 B16 10 F33 11 XXF33 12 Y27 13 B44 2 14 B5 9 15 B54 16 X37 17 XF33 18 B4 22 19 S37 2 20 B9 21 S37 1 22 B13 23 B10 2...

Page 53: ...9 B5 9 10 B44 2 11 Y27 12 B16 13 B54 14 X37 15 XF33 16 XXF33 17 F33 18 B4 22 19 S37 2 20 B9 21 S37 1 22 B13 23 B10 24 B34 3 25 B4 21 26 B3 27 B5 3 28 B44 1 29 B34 2 30 B49 31 B5 1 32 B7 33 B5 8 34 Y26...

Page 54: ...e wiring harness for injectors 12V 1 Y39A1 2 Y39A2 3 Y39A3 4 Y39A4 5 Y39A5 6 Y39A6 7 X4 8 Y39B6 9 Y39B5 10 Y39B4 11 Y39B3 12 Y39B2 13 Y39B1 54 General Information MS150110 00E 2013 10 TIM ID 000004546...

Page 55: ...or injectors 16V 1 Y39A1 2 Y39A2 3 Y39A3 4 Y39A4 5 Y39A5 6 Y39A6 7 Y39A7 8 Y39A8 9 X4 10 Y39B8 11 Y39B7 12 Y39B6 13 Y39B5 14 Y39B4 15 Y39B3 16 Y39B2 17 Y39B1 MS150110 00E 2013 10 General Information 5...

Page 56: ...Engine wiring harness for EIM 1 XD1 2 X1 3 X3 4 X52 5 XY1 6 XB19 7 X37 56 General Information MS150110 00E 2013 10 TIM ID 0000045469 001...

Page 57: ...Engine wiring harness for electric starter 1 EIM terminals 2 Fuse F1 3 Starter terminals MS150110 00E 2013 10 General Information 57 TIM ID 0000045469 001...

Page 58: ...ric pressure mbar 1000 1000 1000 1000 Site altitude above sea level m 100 100 100 100 Power related data power ratings are net brake power as per ISO 3046 Heat exchanger engine mounted Heat exchanger...

Page 59: ...e before engine to R bar 6 3 6 3 6 3 6 3 Lube oil operating pressure low idle meas point before engine R bar 3 0 3 0 3 0 3 0 Fuel system Heat exchanger engine mounted Heat exchanger remote Fuel pressu...

Page 60: ...egrees 10 10 10 10 Transverse inclination continuous max Option max operating inclinations L Degrees 22 5 22 5 22 5 22 5 Capacities Heat exchanger engine mounted Heat exchanger remote Engine coolant e...

Page 61: ...ld sound pressure level Lp 1m distance ISO 6798 3dB A tolerance R dB A 109 109 109 109 Engine surface noise with attenuated in take noise filter BL free field sound power level Lp 1 m distance ISO 679...

Page 62: ...e sea level m 100 100 100 100 Power related data power ratings are net brake power as per ISO 3046 Heat exchanger engine mounted Heat exchanger remote Rated engine speed A rpm 1800 1800 1800 1800 Fuel...

Page 63: ...ure before engine to R bar 6 3 6 3 6 3 6 3 Lube oil operating pressure low idle meas point before engine R bar 3 0 3 0 3 0 3 0 Fuel system Heat exchanger engine mounted Heat exchanger remote Fuel pres...

Page 64: ...egrees 10 10 10 10 Transverse inclination continuous max Option max operating inclinations L Degrees 22 5 22 5 22 5 22 5 Capacities Heat exchanger engine mounted Heat exchanger remote Engine coolant e...

Page 65: ...sound pressure level Lp 1m distance ISO 6798 3dB A tolerance R dB A 110 110 110 110 Engine surface noise with attenuated in take noise filter BL free field sound power level Lp 1 m distance ISO 6798...

Page 66: ...e sea level m 100 100 100 100 Power related data power ratings are net brake power as per ISO 3046 Heat exchanger engine mounted Heat exchanger remote Rated engine speed A rpm 1800 1800 1800 1800 Fuel...

Page 67: ...il operating pressure low idle meas point before engine R bar 3 0 3 0 3 0 3 0 Fuel system Heat exchanger engine mounted Heat exchanger remote Fuel pressure at engine inlet connection min when engine i...

Page 68: ...rees 10 10 10 10 Transverse inclination continuous max Option max operating inclinations L Degrees 22 5 22 5 22 5 22 5 Capacities Heat exchanger engine mounted Heat exchanger remote Engine coolant eng...

Page 69: ...sound pressure level Lp 1m distance ISO 6798 3dB A tolerance R dB A 113 113 113 113 Engine surface noise with attenuated in take noise filter BL free field sound power level Lp 1 m distance ISO 6798...

Page 70: ...e sea level m 100 100 100 100 Power related data power ratings are net brake power as per ISO 3046 Heat exchanger engine mounted Heat exchanger remote Rated engine speed A rpm 1800 1800 1800 1800 Fuel...

Page 71: ...oil operating pressure low idle meas point before engine R bar 3 0 3 0 3 0 3 0 Fuel system Heat exchanger engine mounted Heat exchanger remote Fuel pressure at engine inlet connection min when engine...

Page 72: ...rees 10 10 10 10 Transverse inclination continuous max Option max operating inclinations L Degrees 22 5 22 5 22 5 22 5 Capacities Heat exchanger engine mounted Heat exchanger remote Engine coolant eng...

Page 73: ...sound pressure level Lp 1m distance ISO 6798 3dB A tolerance R dB A 114 114 114 114 Engine surface noise with attenuated in take noise filter BL free field sound power level Lp 1 m distance ISO 6798...

Page 74: ...3 5 Firing order Cylinders Firing order 12 V A1 B5 A5 B3 A3 B6 A6 B2 A2 B4 A4 B1 16 V A1 A7 B4 B6 A4 B8 A2 A8 B3 B5 A3 A5 B2 A6 B1 B7 74 Technical Data MS150110 00E 2013 10 TIM ID 0000023263 002...

Page 75: ...series 12V4000M54 M64 Engine model Length A Width B without silencer Width B with si lencer Height C 12 V 4000 M54 64 approx 2638 mm approx 1690 mm approx 1850 mm approx 2071 mm 16 V 4000 M54 64 appr...

Page 76: ...th B without silencer Width B with si lencer Height C 12 V 4000 M54 64 approx 2884 mm approx 1690 mm approx 1850 mm approx 2071 mm 16 V 4000 M54 64 approx 3393 mm approx 1690 mm approx 1850 mm approx...

Page 77: ...4 Operation 4 1 LOP controls LOP controls Item Measure LOP Start engine via the automation system Automation system Operating In structions MS150110 00E 2013 10 Operation 77 TIM ID 0000045323 001...

Page 78: ...th position of pressure indicator Page 194 HP fuel pump Only for engines without oil priming pump Fill HP fuel pump with new engine oil Page 180 Raw water pump if located above waterline only appli ca...

Page 79: ...Check coolant level Page 226 Coolant system Preheat coolant with preheating unit Fuel prefilter Drain Page 195 Check that suction side pressure indicated at the fuel prefilter pressure gauge is withi...

Page 80: ...automation system Starting the engine via the automation system Item Measure Automation system Start engine via the automation system Automation system Operating In structions 80 Operation MS150110 00...

Page 81: ...rge air cooler Check condensate drain Page 206 Air filter Check signal ring position of service indicator Page 209 Replace air filter Page 207 if the signal ring is completely visible in the service i...

Page 82: ...eks Tasks after extended out of service periods 3 weeks Note Operate fuel treatment system for at least 5 minutes 1 Start up fuel treatment system Page 85 2 Shut down fuel treatment system Page 95 82...

Page 83: ...ves 4 Switch on fuel treatment system Page 88 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 84: ...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 85: ...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 86: ...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 87: ...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 88: ...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 89: ...t Risk of overheating damage to components Initiate emergency stop only in emergency situations Emergency engine shutdown via automation system Item Measure Automation system Emergency shutdown via th...

Page 90: ...led from the engine room Risk of accidents Only execute vessel movements on the instructions of a person who has visual contact with the area outside the vessel Engagement via LOP Item Measure LOP Eng...

Page 91: ...ed from the engine room Risk of accidents Only execute vessel movements on the instructions of a person who has visual contact with the area outside the vessel Disengaging from LOP Item Measure LOP Di...

Page 92: ...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 77 FLUSH pushbutton f...

Page 93: ...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 Engine shutdown via the automati...

Page 94: ...ature the antifreeze concentration is insufficient for the engine room tem perature antifreeze concentration is 50 and engine room temperature is below 40 C Raw water only on engines with engine mount...

Page 95: ...inet until water discharge from the outlet stops 2 Switch off fuel treatment system 3 Close ball valve at the inlet to the fuel treatment system 4 Close ball valve at the outlet of the fuel treatment...

Page 96: ...ressed air gun directly at seals or electronic components such as connectors or ECUs Plant Cleaning 1 Carry out plant cleaning only in areas where an appropriate oil separator is provided environmenta...

Page 97: ...ilter Page 207 W1006 Replace fuel injectors Page 182 W1008 X Replace engine oil filter when changing engine oil or when the interval years is reached at the latest Page 216 W1009 X Check layer thickne...

Page 98: ...ipped 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...

Page 99: ...stem by actuating the key switch Running gear blocked engine cannot be barred manually u Contact Service Engine turns on starting but does not fire Cause Corrective action Poor rotation by starter Bat...

Page 100: ...icator Page 209 Intercooler dirty u Contact Service Exhaust turbocharger defective u Contact Service Coolant leaks at intercooler Cause Corrective action Intercooler leaky major coolant discharge u Co...

Page 101: ...t gas Cause Corrective action Engine is not at operating temperature u Run engine to reach operating temperature Intercooler leaky u Contact Service MS150110 00E 2013 10 Troubleshooting 101 TIM ID 000...

Page 102: ...ult code 1 comprises 3 digits Fault messages may also be caused by faulty sensors actuators Contact Service to have sensors actuators tested and replaced as necessary if troubleshooting as described i...

Page 103: ...may be exposed to heat u Contact Service 5 HI T Charge Air ZKP Number 2 0121 931 Charge air temperature too high limit value 1 Yellow alarm warning Cause Corrective action Charge air cooler not functi...

Page 104: ...tive action Coolant circuit for charge air defective 1 Check charge air cooler and coolant cooler 2 Contact Service 15 LO P Lube Oil ZKP Number 2 0100 921 Lube oil pressure too low limit value 1 Yello...

Page 105: ...2 0127 931 Exhaust temperature too high B side limit value 1 Yellow alarm warning Cause Corrective action Wiring damage 1 Check air filter and wiring Page 248 2 Contact Service 22 SS T Exhaust B ZKP N...

Page 106: ...HI Level Leakage Fuel ZKP Number 2 0151 931 Leak off fuel level too high limit value 1 Yellow alarm warning Cause Corrective action Fuel lines leaking 1 Check fuel system 2 Contact Service 29 HI ETC...

Page 107: ...l filter differential oil pressure too high limit value 1 Yellow alarm warning Cause Corrective action Fuel filter not functioning correctly 1 Replace fuel filter Page 191 2 Contact Service 34 SS P Di...

Page 108: ...204 Yellow alarm warning Cause Corrective action ETC2 failed to cut in u Contact Service 44 LO Coolant Level Charge Air Cooler ZKP Number 2 0153 921 Coolant level of charge air cooler too low limit va...

Page 109: ...ant pressure too low limit value 2 Red alarm engine stop or reduced injection quantity Cause Corrective action Leak in coolant circuit 1 Check coolant level Page 226 2 Check coolant circuit 59 SS T Co...

Page 110: ...ive action Crankcase exhaust system clogged or leaking 1 Reduce power 2 Replace oil mist fine separator element 3 Contact Service 64 SS P Crankcase ZKP Number 2 0106 932 Crankcase pressure too high li...

Page 111: ...age leaks low coolant level 1 Reduce power 2 Check coolant circuit 68 SS T Coolant ZKP Number 2 0120 932 Coolant temperature too high limit value 2 Red alarm engine shutdown Cause Corrective action Co...

Page 112: ...ervice 085 HI T Recirculation ZKP Number 2 0128 931 Recirculation temperature too high limit value 1 Cause Corrective action Charge air temperature before recirculation valve too high u Reduce power 0...

Page 113: ...Red alarm warning Cause Corrective action Starter rotates too slowly or does not rotate at all 1 Check for additional messages 2 Contact Service 93 SS T Preheat ZKP Number 2 1090 922 Preheating tempe...

Page 114: ...g system faulty Yellow alarm warning Cause Corrective action Hour meter faulty u Contact Service 118 LO ECU Power Supply Voltage ZKP Number 2 0140 921 Supply voltage too low limit value 1 Yellow alarm...

Page 115: ...ltage 2 Contact Service 122 HI T ECU ZKP Number 2 0132 921 Electronics temperature too high limit value 1 Yellow alarm warning Cause Corrective action Electronics overheated 1 Reduce power 2 Improve e...

Page 116: ...engine governor indicated for each indiv module u Contact Service 180 AL CAN1 Node Lost ZKP Number 2 0500 680 Connection to a node on CAN bus 1 failed Yellow alarm warning Cause Corrective action Conn...

Page 117: ...governor 1 Check devices connected to CAN 2 Contact Service 184 AL CAN PU Data Flash Error ZKP Number 2 0500 684 CAN PU data flash error Cause Corrective action A program fault occurred while trying t...

Page 118: ...rate incompatibility 1 Check CAN bus for short circuit rectify short circuit as necessary 2 Check shielding improve shielding as necessary 3 Contact Service 189 AL CAN2 Error Passive ZKP Number 2 050...

Page 119: ...is rectified when engine is restarted Page 80 3 Contact Service 203 SD T Charge Air ZKP Number 1 8004 571 Signal error charge air temperature sensor Yellow alarm warning Cause Corrective action Charge...

Page 120: ...ary Page 248 2 Fault is rectified when engine is restarted Page 80 3 Contact Service 207 SD T Exhaust B ZKP Number 1 8004 577 Signal error exhaust temperature sensor on B side Yellow alarm warning Cau...

Page 121: ...ine is restarted Page 80 3 Contact Service 213 SD P Coolant Charge Air Cooler ZKP Number 1 8004 569 Charge air cooler coolant pressure sensor faulty Yellow alarm warning Cause Corrective action Charge...

Page 122: ...ce as necessary Page 248 2 Fault is rectified when engine is restarted Page 80 3 Contact Service 219 SD T Intake Air ZKP Number 1 8004 573 Signal error intake air temperature sensor Yellow alarm warni...

Page 123: ...engine is restarted Page 80 3 Contact Service 223 SD Level Coolant Charge Air Cooler ZKP Number 1 8004 583 Charge air cooler coolant level sensor faulty Yellow alarm warning Cause Corrective action C...

Page 124: ...ring to connector B1 replace as necessary Page 248 2 Fault is rectified when engine is restarted Page 80 3 Contact Service 230 SD Crankshaft Speed ZKP Number 1 8004 498 Signal error crankshaft sensor...

Page 125: ...sensor and wiring B44 2 replace as necessary Page 248 2 Fault is rectified when engine is restarted Page 80 3 Contact Service 239 SD P Diff Fuel ZKP Number 1 8004 598 Differential pressure sensor for...

Page 126: ...nsor faulty Short circuit or wire break u Check sensor and wiring replace as necessary Fault is rectified following engine restart 245 SD ECU Power Supply Voltage ZKP Number 2 8006 589 Signal error en...

Page 127: ...e 80 3 Contact Service 270 SD Frequency Input ZKP Number 2 8006 590 Signal error frequency input Red alarm forced idle Cause Corrective action Frequency input faulty Short circuit or wire break 1 Chec...

Page 128: ...u Replace injector if the fault message appears frequently Page 182 306 AL Timing Cylinder A6 ZKP Number 1 8004 505 Time of flight measuring fault of injector Cause Corrective action Flight time valu...

Page 129: ...u Replace injector if the fault message appears frequently Page 182 312 AL Timing Cylinder B2 ZKP Number 1 8004 511 Time of flight measuring fault of injector Cause Corrective action Flight time valu...

Page 130: ...u Replace injector if the fault message appears frequently Page 182 318 AL Timing Cylinder B8 ZKP Number 1 8004 517 Time of flight measuring fault of injector Cause Corrective action Flight time value...

Page 131: ...ault is rectified when engine is restarted Page 80 3 Contact Service 323 AL Wiring Cylinder A3 ZKP Number 1 8004 522 Wiring fault cylinder A3 Yellow alarm misfire Cause Corrective action Short circuit...

Page 132: ...ault is rectified when engine is restarted Page 80 3 Contact Service 327 AL Wiring Cylinder A7 ZKP Number 1 8004 526 Wiring fault cylinder A7 Yellow alarm misfire Cause Corrective action Short circuit...

Page 133: ...Fault is rectified when engine is restarted Page 80 3 Contact Service 331 AL Wiring Cylinder B1 ZKP Number 1 8004 530 Wiring fault cylinder B1 Yellow alarm misfire Cause Corrective action Short circui...

Page 134: ...ault is rectified when engine is restarted Page 80 3 Contact Service 335 AL Wiring Cylinder B5 ZKP Number 1 8004 534 Wiring fault cylinder B5 Yellow alarm misfire Cause Corrective action Short circuit...

Page 135: ...lt is rectified when engine is restarted Page 80 3 Contact Service 339 AL Wiring Cylinder B9 ZKP Number 1 8004 538 Wiring fault cylinder B9 Yellow alarm misfire Cause Corrective action Short circuit f...

Page 136: ...age 182 3 Fault rectified after each working cycle 4 Contact Service 343 AL Open Load Cylinder A3 ZKP Number 1 8004 542 Injector wiring fault cylinder A3 Yellow alarm misfire Cause Corrective action D...

Page 137: ...age 182 3 Fault rectified after each working cycle 4 Contact Service 347 AL Open Load Cylinder A7 ZKP Number 1 8004 546 Injector wiring fault cylinder A7 Yellow alarm misfire Cause Corrective action D...

Page 138: ...Page 182 3 Fault rectified after each working cycle 4 Contact Service 351 AL Open Load Cylinder B1 ZKP Number 1 8004 550 Injector wiring fault cylinder B1 Yellow alarm misfire Cause Corrective action...

Page 139: ...age 182 3 Fault rectified after each working cycle 4 Contact Service 355 AL Open Load Cylinder B5 ZKP Number 1 8004 554 Injector wiring fault cylinder B5 Yellow alarm misfire Cause Corrective action D...

Page 140: ...e 182 3 Fault rectified after each working cycle 4 Contact Service 359 AL Open Load Cylinder B9 ZKP Number 1 8004 558 Injector wiring fault cylinder B9 Yellow alarm misfire Cause Corrective action Dis...

Page 141: ...shutdown possible Cause Corrective action Electronics faulty 1 Start ITS 2 Replace engine governor if required 3 Check additional messages if ITS indicates diagnosis Electronics OK e g wiring faulty 4...

Page 142: ...e action Short circuit or wire break on transistor output 1 TO 1 1 Check charger valve wiring repair as necessary 2 Replace engine governor 372 AL Wiring TO 2 ZKP Number 1 8004 635 Line disruption Cau...

Page 143: ...reak on transistor output plant side 2 TOP 2 u Check wiring to plant 383 AL Wiring TOP 3 ZKP Number 2 8006 640 Line disruption on digital input 3 Yellow alarm warning Cause Corrective action Short cir...

Page 144: ...2 Cause Corrective action Redundant coolant temperature reading too high engine stop 1 Check wiring and sensor 2 Contact Service 394 LO P Lube Oil Red ZKP Number 2 0112 921 Limit value 1 Cause Correct...

Page 145: ...larm warning Cause Corrective action Wiring faulty No resistance over switch 1 Check wiring Page 248 2 Check target device input 3 Contact Service 402 AL Open Load Digital Input 3 ZKP Number 2 8006 62...

Page 146: ...Check wiring Page 248 2 Check target device input 3 Contact Service 406 AL Open Load Digital Input 7 ZKP Number 2 8006 631 Line disruption on digital input 7 Yellow alarm warning Cause Corrective act...

Page 147: ...aulty current supply 1 Check wiring Page 248 2 Check supply 3 Contact Service 411 LOLO U PDU ZKP Number 2 0141 922 Injector voltage too low limit value 2 Red alarm engine shutdown Cause Corrective act...

Page 148: ...P Number 2 0107 921 Coolant pressure in charge air cooler too low limit 1 Yellow alarm warning Cause Corrective action Leak in coolant circuit u Top up coolant 416 SS P Coolant Charge Air Cooler ZKP N...

Page 149: ...Number 2 0160 922 Limit value 2 Cause Corrective action Input signal of Aux 1 has exceeded not attained limit value 2 depending on configuration u Determine cause of limit value violation and rectify...

Page 150: ...depending on configuration u Determine cause of limit value violation and rectify fault 444 SD U PDU ZKP Number 1 8004 578 Injector power stage supply voltage fault Yellow alarm warning Cause Correct...

Page 151: ...at turbine bypass flap u Contact Service 449 SS P Charge Air ZKP Number 2 0103 932 Charge air pressure too high limit value 2 Red alarm engine shutdown Cause Corrective action Fault at turbine bypass...

Page 152: ...use Corrective action Input signal of Aux 1 plant side has exceeded not attained limit value 1 depending on configuration u Determine cause of limit value violation and rectify fault 456 AL L2 Aux1 Pl...

Page 153: ...pressure faulty short circuit or wire break u Check pressure transmitter and wiring replace as necessary Fault is rectified following engine restart 467 AL L2 T Aux 1 ZKP Number 2 0130 922 Limit valu...

Page 154: ...80 3 Contact Service 471 SD Coil Current ZKP Number 1 8004 592 Signal error HP fuel control block Yellow alarm warning Cause Corrective action Actuation of HP fuel control block faulty Short circuit o...

Page 155: ...t Service 476 AL Crash Rec Init Error ZKP Number 1 8010 007 Initialization error of crash recorder Cause Corrective action Initialization error of crash recorder u Contact Service 478 AL Comb Alarm Ye...

Page 156: ...eak u Check sensor and wiring B4 23 replace as necessary 483 SD T Exhaust D ZKP Number 18 004 597 Cause Corrective action Exhaust temperature sensor on A side faulty Short circuit or wire break u Chec...

Page 157: ...low alarm warning Cause Corrective action Clogged charge air circuit or fault in turbocharger u Reduce power 489 SS ETC3 Overspeed ZKP Number 2 3014 932 Speed of 2nd secondary turbocharger too high li...

Page 158: ...3 Yellow alarm warning Cause Corrective action ETC3 failed to cut in u Check control valve at turbocharger 3 500 AL Wiring POM Starter 1 ZKP Number 1 4500 900 Wiring fault connection of starter 1 at P...

Page 159: ...erator and wiring Page 248 504 AL CAN POM Node Failure ZKP Number 1 4500 904 POM missing on CAN bus Yellow alarm warning Cause Corrective action If alarm 508 occurs in addition the resistor in the POM...

Page 160: ...ssible start cancelation Cause Corrective action Starter on POM could not be engaged 1 Repeat start 2 Check POM starter and wiring Page 248 3 Contact Service 519 Oil Level Calibration Error ZKP Number...

Page 161: ...ed as backup medium for FDH u Contact Service configuration fault 544 AL Configuration Changed ZKP Number 2 0555 003 Yellow alarm Cause Corrective action This alarm is activated when the system config...

Page 162: ...valid enabling code is entered via the SAM display and key controls This enabling code can be requested via the Internet using a special procedure u Request activation code via Internet 576 AL ESCM Ov...

Page 163: ...is too low limit value 1 Yellow alarm warning Cause Corrective action Oil level in oil refill tank too low 1 Check oil level top up as necessary Page 211 2 Contact Service 588 SD P Oil Refill Pump ZK...

Page 164: ...sensor and wiring replace as necessary Page 248 2 Contact Service 601 SD ETC1 ETC2 ZKP Number 1 3011 227 Signal error ETC speed sensor 1 and 2 Yellow alarm warning Cause Corrective action ETC speed se...

Page 165: ...ressure sensor before supplementary filter Yellow alarm warning Cause Corrective action Analog input signal for fuel pressure before supplementary filter faulty Short circuit or wire break 1 Check pre...

Page 166: ...too high u 761 SD T Fuel b Engine ZKP Number 1 0080 900 Cause Corrective action Oil pan temperature sensor faulty Short circuit or wire break 1 Check sensor and wiring B24 replace as necessary Page 2...

Page 167: ...lue 1 Cause Corrective action Lube oil pressure too low u Check ETC oil lubrication 867 AL L1 P Lube Oil ETC A ZKP Number 1 0222 923 Limit value 1 Cause Corrective action Lube oil pressure too low u C...

Page 168: ...ing engine parts Risk of crushing danger of parts of the body being caught or pulled in Before cranking the engine make sure that there are no persons in the engine s danger zone After finishing work...

Page 169: ...o resistance other than compression re sistance must be encountered 4 Rotate crankshaft in engine direction of ro tation Result If the resistance exceeds the normal com pression resistance contact Ser...

Page 170: ...7 1 2 Engine Barring with starting system Barring using the automation system Refer to automation system operating instructions 170 Task Description MS150110 00E 2013 10 TIM ID 0000017532 003...

Page 171: ...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 172: ...Final steps 1 Install injector Page 183 2 Install cylinder head cover Page 179 172 Task Description MS150110 00E 2013 10 TIM ID 0000000015 014...

Page 173: ...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 174: ...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 175: ...re parts Designation Use Part No Qty Engine oil Valve gear Lubrication 1 Remove cylinder head covers Page 179 2 Fill oil chambers of valve bridges with oil 3 Fill oil chambers of rocker arms and adjus...

Page 176: ...ial Spare parts Designation Use Part No Qty Feeler gauge Y20010128 1 Torque wrench 60 320 Nm F30047446 1 Socket wrench 24 mm F30039526 1 Engine oil Preparatory steps 1 Remove cylinder head cover Page...

Page 177: ...engines two crankshaft positions 1 Cylinder A1 is in firing TDC 2 Cylinder A1 is in overlap TDC I Inlet valve X Exhaust valve Diagram for 16V engines two crankshaft positions 1 Cylinder A1 is in firin...

Page 178: ...exceeds 0 1 mm adjust valve clearance Valve clearance adjustment 1 Release locknut 1 2 Insert feeler gauge 3 between valve bridge and rocker arm 3 Using Allen key set adjusting screw 2 so that the spe...

Page 179: ...ery dirty cylinder 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 mounti...

Page 180: ...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 181: ...e s danger zone WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors HP pump Relief bore check 1 Visually inspect relief bore 1 for fuel dis char...

Page 182: ...acement Special tools Material Spare parts Designation Use Part No Qty Injector Spare Parts Catalog Injector Replacement u Remove injector and install new one Page 183 182 Task Description MS150110 00...

Page 183: ...ue wrench 60 320 Nm F30452768 1 Assembly paste Optimoly Paste White T 40477 1 Grease Kluthe Hakuform 30 10 emulsifier X00058061 1 Engine oil O ring Spare Parts Catalog WARNING Fuels are combustible Ri...

Page 184: ...the injector is drained 3 Provide suitable container to collect escap ing fuel 4 Remove adapter 1 5 Remove screw 2 from hold down clamp 1 6 Install puller 2 on cylinder head 7 Remove injector 1 and ho...

Page 185: ...Prior to installation remove plug 2 Coat injector with assembly paste at the seat of the nozzle retaining nut Note A new sealing ring is included in the scope of delivery of the injector 3 Insert new...

Page 186: ...ating face and thread 2 of hold down clamp 1 with en gine oil 10 Insert screw 2 and use torque wrench to tighten to specified initial tightening torque Name Size Type Lubricant Value Standard Screw M1...

Page 187: ...w M12 Tightening torque Engine oil 100 Nm 10 Nm 14 Tighten adapter 1 with torque wrench to the specified tightening torque Name Size Type Lubricant Value Standard Adapter M18 Tightening torque Engine...

Page 188: ...set the emission certification of the engine be comes invalid 18 Reset CDC parameters and enter injector code IIG Page 249 Final steps 1 Install cylinder head cover Page 179 2 Open fuel supply to engi...

Page 189: ...mentary fuel filter Overview 1 Storage tank 2 Day tank 3 Passive standard prefilter with water separator 4 LP pump 5 Supplementary fuel filter 6 Main engine filter MS150110 00E 2013 10 Task Descriptio...

Page 190: ...ls are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke WARNING High level of engine noise when the engine is running Risk of damage to hear...

Page 191: ...engine is running Risk of damage to hearing Wear ear protectors NOTICE Damage to component Severe material damage For filter replacement with the engine running operate the engine at low engine load T...

Page 192: ...filter 1 using an oil filter wrench 3 Clean sealing surface on filter head 4 Check sealing ring of new filter 1 and coat with fuel 5 Screw on filter 1 and tighten manually 6 Turn three way cock into...

Page 193: ...lters are operational 2 Open threaded vent plugs 1 3 Unlock fuel priming pump 2 screw out handle by turning it counterclockwise 4 Operate fuel priming pump 2 until bubble free fuel emerges from the th...

Page 194: ...f ferential pressure gauge 1 After installation of a new filter element align adjustable pointer 2 with pressure indicating pointer 3 of pressure gauge 1 2 Verify that differential pressure is within...

Page 195: ...cal sparks and ignition sources Do not smoke Draining fuel prefilter 1 Cut out the filter to be replaced A or B 1 Filter A cut out 2 Filter B cut out 2 Open vent plug 1 of filter to be drained 3 Open...

Page 196: ...l until fuel emerges from the vent pipe 3 8 Close vent valve 2 9 Open rotary slide valve 4 a little by ap prox 30 and open vent valve s 2 until fuel emerges from the vent pipe 3 10 Close vent valve s...

Page 197: ...at low power Keep away from the engine s danger zone WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke WARNING High level o...

Page 198: ...ng connection 1 on the suction side of the filter 3 Open vent valve 2 and fill with fuel until fuel emerges from the vent pipe 3 4 Close vent valve 2 5 Open rotary slide valve 4 a little by ap prox 30...

Page 199: ...WARNING Tank is pressurized Risk of eye injuries resulting from fluid escaping under high pressure Open tank slowly Wear goggles or safety mask WARNING Fuels are combustible Risk of fire and explosio...

Page 200: ...per screw using a torque wrench Name Size Type Lubricant Value Standard Screw Tightening torque 40 Nm 10 Connect filling pump to filling connection 1 on the suction side of the filter 11 Open vent val...

Page 201: ...mask WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke Fuel prefilter with water separa tor O ring replacement in rota ry...

Page 202: ...chemical burns Observe the instructions of the cleaning agent manufacturer NOTICE Inappropriate cleaning tool Risk of damage to component Observe manufacturer s instructions Use appropriate cleaning t...

Page 203: ...cooler 5 Remove oil lines 1 6 Loosen clamp 1 7 Remove intake housing 3 with actuating cylinder 2 8 Remove coolant lines 2 from compressor casing 3 9 Remove coolant ventilation line 1 from compressor c...

Page 204: ...essor casing 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 205: ...ing a torque wrench Name Size Type Lubricant Value Standard Clamp Tightening torque 15 Nm 2 Nm 6 Install oil lines 1 Tighten threaded adapter at actuating cylinder to specified torque using a torque w...

Page 206: ...jet at people Always wear safety goggles face mask and ear defenders Charge air cooler Checking condensate drain for water dis charge and obstruction 1 With the engine running check if air emerges fro...

Page 207: ...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 208 2 Reset signal ring of contamination indicator P...

Page 208: ...in the flange of the intake housing 3 and clean it 4 Attach air filter 1 with clamp 2 onto in take housing 3 5 Tighten clamp 2 Air filter with intake silencer 1 Loosen clamp 2 2 Remove air filter 1 an...

Page 209: ...isabled Checking signal ring position 1 If the signal ring is completely visible in the control window 2 replace air filter Page 207 2 After installation of new filter press reset button 1 Result Enga...

Page 210: ...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 248 210 Task Desc...

Page 211: ...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 212 5 Insert dipstick into guide tube up to the st...

Page 212: ...y mask Avoid contact with skin Do not inhale oil vapor Oil change without semirotary hand pump Draining oil via drain plug s on oil pan 1 Provide a suitable container to collect the oil 2 Remove drain...

Page 213: ...tening torque Engine oil 100 Nm 10 Nm Filling with new oil 1 Open cap on filler neck 2 Pour oil in at filler neck up to max mark at oil dipstick 3 Close cap on filler neck 4 Check engine oil level Pag...

Page 214: ...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 215: ...filter by 1 to 2 rotations 2 Drain approx 2 liters engine oil to flush out the oil sludge 3 Drain approx 1 liter engine oil into a clean container 4 Close screw 5 Using the equipment and chemicals in...

Page 216: ...ive clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor NOTICE Damage to component Severe material damage For filter replacement with the engine running operate the...

Page 217: ...0 9 Check oil level Page 211 Oil filter with diverter option Oil filter replacement with the engine running 1 To cut out the filter to be replaced set the three way cock to the corresponding posi tion...

Page 218: ...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 inha...

Page 219: ...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 220: ...ally the following instructions are to be observed Replace all seals with new parts Coat O rings with grease Insert O rings in grooves Pay attention to installation position of fillister head screw to...

Page 221: ...s 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 inte...

Page 222: ...m Findings Action Strainer Metallic residues Clean Monitor engine operation Check strainer daily Notify Service Strainer Damaged Fit new part Square section ring Damaged Fit new part O ring Damaged Fi...

Page 223: ...Catalog Sealing ring Spare Parts Catalog Sealing ring Spare Parts Catalog WARNING Hot oil Oil can contain combustion residues which are harmful to health Risk of injury and poisoning Wear protective...

Page 224: ...and rotor base 10 with sealing ring 9 13 Insert new filter sleeve 6 in rotor tube 7 with the smooth paper surface facing the outer wall 14 Check sealing ring 5 fit new one if neces sary 15 Mount rotor...

Page 225: ...Push standpipe 12 onto rotor lower sec tion 13 13 Insert new filter sleeve 9 with stiffener plate 10 into rotor cap 8 ensuring that the smooth surface of the filter sleeve 9 faces the rotor cap 8 14...

Page 226: ...oling system counterclockwise up to the first stop and allow pressure to escape 2 Continue to turn breather valve counterclockwise and remove 3 Check coolant level coolant must be visible at the botto...

Page 227: ...e Special tools Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 228 2 Fill with engine coolant Page 231 MS150110 00E 2013 10 Task Description...

Page 228: ...2 Switch off preheating unit Engine coolant Draining 1 Turn breather valve on expansion tank for engines with remote heat exchanger the expansion tank is part of the remote cooling system countercloc...

Page 229: ...e on exhaust pipework driv ing end 1 6 Open vent valve on seawater cooler 1 or remote heat exchanger 7 Open drain plug 1 and drain coolant at crankcase MS150110 00E 2013 10 Task Description 229 TIM ID...

Page 230: ...screw 1 and drain coolant on coolant pump elbow Final steps 1 Seal all open vent and drain points 2 Set breather valve onto filler neck and close it 230 Task Description MS150110 00E 2013 10 TIM ID 00...

Page 231: ...e clothing gloves and goggles safety mask NOTICE Cold coolant in hot engine can cause thermal stress Possible formation of cracks in the engine Fill top up coolant only into cold engine Preparatory st...

Page 232: ...faces if required 5 Set breather valve onto filler neck and turn until the first stop 6 Start engine Page 80 7 After 10 seconds of running the engine without load shut down the engine Page 93 8 Turn b...

Page 233: ...of damage to hearing Wear ear protectors HT coolant pump Relief bore check 1 Check relief bore for oil and coolant dis charge 2 Stop engine Operating instructions elec tronic system and disable engine...

Page 234: ...own Wear protective clothing gloves and goggles safety mask WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors Engine coolant Sample extrac tio...

Page 235: ...d to warm up the engine coolant The circulating pump 8 ensures the circulation of the preheated engine coolant through the engine The continuous flow heater 5 comprises a heating element The thermosta...

Page 236: ...eating unit 1 On Off switch Cylinders Nominal voltage frequency Heating power kW 12 V and 16 V 230 V 50 Hz 9 400 V 50 Hz 9 230 V 60 Hz 9 440 V 60 Hz 9 236 Task Description MS150110 00E 2013 10 TIM ID...

Page 237: ...prises a heating element A non return flap 3 prevents coolant from flowing through the preheating unit when the engine is running When the coolant temperature has reached the value of the thermostat s...

Page 238: ...se when the engine is running Risk of damage to hearing Wear ear protectors Raw water pump Relief bore check 1 Check relief bore for oil and coolant dis charge 2 Stop engine Page 93 and disable en gin...

Page 239: ...ed Battery charging generator drive Coupling condition check 1 Remove screws 1 2 Remove protective cover 2 3 Check resilient coupling 3 for cracks and plastic deformation 4 If there is serious deforma...

Page 240: ...gine mounting Check Engine mounting Check Item Findings Action Visually inspect mounts Damage Brittleness Deformation Crack formation Swelling visible Replace contact Service 240 Task Description MS15...

Page 241: ...se 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 241 and disable en gine st...

Page 242: ...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 242 Task Description MS150110 00E 2013 10 TIM ID...

Page 243: ...es Do not smoke Checking differential pressure gauge 1 Switch on fuel treatment system Page 88 2 Set the alarm points at the differential pressure gauge to zero Result Alarm is initiated with preset d...

Page 244: ...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 245: ...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 246: ...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 247: ...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 248: ...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 249: ...set the emission certification becomes invalid Resetting parameters for drift correction CDC with DiaSys 1 Use DiaSys to reset the CDC parameters Dialog system DiaSys E531920 2 If no DiaSys is availab...

Page 250: ...ng 2 2 Check whether both switches 3 are actu ated 3 If switches 3 and or guard plate 1 with engine support 4 is are not installed Screw on guard plate 1 with engine support 4 Then screw on switch 3 e...

Page 251: ...starting disabled Check plug connections on ECU 7 1 Check all connectors on ECU for firm seat ing Ensure that the clips 1 are engaged 2 Check screws 2 of cable clamps on ECU for firm seating Ensure th...

Page 252: ...tarting disabled Checking EMU plug connections 1 Check both connectors on EMU 2 for firm seating Ensure that the clips 1 are engag ed 2 Check screws 3 of cable clamps on EMU 2 for firm seating Ensure...

Page 253: ...ng disabled Checking EIM plug connections 1 Check both Tyco plugs 62 pole 2 on EIM for firm seating Ensure that clips 3 are engaged 2 Check screws 1 of cable clamps on EIM for firm seating Ensure that...

Page 254: ...ntrol Unit from engine 1 Note or mark assignment of cables and connectors 2 Remove all screws 3 3 Undo clips 2 on connectors 4 Remove all male connectors 5 Remove screws 1 6 Take off Engine Control Un...

Page 255: ...ll screws 2 3 Undo clips 3 on connectors 4 Disconnect all connectors 5 Remove screws 1 6 Remove ECU 5 with EMU 4 Removing EMU 1 Unscrew screws on base of EMU 4 2 Remove EMU 4 from ECU 5 Installing EMU...

Page 256: ...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 257: ...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 258: ...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 259: ...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 260: ...Engine management system ECU Engine Control Unit Engine governor EDM Engine Data Module Memory module for engine data EIM Engine Interface Module Interface to engine monitoring system EMU Engine Moni...

Page 261: ...nel PCU Propeller Control Unit PIM Peripheral Interface Module RCS Remote Control System RL Redundancy Lost Alarm Redundant CAN bus failure SAE Society of Automotive Engineers U S standardization orga...

Page 262: ...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 263: ...eck and adjustment Page 176 Filter wrench Part No F30379104 Qty Used in 1 7 6 2 Additional fuel filter Replacement Page 190 Qty Used in 1 7 6 3 Fuel filter Replacement Page 191 Qty Used in 7 13 1 Engi...

Page 264: ...Removal and installation Page 183 MTU test kit Part No 5605892099 00 Qty Used in 1 7 12 3 Engine oil Sample extraction and analysis Page 214 Qty Used in 1 7 14 6 Engine coolant Sample extraction and a...

Page 265: ...efilter with water separator Filter ele ment replacement Page 199 Qty Used in 1 7 7 1 Compressor wheel Cleaning Page 202 Ratchet adapter Part No F30027341 Qty Used in 1 7 12 2 Engine oil Change Page 2...

Page 266: ...mm Part No F30039526 Qty Used in 1 7 3 2 Valve clearance Check and adjustment Page 176 Steam jet cleaner Part No Qty Used in 1 4 18 Plant Cleaning Page 96 Torque wrench 0 5 5 Nm Part No 0015384230 Qty...

Page 267: ...No F30510423 Qty Used in 1 7 6 8 Fuel prefilter with water separator Filter ele ment replacement Page 199 Torque wrench 40 200 Nm Part No F30027337 Qty Used in 1 7 12 2 Engine oil Change Page 212 Tor...

Page 268: ...lacement Page 246 Torque wrench 60 320 Nm Part No F30047446 Qty Used in 1 7 3 2 Valve clearance Check and adjustment Page 176 Torque wrench 60 320 Nm Part No F30452768 Qty Used in 1 7 5 2 Injector Rem...

Page 269: ...30 Differential pressure gauge Check 243 Disengaging From LOP 91 E ECU 7 Installation 254 Removal 254 Emergency engine shutdown Via automation system 89 EMU 8 Installation 255 Removal 255 Engaging Fro...

Page 270: ...Venting 193 Fuel treatment system Putting into operation 85 Shutdown 95 Switching on 88 H Hotline 262 HP pump Filling with engine oil 180 Relief bore check 181 HT coolant pump Relief bore check 233 I...

Page 271: ...ring position check 209 Service partners 262 Spare parts service 262 Starter Condition check 210 Supplementary fuel filter Overview 189 T Tasks After extended out of service periods 82 Tasks after ex...

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MTU 12 V 4000 Mx4, Operating Instructions Manual

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