MTU 16 V 4000 M63L Operating Instructions Manual Download Page 153

Page: 153 / 261

6.6 Injection Valve / Injector

6.6.1 Injector – Replacement

Special tools, Material, Spare parts

Designation / Use

Part No.

Qty.

Injector

(→ Spare Parts Catalog)

Replacing injector

Remove injector and install new injector (→ Page 154).

MS150067/02E 2014-04

| Task Description | 153

TIM-ID: 0000000022 - 016

Summary of Contents for 16 V 4000 M63L

Page 1: ...Operating Instructions Diesel engine 16 V 4000 M63L MS150067 02E...

Page 2: ...ten permission of MTU Friedrichshafen GmbH This restriction also applies to copyright distribution translation mi crofilming and storage or processing on electronic systems including data bases and on...

Page 3: ...Commissioning Note...

Page 4: ......

Page 5: ...e task reference table QL1 65 5 Troubleshooting 5 1 Troubleshooting 67 5 2 Fuel treatment system Troubleshooting 70 5 3 Engine governor ADEC ECU 7 fault messages for Series 4000 engines marine applica...

Page 6: ...Preheater Function and leak tightness check 222 6 16 Raw Water Pump with Connections 223 6 16 1 Raw water pump Relief bore check 223 6 17 Engine Mounting Support 224 6 17 1 Engine mounting Check 224...

Page 7: ...nfiguration approved by the manufacturer in writ ing including engine control parameters In compliance with all safety regulations and in adherence with all warning notices in this manual In accordanc...

Page 8: ...rk on or around the product This personnel must be instructed repeatedly Personnel requirements All work on the product shall be carried out by trained and qualified personnel only Training at the Tra...

Page 9: ...t 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...

Page 10: ...ce work Do not blow out the interior of the flywheel housing or the starter with compressed air Clean the flywheel housing inside with a class H dust extraction device Observe the safety data sheet Sa...

Page 11: ...pipes which are to be welded from the product beforehand Hydraulic installation and removal Check satisfactory function and safe operating condition of tools jigs and fixtures to be used Use only the...

Page 12: ...stop feature Store spare parts properly prior to replacement i e protect them against moisture in particular Pack defective electronic components and assemblies in a suitable manner when dispatched f...

Page 13: ...are prohibited by emission regulations Emission control units systems may only be maintained exchanged or repaired if the components used for this purpose are approved by the manu facturer Noncomplian...

Page 14: ...be replaced Carry out leak test in accordance with the specifications Paints and varnishes Observe the relevant safety data sheet for all materials When painting in areas other than spray booths equi...

Page 15: ...event of a situation involving potential danger Consequences Minor or moderate injuries Remedial action NOTICE In the event of a situation involving potentially adverse effects on the product Conseque...

Page 16: ...nt of heat to be dissipated by the coolant absolute gas tightness Turbocharging Sequential turbocharging with internal engine coolant controlled charge air cooling The right hand ex haust turbocharger...

Page 17: ...charging generator Open bus interface to the plant SAE J1939 Emergency stop function with line break monitoring Redundant supply voltage input Emergency air shutoff flap control option Key switch logi...

Page 18: ...marine engine Series 4000M53R to M93L may be operated in low load operation State of the art design and equipment features e g TE coolant circuit sequential turbocharging jacketed coolant cooled exha...

Page 19: ...of rated power takes place in single ETC mode with only one exhaust turbocharger running To ensure the functionality of the control mechanism and of the exhaust flap of the turbocharger which does not...

Page 20: ...after LP pump 1 SOLAS clip on the fuel line on fuel filter head retainer 1 SOLAS clip on the fuel line on HP pump 2 SOLAS clip on the fuel line after fuel filter head 20 Product Summary MS150067 02E...

Page 21: ...LAS clips on the fuel line on fuel filter head Lube oil system oil lines with oil pressure 1 8 bar All lines with SOLAS compliant covers for pipe connections according to MTU standard MTN5233 are show...

Page 22: ...ylinder ETC B1 1 SOLAS clips on air flap switching cylinder ETC B1 2 SOLAS clips on flap control T adapt er ETC B1 1 SOLAS clips on distributor element 2 SOLAS clips on oil return 22 Product Summary M...

Page 23: ...line to ETC 2 SOLAS clip on oil line to flap control 3 SOLAS clip on oil line to recircula tion valve 4 SOLAS clips on oil line from main gallery 1 SOLAS clips on recirculation valve MS150067 02E 201...

Page 24: ...on HP pump oil supply on HP pump 1 SOLAS clip on HP pump oil supply on equipment carrier 1 SOLAS clip on ETC oil supply 2 SOLAS clip on ETC oil supply 24 Product Summary MS150067 02E 2014 04 TIM ID 00...

Page 25: ...on oil filter cartridge Special connections The following types of union are spray proof in case of leakage even without covers and have been con firmed as being SOLAS compliant by GL and DNV MS15006...

Page 26: ...hread The pressure is so greatly reduced by this and the faulty sealing ring 1 that any leakage is not under pressure Plug in pipe union b The sleeve 3 covers the joint to prevent lateral spray Only l...

Page 27: ...ll type seal area 20 Leak fuel connection The HP fuel line is sealed by the thrust ring 8 If leakage in the area of the thrust ring 8 or the HP line 2 occurs the emerging fuel is routed to the leakage...

Page 28: ...8 Air pipe to intercooler 9 Intercooler 10 Recirculation line 11 Exhaust manifold 12 Engine mounts 13 Charge air line 14 Oil pan 15 Oil filler neck 16 Crankcase 17 Cylinder head 18 Fuel filter 19 Bat...

Page 29: ...8 Dry type air filter 9 Exhaust turbocharger 10 Exhaust outlet 11 Air pipe to intercooler 12 Recirculation line 13 Exhaust manifold 14 Intercooler 15 Charge air line 16 Engine mounts 17 Oil pan 18 Oi...

Page 30: ...air filter 8 Exhaust manifold 9 Recirculation line 10 Exhaust turbocharger 11 Exhaust outlet 12 Air pipe to intercooler 13 Intercooler 14 Engine mounts 15 Charge air line 16 Oil pan 17 Oil filler neck...

Page 31: ...ne mounts 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 water inlet KGS Free end Ov...

Page 32: ...Top view 16V 4000 M external cooling 1 B49 charge air temp air recirculation valve Y26 air recirculation valve A 2 B4 A1 B4 B8 single ex haust temp A1 A8 B1 B8 3 B33 fuel temperature in common rail 3...

Page 33: ...filter 3 B5 1 oil pressure down stream of filter 4 B33 fuel temperature in common rail 5 B48 fuel pressure in com mon rail 6 B1 camshaft speed 7 B54 oil refill pump pres sure 8 B6 2 coolant tempera t...

Page 34: ...ooling 1 B4 21 exhaust tempera ture A bank 2 B4 22 exhaust tempera ture B bank 3 B13 crankshaft speed 4 S37 2 safety switch 5 S37 1 safety switch 6 B13 2 crankshaft speed 34 Product Summary MS150067 0...

Page 35: ...mperature 3 B44 1 turbocharger A speed 4 B10 charge air pressure 5 B34 3 fuel pressure up stream of filter 6 B34 2 fuel pressure up stream of filter 7 B34 1 fuel pressure down stream of filter 8 F46 f...

Page 36: ...0 M right side external cooling 1 B44 2 turbocharger B speed 2 Y27 turbocharger control valve 3 B16 coolant pressure 4 B9 charge air tempera ture 36 Product Summary MS150067 02E 2014 04 TIM ID 0000018...

Page 37: ...p view 16V 4000 M integral cooling 1 B4 A1 B4 B8 single ex haust temp A1 A8 B1 B8 2 B33 fuel temperature in common rail 3 F33 coolant level MS150067 02E 2014 04 Product Summary 37 TIM ID 0000018445 00...

Page 38: ...filter 3 B5 1 oil pressure down stream of filter 4 B33 fuel temperature in common rail 5 B48 fuel pressure in com mon rail 6 B1 camshaft speed 7 B54 oil refill pump pres sure 8 B6 2 coolant tempera t...

Page 39: ...ooling 1 B4 21 exhaust tempera ture A bank 2 B4 22 exhaust tempera ture B bank 3 B13 crankshaft speed 4 S37 2 safety switch 5 S37 1 safety switch 6 B13 2 crankshaft speed MS150067 02E 2014 04 Product...

Page 40: ...circulation valve A 3 B3 intake air temperature 4 B44 1 turbocharger A speed 5 B10 charge air pressure 6 B34 3 fuel pressure up stream of filter 7 B34 2 fuel pressure up stream of filter 8 B34 1 fuel...

Page 41: ...e integral cooling 1 B44 2 turbocharger B speed 2 Y27 turbocharger control valve 3 B16 coolant pressure 4 B21 raw water pressure 5 B9 charge air tempera ture MS150067 02E 2014 04 Product Summary 41 TI...

Page 42: ...to the cylinders on the left hand side of the engine and the letter B 3 to refer to the cylinders on the right hand side The cylinders of each bank are numbered consecutively starting with No 1 at th...

Page 43: ...idth B with si lencer Height C 16V 4000 M63L approx 3388 mm approx 1690 mm approx 1850 mm approx 2064 mm Engines with vertical air intake With remote heat exchanger Engine model Length A Width B Heigh...

Page 44: ...g Sequence 2 4 1 Firing order Cylinders Firing order 12 V A1 B5 A5 B3 A3 B6 A6 B2 A2 B4 A4 B1 16 V A1 A7 B4 B6 A4 B8 A2 A8 B3 B5 A3 A5 B2 A6 B1 B7 44 Product Summary MS150067 02E 2014 04 TIM ID 000002...

Page 45: ...0 100 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylinders Engine mounted heat exchanger Remote heat ex changer Rated engine speed A rpm 1800 1800 1800 1800 Fue...

Page 46: ...oil operating pressure before engine from R bar 5 3 5 3 5 3 5 3 Lube oil operating pressure before engine to R bar 6 3 6 3 6 3 6 3 Lube oil operating pressure low idle meas point before engine R bar 2...

Page 47: ...Option max operating inclinations L De grees 22 5 22 5 22 5 22 5 Longitudinal inclination continuous max driving end up Option max operating in clinations L De grees 10 10 10 10 Longitudinal inclinati...

Page 48: ...Engine mounted heat exchanger Remote heat ex changer Engine dry weight with attached standard accessories without coupling R kg 9020 9020 8590 8590 ACOUSTICS Number of cylinders Engine mounted heat ex...

Page 49: ...3 Operation 3 1 Controls Automation system controls Refer to automation system operating instructions MS150067 02E 2014 04 Operation 49 TIM ID 0000016959 003...

Page 50: ...th position of pressure indicator Page 164 HP fuel pump Only for engines without oil priming pump Fill HP fuel pump with new engine oil Page 151 Raw water pump if located above waterline only appli ca...

Page 51: ...Check coolant level Page 208 Coolant system Preheat coolant with preheating unit Fuel prefilter Drain Page 165 Check that suction side pressure indicated at the fuel prefilter pressure gauge is withi...

Page 52: ...3 4 Starting the engine Start the engine via the automation system Refer to automation system operating instructions 52 Operation MS150067 02E 2014 04 TIM ID 0000017525 003...

Page 53: ...rge air cooler Check condensate drain Page 187 Air filter Check signal ring position of service indicator Page 190 Replace air filter Page 188 if the signal ring is completely visible in the service i...

Page 54: ...eks Tasks after extended out of service periods 3 weeks Note Operate fuel treatment system for at least 5 minutes 1 Start up fuel treatment system Page 56 2 Shut down fuel treatment system Page 60 54...

Page 55: ...ves 4 Switch on fuel treatment system Page 59 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 56: ...ic water drain 18 Water level electrode 19 Ball valve sample extrac tion inlet 20 Switchgear cabinet 21 Pump 22 Coarse filter 23 Fuel supply from tank 24 Tank Switching on fuel treatment system 1 Swit...

Page 57: ...ball valve 5 at inlet to fuel treatment system Result The pressure upstream of the fuel treatment system increases until the overflow valve at the pump unit opens and fuel flows through bypass 3 and...

Page 58: ...y pump draws fuel via bypass 2 directly from tank 24 5 Check suction pressure at the engine mounted fuel delivery pump Note If the suction pressure is within the permissible limits and engine operatio...

Page 59: ...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 60: ...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 61: ...3 11 Stopping the engine Stopping the engine via the automation system Refer to automation system operating instructions MS150067 02E 2014 04 Operation 61 TIM ID 0000017528 004...

Page 62: ...stress to the engine plant Risk of overheating damage to components Initiate emergency stop only in emergency situations Emergency stop 1 Refer to automation system operating instructions 2 Follow in...

Page 63: ...ature the antifreeze concentration is insufficient for the engine room tem perature antifreeze concentration is 50 and engine room temperature is below 40 C Raw water only on engines with engine mount...

Page 64: ...ressed air gun directly at seals or electronic components such as connectors or ECUs Plant Cleaning 1 Carry out plant cleaning only in areas where an appropriate oil separator is provided environmenta...

Page 65: ...161 W1005 X Replace air filter Page 188 W1006 Replace injection valves injectors Page 153 W1008 X Replace engine oil filter when changing engine oil or when the interval years is reached at the lates...

Page 66: ...nkcase breather Page 145 W1675 X Replace fuel prefilter or filter element of fuel prefilter Page 169 W1713 Injector Reset drift correction parameters CDC Page 240 Table 1 Maintenance task reference ta...

Page 67: ...rt the system by actuating the key switch Running gear blocked engine cannot be barred manually u Contact Service Engine turns on starting but does not fire Cause Corrective action Poor rotation by st...

Page 68: ...icator Page 190 Intercooler dirty u Contact Service Exhaust turbocharger defective u Contact Service Coolant leaks at intercooler Cause Corrective action Intercooler leaky major coolant discharge u Co...

Page 69: ...st gas Cause Corrective action Engine is not at operating temperature u Run engine to reach operating temperature Intercooler leaky u Contact Service MS150067 02E 2014 04 Troubleshooting 69 TIM ID 000...

Page 70: ...h an overload protection If the maximum permissible current consumption is exceeded e g in case of a blockage or dry running the motor protection relay triggers and the pump is switched off u Reset mo...

Page 71: ...ault 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...

Page 72: ...may be exposed to heat u Contact Service 5 HI T Charge Air ZKP Number 2 0121 931 Charge air temperature too high limit value 1 Yellow alarm warning Cause Corrective action Charge air cooler not funct...

Page 73: ...ctive action Coolant circuit for charge air defective 1 Check charge air cooler and coolant cooler 2 Contact Service 15 LO P Lube Oil ZKP Number 2 0100 921 Lube oil pressure too low limit value 1 Yell...

Page 74: ...2 0127 931 Exhaust temperature too high B side limit value 1 Yellow alarm warning Cause Corrective action Wiring damage 1 Check air filter and wiring Page 239 2 Contact Service 22 SS T Exhaust B ZKP N...

Page 75: ...HI Level Leakage Fuel ZKP Number 2 0151 931 Leak off fuel level too high limit value 1 Yellow alarm warning Cause Corrective action Fuel lines leaking 1 Check fuel system 2 Contact Service 29 HI ETC...

Page 76: ...el filter differential oil pressure too high limit value 1 Yellow alarm warning Cause Corrective action Fuel filter not functioning correctly 1 Replace fuel filter Page 161 2 Contact Service 34 SS P D...

Page 77: ...204 Yellow alarm warning Cause Corrective action ETC2 failed to cut in u Contact Service 44 LO Coolant Level Charge Air Cooler ZKP Number 2 0153 921 Coolant level of charge air cooler too low limit va...

Page 78: ...lant pressure too low limit value 2 Red alarm engine stop or reduced injection quantity Cause Corrective action Leak in coolant circuit 1 Check coolant level Page 208 2 Check coolant circuit 59 SS T C...

Page 79: ...tive action Crankcase exhaust system clogged or leaking 1 Reduce power 2 Replace oil mist fine separator element 3 Contact Service 64 SS P Crankcase ZKP Number 2 0106 932 Crankcase pressure too high l...

Page 80: ...mage leaks low coolant level 1 Reduce power 2 Check coolant circuit 68 SS T Coolant ZKP Number 2 0120 932 Coolant temperature too high limit value 2 Red alarm engine shutdown Cause Corrective action C...

Page 81: ...ervice 085 HI T Recirculation ZKP Number 2 0128 931 Recirculation temperature too high limit value 1 Cause Corrective action Charge air temperature before recirculation valve too high u Reduce power 0...

Page 82: ...Red alarm warning Cause Corrective action Starter rotates too slowly or does not rotate at all 1 Check for additional messages 2 Contact Service 93 SS T Preheat ZKP Number 2 1090 922 Preheating tempe...

Page 83: ...g system faulty Yellow alarm warning Cause Corrective action Hour meter faulty u Contact Service 118 LO ECU Power Supply Voltage ZKP Number 2 0140 921 Supply voltage too low limit value 1 Yellow alarm...

Page 84: ...ltage 2 Contact Service 122 HI T ECU ZKP Number 2 0132 921 Electronics temperature too high limit value 1 Yellow alarm warning Cause Corrective action Electronics overheated 1 Reduce power 2 Improve e...

Page 85: ...engine governor indicated for each indiv module u Contact Service 180 AL CAN1 Node Lost ZKP Number 2 0500 680 Connection to a node on CAN bus 1 failed Yellow alarm warning Cause Corrective action Con...

Page 86: ...governor 1 Check devices connected to CAN 2 Contact Service 184 AL CAN PU Data Flash Error ZKP Number 2 0500 684 CAN PU data flash error Cause Corrective action A program fault occurred while trying...

Page 87: ...rate incompatibility 1 Check CAN bus for short circuit rectify short circuit as necessary 2 Check shielding improve shielding as necessary 3 Contact Service 189 AL CAN2 Error Passive ZKP Number 2 050...

Page 88: ...is rectified when engine is restarted Page 52 3 Contact Service 203 SD T Charge Air ZKP Number 1 8004 571 Signal error charge air temperature sensor Yellow alarm warning Cause Corrective action Charg...

Page 89: ...sary Page 239 2 Fault is rectified when engine is restarted Page 52 3 Contact Service 207 SD T Exhaust B ZKP Number 1 8004 577 Signal error exhaust temperature sensor on B side Yellow alarm warning Ca...

Page 90: ...ine is restarted Page 52 3 Contact Service 213 SD P Coolant Charge Air Cooler ZKP Number 1 8004 569 Charge air cooler coolant pressure sensor faulty Yellow alarm warning Cause Corrective action Charge...

Page 91: ...ace as necessary Page 239 2 Fault is rectified when engine is restarted Page 52 3 Contact Service 219 SD T Intake Air ZKP Number 1 8004 573 Signal error intake air temperature sensor Yellow alarm warn...

Page 92: ...n engine is restarted Page 52 3 Contact Service 223 SD Level Coolant Charge Air Cooler ZKP Number 1 8004 583 Charge air cooler coolant level sensor faulty Yellow alarm warning Cause Corrective action...

Page 93: ...iring to connector B1 replace as necessary Page 239 2 Fault is rectified when engine is restarted Page 52 3 Contact Service 230 SD Crankshaft Speed ZKP Number 1 8004 498 Signal error crankshaft sensor...

Page 94: ...k sensor and wiring B44 2 replace as necessary Page 239 2 Fault is rectified when engine is restarted Page 52 3 Contact Service 239 SD P Diff Fuel ZKP Number 1 8004 598 Differential pressure sensor fo...

Page 95: ...nsor faulty Short circuit or wire break u Check sensor and wiring replace as necessary Fault is rectified following engine restart 245 SD ECU Power Supply Voltage ZKP Number 2 8006 589 Signal error en...

Page 96: ...e 52 3 Contact Service 270 SD Frequency Input ZKP Number 2 8006 590 Signal error frequency input Red alarm forced idle Cause Corrective action Frequency input faulty Short circuit or wire break 1 Chec...

Page 97: ...u Replace injector if the fault message appears frequently Page 153 306 AL Timing Cylinder A6 ZKP Number 1 8004 505 Time of flight measuring fault of injector Cause Corrective action Flight time valu...

Page 98: ...h u Replace injector if the fault message appears frequently Page 153 312 AL Timing Cylinder B2 ZKP Number 1 8004 511 Time of flight measuring fault of injector Cause Corrective action Flight time val...

Page 99: ...u Replace injector if the fault message appears frequently Page 153 318 AL Timing Cylinder B8 ZKP Number 1 8004 517 Time of flight measuring fault of injector Cause Corrective action Flight time valu...

Page 100: ...ault is rectified when engine is restarted Page 52 3 Contact Service 323 AL Wiring Cylinder A3 ZKP Number 1 8004 522 Wiring fault cylinder A3 Yellow alarm misfire Cause Corrective action Short circuit...

Page 101: ...ault is rectified when engine is restarted Page 52 3 Contact Service 327 AL Wiring Cylinder A7 ZKP Number 1 8004 526 Wiring fault cylinder A7 Yellow alarm misfire Cause Corrective action Short circuit...

Page 102: ...Fault is rectified when engine is restarted Page 52 3 Contact Service 331 AL Wiring Cylinder B1 ZKP Number 1 8004 530 Wiring fault cylinder B1 Yellow alarm misfire Cause Corrective action Short circui...

Page 103: ...ault is rectified when engine is restarted Page 52 3 Contact Service 335 AL Wiring Cylinder B5 ZKP Number 1 8004 534 Wiring fault cylinder B5 Yellow alarm misfire Cause Corrective action Short circuit...

Page 104: ...lt is rectified when engine is restarted Page 52 3 Contact Service 339 AL Wiring Cylinder B9 ZKP Number 1 8004 538 Wiring fault cylinder B9 Yellow alarm misfire Cause Corrective action Short circuit f...

Page 105: ...age 153 3 Fault rectified after each working cycle 4 Contact Service 343 AL Open Load Cylinder A3 ZKP Number 1 8004 542 Injector wiring fault cylinder A3 Yellow alarm misfire Cause Corrective action D...

Page 106: ...age 153 3 Fault rectified after each working cycle 4 Contact Service 347 AL Open Load Cylinder A7 ZKP Number 1 8004 546 Injector wiring fault cylinder A7 Yellow alarm misfire Cause Corrective action D...

Page 107: ...Page 153 3 Fault rectified after each working cycle 4 Contact Service 351 AL Open Load Cylinder B1 ZKP Number 1 8004 550 Injector wiring fault cylinder B1 Yellow alarm misfire Cause Corrective action...

Page 108: ...age 153 3 Fault rectified after each working cycle 4 Contact Service 355 AL Open Load Cylinder B5 ZKP Number 1 8004 554 Injector wiring fault cylinder B5 Yellow alarm misfire Cause Corrective action D...

Page 109: ...e 153 3 Fault rectified after each working cycle 4 Contact Service 359 AL Open Load Cylinder B9 ZKP Number 1 8004 558 Injector wiring fault cylinder B9 Yellow alarm misfire Cause Corrective action Dis...

Page 110: ...shutdown possible Cause Corrective action Electronics faulty 1 Start ITS 2 Replace engine governor if required 3 Check additional messages if ITS indicates diagnosis Electronics OK e g wiring faulty 4...

Page 111: ...e action Short circuit or wire break on transistor output 1 TO 1 1 Check charger valve wiring repair as necessary 2 Replace engine governor 372 AL Wiring TO 2 ZKP Number 1 8004 635 Line disruption Cau...

Page 112: ...reak on transistor output plant side 2 TOP 2 u Check wiring to plant 383 AL Wiring TOP 3 ZKP Number 2 8006 640 Line disruption on digital input 3 Yellow alarm warning Cause Corrective action Short cir...

Page 113: ...2 Cause Corrective action Redundant coolant temperature reading too high engine stop 1 Check wiring and sensor 2 Contact Service 394 LO P Lube Oil Red ZKP Number 2 0112 921 Limit value 1 Cause Correct...

Page 114: ...larm warning Cause Corrective action Wiring faulty No resistance over switch 1 Check wiring Page 239 2 Check target device input 3 Contact Service 402 AL Open Load Digital Input 3 ZKP Number 2 8006 62...

Page 115: ...Check wiring Page 239 2 Check target device input 3 Contact Service 406 AL Open Load Digital Input 7 ZKP Number 2 8006 631 Line disruption on digital input 7 Yellow alarm warning Cause Corrective act...

Page 116: ...aulty current supply 1 Check wiring Page 239 2 Check supply 3 Contact Service 411 LOLO U PDU ZKP Number 2 0141 922 Injector voltage too low limit value 2 Red alarm engine shutdown Cause Corrective act...

Page 117: ...P Number 2 0107 921 Coolant pressure in charge air cooler too low limit 1 Yellow alarm warning Cause Corrective action Leak in coolant circuit u Top up coolant 416 SS P Coolant Charge Air Cooler ZKP N...

Page 118: ...Number 2 0160 922 Limit value 2 Cause Corrective action Input signal of Aux 1 has exceeded not attained limit value 2 depending on configuration u Determine cause of limit value violation and rectify...

Page 119: ...depending on configuration u Determine cause of limit value violation and rectify fault 444 SD U PDU ZKP Number 1 8004 578 Injector power stage supply voltage fault Yellow alarm warning Cause Correct...

Page 120: ...at turbine bypass flap u Contact Service 449 SS P Charge Air ZKP Number 2 0103 932 Charge air pressure too high limit value 2 Red alarm engine shutdown Cause Corrective action Fault at turbine bypass...

Page 121: ...use Corrective action Input signal of Aux 1 plant side has exceeded not attained limit value 1 depending on configuration u Determine cause of limit value violation and rectify fault 456 AL L2 Aux1 Pl...

Page 122: ...pressure faulty short circuit or wire break u Check pressure transmitter and wiring replace as necessary Fault is rectified following engine restart 467 AL L2 T Aux 1 ZKP Number 2 0130 922 Limit valu...

Page 123: ...52 3 Contact Service 471 SD Coil Current ZKP Number 1 8004 592 Signal error HP fuel control block Yellow alarm warning Cause Corrective action Actuation of HP fuel control block faulty Short circuit o...

Page 124: ...t Service 476 AL Crash Rec Init Error ZKP Number 1 8010 007 Initialization error of crash recorder Cause Corrective action Initialization error of crash recorder u Contact Service 478 AL Comb Alarm Ye...

Page 125: ...eak u Check sensor and wiring B4 23 replace as necessary 483 SD T Exhaust D ZKP Number 18 004 597 Cause Corrective action Exhaust temperature sensor on A side faulty Short circuit or wire break u Chec...

Page 126: ...low alarm warning Cause Corrective action Clogged charge air circuit or fault in turbocharger u Reduce power 489 SS ETC3 Overspeed ZKP Number 2 3014 932 Speed of 2nd secondary turbocharger too high li...

Page 127: ...3 Yellow alarm warning Cause Corrective action ETC3 failed to cut in u Check control valve at turbocharger 3 500 AL Wiring POM Starter 1 ZKP Number 1 4500 900 Wiring fault connection of starter 1 at P...

Page 128: ...erator and wiring Page 239 504 AL CAN POM Node Failure ZKP Number 1 4500 904 POM missing on CAN bus Yellow alarm warning Cause Corrective action If alarm 508 occurs in addition the resistor in the POM...

Page 129: ...ssible start cancelation Cause Corrective action Starter on POM could not be engaged 1 Repeat start 2 Check POM starter and wiring Page 239 3 Contact Service 519 Oil Level Calibration Error ZKP Number...

Page 130: ...ed as backup medium for FDH u Contact Service configuration fault 544 AL Configuration Changed ZKP Number 2 0555 003 Yellow alarm Cause Corrective action This alarm is activated when the system config...

Page 131: ...valid enabling code is entered via the SAM display and key controls This enabling code can be requested via the Internet using a special procedure u Request activation code via Internet 576 AL ESCM Ov...

Page 132: ...is too low limit value 1 Yellow alarm warning Cause Corrective action Oil level in oil refill tank too low 1 Check oil level top up as necessary Page 192 2 Contact Service 588 SD P Oil Refill Pump ZK...

Page 133: ...sensor and wiring replace as necessary Page 239 2 Contact Service 601 SD ETC1 ETC2 ZKP Number 1 3011 227 Signal error ETC speed sensor 1 and 2 Yellow alarm warning Cause Corrective action ETC speed se...

Page 134: ...ressure sensor before supplementary filter Yellow alarm warning Cause Corrective action Analog input signal for fuel pressure before supplementary filter faulty Short circuit or wire break 1 Check pre...

Page 135: ...too high u 761 SD T Fuel b Engine ZKP Number 1 0080 900 Cause Corrective action Oil pan temperature sensor faulty Short circuit or wire break 1 Check sensor and wiring B24 replace as necessary Page 2...

Page 136: ...lue 1 Cause Corrective action Lube oil pressure too low u Check ETC oil lubrication 867 AL L1 P Lube Oil ETC A ZKP Number 1 0222 923 Limit value 1 Cause Corrective action Lube oil pressure too low u C...

Page 137: ...ng engine 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...

Page 138: ...o resistance other than compression re sistance must be encountered 4 Rotate crankshaft in engine direction of ro tation Result If the resistance exceeds the normal com pression resistance contact Ser...

Page 139: ...6 1 2 Engine Barring with starting system Barring using the automation system Refer to automation system operating instructions MS150067 02E 2014 04 Task Description 139 TIM ID 0000017532 003...

Page 140: ...attern First signs of marks left by lower cooling bores Running pattern seems darker No action required Darker areas of even or varying color intensity Beginning and end of the discoloration are not s...

Page 141: ...Final steps 1 Install injector Page 154 2 Install cylinder head cover Page 150 MS150067 02E 2014 04 Task Description 141 TIM ID 0000000015 016...

Page 142: ...nd the liner It appears rather darker within the honed struc ture in contrast to the bright metallic running surface The honing pattern is undis turbed Discolorations extend in stroke direction and ma...

Page 143: ...tion are similar A thorough investigation and compliance with the above evaluation criteria allow an unambiguous evaluation To avoid unnecessary disassembly work it is recommended that another inspect...

Page 144: ...tilation Overview For 16V engines 1 Vent pipe 2 Impactor carrier 3 Bracket 4 Oil line 5 Service block 6 Vent housing 7 Spigot pipe 8 Drain pipe 9 Bracket 10 Plug 11 Oil separator 144 Task Description...

Page 145: ...Oil can contain combustion residues which are harmful to health Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Rep...

Page 146: ...re parts Designation Use Part No Qty Engine oil Valve gear Lubrication 1 Remove cylinder head covers Page 150 2 Fill oil chambers of valve bridges with oil 3 Fill oil chambers of rocker arms and adjus...

Page 147: ...e parts Designation Use Part No Qty Feeler gauge Y20098771 1 Torque wrench 60 320 Nm F30452768 1 Box wrench socket 24 mm F30039526 1 Engine oil Preparatory steps 1 Remove cylinder head cover Page 150...

Page 148: ...inder A1 the piston is in overlap TDC 2 Check valve clearance with cold engine Inlet long rocker arm 0 2 mm 0 05 mm Exhaust short rocker arm 0 5 mm 0 05 mm 3 Check all valve clearances in two cranksha...

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

Page 150: ...r head covers 1 prior to removal 2 Remove screws 3 4 with washers 2 5 3 Take off cylinder head cover 1 with O ring 6 from cylinder head 7 Installing cylinder head cover 1 Clean mounting surface 2 Chec...

Page 151: ...G Oils oil vapors are combustible explosive Risk of fire and explosion Avoid open flames electric sparks and ignition sources Do not smoke NOTICE HP fuel pump not filled with engine oil Damage to comp...

Page 152: ...e s danger zone WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors HP pump Relief bore check 1 Visually inspect relief bore 1 for fuel dis char...

Page 153: ...or Replacement Special tools Material Spare parts Designation Use Part No Qty Injector Spare Parts Catalog Replacing injector u Remove injector and install new injector Page 154 MS150067 02E 2014 04 T...

Page 154: ...h 60 320 Nm F30452768 1 Ratchet adapter F30027341 1 Assembly paste Optimoly Paste White T 40477 1 Assembly compound Kluthe Hakuform 30 11C Emulgier X00059351 1 Engine oil O ring Spare Parts Catalog WA...

Page 155: ...emove injector with installation removal jig 7 Remove installation removal jig 8 Remove sealing ring 4 from injector or use a self made hook to take it out of the cylinder head 9 Remove O rings 3 O ri...

Page 156: ...osition of sealing ring 4 Fit new O rings 3 included in the scope of delivery of the injector O ring 2 and damping ring 1 onto the injector and coat with assembly compound Kluthe Hakuform 30 11C Emulg...

Page 157: ...reload torque Engine oil 5 Nm to 10 Nm 13 Tighten screw 2 with torque wrench to the specified tightening torque Name Size Type Lubricant Value Standard Screw M12 Tightening torque 100 Nm 10 Nm 14 Tigh...

Page 158: ...ill void the emissions certification 18 Reset drift compensation CDC with Dia Sys E531920 If DiaSys is not available contact Service Final steps 1 Install cylinder head cover Page 150 2 Open fuel supp...

Page 159: ...mentary fuel filter Overview 1 Storage tank 2 Day tank 3 Passive standard prefilter with water separator 4 LP pump 5 Supplementary fuel filter 6 Main engine filter MS150067 02E 2014 04 Task Descriptio...

Page 160: ...ls are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke WARNING High level of engine noise when the engine is running Risk of damage to hear...

Page 161: ...engine is running Risk of damage to hearing Wear ear protectors NOTICE Damage to component Severe material damage For filter replacement with the engine running operate the engine at low engine load T...

Page 162: ...filter 1 using an oil filter wrench 3 Clean sealing surface on filter head 4 Check sealing ring of new filter 1 and coat with fuel 5 Screw on filter 1 and tighten manually 6 Turn three way cock into...

Page 163: ...lters are operational 2 Open threaded vent plugs 1 3 Unlock fuel priming pump 2 screw out handle by turning it counterclockwise 4 Operate fuel priming pump 2 until bubble free fuel emerges from the th...

Page 164: ...f ferential pressure gauge 1 After installation of a new filter element align adjustable pointer 2 with pressure indicating pointer 3 of pressure gauge 1 2 Verify that differential pressure is within...

Page 165: ...cal sparks and ignition sources Do not smoke Draining fuel prefilter 1 Cut out the filter to be replaced A or B 1 Filter A cut out 2 Filter B cut out 2 Open vent plug 1 of filter to be drained 3 Open...

Page 166: ...l until fuel emerges from the vent pipe 3 8 Close vent valve 2 9 Open rotary slide valve 4 a little by ap prox 30 and open vent valve s 2 until fuel emerges from the vent pipe 3 10 Close vent valve s...

Page 167: ...at low power Keep away from the engine s danger zone WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke WARNING High level o...

Page 168: ...ng connection 1 on the suction side of the filter 3 Open vent valve 2 and fill with fuel until fuel emerges from the vent pipe 3 4 Close vent valve 2 5 Open rotary slide valve 4 a little by ap prox 30...

Page 169: ...WARNING Tank is pressurized Risk of eye injuries resulting from fluid escaping under high pressure Open tank slowly Wear goggles or safety mask WARNING Fuels are combustible Risk of fire and explosio...

Page 170: ...ng torque maximum half a turn per screw Name Size Type Lubricant Value Standard Screw Tightening torque 40 Nm 10 Connect filling pump to filling connection 1 on the suction side of the filter 11 Open...

Page 171: ...mask WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke Fuel prefilter with water separa tor O ring replacement in rota ry...

Page 172: ...ger 1 Impeller housing left 2 Impeller housing right 3 Washer 4 Nut 5 Shaft 6 Bearing bush 7 Shaft 8 Sprung pin 9 Sealing ring 10 Sealing flange 11 Bolt 12 Turbine housing right 13 Turbine housing lef...

Page 173: ...her 8 Bearing bush 9 Washer 10 Circlip 11 Circlip 12 Washer 13 Bearing bush 14 O ring 15 Bearing housing 16 Bolt 17 Nut 18 Dished washer 19 Dished washer 20 Dished washer 21 Stud bolt 22 Bolt 23 Washe...

Page 174: ...ring 9 Ring retainer 10 O ring 11 Retaining ring 12 Impeller 13 Magnetic nut 14 Grooved pin 15 Identification plate 16 Impeller housing 17 Plug bolt 18 Sealing ring 19 Sealing ring 20 Plug bolt 21 Cl...

Page 175: ...sher 8 Bearing bush 9 Washer 10 Circlip 11 Circlip 12 Washer 13 Bearing bush 14 O ring 15 Bearing housing 16 Bolt 17 Nut 18 Dished washer 19 Dished washer 20 Dished washer 21 Stud bolt 22 Bolt 23 Wash...

Page 176: ...Piston ring 9 Ring retainer 10 O ring 11 Retaining ring 12 Impeller 13 Magnetic nut 14 Bolt 15 Washer 16 Clamping piece 17 Impeller housing 18 Plug bolt 19 Sealing ring 20 Identification plate 21 Gro...

Page 177: ...Impeller housing 1 Impeller housing 2 Plug bolt 3 Sealing ring Bearing housing 1 Bearing housing 2 Sprung pin MS150067 02E 2014 04 Task Description 177 TIM ID 0000037654 001...

Page 178: ...Thrust bearing 1 Ball 2 Thrust bearing Magnetic nut 1 Magnetic nut 2 Magnet 178 Task Description MS150067 02E 2014 04 TIM ID 0000037654 001...

Page 179: ...he instructions of the cleaning agent manufacturer NOTICE Inappropriate cleaning tool Risk of damage to component Observe manufacturer s instructions Use appropriate cleaning tool NOTICE Incorrect ins...

Page 180: ...er 5 Remove oil lines 2 6 Loosen clamp 1 7 Remove intake housing 3 with actuating cylinder 2 8 Remove coolant lines 1 from compressor housing 3 9 Remove coolant ventilation line 2 from compressor hous...

Page 181: ...ing with a smooth paint brush or brush 2 Clean compressor wheel 2 and bearing housing 1 3 Thoroughly remove cleaner from all compo nents 4 Fit new sealing rings between bearing housing compressor hous...

Page 182: ...e 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 torq...

Page 183: ...filter Page 189 3 Seal all openings with suitable covers 4 Remove charge air pipework 1 from ex haust turbocharger to intercooler 5 Remove oil lines 2 6 Loosen clamp 1 7 Remove intake housing 3 with a...

Page 184: ...e Do not use wire brushes scrapers or simi lar 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 cle...

Page 185: ...ening 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 cyl inder 2 5 Align clamp 1 and tighten to spe...

Page 186: ...me 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 fil...

Page 187: ...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 from...

Page 188: ...re parts Designation Use Part No Qty Air filter Spare Parts Catalog Replacing the air filter 1 Remove old air filter and install new air filter Page 189 2 Reset signal ring of contamination indicator...

Page 189: ...in the flange of the intake housing 3 and clean it 4 Attach air filter 1 with clamp 2 onto in take housing 3 5 Tighten clamp 2 Air filter with intake silencer 1 Loosen clamp 2 2 Remove air filter 1 a...

Page 190: ...isabled Checking signal ring position 1 If the signal ring is completely visible in the control window 2 replace air filter Page 188 2 After installation of new filter press reset button 1 Result Enga...

Page 191: ...eck Preconditions Engine is stopped and starting disabled Checking starter condition 1 Check securing screws of starter for secure seating and tighten if required 2 Check wiring Page 239 MS150067 02E...

Page 192: ...xchanger flowing back into the oil pan 3 The oil level must reach mark 1 or exceed mark 1 by up to 2 cm 4 Top up with oil to mark 1 as necessary Page 193 5 Insert dipstick into guide tube up to the st...

Page 193: ...y mask Avoid contact with skin Do not inhale oil vapor Oil change without semirotary hand pump Draining oil via drain plug s on oil pan 1 Provide a suitable container to collect the oil 2 Remove drain...

Page 194: ...tening torque Engine oil 100 Nm 10 Nm Filling with new oil 1 Open cap on filler neck 2 Pour oil in at filler neck up to max mark at oil dipstick 3 Close cap on filler neck 4 Check engine oil level Pag...

Page 195: ...ar protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear p...

Page 196: ...filter by 1 to 2 rotations 2 Drain approx 2 liters engine oil to flush out the oil sludge 3 Drain approx 1 liter engine oil into a clean container 4 Close screw 5 Using the equipment and chemicals in...

Page 197: ...ve clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor NOTICE Damage to component Severe material damage For filter replacement with the engine running operate the...

Page 198: ...9 9 Check oil level Page 192 Oil filter with diverter option Oil filter replacement with the engine running 1 To cut out the filter to be replaced set the three way cock to the corresponding posi tion...

Page 199: ...e clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor WARNING Compressed air gun ejects a jet of pressurized air Risk of injury to eyes and damage to hearing risk o...

Page 200: ...part Cleaning strainer 1 Wash strainer 5 with cleaner 2 Remove stubborn deposits with soft brush 3 Blow out strainer 5 with compressed air from inside Installing strainer 1 Coat square section ring 4...

Page 201: ...Catalog Sealing ring Spare Parts Catalog Sealing ring Spare Parts Catalog WARNING Hot oil Oil can contain combustion residues which are harmful to health Risk of injury and poisoning Wear protective...

Page 202: ...and rotor base 10 with sealing ring 9 13 Insert new filter sleeve 6 in rotor tube 7 with the smooth paper surface facing the outer wall 14 Check sealing ring 5 fit new one if neces sary 15 Mount rotor...

Page 203: ...Push standpipe 12 onto rotor lower sec tion 13 13 Insert new filter sleeve 9 with stiffener plate 10 into rotor cap 8 ensuring that the smooth surface of the filter sleeve 9 faces the rotor cap 8 14...

Page 204: ...t Circuit General High Temperature Circuit 6 15 1 Drain and vent points Coolant lines on ETC 1 Vent point Coolant line to intercooler 1 Vent point 204 Task Description MS150067 02E 2014 04 TIM ID 0000...

Page 205: ...1 Vent point Coolant line to raw water cooler 1 Vent point MS150067 02E 2014 04 Task Description 205 TIM ID 0000014545 004...

Page 206: ...Vent line Distribution cross 1 Vent point Coolant drain point engine driving end 1 Drain point 206 Task Description MS150067 02E 2014 04 TIM ID 0000014545 004...

Page 207: ...Coolant drain point engine free end 1 Drain point MS150067 02E 2014 04 Task Description 207 TIM ID 0000014545 004...

Page 208: ...se 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 cast in eye i...

Page 209: ...e Special tools Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 210 2 Fill with engine coolant Page 213 MS150067 02E 2014 04 Task Description...

Page 210: ...2 Switch off preheating unit Engine coolant Draining 1 Turn breather valve on expansion tank for engines with remote heat exchanger the expansion tank is part of the remote cooling system countercloc...

Page 211: ...e on exhaust pipework driv ing end 1 6 Open vent valve on seawater cooler 1 or remote heat exchanger 7 Open drain plug 1 and drain coolant at crankcase MS150067 02E 2014 04 Task Description 211 TIM ID...

Page 212: ...screw 1 and drain coolant on coolant pump elbow Final steps 1 Seal all open vent and drain points 2 Set breather valve onto filler neck and close it 212 Task Description MS150067 02E 2014 04 TIM ID 00...

Page 213: ...e clothing gloves and goggles safety mask NOTICE Cold coolant in hot engine can cause thermal stress Possible formation of cracks in the engine Fill top up coolant only into cold engine Preparatory st...

Page 214: ...faces if required 5 Set breather valve onto filler neck and turn until the first stop 6 Start engine Page 52 7 After 10 seconds of running the engine without load shut down the engine Page 61 8 Turn b...

Page 215: ...of damage to hearing Wear ear protectors HT coolant pump Relief bore check 1 Check relief bore for oil and coolant dis charge 2 Stop engine Operating instructions elec tronic system and disable engine...

Page 216: ...own Wear protective clothing gloves and goggles safety mask WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors Engine coolant Sample extrac tio...

Page 217: ...alding Let the engine cool down Wear protective clothing gloves and goggles safety mask Engine coolant filter Replace ment 1 Remove locking device 1 2 Close shut off cock 3 3 Remove engine coolant fil...

Page 218: ...d to warm up the engine coolant The circulating pump 8 ensures the circulation of the preheated engine coolant through the engine The continuous flow heater 5 comprises a heating element The thermosta...

Page 219: ...eating unit 1 On Off switch Cylinders Nominal voltage frequency Heating power kW 12 V and 16 V 230 V 50 Hz 9 400 V 50 Hz 9 230 V 60 Hz 9 440 V 60 Hz 9 MS150067 02E 2014 04 Task Description 219 TIM ID...

Page 220: ...prises a heating element A non return flap 3 prevents coolant from flowing through the preheating unit when the engine is running When the coolant temperature has reached the value of the thermostat s...

Page 221: ...y to heating element 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...

Page 222: ...asses facial protection 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 tempe...

Page 223: ...se when the engine is running Risk of damage to hearing Wear ear protectors Raw water pump Relief bore check 1 Check relief bore for oil and coolant dis charge 2 Stop engine Page 61 and disable en gin...

Page 224: ...gine mounting Check Engine mounting Check Item Findings Action Visually inspect mounts Damage Brittleness Deformation Crack formation Swelling visible Replace contact Service 224 Task Description MS15...

Page 225: ...ed Battery charging generator drive Coupling condition check 1 Remove screws 1 2 Remove protective cover 2 3 Check resilient coupling 3 for cracks and plastic deformation 4 If there is serious deforma...

Page 226: ...ise when the engine is running Risk of damage to hearing Wear ear protectors Bilge pump Relief bore check 1 Check relief bores for oil and water dis charge 2 Stop engine Page 61 and disable en gine st...

Page 227: ...System 6 20 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 MS150067 02E 2014 04 Task Description 227 TIM ID...

Page 228: ...es Do not smoke Checking differential pressure gauge 1 Switch on fuel treatment system Page 59 2 Set the alarm points at the differential pressure gauge to zero Result Alarm is initiated with preset d...

Page 229: ...ect connector from water level probe 4 Immerse water level probe into a tank filled with water until water level reaches the thread 5 Switch system on Result Water drain valve opens 6 Leave water leve...

Page 230: ...k pressure at the pressure gauge in the inlet to the fuel treatment system and note down 3 Check pump pressure with reduced suction a Reduce suction pressure of pump to 0 8 bar with the shutoff valve...

Page 231: ...mponents and lines Damage to component Ensure that components lines are installed so that they are never under tension or strain Ensure correct installation position of components Coalescer filter ele...

Page 232: ...htening torque Engine oil 30 Nm 3 Nm 17 Fit gasket 10 18 Install cover 19 Install screws 1 washers 2 and nuts 9 20 Tighten nuts 9 21 Open ball valve at the inlet and outlet of the fuel treatment syste...

Page 233: ...filter B34 2 Fuel pressure upstream of filter B34 3 Fuel pressure upstream of external filter B44 1 Rotation speed exhaust turbocharger A B44 2 Rotation speed exhaust turbocharger B B48 HP fuel press...

Page 234: ...ensors 12V engine 1 M8 2 B1 3 B6 4 X2 5 X37 6 XXF33 7 F33 8 B16 9 XF33 10 B54 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 B49 21 B44 1 22 Y26 23 B5 3 24 B3 25 B4 21 26...

Page 235: ...2 7 X37 8 XF33 9 B54 10 B16 11 XXF33 12 F33 13 B4 22 14 B9 15 S37 1 16 B34 3 17 B34 2 18 B34 1 19 B50 20 B49 21 B44 1 22 Y26 23 B5 3 24 B3 25 B4 21 26 B10 27 B13 28 S37 2 29 B7 30 B5 1 31 B48 32 B33 3...

Page 236: ...iring harness 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 236 Task Description MS150067 02E 2014 04 TIM ID 0000038...

Page 237: ...injectors 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 MS150067 02E 2014 04 Task Description...

Page 238: ...Engine wiring harness for electric starter 1 Connection terminals EIM 2 Fuse F1 3 Connection terminals starter 238 Task Description MS150067 02E 2014 04 TIM ID 0000038739 002...

Page 239: ...tion 4 Replace cable clips if defective 5 Check that cable clamps are firm tighten loose cable clamps 6 Replace faulty cable clamps 7 Visually inspect the following electrical line components for dama...

Page 240: ...starting disabled Note Failure to reset drift compensation CDC parameters will void the emissions certification Resetting CDC parameters with DiaSys u Dialog system DiaSys E531920 Resetting CDC parame...

Page 241: ...ng 2 2 Check whether both switches 3 are actu ated 3 If switches 3 and or guard plate 1 with engine support 4 is are not installed Screw on guard plate 1 with engine support 4 Then screw on switch 3 e...

Page 242: ...starting disabled Check plug connections on ECU 7 1 Check all connectors on ECU for firm seat ing Ensure that the clips 1 are engaged 2 Check screws 2 of cable clamps on ECU for firm seating Ensure th...

Page 243: ...arting disabled Checking EMU plug connections 1 Check both connectors on EMU 2 for firm seating Ensure that the clips 1 are engag ed 2 Check screws 3 of cable clamps on EMU 2 for firm seating Ensure t...

Page 244: ...ng disabled Checking EIM plug connections 1 Check both Tyco plugs 62 pole 2 on EIM for firm seating Ensure that clips 3 are engaged 2 Check screws 1 of cable clamps on EIM for firm seating Ensure that...

Page 245: ...ntrol Unit from engine 1 Note or mark assignment of cables and connectors 2 Remove all screws 3 3 Undo clips 2 on connectors 4 Remove all male connectors 5 Remove screws 1 6 Take off Engine Control Un...

Page 246: ...rews 2 3 Undo latches 3 of the connectors 4 Disconnect all connectors 5 Remove screws 1 6 Remove ECU 5 with EMU 4 Removing EMU 1 Unscrew screws on base of EMU 4 2 Remove EMU 4 from ECU 5 Installing EM...

Page 247: ...When doing so observe correct assignment between cables and plugs 2 Check seal before installing Result Replace seal if porous or defective Downloading software 1 The new EIM still does not have appro...

Page 248: ...r operation 4 Application loader active 5 External RAM faulty 6 External FLASH faulty 7 No firmware 8 Application crashed Fuse lamp SILA A second indicator is the fuse lamp This is also integrated in...

Page 249: ...oring current path failed S8 10 Emergency stop current path failed 24V internal S9 11 ES pushbutton current path failed 24V external S10 12 Key switch current path failed S11 13 SDAF 1 2 current path...

Page 250: ...fuse S4 fail ure 1 2 second steps Note These bit sequences are transmitted constantly Information about the status of the current paths of the EIM is also provided in the CAN message Sta tus internal...

Page 251: ...Engine management system ECU Engine Control Unit Engine governor EDM Engine Data Module Memory module for engine data EIM Engine Interface Module Interface to engine monitoring system EMU Engine Moni...

Page 252: ...nel PCU Propeller Control Unit PIM Peripheral Interface Module RCS Remote Control System RL Redundancy Lost Alarm Redundant CAN bus failure SAE Society of Automotive Engineers U S standardization orga...

Page 253: ...e work in case of malfunction or changed operating conditions or for spare parts supply Your contact person in our Customer Assistance Center E mail info mtu online com Tel 49 7541 9077777 Fax 49 7541...

Page 254: ...Barring manually Page 137 Box wrench socket 24 mm Part No F30039526 Qty Used in 1 6 4 2 Valve clearance Check and adjustment Page 147 Feeler gauge Part No Y20098771 Qty Used in 1 6 4 2 Valve clearanc...

Page 255: ...Used in 1 6 15 8 Engine coolant filter Replacement Page 217 Installation removal jig Part No F6789889 Qty Used in 1 6 6 2 Injector Removal and installation Page 154 Milling cutter Part No F30452739 Q...

Page 256: ...efilter with water separator Filter ele ment replacement Page 169 Qty Used in 1 6 8 2 Compressor wheel Cleaning Page 179 Ratchet adapter Part No F30027341 Qty Used in 1 6 6 2 Injector Removal and inst...

Page 257: ...Part No 0015384230 Qty Used in 1 6 6 2 Injector Removal and installation Page 154 Torque wrench 10 60 Nm Part No F30452769 Qty Used in 1 6 6 2 Injector Removal and installation Page 154 Qty Used in 1...

Page 258: ...ing and filter sleeve replacement Page 201 Torque wrench 6 50 Nm Part No F30027336 Qty Used in 1 6 20 5 Coalescer filter element Replacement Page 231 Torque wrench 60 320 Nm Part No F30452768 Qty Used...

Page 259: ...der liner Endoscopic examination 140 Instructions and comments on endoscopic and visual examination 142 D Designations Engine sides and cylinders 42 Differential pressure gauge Check 228 Drain and ven...

Page 260: ...uel treatment system Putting into operation 56 Shutdown 60 Switching on 59 H Hotline 253 HP pump Filling with engine oil 151 Relief bore check 152 HT coolant pump Relief bore check 215 I Injector Inst...

Page 261: ...check 190 Service partners 253 Spare parts service 253 Starter Condition check 191 Supplementary fuel filter Overview 159 T Tasks After extended out of service periods 54 Tasks after extended out of s...

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MTU 16 V 4000 M63L, Operating Instructions Manual

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Summary of Contents for 16 V 4000 M63L

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