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MTU 12V4000M73 series, Operating Instructions Manual

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MTU 12V4000M73 series Operating Instructions Manual Download Page 46

2.5 Sensors and actuators – Overview

12V4000M top view

1 B4.A1 (T-Exhaust cylinder

A1)

2 B4.21 (T-Exhaust, A side)
3 B4.A2 (T-Exhaust cylinder

A2)

4 B4.A3 (T-Exhaust cylinder

A3)

5 B49 (T-Charge-air, air recir-

culation valve)

6 B4.A4 (T-Exhaust cylinder

A4)

7 B4.A5 (T-Exhaust cylinder

A5)

8 B4.A6 (T-Exhaust cylinder

A6)

9 B5.2 (P-Lube oil after filter)

10 B48 (P-Fuel in common rail)
11 B34.2 (P-Fuel before filter)
12 B34.1 (P-Fuel after filter)
13 B5.3 (P-Lube oil before fil-

ter)

14 F33 (H-Coolant)

15 B4.B6 (T-Exhaust cylinder

B6)

16 B4.B5 (T-Exhaust cylinder

B5)

17 B4.B4 (T-Exhaust cylinder

B4)

18 B4.B3 (T-Exhaust cylinder

B3)

19 B4.B2 (T-Exhaust cylinder

B2)

20 B4.22 (T-Exhaust, B side)
21 B4.B1 (T-Exhaust cylinder

B1)

44 | General Information | MS150045/03E 2018-08

TIM-ID: 0000032308 - 004

Summary of Contents for 12V4000M73 series

Page 1: ...Operating Instructions Diesel engine 12V4000M73x 16V4000M73x MS150045 03E...

Page 2: ...shafen GmbH This publication is protected by copyright and may not be used in any way whether in whole or in part without the prior writ ten consent of MTU Friedrichshafen GmbH This particularly appli...

Page 3: ......

Page 4: ......

Page 5: ...alloy intercooler 82 3 9 16V4000M73 engine data IMO Tier II engine mounted heat exchanger 85 3 10 Engine data 16V4000M73L 88 3 11 16V4000M73L engine data IMO engine mounted heat exchanger copper based...

Page 6: ...Air filter Replacement 209 7 11 2 Air filter Removal and installation 210 7 12 Air Intake 211 7 12 1 Contamination indicator Signal ring position check 211 7 12 2 Air pipework from air filter to ETC...

Page 7: ...252 7 23 6 Engine Monitoring Unit EMU 8 Removal and installation 253 7 23 7 Engine Interface Module EIM 2 Removal and installation 254 7 23 8 Engine Interface Module EIM 2 Diagnostic features 255 7 2...

Page 8: ...t 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 Noncompliance...

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: ...ons 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: ...tor 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 prod...

Page 13: ...ds 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 electrical...

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 Ultr...

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 o...

Page 21: ...pallet or transport with equipment for heavy loads forklift truck Prior to transporting the engine it is imperative to install transportation locking devices for crankshaft and engine mounts Secure t...

Page 22: ...orques 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 fricti...

Page 23: ...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 24: ...e 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 perm...

Page 25: ...n 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 Form...

Page 26: ...ightening 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 M...

Page 27: ...l 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 p...

Page 28: ...ns 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 29: ...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 30: ...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 31: ...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 32: ...RFS 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 union...

Page 33: ...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 34: ...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 32 General Informa...

Page 35: ...Engine mounting 12 HP fuel pump 13 Automatic oil filter 14 Fuel filter 15 Centrifugal oil filter s 16 Coolant cooler Engine model designation Key to the engine model designation 16V4000Mxyz 12 16 Num...

Page 36: ...ss Turbocharging system Sequential turbocharging with internal engine coolant controlled charge air cooling The right hand exhaust turbocharger is cut in and cut out with electronically controlled hyd...

Page 37: ...erface 2x MCS5 CAN CAN dialog output 1xMCS5 CAN Emergency stop from EMU and ECU Electric starter Terminal 45 starter A B engaged Pneumatic starter Starting air pressure valve Starting air pressure sen...

Page 38: ...al engine gear control Flashing lamp and horn for summary alarm in engine room Interface to CAN field bus for connected communicating monitoring system components SOLAS Fire safety specifications The...

Page 39: ...l line to HP pump Lube oil system oil lines with oil pressure 1 8 bar 1 Connection ETC oil supply free end 1 Oil line on equipment carrier MS150045 03E 2018 08 General Information 37 TIM ID 0000010056...

Page 40: ...1 Oil supply to HP pump 1 Oil supply to flap control free end 1 ETC oil supply on main oil gallery 38 General Information MS150045 03E 2018 08 TIM ID 0000010056 006...

Page 41: ...for turbo charger B1 2 T piece of flap control 1 Actuating cylinder of exhaust flap for turbocharger B1 1 Oil line from main oil gallery 2 Oil line to main oil gallery MS150045 03E 2018 08 General Inf...

Page 42: ...valve Special connections In case of leaks the following connection types are spray protected even without a cover and have been con firmed compliant with SOLAS by GL and DNV 40 General Information M...

Page 43: ...he thread 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 connection b The sleeve 3 covers the union to prevent lateral sp...

Page 44: ...er tube 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 chambe...

Page 45: ...cordance 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 46: ...4 A6 T Exhaust cylinder A6 9 B5 2 P Lube oil after filter 10 B48 P Fuel in common rail 11 B34 2 P Fuel before filter 12 B34 1 P Fuel after filter 13 B5 3 P Lube oil before fil ter 14 F33 H Coolant 15...

Page 47: ...arger A 5 B10 P Charge air 6 B57 1 T Main bearing 7 B57 2 T Main bearing 8 B57 3 T Main bearing 9 B57 4 T Main bearing 10 B57 5 T Main bearing 11 B57 6 T Main bearing 12 B57 7 T Main bearing 13 B5 1 P...

Page 48: ...ee end 1 F46 H Fuel leakage 2 B33 T Fuel rail 3 B1 N Camshaft 4 B54 P Oil refill pump 5 B6 2 T Coolant 6 B6 T Coolant 7 Connector XD1 Dialog unit 46 General Information MS150045 03E 2018 08 TIM ID 000...

Page 49: ...Spray oil conrod bearing 5 B77 B5 T Spray oil conrod bearing 6 B77 B4 T Spray oil conrod bearing 7 B77 B3 T Spray oil conrod bearing 8 B77 B2 T Spray oil conrod bearing 9 B77 B1 T Spray oil conrod bea...

Page 50: ...12V4000M driving end 1 B13 N Crankshaft 2 S37 2 Safety switch 3 S37 1 Safety switch 4 B13 2 N Crankshaft 48 General Information MS150045 03E 2018 08 TIM ID 0000032308 004...

Page 51: ...haust cylinder A8 12 B5 2 P Lube oil after filter 13 B5 3 P Lube oil before fil ter 14 B34 2 P Fuel before filter 15 B34 1 P Fuel after filter 16 B48 P Fuel in common rail 17 F33 H Coolant 18 B4 B8 T...

Page 52: ...ger A 5 B10 P Charge air 6 B57 1 T Main bearing 7 B57 2 T Main bearing 8 B57 3 T Main bearing 9 B57 4 T Main bearing 10 B57 5 T Main bearing 11 B57 6 T Main bearing 12 B57 7 T Main bearing 13 B57 8 T...

Page 53: ...ee end 1 F46 H Fuel leakage 2 B33 T Fuel rail 3 B1 N Camshaft 4 B54 P Oil refill pump 5 B6 2 T Coolant 6 B6 T Coolant 7 Connector XD1 Dialog unit MS150045 03E 2018 08 General Information 51 TIM ID 000...

Page 54: ...pray oil conrod bearing 6 B77 B6 T Spray oil conrod bearing 7 B77 B5 T Spray oil conrod bearing 8 B77 B4 T Spray oil conrod bearing 9 B77 B3 T Spray oil conrod bearing 10 B77 B2 T Spray oil conrod bea...

Page 55: ...16V4000M driving end 1 S37 1 Safety switch 2 B13 2 N Crankshaft 3 B13 N Crankshaft 4 S37 2 Safety switch MS150045 03E 2018 08 General Information 53 TIM ID 0000032308 004...

Page 56: ...Fuel pressure after filter B34 2 Fuel pressure before filter B44 1 Exhaust turbocharger A speed B44 2 Exhaust turbocharger B speed B48 HP fuel pressure B49 Charge air before recirulation B50 Crankcase...

Page 57: ...essure XD1 Dialog unit XY1 Starter Engine wiring harness for sensors 12V 1 B50 2 B7 3 B5 1 4 B5 3 5 B34 2 6 B34 1 7 F46 8 B48 9 B33 10 B1 11 XG03 12 S37 1 13 B10 14 B4 21 15 M8 16 X2 17 X37 18 B6 19 B...

Page 58: ...B5 3 5 B34 2 6 B34 1 7 F46 8 B48 9 B33 10 XG03 11 B1 12 S37 1 13 B10 14 B4 21 15 M8 16 X2 17 X37 18 B6 19 B4 22 20 B9 21 S37 2 22 B13 23 B16 24 B44 2 25 Y27 26 F33 27 B49 28 B44 1 29 B3 30 Y26 56 Gene...

Page 59: ...injectors 12V 1 Y39A1 2 Y39A2 3 Y39A3 4 Y39A4 5 Y39A5 6 Y39A6 7 X4 8 E4 3 9 E4 4 10 E4 5 11 Y39B5 12 Y39B6 13 E4 2 14 E4 1 15 Y39B4 16 Y39B3 17 Y39B2 18 Y39B1 MS150045 03E 2018 08 General Information...

Page 60: ...39A1 2 Y39A2 3 Y39A3 4 Y39A4 5 Y39A5 6 Y39A6 7 Y39A7 8 Y39A8 9 X4 10 E4 3 11 E4 4 12 E4 5 13 Y39B7 14 Y39B8 15 E4 2 16 E4 1 17 Y39B6 18 Y39B5 19 Y39B4 20 Y39B3 21 Y39B2 22 Y39B1 58 General Information...

Page 61: ...Engine wiring harness for EIM 1 XD1 2 X1 3 X3 4 X52 5 XY1 6 X11 7 XB19 8 X37 MS150045 03E 2018 08 General Information 59 TIM ID 0000032681 003...

Page 62: ...Engine wiring harness for electric starter 1 EIM terminals 2 Fuse F1 3 Starter terminals 60 General Information MS150045 03E 2018 08 TIM ID 0000032681 003...

Page 63: ...et temperature C 25 Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylinders 12 Rated engine speed A r...

Page 64: ...nlet connection min when engine is running L bar 0 3 Fuel pressure at engine inlet connection max when engine is starting L bar 1 5 Fuel supply flow max R Liters mi n 28 GENERAL OPERATING DATA Number...

Page 65: ...ters 225 Oil pan capacity at dipstick mark min standard oil system Option max operating inclinations L Liters 190 Oil pan capacity at dipstick mark max standard oil system Option max operating inclina...

Page 66: ...re C 25 Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylinders 12 Rated engine speed A rpm 1970 Fuel...

Page 67: ...nlet connection min when engine is running L bar 0 3 Fuel pressure at engine inlet connection max when engine is starting L bar 1 5 Fuel supply flow max R Liters mi n 28 GENERAL OPERATING DATA Number...

Page 68: ...ters 225 Oil pan capacity at dipstick mark min standard oil system Option max operating inclinations L Liters 190 Oil pan capacity at dipstick mark max standard oil system Option max operating inclina...

Page 69: ...ometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylinders 12 Rated engine speed A rpm 1970 Fuel stop power...

Page 70: ...nlet connection min when engine is running L bar 0 3 Fuel pressure at engine inlet connection max when engine is starting L bar 1 5 Fuel supply flow max R Liters mi n 28 GENERAL OPERATING DATA Number...

Page 71: ...ters 225 Oil pan capacity at dipstick mark min standard oil system Option max operating inclinations L Liters 190 Oil pan capacity at dipstick mark max standard oil system Option max operating inclina...

Page 72: ...rometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylinders 12 Rated engine speed A rpm 2050 Fuel stop powe...

Page 73: ...nlet connection min when engine is running L bar 0 3 Fuel pressure at engine inlet connection max when engine is starting L bar 1 5 Fuel supply flow max R Liters mi n 29 GENERAL OPERATING DATA Number...

Page 74: ...ters 225 Oil pan capacity at dipstick mark min standard oil system Option max operating inclinations L Liters 190 Oil pan capacity at dipstick mark max standard oil system Option max operating inclina...

Page 75: ...ure C 25 Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylinders 12 Rated engine speed A rpm 2050 Fue...

Page 76: ...nlet connection min when engine is running L bar 0 3 Fuel pressure at engine inlet connection max when engine is starting L bar 1 5 Fuel supply flow max R Liters mi n 29 GENERAL OPERATING DATA Number...

Page 77: ...ters 225 Oil pan capacity at dipstick mark min standard oil system Option max operating inclinations L Liters 190 Oil pan capacity at dipstick mark max standard oil system Option max operating inclina...

Page 78: ...erature C 25 Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylinders 12 Rated engine speed A rpm 2050...

Page 79: ...nlet connection min when engine is running L bar 0 3 Fuel pressure at engine inlet connection max when engine is starting L bar 1 5 Fuel supply flow max R Liters mi n 29 GENERAL OPERATING DATA Number...

Page 80: ...ters 225 Oil pan capacity at dipstick mark min standard oil system Option max operating inclinations L Liters 190 Oil pan capacity at dipstick mark max standard oil system Option max operating inclina...

Page 81: ...rature C 25 Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylinders 16 Rated engine speed A rpm 1970...

Page 82: ...nlet connection min when engine is running L bar 0 3 Fuel pressure at engine inlet connection max when engine is starting L bar 1 5 Fuel supply flow max R Liters mi n 28 GENERAL OPERATING DATA Number...

Page 83: ...Liters 270 Oil pan capacity at dipstick mark min standard oil system Option max operating inclinations L Liters 215 Oil pan capacity at dipstick mark max standard oil system Option max operating incli...

Page 84: ...re C 25 Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylinders 16 Rated engine speed A rpm 1970 Fuel...

Page 85: ...nlet connection min when engine is running L bar 0 3 Fuel pressure at engine inlet connection max when engine is starting L bar 1 5 Fuel supply flow max R Liters mi n 28 GENERAL OPERATING DATA Number...

Page 86: ...Liters 270 Oil pan capacity at dipstick mark min standard oil system Option max operating inclinations L Liters 215 Oil pan capacity at dipstick mark max standard oil system Option max operating incli...

Page 87: ...ometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylinders 16 Rated engine speed A rpm 1970 Fuel stop power...

Page 88: ...nlet connection min when engine is running L bar 0 3 Fuel pressure at engine inlet connection max when engine is starting L bar 1 5 Fuel supply flow max R Liters mi n 28 GENERAL OPERATING DATA Number...

Page 89: ...Liters 270 Oil pan capacity at dipstick mark min standard oil system Option max operating inclinations L Liters 215 Oil pan capacity at dipstick mark max standard oil system Option max operating incli...

Page 90: ...ar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Rating I Unit Value Rated engine speed A rpm 2050 Fuel stop power ISO 3046 A kW 2880 SI...

Page 91: ...tion R liters min 1 5 GENERAL OPERATING DATA General operating data I Unit Value Firing speed from R rpm 80 Firing speed to R rpm 120 STARTING electric Starting electric I Unit Value Starter rated vol...

Page 92: ...k min standard oil system option max op erating inclinations L Liters 215 Oil pan capacity at dipstick mark max standard oil system option max operating inclinations L Liters 260 MASSES MAIN DIMENSION...

Page 93: ...ture C 25 Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylinders 16 Rated engine speed A rpm 2050 Fu...

Page 94: ...nlet connection min when engine is running L bar 0 3 Fuel pressure at engine inlet connection max when engine is starting L bar 1 5 Fuel supply flow max R Liters mi n 29 GENERAL OPERATING DATA Number...

Page 95: ...Liters 270 Oil pan capacity at dipstick mark min standard oil system Option max operating inclinations L Liters 215 Oil pan capacity at dipstick mark max standard oil system Option max operating incli...

Page 96: ...erature C 25 Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylinders 16 Rated engine speed A rpm 2050...

Page 97: ...nlet connection min when engine is running L bar 0 3 Fuel pressure at engine inlet connection max when engine is starting L bar 1 5 Fuel supply flow max R Liters mi n 29 GENERAL OPERATING DATA Number...

Page 98: ...Liters 270 Oil pan capacity at dipstick mark min standard oil system Option max operating inclinations L Liters 215 Oil pan capacity at dipstick mark max standard oil system Option max operating incli...

Page 99: ...gth A Width B Height C 12V4000M73 93 L approx 2991 mm approx 1463 mm approx 2368 mm 16V4000M73 93 L approx 3583 mm approx 1463 mm approx 2368 mm 20V4000M73 93 L approx 4192 mm approx 1484 mm approx 23...

Page 100: ...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 20V A1 B5 A8 B7 A5 B2 A7 B10 A2 B3 A10 B6 A3 B4 A6 B9 A4 B1 A9 B8 98 Technical Data MS150045 03E 2018...

Page 101: ...4 Operation 4 1 Operation LOP controls Refer to automation system BlueLine BlueVision operating instructions MS150045 03E 2018 08 Operation 99 TIM ID 0000031215 001...

Page 102: ...ted above waterline Fill with water approx 3 to 4 liters Coolant circuit If engine is out of service for more than one year change coolant Page 230 Coolant circuit Check coolant level Page 228 Coolant...

Page 103: ...required Coolant circuit Check coolant level Page 228 Coolant circuit Heat coolant with coolant preheating unit Engine control system Switch master switch to ON Press illuminated pushbutton READY FOR...

Page 104: ...fied 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 a...

Page 105: ...4 5 Starting the engine Start the engine via the automation system Refer to automation system operating instructions MS150045 03E 2018 08 Operation 103 TIM ID 0000017525 003...

Page 106: ...sures and temperatures Check engine and external lines for leaks Check for abnormal running noises and vibration Check exhaust color Page 128 Air filter Check signal ring position of service indicator...

Page 107: ...s 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 108 2 Shut down fuel treatment system Page 124 MS1...

Page 108: ...ually 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 Indicate...

Page 109: ...es 4 Switch on fuel treatment system Page 111 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 110: ...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 fue...

Page 111: ...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 112: ...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 113: ...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 114: ...me thermal and mechanical stress es Overheating of and therefore damage to components is possible Before shutting down the engine allow it to idle until the engine temperatures decrease and constant l...

Page 115: ...After engine shutdown Item Action Coolant circulating pump Allow to run on for sufficient time after stopping MS150045 03E 2018 08 Operation 113 TIM ID 0000002285 005...

Page 116: ...n extremely high load Risk of overheating damage to components Trigger an emergency stop only in emergency situations Emergency engine stop at BlueLine automation system Item Measure Engine Emergency...

Page 117: ...LOP Press illuminated pushbutton CLUTCH IN Page 99 Illuminated pushbutton CLUTCH IN flashes Clutch is engaged After receiving the feedback signal from the clutch illuminated pushbut ton CLUTCH IN lig...

Page 118: ...UPLING OUT button flashes Coupling is disengaged After receiving the feedback signal from coupling the COUPLING OUT but ton is illuminated brightly Disengaging coupling with reversing gearbox FPP WJ I...

Page 119: ...for too long Follow instructions of the waterjet manufacturer Flushing with reversing gearbox and flushing mode Item Measure LOP Press and hold down FLUSH illuminated pushbutton Page 99 FLUSH illumin...

Page 120: ...engine at idle speed for at least 10 minutes until engine temperatures have dropped and constant values are displayed Stopping the engine from LOP Item Measure LOP Disengage gearbox Page 99 LOP Opera...

Page 121: ...Before shutting down disengage gear and run the engine at idle speed for at least 10 minutes until engine temperatures have dropped and constant values are displayed Stopping the engine at the BlueLi...

Page 122: ...cting the power supply to the ECU On engines with emergency air shutoff flaps the flaps close Illuminated pushbutton EMERGENCY STOP flashes Horn flashing lamp etc are tripped After an emergency stop a...

Page 123: ...4 20 Stopping the engine Stopping the engine via the automation system Refer to automation system operating instructions MS150045 03E 2018 08 Operation 121 TIM ID 0000017528 004...

Page 124: ...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 125: ...and if no antifreeze has been added to the coolant the engine room is not heated the coolant is not kept at a suitable temperature the antifreeze concentration is insufficient for the engine room temp...

Page 126: ...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 127: ...n 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 128: ...e 193 W1002 Check valve clearance Page 178 W1005 Replace air filter Page 209 W1006 Replace injectors Page 185 W1008 Replace engine oil filter at each oil change or when the time limit years is reached...

Page 129: ...e motor is 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...

Page 130: ...ess faulty fuse lamp on EIM flashes with relevant flashing code u Check fuse replace as necessary and re start system by actuating key switch Engine blocked crankshaft cannot be rotated by hand 1 Chec...

Page 131: ...re too high Cause Corrective action Engine Overload u Reduce load Air inlet temperature too high u Check fans and air supply ventilation ducts for engine room Incorrect engine coolant concentration 1...

Page 132: ...inder compression 2 Replace cylinder head Instructions for Exchange of Sub assemblies Piston rings or cylinder liner defective 1 Check cylinder compression 2 Carry out endoscopic examination of cylind...

Page 133: ...lt 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 in...

Page 134: ...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 135: ...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 136: ...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 137: ...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 138: ...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 139: ...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 140: ...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 141: ...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 142: ...10 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 3...

Page 143: ...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 144: ...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 145: ...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 146: ...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 147: ...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 148: ...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 149: ...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 150: ...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 151: ...ssages 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 152: ...tput 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 c...

Page 153: ...emperature 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 In...

Page 154: ...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 155: ...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 156: ...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 Correcti...

Page 157: ...on 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 coo...

Page 158: ...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 159: ...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 r...

Page 160: ...e Part No Qty Shield A5 735233000101 20 Shield A6 735233000102 2 Shield A7 735233000103 3 Shield A8 735233000104 3 Shield B2 735233000200 2 Shield B4 735233000202 1 Shield E5 735233000500 3 Installing...

Page 161: ...possible Page 166 When affixing adhesive connections ensure that escaping fluid can flow out without pressure Page 166 Fuel system fuel lines with fuel pressure 1 8 bar Item Type of shielding Install...

Page 162: ...uel line to HP pump 2 Shield E5 Fuel line to HP pump Lube oil system oil lines with oil pressure 1 8 bar Item Type of shielding Installation location 1 2 x shield A5 Actuating cylinder exhaust flap ET...

Page 163: ...x shield A5 Actuating cylinder air flap ETC B1 2 3 x shield A5 T adapter for flap control ETC B1 Item Type of shielding Installation location 1 4 x shield A5 Distributor 2 3 x shield A5 Oil return MS1...

Page 164: ...is installed Item Type of shielding Installation location 1 Shield A7 Oil line to ETC 2 Shield A5 Oil line to flap control 3 Shield A5 Oil line to recirculation valve 4 2 x shield E5 Oil line from ma...

Page 165: ...elding Installation location 1 2 x shield A5 Air recirculation valve Item Type of shielding Installation location 1 Shield A6 Oil supply line to HP pump To HP pump MS150045 03E 2018 08 SOLAS 163 TIM I...

Page 166: ...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 A7 ETC oil s...

Page 167: ...ld B2 Oil line on equipment carrier 1 Shield B2 Oil line on pressure reducing valve This shield must be installed on the assembly line Assembly in this position is no longer possible after painting MS...

Page 168: ...tape 1 such that lettering 2 faces out 3 Wrap adhesive tape without tensioning 4 Pull out cable clamp 3 after affixing adhe sive tape Taping sealing cone unions installation locations 1 Page 159 2 Wra...

Page 169: ...stallation locations 1 Page 159 2 Place adhesive tape flush in position 3 Wind adhesive tape in three layers until area from screw center to line is covered at least 30 mm MS150045 03E 2018 08 SOLAS 1...

Page 170: ...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 171: ...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 172: ...ueLine automation system Starting barring procedure at LOP 8 BlueLine Operating Instructions BlueVision automation system Starting barring procedure at LOP 8 BlueLine Operating Instructions 170 Engine...

Page 173: ...g pattern 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 discolorati...

Page 174: ...Final steps 1 Install injector Page 186 2 Install cylinder head cover Page 182 172 Cylinder Liner MS150045 03E 2018 08 TIM ID 0000000015 017...

Page 175: ...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 176: ...s are similar A thorough investigation and compliance with the above evaluation criteria allow an unambiguous evaluation To avoid unnecessary disassembly work it is recommended that another inspection...

Page 177: ...contain residue 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 goggle...

Page 178: ...ecified tightening torque Name Size Type Lubricant Value Standard Screw Tightening torque Engine oil 10 Nm 2 Nm 6 Replace further filter elements in the same way 7 Check oil separator for leaks 176 Cr...

Page 179: ...Spare parts Designation Use Part No Qty Engine oil Valve gear Lubrication 1 Remove cylinder head covers Page 182 2 Fill oil chambers of valve bridges with oil 3 Fill oil chambers of rocker arms and ad...

Page 180: ...screw driver F30002815 1 Torque wrench 60 320 Nm F30452768 1 Socket wrench 24 mm F30039526 1 Engine oil Preparatory steps 1 Remove cylinder head covers Page 182 2 Install barring tool Page 168 Note Po...

Page 181: ...er of the flywheel 4 The additional OT A1 mark 1 if applicable on the outer perimeter of the flywheel must not be used for reference Diagram for 8V engines Two crankshaft positions Diagram for 12V eng...

Page 182: ...ance adjustment with cold engine Inlet valves long rocker arm 0 2 mm 0 05 mm Exhaust valves short rocker arm 0 5 mm 0 05 mm 3 Check all valve clearances in two crankshaft positions firing TDC and over...

Page 183: ...g gauge must just pass through the gap 4 Pass valve setting gauge 3 between valve bridge and rocker arm 5 Tighten locknut 1 to specified torque using a torque wrench holding the adjusting screw 2 in p...

Page 184: ...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 C...

Page 185: ...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 186: ...ox 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 Standar...

Page 187: ...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 186 MS150045 03E 2018 08 Injec...

Page 188: ...osive 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 or...

Page 189: ...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 190: ...on 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 injector...

Page 191: ...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 192: ...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 193: ...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 Lubric...

Page 194: ...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 195: ...ry 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 p...

Page 196: ...screw cut out fuel filter using an oil filter wrench 3 Clean sealing surface on filter head 4 Check sealing ring of new fuel filter and coat with fuel 5 Screw on fuel filter and tighten by hand 6 Retu...

Page 197: ...ial 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 t...

Page 198: ...ately 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 comb...

Page 199: ...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 valve...

Page 200: ...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 a...

Page 201: ...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 202: ...rough 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 protec...

Page 203: ...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 204: ...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 16...

Page 205: ...in the relevant safety data sheet Wear protective gear as specified in the relevant safety data sheet NOTICE Incorrect installation of components and lines Damage to component Ensure that components l...

Page 206: ...er 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 vent line 2 from compres sor housing 3...

Page 207: ...essor housing with a smooth paint brush or brush 2 Clean compressor wheel 2 and bearing housing 1 3 Thoroughly remove cleaner from all compo nents 4 Replace sealing rings between bearing hous ing comp...

Page 208: ...d torque using a torque wrench Name Size Type Lubricant Value Standard Clamp Tightening torque 15 Nm 2 Nm 6 Install oil lines 2 Tighten screw fitting union at actuating cylinder to specified torque us...

Page 209: ...rect air jet at people Always wear safety goggles face mask and ear defenders Checking condensate drain of intercooler for coolant leakage and obstruction u With the engine running check outlet of the...

Page 210: ...tion with leak ing intercooler 1 Remove injectors Page 186 2 Bar engine manually Page 168 3 Bar engine with starting system to blow out combustion chambers Page 168 4 Install injectors Page 186 208 Ch...

Page 211: ...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 210 2 Reset signal ring of contamination indicator...

Page 212: ...otective gloves safety goggles respiratory protection etc is to be used NOTICE Stepping or climbing on the genset to perform installation tasks is to be avoided Otherwise there is a risk of component...

Page 213: ...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 214: ...se Part No Qty Air hose 0229979482 2 Checking air pipework from air filter to ETC Item Findings Measure Visually check outer layer of air hose Damage Deformation Cracks Cuts Brittleness Scuffing visib...

Page 215: ...ons 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 247 M...

Page 216: ...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 217: ...fety 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 dr...

Page 218: ...torque 100 Nm 10 Nm Filling with new oil 1 Open cover 1 on filler neck 2 Pour oil in at filler neck up to max mark at oil dipstick 3 Close cap 1 on filler neck 4 Check engine oil level Page 214 5 Aft...

Page 219: ...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 220: ...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 221: ...ow 50 C before beginning work Wear protective 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 r...

Page 222: ...t 3 O ring 4 Cover 5 Nut 6 Strainer 7 O ring 8 Spring 9 O ring 10 Cover 11 Screw 12 Sealing ring 13 Screw fitting union 14 Sealing ring 15 Union 16 Scavenge oil line 17 Screw 18 Gearbox flange 19 O ri...

Page 223: ...ug screw 7 Sealing ring 8 Plug screw 9 Sealing ring 10 Plug screw 11 Sealing ring 12 Threaded bushing 13 Plug screw 14 Plug screw 15 Sealing ring 16 Sealing ring 17 Bypass valve 18 O ring 19 Cover 20...

Page 224: ...bushing 5 Sight glass 6 Flat gasket 7 O ring 8 O ring 9 Clamping ring 10 Spring washer 11 Screw 12 Screw 13 Worm gear 14 Grooved pin 15 Turbine housing 16 Impeller 17 Washer 18 Stud 19 Nut 222 Oil Fil...

Page 225: ...and goggles safety mask Take measures against electrostatic charging WARNING Oil is hot Oil can contain residue substances which are harmful to health Risk of injury and poisoning Allow the product t...

Page 226: ...maged Replace Square section ring Damaged Replace O ring Damaged Replace Cleaning strainer 1 Wash strainer 6 with cleaner 2 Remove stubborn deposits with soft brush 3 Blow out strainer 6 with compress...

Page 227: ...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 below 50 C before beginning work Wear protective clothing pr...

Page 228: ...ealing ring 9 13 Insert new filter sleeve 6 in rotor pipe 7 with the smooth paper surface facing the out er wall 14 Check sealing ring 5 replace if necessary 15 Install rotor cover 4 with sealing ring...

Page 229: ...Temperature Circuit 7 16 1 Venting points Coolant line on ETC 1 Venting point Vent line Cross distribution expansion tank 1 Venting point MS150045 03E 2018 08 Coolant System General High Temperature C...

Page 230: ...e and remove 3 Check engine coolant level engine coolant must be visible at bottom edge of cast in eye of filler neck Checking coolant level at exter nal cooler Note Engine coolant must be visible at...

Page 231: ...level at sight glass 1 Check coolant level coolant level must be between min and max mark 2 Top up coolant if necessary Page 232 MS150045 03E 2018 08 Coolant System General High Temperature Circuit 22...

Page 232: ...Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 231 2 Fill with engine coolant Page 232 230 Coolant System General High Temperature Circuit...

Page 233: ...nk counterclockwise to first stop and allow pressure to escape 2 Continue to turn breather valve counterclock wise and remove 3 Draw off precipitated corrosion inhibitor oil from the expansion tank th...

Page 234: ...ne cool down Wear protective clothing gloves and goggles safety mask NOTICE Cold coolant in hot engine can cause thermal stress Possible formation of cracks in the engine Fill top up coolant only into...

Page 235: ...til overflow edge is reached 13 With the expansion tank open run the engine up to nominal speed full load under load 14 Leave the engine idling for approx 5 minutes until the coolant temperature stab...

Page 236: ...ce engine speed to idle speed 11 With the engine idling fill expansion tank un til overflow edge is reached 12 Stop engine Page 112 and remove pump 13 With the expansion tank open start the en gine an...

Page 237: ...ear ear protectors Engine coolant pump relief bore check 1 Check relief bore for oil and coolant dis charge 2 Stop engine Page 103 and disable engine start observe general safety instructions on maint...

Page 238: ...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 239: ...isk of damage to hearing Wear ear protectors Raw water pump relief bore check 1 Check relief bore for oil and raw water dis charge 2 Stop engine Page 103 and disable engine start observe general safet...

Page 240: ...tion check 1 Install barring tool Page 168 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 slowl...

Page 241: ...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 242: ...ne 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 112 and disable engi...

Page 243: ...System 7 21 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 MS150045 03E 2018 08 Fuel Supply System 241 TIM I...

Page 244: ...Wear protective clothing protective gloves and safety glasses facial protection Checking differential pressure gage alarm function 1 Switch on fuel treatment system Page 111 2 Set the alarm points at...

Page 245: ...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 246: ...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 247: ...eanliness 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 installatio...

Page 248: ...g 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 Result...

Page 249: ...intact 4 Replace faulty 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 h...

Page 250: ...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 251: ...eck 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 n...

Page 252: ...king 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 that cable clamps are...

Page 253: ...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 no...

Page 254: ...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 255: ...nect all connectors 5 Remove screws 1 6 Remove Engine Control Unit 5 with Engine Monitoring Unit 4 Removing Engine Monitoring Unit 1 Unscrew screws on base of EMU 4 2 Remove EMU 8 4 from ECU 5 Install...

Page 256: ...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 257: ...on 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 the...

Page 258: ...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 259: ...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 MS150045 03E 20...

Page 260: ...7 1 Cleaning LOP 1 Wipe LCD screen with dry cloth without applying excessive pressure 2 Remove dirt from pushbuttons using solvent 3 Remove coarse dirt on housing surface using solvent Cleaning connec...

Page 261: ...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 262: ...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 263: ...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 264: ...learance Check and adjustment Page 178 Barring tool Part No F6555766 Qty Used in 1 7 2 1 Engine Barring manually Page 168 Endoscope Part No Y20097353 Qty Used in 1 7 18 1 Battery charging generator dr...

Page 265: ...8207 Qty Used in 1 7 6 1 HP fuel pump Filling with engine oil Page 183 High pressure cleaner Part No Qty Used in 1 4 24 Plant Cleaning Page 125 Installation removal jig Part No F6789889 Qty Used in 1...

Page 266: ...ine oil Sample extraction and analysis Page 217 Qty Used in 1 7 14 4 Engine oil Sample extraction and analysis Page 219 MTU test kit Part No F6798833 Qty Used in 1 7 16 7 Engine coolant Sample extract...

Page 267: ...Part No F30027341 Qty Used in 1 7 14 2 Engine oil Change Page 215 Ratchet bit Part No F30027341 Qty Used in 7 5 3 Cylinder head cover Removal and installation Page 182 Ratchet bit Part No F30027340 Q...

Page 268: ...Part No F30006212 Qty Used in 1 7 2 1 Engine Barring manually Page 168 Rigid endoscope Part No Y20097353 Qty Used in 1 7 3 1 Cylinder liner Endoscopic examination Page 171 Socket wrench 24 mm Part No...

Page 269: ...el Cleaning Page 203 Qty Used in 1 7 15 3 Centrifugal oil filter Cleaning and filter sleeve re placement Page 225 Torque wrench 4 20 Nm Part No F30044239 Qty Used in 1 7 4 1 Crankcase breather Oil sep...

Page 270: ...3446 Qty Used in 1 7 21 5 Coalescer filter element Replacement Page 245 Valve setting gauge Part No Y4349603 Qty Used in 1 7 5 2 Valve clearance Check and adjustment Page 178 268 Special Tools MS15004...

Page 271: ...175 Cylinder Designation 43 Cylinder head cover Installation 182 Removal 182 Cylinder liner Endoscopic examination 171 Endoscopic inspection Instructions and comments on endoscopic and visu al examina...

Page 272: ...Engine free end Definition 43 Engine governor ADEC ECU 7 Fault messages 131 Engine governor ECU 7 Installation 252 Removal 252 Engine Monitoring Unit EMU 8 Plug connections check 250 Engine mounting C...

Page 273: ...revention 16 Fluids and lubricants 16 Important provisions 6 8 Initial start up 10 Maintenance work 12 Operation 10 Organizational requirements 9 Personnel requirements 9 Repair work 12 Safety require...

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