MTU 12V4000M*3 series Operating Instructions Manual Download Page 7

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10 Appendix B

10.1 Special Tools

272

10.2 Index

279

MS15035/00E 2018-08

| Table of Contents | 5

DCL-ID: 0000051760 - 001

Summary of Contents for 12V4000M*3 series

Page 1: ...Operating Instructions Diesel engine 12V4000Mx3x 16V4000Mx3x MS15035 00E...

Page 2: ...yl 1A continuous operation unrestricted Table 1 Applicability 2018 Copyright MTU Friedrichshafen GmbH This publication is protected by copyright and may not be used in any way whether in whole or in p...

Page 3: ......

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Page 5: ...ng an automatic safety shutdown 97 5 6 Stopping the engine 98 5 7 Operational checks 99 5 8 Emission label Check 100 5 9 Tasks after extended out of service periods 3 weeks 101 5 10 Checks prior to st...

Page 6: ...eplacement 221 8 17 Coolant Circuit General High Temperature Circuit 225 8 17 1 Engine coolant level Check 225 8 17 2 Engine coolant Change 226 8 17 3 Engine coolant Draining 227 8 17 4 Engine coolant...

Page 7: ...10 Appendix B 10 1 Special Tools 272 10 2 Index 279 MS15035 00E 2018 08 Table of Contents 5 DCL ID 0000051760 001...

Page 8: ...ct are prohibited by emission regulations Emission related components must only be serviced ex changed or repaired if the components used for this purpose are approved by the manufacturer Noncomplianc...

Page 9: ...sed military applications other than by US government agen cies Please note the following when replacing components with emission labels The relevant emission labels must be affixed to the spare part...

Page 10: ...ions contained in this manual in particular with regard to the specified tightening torques With the exclusive use of technical personnel trained in commissioning operation maintenance and re pair The...

Page 11: ...ualified personnel only Training at the Training Center of the manufacturer Qualified personnel from the areas mechanical engineering plant construction and electrical engineering and also for work wi...

Page 12: ...ator terminals or cables against accidental contact Check that all connections have been correctly allocated e g polarity fuel line reduction agent line supply return Immediately after putting the pro...

Page 13: ...ids and lubricants immediately or soak up with a suitable binding agent Operation of electrical equipment When electrical equipment is in operation certain components of these appliances are electrica...

Page 14: ...fitted Lock circuit breakers Before starting work on CaPoS if used Switch off the charging system DC DC converter Discharge the UltraCap modules using the appropriate discharger Short circuit the Ult...

Page 15: ...ines near hot components Miscellaneous Sufficient ventilation must be guaranteed during the work Wear a breathing mask offering protection against soot dust and mineral fibers filter class P3 when wor...

Page 16: ...d the pipework at the relevant designated points For hydraulic installation screw on the jig with the piston retracted For hydraulic removal screw on the jig with the piston extended For a hydraulic i...

Page 17: ...rly prior to replacement i e protect them against moisture in particular Package faulty electronic components or assemblies properly before dispatching for repair Moisture proof Shock proof Wrapped in...

Page 18: ...sure that suitable extinguishing agents fire extinguishers are always available and that staff are familiar with their correct handling A fire can result in the creation of toxic substances Always wea...

Page 19: ...s well ventilated Make sure that neighboring work areas are not adversely affected Avoid open flames in the surrounding area No smoking Observe fire prevention regulations Always wear a mask providing...

Page 20: ...Consequences Material damage Remedial action Additional product information Warning notices 1 This manual with all safety instructions and warning notices must be issued to all personnel involved in...

Page 21: ...en weight forklift truck Prior to transporting the engine genset system it is imperative to install the transport locking device for the crankshaft Prior to transporting the engine genset system it is...

Page 22: ...ger installed vertical air intake 1 Maximum permissible diag onal pull 10 2 Center of gravity Max permissible diagonal pull must be observed Max permissible diagonal pull in longitudinal direction is...

Page 23: ...pull must be observed Max permissible diagonal pull in longitudinal direction is 10 degrees simultaneous diagonal pull in trans verse direction is impermissible Max permissible diagonal pull in trans...

Page 24: ...pull must be observed Max permissible diagonal pull in longitudinal direction is 10 degrees simultaneous diagonal pull in trans verse direction is impermissible Max permissible diagonal pull in transv...

Page 25: ...ion is 10 degrees simultaneous diagonal pull in trans verse direction is impermissible Max permissible diagonal pull in transverse direction is 10 degrees simultaneous diagonal pull in longitu dinal d...

Page 26: ...must be reinstalled on both engine sides accord ing to the instructions 3 If the engine is to be moved together with the generator the transport locking device for the generator must also be installe...

Page 27: ...the ring gear 4 Screw in screw 1 in bores of holder 3 until holder 3 is locked in position Note Screw 1 must be tightened stepwise and alternately on both sides of the flywheel housing 5 Tighten scre...

Page 28: ...om the guard plates and engine supports to secure them on the engine u Install engine supports 2 on both sides with guard plates 1 washers 3 and screws 4 and tighten to specified tightening torque tig...

Page 29: ...torques MA are specified for screws of strength class 8 8 surface condition bare phosphatized or galvanized and 10 9 surface condition bare or phosphatized The values in the table are based on a frict...

Page 30: ...s for studs Thread screwed into Steel M A Nm Gray cast iron MA Nm AI alloy MA Nm M6 9 6 6 M8 11 9 10 M10 17 13 13 M12 27 23 18 M14 37 33 33 M16 55 45 MA tightening torques Tightening torques for setsc...

Page 31: ...re based on a friction coefficient tot 0 125 Threads and mating faces of screws and nuts must be coated with engine oil prior to assembly An assembly tolerance of 10 of the figures in the table is per...

Page 32: ...en tightening MA tightening torques Tightening torques for plug screws as per MTN 5183 1 standard This standard applies to plug screws to DIN 908 DIN 910 and DIN 7604 with threaded end to DIN 3852 For...

Page 33: ...Tightening torques for plug screws to DIN 908 DIN 910 and DIN 7604A with short threaded end Thread screwed into Steel gray cast iron MA Nm AI alloy MA Nm M10 x 1 15 15 M12 x 1 5 25 25 M14 x 1 5 35 30...

Page 34: ...el gray cast iron M A Nm AI alloy MA Nm M8 x 1 10 10 M22 x 1 5 80 65 M26 x 1 5 105 90 M30 x 1 5 130 130 M38 x 1 5 140 120 M45 x 1 5 160 140 MA tightening torques Tightening torque for banjo screws as...

Page 35: ...ons during the tightening process Tightening torques for steel banjo screws Thread inserted in steel gray cast iron aluminum alloy MA Nm M8 x 1 10 M10 x 1 15 M12 x 1 5 20 M14 x 1 5 25 M16 x 1 5 25 M18...

Page 36: ...nd oiled or galvanized Threads and mating faces beneath heads must be coated with engine oil prior to assembly An assembly tolerance of 10 of the figures in the table is permitted due to unavoidable d...

Page 37: ...ng the union nut firmly by hand noticeable increase in force it should be tightened another 1 4 turn 90 past this point Tightening torques for spigot unions with O ring to ISO 6149 2 Thread Torque Nm...

Page 38: ...n valves see ISO 6149 47 and ISO 7789 Tightening torques for screwed plugs with O ring as per ISO 6149 3 Thread Torque Nm 10 M8 x 1 8 M10 x 1 15 M12 x 1 5 25 M14 x 1 5 35 M16 x 1 5 40 M18 x 1 5 45 M22...

Page 39: ...ORFS fittings In contrast to the instructions for pipe unions hose fittings with sealing heads and the matching adapters must be fitted and connected as follows Hose fitting metallic sealing with unio...

Page 40: ...2 35 290 M52 x 2 38 42 330 Sealing head with BSP union nut BSPP thread Torque Nm G1 4 20 G3 8 34 G1 2 60 G5 8 69 G3 4 115 G1 140 G1 1 4 210 G1 1 2 290 G2 400 SAE sealing cone with union nut JIC 37 UNF...

Page 41: ...e Torque Nm 9 16 18 4 14 2 11 16 16 6 24 3 13 16 16 8 43 4 1 14 10 60 8 1 3 16 12 12 90 5 1 3 16 12 14 90 5 1 7 16 12 16 125 10 1 11 16 12 20 170 20 2 12 24 200 25 2 1 2 20 32 460 30 MS15035 00E 2018...

Page 42: ...ccordance with DIN ISO 1204 as viewed from driving end 4 For cylinder designation in accordance with DIN ISO 1204 the letter Ax refers to the cylinders on the left hand side of the engine 1 and letter...

Page 43: ...ternal engine coolant controlled charge air cooling The right hand exhaust turbocharger is cut in and cut out on 12V and 16V engines with electronically controlled hydraulically actu ated flaps Coolin...

Page 44: ...via M threaded pins 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 Emergency s...

Page 45: ...on and or carbon particle deposits in the engine it is rec ommended to carry out a cleaning cycle for at least 20 minutes after extended low load operation periods During the cleaning cycle engine spe...

Page 46: ...ead The pressure is so greatly reduced by this and the faulty sealing ring 1 that any leakage is not under pres sure Plug in pipe union b The sleeve 3 covers the joint to prevent lateral spray Only le...

Page 47: ...ine 19 Ball type seal area 20 Leak fuel connection The HP fuel line is sealed by the thrust ring 8 In case of leakage around the thrust ring 8 or the HP line 5 fuel escapes into the leakage chamber Th...

Page 48: ...7 Exhaust outlet 8 Air pipe to charge air cooler 9 Charge air cooler 10 Recirculation line 11 Exhaust manifold 12 Engine mounting 13 Charge air line 14 Oil pan 15 Oil filler neck 16 Crankcase 17 Cyli...

Page 49: ...e air filter 9 Exhaust turbocharger 10 Exhaust outlet 11 Air pipe to charge air cooler 12 Recirculation line 13 Exhaust manifold 14 Charge air cooler 15 Charge air line 16 Engine mounting 17 Oil pan 1...

Page 50: ...ther 7 Dry type air filter 8 Exhaust manifold 9 Recirculation line 10 Exhaust turbocharger 11 Exhaust outlet 12 Air pipe to charge air cooler 13 Charge air cooler 14 Engine mounting 15 Charge air line...

Page 51: ...5 Charge air line 16 Engine mounting 17 Oil pan 18 Oil filler neck 19 Crankcase 20 Cylinder head 21 Fuel filter 22 Oil filter 23 HP fuel pump 24 Battery charging generator 25 Bilge pump option 26 Raw...

Page 52: ...engine side 12V4000Mx3 1 B50 P Crankcase 2 B3 T Intake air 3 B44 1 N Turbocharger A 4 B10 P Charge air 5 B34 3 fuel pressure before filter only if supplementary fuel filter is fitted 6 B34 2 P Fuel b...

Page 53: ...optional 4 B5 3 lube oil pressure be fore filter 5 B5 1 P Lube oil after filter 6 B48 P Fuel in common rail 7 B1 N Camshaft 8 B54 oil refill pump pres sure optional 9 B6 2 coolant temperature optiona...

Page 54: ...Right engine side 12V4000Mx3 1 B44 2 N Turbocharger B 2 Y27 turbocharger control valve 3 B16 P Coolant 4 B9 T Charge Air 52 General Information MS15035 00E 2018 08 TIM ID 0000012941 004...

Page 55: ...x3 1 B4 21 T Exhaust A side 2 B4 22 T Exhaust B bank 3 B13 N Crankshaft 4 S37 2 S Safety switch 5 S37 1 S Safety switch 6 B13 2 N Crankshaft speed optional MS15035 00E 2018 08 General Information 53 T...

Page 56: ...urbocharger A 2 B49 Y26 T Charge air be fore recirculation valve recirculation valve A 3 B4 T Individual exhaust temperature A1 A6 B1 B6 optional 4 B5 9 P Lube oil before tur bocharger B 54 General In...

Page 57: ...la tion valve recirculation valve A 3 B3 T Intake air 4 B44 1 N Turbocharger A 5 B10 P Charge air 6 B34 3 fuel pressure before filter only if supplementary fuel filter is fitted 7 B34 2 P Fuel before...

Page 58: ...fter filter optional 4 B5 1 P Lube oil after filter 5 B5 3 P Lube oil before fil ter 6 B1 N Camshaft 7 B54 P Oil refill pump op tional 8 B6 2 T Coolant tempera ture optional 9 B6 T Coolant 10 XD1 conn...

Page 59: ...ne side 12V4000Mx3 1 B44 2 N Turbocharger B 2 Y27 turbocharger control valve 3 B16 P Coolant 4 B21 raw water pressure optional 5 B9 T Charge Air MS15035 00E 2018 08 General Information 57 TIM ID 00000...

Page 60: ...0Mx3 1 B4 21 T Exhaust A side 2 B4 22 T Exhaust B bank 3 B13 N Crankshaft 4 S37 2 S Safety switch 5 S37 1 S Safety switch 6 B13 2 N Crankshaft op tional 58 General Information MS15035 00E 2018 08 TIM...

Page 61: ...B5 8 P Lube before exhaust turbocharger A 2 B4 cylinder exhaust tem perature A1 A6 B1 B6 op tional 3 F33 H Coolant 4 B5 9 P Lube oil before tur bocharger B MS15035 00E 2018 08 General Information 59...

Page 62: ...engine side 16V4000Mx3 1 B50 P Crankcase 2 B3 T Intake air 3 B44 1 N Turbocharger A 4 B10 P Charge air 5 B34 3 fuel pressure before filter only if supplementary fuel filter is fitted 6 B34 2 P Fuel b...

Page 63: ...ter optional 4 B5 3 P Lube oil before fil ter 5 B5 1 P Lube oil after filter 6 B48 P Fuel in common rail 7 B1 N Camshaft 8 B54 P Oil refill pump op tional 9 B6 2 T Coolant optional 10 B6 T Coolant 11...

Page 64: ...Right engine side 16V4000Mx3 1 B44 2 N Turbocharger B 2 Y27 turbocharger control valve 3 B16 P Coolant 4 B9 T Charge Air 62 General Information MS15035 00E 2018 08 TIM ID 0000018445 005...

Page 65: ...0Mx3 1 B4 21 T Exhaust A side 2 B4 22 T Exhaust B bank 3 B13 N Crankshaft 4 S37 2 S Safety switch 5 S37 1 S Safety switch 6 B13 2 N Crankshaft op tional MS15035 00E 2018 08 General Information 63 TIM...

Page 66: ...turbocharger A 2 B49 Y26 T Charge air be fore recirculation valve recirculation valve A 3 B4 cylinder exhaust tem perature A1 A6 B1 B6 op tional 4 B5 9 P Lube oil before tur bocharger B 64 General Inf...

Page 67: ...circula tion valve recirculation valve A 3 B3 T Intake air 4 B44 1 N Turbocharger A 5 B10 P Charge air 6 B34 3 fuel pressure before filter only if supplementary fuel filter is fitted 7 B34 2 P Fuel be...

Page 68: ...e oil after filter optional 4 B5 1 P Lube oil after filter 5 B5 3 P Lube oil before fil ter 6 B1 N Camshaft 7 B54 P Oil refill pump op tional 8 B6 2 T Coolant optional 9 B6 T Coolant 10 XD1 connector...

Page 69: ...ne side 16V4000Mx3 1 B44 2 N Turbocharger B 2 Y27 turbocharger control valve 3 B16 P Coolant 4 B21 raw water pressure optional 5 B9 T Charge Air MS15035 00E 2018 08 General Information 67 TIM ID 00000...

Page 70: ...0Mx3 1 B4 21 T Exhaust A side 2 B4 22 T Exhaust B side 3 B13 N Crankshaft 4 S37 2 S Safety switch 5 S37 1 S Safety switch 6 B13 2 N Crankshaft op tional 68 General Information MS15035 00E 2018 08 TIM...

Page 71: ...B5 8 P Lube before exhaust turbocharger A 2 B4 cylinder exhaust tem perature A1 A6 B1 B6 op tional 3 F33 H Coolant 4 B5 9 P Lube oil before tur bocharger B MS15035 00E 2018 08 General Information 69...

Page 72: ...Module applies to this product type Actual value must be greater than the specified value Actual value must be smaller than the specified value Insufficiently guaranteed value tolerance 10 Insufficien...

Page 73: ...IMO Tier II Marpol convention EU nonroad St IIIA 97 68 EC IMO Tier I Marpol Comp IMO Tier II Marpol Comp EPA Marine T2 Comp 40CFR94 Reference conditions ID 1 2 3 4 Intake air temperature C 25 25 45 4...

Page 74: ...ating pressure before en gine to R bar 6 3 6 3 6 3 6 3 Lube oil operating pressure low idle meas point before engine R bar 2 5 2 5 2 5 2 5 Fuel system ID 1 2 3 4 Fuel pressure at engine inlet connecti...

Page 75: ...verse inclination continuous max option max operating inclinations L Degrees 15 15 15 15 Transverse inclination temporary max option max operating inclinations L Degrees 22 5 22 5 22 5 22 5 Capacities...

Page 76: ...p 1 m distance ISO 6798 3 dB A tolerance R dB A 106 106 106 106 Engine surface noise with attenuated in take noise filter BL free field sound power level Lp 1 m distance ISO 6798 2 dB A tolerance R dB...

Page 77: ...plies to this product type Actual value must be greater than the specified value Actual value must be smaller than the specified value Insufficiently guaranteed value tolerance 10 Insufficiently guara...

Page 78: ...IMO Tier II Marpol convention EU nonroad St IIIA 97 68 EC IMO Tier I Marpol Comp IMO Tier II Marpol Comp EPA Marine T2 Comp 40CFR94 Reference conditions ID 1 2 3 4 Intake air temperature C 25 25 45 4...

Page 79: ...ine to R C 94 94 95 95 Lube oil operating pressure before en gine from R bar 5 3 5 3 5 3 5 3 Lube oil operating pressure before en gine to R bar 6 3 6 3 6 3 6 3 Lube oil operating pressure low idle me...

Page 80: ...tions L Degrees 15 15 15 15 Longitudinal inclination temporary max driving end up option max operating in clinations L Degrees 17 5 17 5 17 5 17 5 Transverse inclination continuous max option max oper...

Page 81: ...ntenance W5 R kg 460 460 460 460 Sound ID 1 2 3 4 Exhaust noise unsilenced BL free field sound pressure level Lp 1 m distance ISO 6798 3 dB A tolerance R dB A 107 107 107 107 Engine surface noise with...

Page 82: ...plies to this product type Actual value must be greater than the specified value Actual value must be smaller than the specified value Insufficiently guaranteed value tolerance 10 Insufficiently guara...

Page 83: ...IMO Tier II Marpol convention EU nonroad St IIIA 97 68 EC IMO Tier I Marpol Comp IMO Tier II Marpol Comp EPA Marine T2 Comp 40CFR94 Reference conditions ID 1 2 3 4 Intake air temperature C 25 25 45 4...

Page 84: ...ating pressure before en gine to R bar 6 3 6 3 6 3 6 3 Lube oil operating pressure low idle meas point before engine R bar 2 5 2 5 2 5 2 5 Fuel system ID 1 2 3 4 Fuel pressure at engine inlet connecti...

Page 85: ...verse inclination continuous max option max operating inclinations L Degrees 15 15 15 15 Transverse inclination temporary max option max operating inclinations L Degrees 22 5 22 5 22 5 22 5 Capacities...

Page 86: ...Sound ID 1 2 3 4 Exhaust noise unsilenced BL free field sound pressure level Lp 1 m distance ISO 6798 3 dB A tolerance R dB A 111 111 111 111 84 Technical Data MS15035 00E 2018 08 TIM ID 0000018491 0...

Page 87: ...plies to this product type Actual value must be greater than the specified value Actual value must be smaller than the specified value Insufficiently guaranteed value tolerance 10 Insufficiently guara...

Page 88: ...IMO Tier II Marpol convention EU nonroad St IIIA 97 68 EC IMO Tier I Marpol Comp IMO Tier II Marpol Comp EPA Marine T2 Comp 40CFR94 Reference conditions ID 1 2 3 4 Intake air temperature C 25 25 45 4...

Page 89: ...ating pressure before en gine to R bar 6 3 6 3 6 3 6 3 Lube oil operating pressure low idle meas point before engine R bar 2 5 2 5 2 5 2 5 Fuel system ID 1 2 3 4 Fuel pressure at engine inlet connecti...

Page 90: ...ransverse inclination continuous max option max operating inclinations L Degrees 15 15 15 15 Transverse inclination temporary max option max operating inclinations L Degrees 22 5 22 5 22 5 22 5 Capaci...

Page 91: ...ound ID 1 2 3 4 Exhaust noise unsilenced BL free field sound pressure level Lp 1 m distance ISO 6798 3 dB A tolerance R dB A 110 110 110 110 MS15035 00E 2018 08 Technical Data 89 TIM ID 0000010816 003...

Page 92: ...4 5 Firing order Cylinders Firing order 12V A1 B5 A5 B3 A3 B6 A6 B2 A2 B4 A4 B1 16V A1 A7 B4 B6 A4 B8 A2 A8 B3 B5 A3 A5 B2 A6 B1 B7 90 Technical Data MS15035 00E 2018 08 TIM ID 0000023263 003...

Page 93: ...50 mm approx 2071 mm 16V 4000 M53 63 approx 3108 mm approx 1690 mm approx 1850 mm approx 2064 mm With engine mounted heat exchanger Engine model Length A Width B without silencer Width B with si lence...

Page 94: ...448 mm 16V 4000 M53 63 approx 3108 mm approx 1613 mm approx 2361 mm approx 2441 mm With engine mounted heat exchanger Engine model Length A Width B Height C without silencer Height C with si lencer 12...

Page 95: ...5 Operation 5 1 Controls Automation system controls Refer to automation system operating instructions MS15035 00E 2018 08 Operation 93 TIM ID 0000016959 003...

Page 96: ...gn adjustable pointer with position of pressure indicator Page 189 HP fuel pump Only for engines without oil priming pump Fill HP fuel pump with fresh engine oil Page 171 Raw water pump if located abo...

Page 97: ...Check coolant level Page 225 Coolant system Preheat coolant with preheating unit Fuel prefilter Drain Page 190 Check that suction side pressure indicated at the fuel prefilter pressure gauge is withi...

Page 98: ...5 4 Starting the engine Start the engine via the automation system Refer to automation system operating instructions 96 Operation MS15035 00E 2018 08 TIM ID 0000017525 003...

Page 99: ...ified or eliminated contact Service Note If an engine has been shutdown by a fault red alarm the engine may only be re started when the fault has been identified and eliminated Procedure following an...

Page 100: ...5 6 Stopping the engine Stopping the engine via the automation system Refer to automation system operating instructions 98 Operation MS15035 00E 2018 08 TIM ID 0000017528 004...

Page 101: ...nd exhaust color Page 115 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 indicator control wind...

Page 102: ...emission label for intactness 3 Check that emission label is fully legible 4 Check content of emission label Does the label on the engine match the label document in the Business Portal Equipment Does...

Page 103: ...ks Tasks after extended out of service periods 3 weeks Note Operate fuel treatment system for at least 5 minutes 1 Start up fuel treatment system Page 103 2 Shut down fuel treatment system Page 107 MS...

Page 104: ...ves 4 Switch on fuel treatment system Page 106 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...

Page 105: ...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 fu...

Page 106: ...speed 4 Close 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...

Page 107: ...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 admissible limits and engine operation...

Page 108: ...re switching on ensure that all housings are closed Before switching on ensure that no work is in progress anywhere on the entire system Fuel treatment system Switching on 1 Carry out checks prior to...

Page 109: ...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 110: ...ystem to an extremely high load Risk of overheating damage to components Trigger an emergency stop only in emergency situations Emergency stop 1 Refer to automation system operating instructions 2 Fol...

Page 111: ...entration is insufficient for the engine room temperature antifreeze concentration is 50 and engine room temperature is below 40 C Raw water only on engines with engine mounted heat exchanger Drain if...

Page 112: ...un directly at seals or electronic components such as connectors or ECUs Cleaning the plant 1 Carry out plant cleaning only in areas where an appropriate oil separator is provided environmental protec...

Page 113: ...place fuel injectors Page 174 W1008 X Fit new engine oil filters each time the engine oil is changed or at the latest on expiry of the time limit given in years Page 219 W1009 Check thickness of oil r...

Page 114: ...asks W1713 Injector reset drift compensation parameters CDC Page 268 W1864 X Check and clean oil indicator filter Page 216 Table 2 Maintenance task reference table QL1 112 Maintenance MS15035 00E 2018...

Page 115: ...005 X Fit new air filters Page 207 W1006 Replace fuel injectors Page 174 W1008 X Fit new engine oil filters each time the engine oil is changed or at the latest on expiry of the time limit given in ye...

Page 116: ...s W1675 X Fit new fuel prefilter or new fuel prefilter insert W1713 Injector reset drift compensation parameters CDC Page 268 Table 3 Maintenance task reference table QL1 114 Maintenance MS15035 00E 2...

Page 117: ...y and re start the system by actuating the key switch Engine blocked engine cannot be barred manually u Contact Service Engine turns on starting but does not fire Cause Corrective action Poor rotation...

Page 118: ...dicator Page 209 Intercooler dirty u Contact Service Exhaust turbocharger faulty u Contact Service Coolant leaks at intercooler Cause Corrective action Intercooler leaking major coolant discharge u Co...

Page 119: ...t gas Cause Corrective action Engine is not at operating temperature u Run engine to reach operating temperature Intercooler leaking u Contact Service MS15035 00E 2018 08 Troubleshooting 117 TIM ID 00...

Page 120: ...s equipped 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...

Page 121: ...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 122: ...ilure ZKP Number 1 8004 204 Cause Corrective action ETC2 could not be cut in 1 Reduce power 2 Contact Service 81 AL Rail Leakage ZKP Number 1 8004 046 Cause Corrective action Pressure gradient in rail...

Page 123: ...lace as necessary 2 Error cleared after restarting the engine 202 SD T Fuel ZKP Number 1 8004 572 Cause Corrective action Coolant temperature sensor faulty Short circuit or wire break 1 Check sensor a...

Page 124: ...bling B4 22 replace as necessary 208 SD P Charge Air ZKP Number 1 8004 566 Cause Corrective action Charge air pressure sensor faulty Short circuit or wire break 1 Check sensor and cabling B10 replace...

Page 125: ...Check sensor and cabling B48 replace as necessary 2 Error cleared after restarting the engine 216 SD T Lube Oil ZKP Number 1 8004 575 Cause Corrective action Lube oil temperature sensor faulty Short...

Page 126: ...ror cleared after restarting the engine 227 SD P Lube Oil before Filter ZKP Number 1 8004 620 Cause Corrective action Sensor for lube oil pressure before filter faulty Short circuit or wire break 1 Ch...

Page 127: ...Error cleared after restarting the engine 233 SD Charger 2 Speed ZKP Number 1 3011 129 Cause Corrective action Speed sensor of secondary turbocharger faulty Short circuit or wire break 1 Check sensor...

Page 128: ...ed after restarting the engine 301 AL Timing Cylinder A1 ZKP Number 1 8004 500 Cause Corrective action Time of flight measuring fault of injector in cylinder A1 Time of flight measured value extremely...

Page 129: ...ctive action Time of flight measuring fault of injector in cylinder A6 Time of flight measured value extremely low or extremely high u If alarm occurs frequently replace solenoid valve of injector 307...

Page 130: ...510 Cause Corrective action Time of flight measuring fault of injector B1 Time of flight measured value extremely low or extremely high u If alarm occurs frequently replace solenoid valve of injector...

Page 131: ...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 replace solenoid valve of injector 317 AL Ti...

Page 132: ...leared after restarting the engine 322 AL Wiring Cylinder A2 ZKP Number 1 8004 521 Cause Corrective action Short circuit in injector cabling to cylinder A2 Result Misfiring 1 Rectify injector solenoid...

Page 133: ...by exchanging injectors 2 Error cleared after restarting the engine 328 AL Wiring Cylinder A8 ZKP Number 1 8004 527 Cause Corrective action Short circuit in injector cabling to cylinder A8 Result Misf...

Page 134: ...by exchanging injectors 2 Error cleared after restarting the engine 334 AL Wiring Cylinder B4 ZKP Number 1 8004 533 Cause Corrective action Cabling fault in injector cabling to cylinder B4 Result Mis...

Page 135: ...s 2 Error cleared after restarting the engine 340 AL Wiring Cylinder B10 ZKP Number 1 8004 539 Cause Corrective action Cabling fault in injector cabling to cylinder B10 Result Misfiring 1 Rectify inje...

Page 136: ...jector replacement 2 Error clearance After each working cycle 346 AL Open Load Cylinder A6 ZKP Number 1 8004 545 Cause Corrective action Disruption fault in injector cabling to cylinder A6 Result Misf...

Page 137: ...by replacing the injector 2 Error clearance After each working cycle 352 AL Open Load Cylinder B2 ZKP Number 1 8004 551 Cause Corrective action Disruption fault in injector cabling to cylinder B2 Res...

Page 138: ...y replacing the injector 2 Error clearance After each working cycle 358 AL Open Load Cylinder B8 ZKP Number 1 8004 557 Cause Corrective action Disruption fault in injector cabling to cylinder B8 Resul...

Page 139: ...essages e g cabling faults 363 AL Stop Power Stage ZKP Number 1 8004 560 Cause Corrective action Internal electronic fault electronics possibly faulty If bit 1 1020 021 Power Stage Failure Stop Engine...

Page 140: ...utput 3 TO 3 u Check wiring of charger valve 2 marine engine 374 AL Wiring TO 4 ZKP Number 1 8004 637 Cause Corrective action Short circuit or wire break on transistor output 4 TO 4 u Check wiring of...

Page 141: ...temperature sensor faulty Short circuit or wire break u Check sensor and cabling B3 replace as necessary 444 SD U PDU ZKP Number 1 8004 578 Cause Corrective action Injector power stage sensor defect I...

Page 142: ...circuit or wire break u Check sensor and cabling replace as necessary 471 SD Coil Current ZKP Number 1 8004 592 Cause Corrective action Control of HP fuel control block faulty Short circuit or wire br...

Page 143: ...y Short circuit or wire break u Check sensor and cabling B4 24 replace as necessary 492 AL ETC4 CutIn Failure ZKP Number 1 8004 202 Cause Corrective action ETC4 could not be cut in u Check control val...

Page 144: ...4500 903 Cause Corrective action The battery charging generator does not charge the battery u Check battery charging generator and cabling 504 AL CAN POM node Lost ZKP Number 1 4500 904 Cause Correct...

Page 145: ...ion Redundant lube oil pressure sensor faulty Short circuit or wire break u Check sensor and cabling replace as necessary 526 SD T Coolant R2 ZKP Number 1 8004 639 Cause Corrective action Redundant co...

Page 146: ...after the emergency stop signal was output u The delay between the emergency stop signal and this alarm signal is set in parameter 1 1005 4 588 SD P Oil Refill Pump ZKP Number 1 0159 910 Cause Correc...

Page 147: ...y 625 SD P Fuel before Prefilter ZKP Number 1 8004 600 Cause Corrective action Analog input signal for pressure before prefilter faulty Short circuit or wire break 1 Check pressure sensor and cabling...

Page 148: ...y Shield A5 735233000101 18 Shield A6 735233000102 2 Shield A7 735233000103 3 Shield A8 735233000104 4 Shield B2 735233000200 2 Shield B4 735233000202 1 Shield B6 735233000204 2 Shield E5 735233000500...

Page 149: ...down to ambient temperature Special tools Material Spare parts Designation Use Part No Qty Oil filter shield X00040625 5 Shield for switchable oil filter X00040625 4 Installing SOLAS shield 1 Pinpoin...

Page 150: ...ve connections ensure that escaping fluid can flow out without pressure Page 157 Fuel system fuel lines with fuel pressure 1 8 bar Item Type of shielding Installation location 1 Shield A8 After LP fue...

Page 151: ...r only with great difficulty following assembly of the air pipework and or fuel filters Item Type of shielding Installation location 1 Shield E5 Fuel line on HP pump 2 Shield E5 Fuel line downstream o...

Page 152: ...mbly line This location is no longer accessible or only with great difficulty following assembly of the air pipework Lube oil system oil lines with oil pressures exceeding 1 8 bar Item Type of shieldi...

Page 153: ...ng A5 Switching cylinder air flap ETC B1 2 3 x shielding A5 T adapter for flap control ETC B1 Item Type of shielding Installation location 1 5 x shielding A5 Distributor piece 2 2 x shielding A5 Oil r...

Page 154: ...Oil line to ETC 2 Shield A5 Oil line to flap control 3 Shield A5 Oil line to recirculation valve 4 2 x shielding E5 Oil line from main gallery These shields must be installed on the assembly line The...

Page 155: ...lding Installation location 1 2 x shielding A5 Air recirculation valve Item Type of shielding Installation location 1 Shield A6 Oil supply line to HP pump on HP pump MS15035 00E 2018 08 SOLAS 153 TIM...

Page 156: ...n equipment carrier This shield must be installed on the assembly line Assembly in this position is no longer possible after painting Item Type of shielding Installation location 1 Shield A6 ETC oil s...

Page 157: ...f shielding Installation location 1 Shield B2 Oil line on equipment carrier 2 Shield B2 Oil line on pressure reducing valve This shield must be installed on the assembly line Assembly in this position...

Page 158: ...Item Type of shielding Installation location 1 Cover Oil easy change fuel filter 156 SOLAS MS15035 00E 2018 08 TIM ID 0000069196 002...

Page 159: ...ealing cone unions Note For installation positions of sealing cone un ions see Page 148 1 Wrap three layers of adhesive tape from the middle of the sealing cone union to area A for at least 30 mm ensu...

Page 160: ...gine parts Risk of crushing danger of parts of the body being caught or pulled in Before barring the engine make sure that there are no persons in the engine s danger zone After finishing work on the...

Page 161: ...o barring device 2 Note No resistance other than compression resist ance must be encountered 4 Rotate crankshaft in engine direction of rota tion Result If the resistance exceeds the normal com pressi...

Page 162: ...8 2 2 Barring engine with starting system Barring using the automation system Refer to automation system operating instructions 160 Engine MS15035 00E 2018 08 TIM ID 0000017532 004...

Page 163: ...top piston ring and bottom edge of carbon scraper ring First signs of marks left by top piston ring Bright mark on entire circumference Faultless even honing pattern First signs of marks left by lowe...

Page 164: ...epending on findings Do not take any action or carry out a further endoscopic examination as part of maintenance work or contact Service cylinder liner must be replaced Final steps 1 Install injector...

Page 165: ...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 interrup...

Page 166: ...ks 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 inspectio...

Page 167: ...substances which are harmful to health Risk of injury and poisoning Allow the product to cool to below 50 C before beginning work Wear protective clothing protective gloves and goggles safety mask Av...

Page 168: ...Spare parts Designation Use Part No Qty Engine oil Valve gear Lubrication 1 Remove cylinder head covers Page 170 2 Fill oil chambers of valve bridges with oil 3 Fill oil chambers of rocker arms and ad...

Page 169: ...349603 1 Torque wrench 60 320 Nm F30452768 1 Socket wrench 24 mm F30039526 1 Engine oil Preparatory steps 1 Remove cylinder head covers Page 170 2 Install barring device Page 158 Note The pointer 1 is...

Page 170: ...umference if applica ble 4 Additional OT A1 1 marking on the outer circumference of flywheel must not be used Diagram for 12V engines two crankshaft positions Diagram for 16V engines two crankshaft po...

Page 171: ...d rocker arm 5 If the deviation from the reference value exceeds 0 1 mm adjust valve clearance Adjusting valve clearance 1 Loosen locknut 1 2 Insert feeler gage 3 between valve bridge and rocker arm N...

Page 172: ...s 3 4 with washers 2 5 3 Take off cylinder head cover with O ring 6 from cylinder head 7 Installing cylinder head cover 1 Clean installation surface 2 Check O ring 6 for damage replace as necessary 3...

Page 173: ...y through swallowing risk of poisoning through inhalation irritation to eyes and skin Seek medical attention immediately do not induce vomiting Do not inhale vapors or mist Wear protective clothing pr...

Page 174: ...box 2 Use fuel suction device to fill HP pump with 2 liters of clean engine oil 3 Screw in union 1 and use torque wrench to tighten to specified tightening torque Name Size Type Lubricant Value Standa...

Page 175: ...oad only Keep clear of the danger zone of the engine WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors HP fuel pump checking relief bore 1 Vis...

Page 176: ...eplacement Special tools Material Spare parts Designation Use Part No Qty Injector Spare Parts Catalog Replacing injector u Remove injector and install new injector Page 175 174 Injection Valve Inject...

Page 177: ...losive Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke Wear protective clothing protective gloves and safety glasses facial protection WARNING Liquid o...

Page 178: ...of components Damage to component Observe manufacturer s instructions Check components for special cleanliness Preparatory steps 1 Allow HP system to cool down 2 Shut off fuel supply to engine 3 Remov...

Page 179: ...ion removal jig and take off hold down clamp 11 Remove installation removal jig Note The sealing ring 4 for sealing the combus tion chamber must only be used once 12 Remove sealing ring 4 from injecto...

Page 180: ...HP line only before in stallation of the adapter 3 Remove seal plug Note The damper ring is already in place for new assembly Coat damper ring with assembly compound 4 Fit damper ring 1 on injector a...

Page 181: ...Use torque wrench to tighten screw 2 to specified tightening torque Name Size Type Lubricant Value Standard Screw M12 Tightening torque Engine oil 100 Nm 10 Nm 16 Use torque wrench to tighten adapter...

Page 182: ...angle of rotation and without releasing the tool tighten immediately again to the specified tightening torque following the same sequence Tightening sequence 1 Adapter 4 2 Rail 6 Name Size Type Lubri...

Page 183: ...will void the emissions certification of the engine u Reset drift compensation CDC with DiaSys Dialog system DiaSys E531920 If DiaSys is not available contact Service Final steps 1 Install cylinder he...

Page 184: ...al injury through swallowing risk of poisoning through inhalation irritation to eyes and skin Seek medical attention immediately do not induce vomiting Do not inhale vapors or mist Wear protective clo...

Page 185: ...el priming pump 2 until bubble free fuel emerges from the threaded vent plugs 1 5 Close threaded vent plugs 1 6 Screw in handle by turning it clockwise 7 Verify that fuel priming pump 2 is locked Hand...

Page 186: ...fuel filter Overview 1 Storage tank 2 Day tank 3 Passive fuel prefilter with water separator 4 LP pump 5 Additional fuel filter switch able 6 Main engine filter switcha ble 184 Fuel Filter MS15035 00...

Page 187: ...gh 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 engine running opera...

Page 188: ...Remove the cut out oil filter 2 using an oil filter wrench 3 Clean sealing surface on filter head 4 Check sealing ring of new filter 2 and coat with fuel 5 Screw on filter 2 and tighten manually 6 Tu...

Page 189: ...losive Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke Wear protective clothing protective gloves and safety glasses facial protection WARNING High lev...

Page 190: ...same way 9 Vent fuel system Replacing fuel filter with the en gine running 1 Cut out the filter to be replaced B Left hand filter cut out C Right hand filter cut out 2 Unscrew cut out easy change filt...

Page 191: ...tial pressure gage 1 When putting the new filter element into op eration Align adjustable pointer 2 with pressure indicating pointer 3 of pressure gage 1 2 Verify that differential pressure is within...

Page 192: ...iately do not induce vomiting Do not inhale vapors or mist Wear protective clothing protective gloves and safety glasses If contact is made with skin wash off with water and soap WARNING Fuels are com...

Page 193: ...e valve 2 a little turning to approx 30 to introduce fuel into the filter housing with the new filter element 7 Close vent valve 1 as soon as fuel emerges from vent pipe 4 8 Turn the rotary slide valv...

Page 194: ...n Seek medical attention immediately do not induce vomiting Do not inhale vapors or mist Wear protective clothing protective gloves and safety glasses If contact is made with skin wash off with water...

Page 195: ...ded vent plug 1 and drain valve 2 5 Open rotary slide valve 2 a little turning to approx 30 to introduce fuel into the filter housing with the new filter element 6 Close vent valves 1 as soon as fuel...

Page 196: ...hrough swallowing risk of poisoning through inhalation irritation to eyes and skin Seek medical attention immediately do not induce vomiting Do not inhale vapors or mist Wear protective clothing prote...

Page 197: ...osen screws 1 and 2 7 Turn filter housing aside around screw 2 un til filter element is accessible 8 Remove filter element 5 with spring 6 9 Insert a new filter element in the filter hous ing 10 Inser...

Page 198: ...g with the new filter element 14 Close vent valve 1 as soon as fuel emerges from vent pipe 4 15 Turn the rotary slide valve to the upright posi tion 3 until it engages Result Both filters are cut in 1...

Page 199: ...ly do not induce vomiting Do not inhale vapors or mist Wear protective clothing protective gloves and safety glasses If contact is made with skin wash off with water and soap WARNING Fuels are combust...

Page 200: ...ided in the relevant safety data sheet Wear protective gear as specified in the relevant safety data sheet NOTICE Inappropriate cleaning tool Risk of damage to component Observe manufacturer s instruc...

Page 201: ...5 Remove oil lines 2 6 Loosen clamp 1 7 Remove intake housing 3 with actuating cyl inder 2 8 Remove coolant lines 1 from compressor housing 3 9 Remove coolant ventilation line 2 from com pressor housi...

Page 202: ...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 hous ing compressor housin...

Page 203: ...using a torque wrench Name Size Type Lubricant Value Standard Clamp Tightening torque 15 Nm 2 Nm 6 Install oil lines 2 Tighten threaded adapter at actuating cylinder to specified torque using a torque...

Page 204: ...lter Page 208 3 Seal all openings with suitable covers 4 Remove charge air pipework 1 from exhaust turbocharger to intercooler 5 Remove oil lines 2 6 Loosen clamp 1 7 Remove intake housing 3 with actu...

Page 205: ...Do not use wire brushes scrapers or similar tools for cleaning 1 Clean compressor housing with a smooth paint brush or brush 2 Clean compressor wheel 2 and bearing housing 1 3 Thoroughly remove clean...

Page 206: ...ing torque Engine oil 20 Nm 2 5 Nm 3 Install coolant ventilation line and coolant lines on compressor housing 4 Install intake housing 3 with actuating cylin der 2 5 Align clamp 1 and tighten to speci...

Page 207: ...e Size Type Lubricant Value Standard Threaded adapter 10 G 1 4 A Tightening torque Engine oil 40 Nm 4 Nm 7 Install charge air pipework 1 between exhaust turbocharger and intercooler 8 Install air filt...

Page 208: ...irect air jet at people Always wear safety goggles face mask and ear defenders Intercooler Checking conden sate drain for water discharge and obstruction 1 With the engine running check if air emerges...

Page 209: ...l Spare parts Designation Use Part No Qty Air filter Spare Parts Catalog Replacing air filter 1 Remove old air filter and install new air filter Page 208 2 Reset signal ring of contamination indicator...

Page 210: ...e flange of the intake housing 3 and clean it 4 Attach air filter 1 with clamp 2 onto intake housing 3 5 Tighten clamp 2 Air filter with intake silencer 1 Loosen clamp 2 2 Remove air filter 1 and clam...

Page 211: ...r if opening of the entrance door can be prevented Only operate the engine with installed air filters Never open air carrying components during operation Ensure that the engine room is well ventilated...

Page 212: ...ions Engine is stopped and starting disabled Starter Condition check 1 Check securing screws of starter and nut on cable connection for secure seating and tighten if required 2 Check cabling Page 257...

Page 213: ...l level may be up to 2 cm above mark 1 This may be caused e g by oil from oil filters and heat ex changers flowing back into the oil pan After extended standstill the oil level 2 cm above mark 2 is th...

Page 214: ...sk Avoid contact with skin Do not inhale oil vapor Oil change without semirotary hand pump Draining oil at drain plug s on oil pan 1 Provide a suitable vessel in which to collect the engine oil 2 Remo...

Page 215: ...ngine oil 100 Nm 10 Nm Filling with new engine oil 1 Open cap 1 on filler neck 2 Pour oil in at filler neck up to max mark on oil dipstick 3 Close cap on filler neck 4 Check engine oil level Page 211...

Page 216: ...rotective clothing protective gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor WARNING High level of engine noise when the engine is running Risk of damage to hearing Wea...

Page 217: ...pot test Proportion of water Fuel dilution Engine oil sample extraction and analysis engine with switchable oil filter 1 With the engine running at operating temper ature open screw on flange of centr...

Page 218: ...l to health Risk of injury and poisoning Allow the product to cool to below 50 C before beginning work Wear protective clothing protective gloves and goggles safety mask Avoid contact with skin Do not...

Page 219: ...ubborn deposits from strainer as necessary 4 Blow out strainer 6 with compressed air from outside to inside Checking strainer Item Findings Task Strainer Metallic residues Clean Monitor engine operati...

Page 220: ...strainer as necessary 4 Blow out strainer 5 with compressed air from outside to inside Checking strainer Item Findings Task Strainer Metallic residues Clean Monitor engine operation Check strainer dai...

Page 221: ...e 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 engine at...

Page 222: ...Check engine oil level Page 211 Engine oil filter with diverter option Oil filter replacement with engine running 1 To cut out the filter to be replaced set the three way cock to the corresponding pos...

Page 223: ...leeves Spare Parts Catalog Sealing rings Spare Parts Catalog WARNING Oil is hot Oil can contain residue substances which are harmful to health Risk of injury and poisoning Allow the product to cool to...

Page 224: ...conical disk 8 and rotor base 13 9 Wash rotor cover 3 rotor tube 7 conical disk 8 and rotor base 13 with cold cleaner 10 Blow out with compressed air 11 Check sealing rings 9 10 12 and replace if nece...

Page 225: ...se of movement 19 Check sealing ring 16 replace as necessary 20 Fit sealing ring 16 on housing 15 21 Fit hood 1 22 Tighten Tommy nut 2 by hand 23 Install clamp 17 and tighten to specified torque using...

Page 226: ...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 Check sealing ri...

Page 227: ...unterclockwise up to the first stop and allow pressure to escape 2 Continue to turn breather valve counterclockwise and remove 3 Check coolant level coolant must be visible at the bottom edge of the c...

Page 228: ...Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 227 2 Fill with engine coolant Page 230 226 Coolant Circuit General High Temperature Circuit...

Page 229: ...reheating 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 counterclockwise up to the...

Page 230: ...pework driving end 1 6 Open vent valve on seawater cooler 1 or re mote heat exchanger 7 Open drain plug 1 and drain coolant at crankcase 228 Coolant Circuit General High Temperature Circuit MS15035 00...

Page 231: ...in 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 MS15035 00E 2018 08 Coolant Circuit General High Temperature Circu...

Page 232: ...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 Note On engines with a separate heat...

Page 233: ...g faces if required 5 Set breather valve onto filler neck and turn until the first stop 6 Start engine Page 96 7 After 10 seconds of running the engine with out load shut down the engine Page 98 8 Tur...

Page 234: ...ge 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 for Electronic System and disable engine sta...

Page 235: ...ne is running Risk of damage to hearing Wear ear protectors Engine coolant Sample extrac tion and analysis 1 Open drain valve on engine coolant pump el bow with the engine running 2 Drain off approx 1...

Page 236: ...engine coolant The circulating pump 8 ensures the circula tion of the preheated engine coolant through the engine The continuous flow heater 5 comprises a heating element The thermostat 7 switches off...

Page 237: ...On Off switch Cylinders Rated voltage frequency Heating power kW 12V and 16V 230 V 50 Hz 9 400 V 50 Hz 9 230 V 60 Hz 9 440 V 60 Hz 9 MS15035 00E 2018 08 Coolant Circuit General High Temperature Circui...

Page 238: ...ement 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 setting 5 the thermo...

Page 239: ...ment 2 Close shut off valve in coolant line before and after preheater 3 Drain coolant at drain valve into a clean container 4 Clean and flush coolant circuit 5 Check hoses for cracks and other damage...

Page 240: ...tection Checking operation Note The coolant temperature must correlate to the control range of the thermostat when the preheater is ready for operation 1 Check coolant preheating temperature 2 Set the...

Page 241: ...n 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 98 and disable engine start...

Page 242: ...ition check 1 Install barring tool Page 158 2 Guide endoscope optics between guard plate 1 and battery charging generator car rier 2 arrow Note Seek the assistance of a second person 3 Bar engine slow...

Page 243: ...ine noise 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 98 and disable engi...

Page 244: ...ife or destruction of the mounts Cover engine mounts when working with fuel or oil Remove contaminations on the rubber mounts immediately with a dry cloth and degrease them Engine mounting Check Item...

Page 245: ...System 8 22 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 MS15035 00E 2018 08 Fuel Supply System 243 TIM I...

Page 246: ...Wear protective clothing protective gloves and safety glasses facial protection Checking differential pressure gage alarm function 1 Switch on fuel treatment system Page 106 2 Set the alarm points at...

Page 247: ...om water level probe 2 Unscrew water level probe 3 Disconnect plug from water level probe 4 Immerse water level probe into a tank filled with water until water level reaches the thread 5 Switch on pla...

Page 248: ...the outlet of the fuel treatment system c Check pressure at the pressure gauge in the inlet to the fuel treatment system and note down 3 Checking pump pressure with reduced suction a Reduce suction p...

Page 249: ...leanliness NOTICE Incorrect installation of components and lines Damage to component Ensure that components lines are installed so that they are never under tension or strain Ensure correct installati...

Page 250: ...ng torque Engine oil 30 Nm 3 Nm 17 Fit seal 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 Resul...

Page 251: ...ir pressure B13 Crankshaft speed B16 Coolant pressure B33 Fuel temperature B34 1 Fuel pressure after filter B34 2 Fuel pressure before filter B34 3 Fuel pressure before external filter B44 1 Rotation...

Page 252: ...ck X52 EIM engine box XB19 Starting air pressure XD1 Dialog XG03 Battery charging generator XY1 Starting system Valves Y26 Charge air recirculation Y27 Exhaust turbocharger Injectors Y39A1 to Y39AX En...

Page 253: ...3 9 XXF33 10 B16 11 B44 2 12 Y27 13 B4 22 14 B9 15 S37 1 16 B34 3 17 B34 2 18 B34 1 19 B50 20 Y26 21 B44 1 22 B49 23 B3 24 B5 3 25 B4 21 26 B10 27 B13 28 S37 2 29 B7 30 B5 1 31 B48 32 B33 33 F46 34 XG...

Page 254: ...4 2 9 Y27 10 F33 11 XXF33 12 B16 13 B4 22 14 B9 15 S37 1 16 B34 3 17 B34 2 18 B34 1 19 B50 20 Y26 21 B44 1 22 B49 23 B3 24 B5 3 25 B4 21 26 B10 27 B13 28 S37 2 29 B7 30 B5 1 31 B48 32 B33 33 F46 34 XG...

Page 255: ...ess for injectors 12V engine 1 Y39A1 2 Y39A2 3 Y39A3 4 Y39A4 5 Y39A5 6 Y39A6 7 X4 8 Y39B6 9 Y39B5 10 Y39B4 11 Y39B3 12 Y39B2 13 Y39B1 MS15035 00E 2018 08 Wiring General for Engine Gearbox Unit 253 TIM...

Page 256: ...16V engine 1 Y39A1 2 Y39A2 3 Y39A3 4 Y39A4 5 Y39A5 6 Y39A6 7 Y39A7 8 Y39A8 9 X4 10 Y39B8 11 Y39B7 12 Y39B6 13 Y39B5 14 Y39B4 15 Y39B3 16 Y39B2 17 Y39B1 254 Wiring General for Engine Gearbox Unit MS150...

Page 257: ...Engine wiring harness for EIM 1 XD1 2 X1 3 X3 4 X52 5 XY1 6 X11 7 XB19 8 X37 MS15035 00E 2018 08 Wiring General for Engine Gearbox Unit 255 TIM ID 0000038739 003...

Page 258: ...Engine wiring harness for electric starter 1 Connection terminals EIM 2 Fuse F1 3 Connection terminals start er 256 Wiring General for Engine Gearbox Unit MS15035 00E 2018 08 TIM ID 0000038739 003...

Page 259: ...ty cable clips 5 Check cable clamps for secure fit tighten loose clamps 6 Replace faulty cable clamps 7 Visually inspect the following electrical components for damage Connector housings Contacts Plug...

Page 260: ...heel housing 4 2 Check whether both switches 3 are actuat ed 3 If switches 3 and or guard plate 2 with en gine support 1 is are not installed Screw on guard plate 2 with engine sup port 1 Then screw o...

Page 261: ...heck plug connections on ECU 7 1 Check all connectors on ECU for firm seating Ensure that the clips 1 are engaged 2 Check screws 2 of cable clamps on ECU for firm seating Ensure that cable clamps are...

Page 262: ...g EMU plug connections 1 Check both connectors on EMU 2 for firm seating Make sure that frames 3 are engag ed 2 Check screws 1 of cable clamps on EMU 2 for firm seating Make sure that cable clamps are...

Page 263: ...EIM plug connections 1 Check both Tyco plugs 62 pole 2 on EIM for firm seating Ensure that clips 3 are en gaged 2 Check screws 1 of cable clamps on EIM for firm seating Ensure that cable clamps are n...

Page 264: ...ine governor from engine 1 Note or mark assignment of cables and plugs 2 Remove all screws 3 3 Undo clips 2 on connectors 4 Remove all male connectors 5 Remove screws 1 6 Take off engine governor Inst...

Page 265: ...rews 2 3 Undo clips 3 on connectors 4 Remove all male 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 1 P...

Page 266: ...ion 4 Application loader active 5 External RAM defective 6 External FLASH defective 7 No firmware 8 Application crashed Fuse lamp SILA A second indicator is the fuse lamp This is also integrated in th...

Page 267: ...10 Emergency stop current path failed 24 V internal S9 11 ES pushbutton current path failed 24 V external S10 12 Key switch current path failed S11 13 SDAF 1 and 2 current path failed S12 14 PIM curr...

Page 268: ...e 1 2 second steps Note These bit patterns are continuously transmitted The CAN message Status of internal power supply also contains information on the current path states of the EIM 2 266 Accessorie...

Page 269: ...so observe correct assignment between cables and connectors 2 Check seal before installing Result Replace seal if porous or defective Downloading software 1 The new EIM 2 still does not have appropri...

Page 270: ...sation CDC parameters will void the emissions certification Resetting CDC parameters with DiaSys u Dialog system DiaSys E531920 Resetting CDC parameters without DiaSys u If no DiaSys is available cont...

Page 271: ...panel DL Default Lost Alarm Default CAN bus failure ECS Engine Control System Engine management system ECU Engine Control Unit Engine governor EDM Engine Data Module Memory module for engine data EIM...

Page 272: ...OT Oberer Totpunkt Top Dead Center P xyz Pressure xyz Pressure measuring point xyz PAN Panel Control panel PCU Propeller Control Unit Propeller controller PIM Peripheral Interface Module RCS Remote C...

Page 273: ...of a malfunction for information on changes in conditions of use and for supplying spare parts Your contact person in our Customer Assistance Center E mail info mtu online com Tel 49 7541 9077777 Fax...

Page 274: ...c examination Page 161 Endoscope Part No Y20097353 Qty Used in 1 8 3 1 Cylinder liner Endoscopic examination Page 161 Qty Used in 1 8 19 1 Battery charging generator drive Coupling condi tion check Pa...

Page 275: ...er Replacement Page 219 Fuel suction device Part No F30378207 Qty Used in 1 8 6 1 HP fuel pump Filling with engine oil Page 171 High pressure cleaner Part No Qty Used in 1 5 16 Plant Cleaning Page 110...

Page 276: ...d in 1 8 15 3 Engine oil Sample extraction and analysis Page 214 MTU test kit Part No F6798833 Qty Used in 1 8 17 6 Engine coolant Sample extraction and analysis Page 233 Oil filter wrench Part No F30...

Page 277: ...8 5 3 Cylinder head cover Removal and installation Page 170 Qty Used in 1 8 15 2 Engine oil Change Page 212 Ratchet bit Part No F30027340 Qty Used in 1 8 7 2 Injector Removal and installation jackete...

Page 278: ...rt locking device Page 24 Qty Used in 1 8 6 1 HP fuel pump Filling with engine oil Page 171 Qty Used in 1 8 7 2 Injector Removal and installation jacketed fuel system Page 175 Qty Used in 1 8 9 7 Fuel...

Page 279: ...ugal oil filter Cleaning and filter sleeve re placement Page 221 Torque wrench 60 320 Nm Part No F30452768 Qty Used in 1 2 3 Crankshaft transport locking device Page 24 Qty Used in 1 8 5 2 Valve clear...

Page 280: ...43446 Qty Used in 1 8 22 5 Coalescer filter element Replacement Page 247 Valve setting gage Part No Y4349603 Qty Used in 1 8 5 2 Valve clearance Check and adjustment Page 167 278 Special Tools MS15035...

Page 281: ...ement 165 Crankshaft Transport locking device Installation removal 24 Cylinder Designation 40 Cylinder head cover Installation 170 Removal 170 Cylinder liner Endoscopic examination 161 Endoscopic insp...

Page 282: ...118 treatment system Shutdown 107 Fuel filter Replacement 187 Fuel prefilter Adjustment Differential pressure gage 189 Check Differential pressure gage 189 Fuel prefilter with water separator Drainin...

Page 283: ...Warning notices standards 18 Sensors Overview 60 Sensors and actuators Overview 50 Service partners 271 SOLAS shielding Adhesive tape application 157 Installation 147 As per MTN 5233 146 Installation...

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MTU 12V4000M*3 series, Operating Instructions Manual

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Summary of Contents for 12V4000M*3 series

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