MTU 16V4000M73 series Operating Instructions Manual Download Page 41

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SCR catalytic converter, left side

M81.3 Dosing unit 1.1
M81.4 Dosing unit 1.2
M81.5 Dosing unit 1.3

M80.1X1 X-VE 1.1 / X1

M80.1X2 X-VE 1.1 / X2
M80.2X1 X-VE 1.2 / X1
M80.2X2 X-VE 1.2 / X2
M80.3X1 X-VE 1.3 / X1

M80.3X2 X-VE 1.3 / X2

XWA1 Adaptation bypass

MS150123/01E 2017-05

| General Information | 41

TIM-ID: 0000071648 - 002

Summary of Contents for 16V4000M73 series

Page 1: ...Operating Instructions Diesel engine with exhaust gas aftertreatment 16V4000M73 16V4000M73L MS150123 01E ...

Page 2: ... any way whether in whole or in part without the prior writ ten consent of MTU Friedrichshafen GmbH This particularly applies to its reproduction distribution editing translation micro filming and storage or processing in electronic systems including databases and online services All information in this publication was the latest information available at the time of going to print MTU Friedrichsha...

Page 3: ...ervice periods 3 weeks 64 5 7 Fuel treatment system control cabinet Controls 65 5 8 Checks prior to start up 66 5 9 Fuel treatment system Initial start up 67 5 10 Fuel treatment system Switching on 70 5 11 Engine with exhaust gas aftertreatment Emergency stop via automation system 71 5 12 Engagement via LOP 73 5 13 Disengaging from LOP 74 5 14 Waterjet Flushing from LOP optional 75 5 15 Engine shu...

Page 4: ...oling 207 8 16 1 Automatic oil filter Overview 207 8 16 2 Automatic oil filter Preparatory steps 210 8 16 3 Automatic oil filter Removal 211 8 16 4 Automatic oil filter Disassembly 213 8 16 5 Automatic oil filter Cleaning 214 8 16 6 Automatic oil filter Checking flushing arm rotation 215 8 16 7 Automatic oil filter Check 216 8 16 8 Automatic oil filter Assembly 217 8 16 9 Automatic oil filter Inst...

Page 5: ... 24 3 Engine Monitoring Unit EMU 8 Plug connection check 271 8 24 4 Interface module EIM plug connections Check 272 8 24 5 Engine governor ECU 9 Removal and installation 273 8 24 6 Engine Monitoring Unit EMU 8 Removal and installation 274 8 24 7 Engine Interface Module EIM Removal and installation 275 8 24 8 Engine Interface Module EIM Diagnostic features 276 8 25 Emergency Instrumentation Local O...

Page 6: ... execution of calibration processes that might affect the emission characteristics of the product are prohibited by emission regulations Emission control units systems may only be maintained ex changed or repaired if the components used for this purpose are approved by the manufacturer Noncompliance with these regulations will invalidate the design type approval issued by the emissions regu lation...

Page 7: ...h regard to the specified tightening torques With the exclusive use of technical personnel trained in commissioning operation maintenance and re pair By contracting only workshops authorized by the manufacturer to carry out repair and overhaul The product must not be operated in explosive atmospheres unless the engine fulfills the conditions for such use and approval has been granted Any other use...

Page 8: ...ese personnel must be instructed repeatedly Personnel requirements All work on the product must be carried out by trained instructed and qualified personnel only Training at the Training Center of the manufacturer Qualified personnel from the areas mechanical engineering plant construction and electrical engineering The operator must define the responsibilities of the personnel involved in operati...

Page 9: ...s against accidental contact Check that all connections have been correctly allocated e g polarity fuel line urea solution line sup ply return Immediately after putting the product into operation make sure that all control and display instruments as well as the signaling and alarm systems work properly Smoking is prohibited in the area of the product Safety regulations during operation The operato...

Page 10: ...quipment is in operation certain components of these appliances are electrically live Follow the applicable operating and safety instructions when operating the devices and heed warnings at all times 10 Safety MS150123 01E 2017 05 TIM ID 0000040533 016 ...

Page 11: ... breakers Before starting work on CaPoS if used Switch of the charging system DC DC converter Discharge the UltraCap modules using the appropriate discharger Short circuit the UltraCap modules with a suitable wire jumper Close the main valve on the compressed air system and vent the compressed air line when pneumatic start ers are fitted Before working on the exhaust gas treatment system close the...

Page 12: ...scellaneous Wear a breathing mask offering protection against soot dust and mineral fibers filter class P2 when work ing on exhaust components Wear protective gloves and goggles for protection against acidic condensate Do not touch elastomeric seals e g Viton sealing rings with your bare hands if they have a carbonized or resinous appearance Elastomer components e g engine mounts damping elements ...

Page 13: ...with the piston extended For a hydraulic installation removal device with central expansion pressure supply screw spindle into shaft end until correct sealing is established During hydraulic installation and removal ensure that nobody is standing in the immediate vicinity of the component to be installed removed Working with batteries Observe the safety instructions of the manufacturer when workin...

Page 14: ... proof Shock proof Wrapped in antistatic foil as necessary Working with laser equipment Work with laser devices shall be carried out by trained and qualified personnel only Follow the safety in structions in the manufacturer s user manual when working with laser equipment Wear special laser safety glasses when working with laser equipment danger of concentrated radiation Laser equipment must be fi...

Page 15: ... per sonal protective equipment when handling components Noise Wear ear protectors in work areas with a sound pressure level in excess of 85dB A Noise can lead to an increased risk of accident if acoustic signals warning shouts or noises indicating dan ger are drowned Environmental protection and disposal Dispose of used fluids lubricants and components in accordance with local regulations Within ...

Page 16: ...pray stands provided with fume extraction systems ensure that the area is well ventilated Make sure that neighboring work areas are not impaired Avoid open flames in the vicinity No smoking Observe fire prevention regulations Always wear a mask providing protection against paint and solvent vapors Liquid nitrogen Observe the relevant safety data sheet for all materials Work with liquid nitrogen ma...

Page 17: ...n NOTICE In the event of a situation involving potentially adverse effects on the product Consequences Material damage Remedial action Additional product information Warning notices 1 This manual with all safety instructions and safety notices must be issued to all personnel involved in opera tion maintenance repair assembly installation or transportation 2 The higher level warning notice is used ...

Page 18: ...ystem engine slowly The lifting ropes or chains must not butt against the exhaust gas aftertreatment system engine or its components during the lifting proce dure Readjust lifting tackle as necessary 10 For special packaging with aluminum foil Suspend the engine by the lifting eyes on the bearing pedestal or transport by means of handling equipment forklift truck capable of bearing the load 11 Sec...

Page 19: ...p or tip over Danger of crushing limbs and body parts Secure the load When securing the load only used the permitted fastening points and fastening equipment WARNING Heavy part risk of falling or overturning due to lack of stability Risk of crushing body or limbs Use appropriate lifting gear and appliances Wear safety shoes Lifting instructions 16V engine 1 Max admissible diagonal pull 10 2 Center...

Page 20: ...hout bypass 1 Max admissible diagonal pull 120 2 Center of gravity 3 Reference point A 1675 mm B 1057 mm C 527 mm D 2 mm E 253 mm F 921 mm G 549 mm H 134 mm Take note of the center of gravity of SCR catalytic converter Refer to the installation arrangement drawings for details of the center of gravity of the SCR catalytic con verter 20 Transport MS150123 01E 2017 05 TIM ID 0000071532 002 ...

Page 21: ...the same time Use the big opening in the middle arrowed as attachment point for the lifting equipment It is recommended to use a dia 8 4 strand chain minimum grade 8 alternatively dia 10 A crossbeam may be used Ensure that the lifting equipment does not damage components The SCR mount catalytic converter must be parallel to the ground when setting it down to ensure that all four mounts 3 touch the...

Page 22: ... transport the transport locking device must be reinstalled on both sides according to the instructions 3 If the engine is to be moved together with the generator the transport locking device for the generator must also be installed 4 Always use the screws supplied with or installed in the transport locking device to secure it on the engine 5 Starting or barring the engine is allowed only with the...

Page 23: ... the ring gear 4 Insert screw 1 in bores of holder 3 until holder 3 is secured Note The screw 1 must be tightened alternately on both sides of the flywheel housing 5 Tighten screw 1 to specified tightening torque Name Size Type Lubricant Value Standard Screw M10 Tightening torque Engine oil 30 Nm 3 Nm 6 Place locknut 2 of screw 1 on plate 6 and lock it Removing the transport locking device from dr...

Page 24: ...supplied or with the screws removed from the guard plates or engine supports u Install engine supports 3 on both sides with guard plates washers 1 and screws 2 and tighten to speci fied tightening torque tightening Name Size Type Lubricant Value Standard Screw M16 Tightening torque Engine oil 250 Nm 25 Nm 24 Transport MS150123 01E 2017 05 TIM ID 0000073120 002 ...

Page 25: ...gnated in accordance 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 Bx refers to the cylinders on the right hand side 3 The cylinders of each bank are numbered consecutively starting with x 1 at driving end 4 The numbering of other engine components also s...

Page 26: ...aust pipe bellows 3 Exhaust system optional 4 Connecting pipe 5 SCR catalytic converter 6 Bypass line 7 Heat shield 8 DCM Distributed Control Module control unit 9 Pre delivery module 10 Power distribution Shown without insulation 26 General Information MS150123 01E 2017 05 TIM ID 0000071545 001 ...

Page 27: ...ing 12 HP fuel pump 13 Automatic oil filter 14 Fuel filter 15 Centrifugal oil filter s 16 Engine governor 17 Raw water cooler Engine model designation Key to the engine model designation 16V4000Mxyz 16 Number of cylinders V Cylinder arrangement V engine 4000 Series M Application M Marine x Application segment 0 1 2 3 9 y Design index 0 1 2 3 9 z L enhanced power speed MS150123 01E 2017 05 General ...

Page 28: ...ine 3 SOLAS insulation 4 Heat shield 5 Dosing units 6 Supply units 7 Bearing 8 DCM Distributed Control Module 9 Pre feed module 10 Power distribution 11 Wiring harness 12 Exhaust inlet flange to after treatment system Shown without insulation 28 General Information MS150123 01E 2017 05 TIM ID 0000071889 002 ...

Page 29: ...pply units 5 Heat shield 6 Replaceable catalyst mod ules 7 Bearing 8 Exhaust pipe bellows after SCR catalytic converter 9 Exhaust flap main flow 10 Exhaust outlet flange from aftertreatment system 11 Exhaust flap bypass flow Shown without insulation MS150123 01E 2017 05 General Information 29 TIM ID 0000071889 002 ...

Page 30: ...by the coolant absolute gas tightness reached Turbocharging Sequential turbocharging with internal engine coolant controlled charge air cooling The right hand exhaust turbocharger is cut in and cut out on 12V and 16V engines with electronically controlled hydraulically actu ated flaps Cooling system Engine cooling as split circuit cooling system with plate core heat exchanger Heating of the charge...

Page 31: ...e 2x MCS5 CAN CAN dialog output 1xMCS5 CAN ECU and EMU emergency stop Electric starter Terminal 45 of starter A B starter engaged Pneumatic starter Start air pressure valve Start air pressure sensor Barring gear barring gear 1 and 2 Generator with excitation control Electronic Engine Control Unit ECU Functions Engine speed control with fuel and speed limitation according to engine status and opera...

Page 32: ...ith exhaust gas with built in mixing channel Hydrogen Carbon Adsorption Preventing System HAPS to prevent the SCR catalytic converter from over heating Compliance with the IMO III emissions regulations due to closed loop control with NOx sensor Monitoring of NH3 emissions by NH3 sensor Urea solution dosage can be deactivated for IMO II operation Low load operation 1 Low load operation 2 Cleaning c...

Page 33: ...S Fire safety requirements Installation locations of SOLAS shielding Page 121 Special connections In case of leakage the following connection types are spray protected even without a cover and have been confirmed compliant with SOLAS by GL and DNV Plugs and sensors a Screw plugs 4 are either sealed with copper sealing rings 1 as per DIN or O rings ISO The fluid must first pass the thread in case o...

Page 34: ...19 Ball 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 leak age chamber The leak fuel is drained off without pressure via the leak fuel transfer bore 7 The leakage chamber is sealed by the O rings 3 This prevents leaking fuel from escaping The connection is...

Page 35: ...emperature B44 1 Turbocharger A speed B49 Charge air temperature from air recirculation valve B7 Lube oil temperature B5 3 Lube oil pressure before fil ter B48 Fuel pressure rail B34 2 Fuel pressure before filter B34 1 Fuel pressure after filter F33 Coolant level B4 22 Exhaust bulk temperature B side MS150123 01E 2017 05 General Information 35 TIM ID 0000071648 002 ...

Page 36: ...harge air pressure B57 1 Main bearing temperature XY1 1 Pneumatic starter B57 2 Main bearing temperature B57 3 Main bearing temperature B57 4 Main bearing temperature B57 5 Main bearing temperature B57 6 Main bearing temperature B57 7 Main bearing temperature XG03 Battery charging generator 36 General Information MS150123 01E 2017 05 TIM ID 0000071648 002 ...

Page 37: ... ture A1 B44 2 Turbocharger B speed XA80 DCM SCR connection B16 Coolant pressure B21 Raw water pressure option B77 B1 Bx Splash oil temperature for conrod bearings option B9 Charge air temperature MS150123 01E 2017 05 General Information 37 TIM ID 0000071648 002 ...

Page 38: ...0M F46 H Fuel Leakage B33 Fuel temperature rail B1 Camshaft speed B54 Oil refill pump pressure B6 2 Coolant temperature op tion B6 Coolant temperature 38 General Information MS150123 01E 2017 05 TIM ID 0000071648 002 ...

Page 39: ...Driving end 12V4000M B13 Crankshaft speed S37 2 Safety switch S37 1 Safety switch B13 2 Crankshaft speed option MS150123 01E 2017 05 General Information 39 TIM ID 0000071648 002 ...

Page 40: ...1 7 P Exhaust before SCR B88 3 NOx before SCR A side B85 1 T Exhaust before SCR A side B102 P Urea Solution PFM after Filter M81 2 PFM pump 2 M81 1 PFM pump 1 B103 K T Urea Solution X3 Connection to ECU9 B85 3 T Exhaust before SCR B side B88 5 NOx before SCR B side 40 General Information MS150123 01E 2017 05 TIM ID 0000071648 002 ...

Page 41: ... 1 M81 4 Dosing unit 1 2 M81 5 Dosing unit 1 3 M80 1X1 X VE 1 1 X1 M80 1X2 X VE 1 1 X2 M80 2X1 X VE 1 2 X1 M80 2X2 X VE 1 2 X2 M80 3X1 X VE 1 3 X1 M80 3X2 X VE 1 3 X2 XWA1 Adaptation bypass MS150123 01E 2017 05 General Information 41 TIM ID 0000071648 002 ...

Page 42: ...Dosing unit 2 1 M81 7 Dosing unit 2 2 M81 8 Dosing unit 2 3 M80 4X1 X VE 2 1 X1 M80 4X2 X VE 2 1 X2 M80 5X1 X VE2 2 X1 M80 5X2 X VE2 2 X2 M80 6X1 X VE 2 3 X1 M80 6X2 X VE 2 3 X2 42 General Information MS150123 01E 2017 05 TIM ID 0000071648 002 ...

Page 43: ...2X1 Relay 2 connector 1 actua tor K100 2X2 Relay 2 connector 2 actua tor B85 6 T Exhaust after SCR B88 8 NOx after SCR B100 2 X Ammoniac Sensor after SCR B91 8 P Exhaust after SCR M60 1 X SCR Bypass Flap 1 M60 2 X SCR Bypass Flap 2 XWA1 Adaptation bypass MS150123 01E 2017 05 General Information 43 TIM ID 0000071648 002 ...

Page 44: ...efore filter Y27 Turbocharger valve Engine wiring harness injectors connector assignment X3 Governor ECU Y39Ax Injectors engine A side E4 X KF thermostat heating Y39Bx Injectors engine B side Adaptation connector assignment X1 Governor ECU XB19 Starting air pressure X11 EMU Power XD1 Dialog unit X37 Start interlock XD1 E Ground XD1 X52 EIM engine box XY1 Starter Wiring harness SCR catalytic conver...

Page 45: ... B5 1 Lube oil pressure after filter B5 3 Lube oil pressure before fil ter B34 2 Fuel pressure before filter B34 1 Fuel pressure after filter F46 Leak fuel level B48 HP fuel pressure B33 Fuel temperature XG03 Battery charging generator S37 1 Start interlock limit switch A B10 Charge air pressure B4 21 Exhaust gas temperature A X2 Adaptation governor ECU XA80 Exhaust gas aftertreatment XA80 E Groun...

Page 46: ...ring harness for injectors 16V Y39Ax Injectors engine A side X3 Adaptation governor ECU E4 x KF thermostat heating Y39Bx Injectors engine B side 46 General Information MS150123 01E 2017 05 TIM ID 0000075361 001 ...

Page 47: ...D1 E Ground XD1 X37 Connection for start inter lock XB19 Adaption starting air pres sure X52 Connection to EIM engine box XY1 Adaption starting system X11 Adaption EMU Power X1 Connection to ECU MS150123 01E 2017 05 General Information 47 TIM ID 0000075361 001 ...

Page 48: ...Engine wiring harness for electric starter 1 EIM terminals 2 Fuse F1 3 Starter terminals 48 General Information MS150123 01E 2017 05 TIM ID 0000075361 001 ...

Page 49: ...0 5X2 X VE2 2 X2 M80 6X1 X VE 2 3 X1 M80 6X2 X VE 2 3 X2 B103 K T Urea Solution M81 1 PFM pump 1 M81 2 PFM pump 2 B102 P Urea Solution PFM after Filter B88 3 NOx before SCR A side B85 1 T Exhaust before SCR A side X43 2 Connector DCM sensor 1 2 X41 2 Connector DCM system 1 2 X43 3 Connector DCM sensor PFM X41 3 Connector DCM system PFM X43 4 Connector DCM sensor 2 X41 4 Connector DCM system 2 X43 ...

Page 50: ...ector 1 actua tor K100 1X1 Relay 1 connector 1 actua tor K100 2X2 Relay 2 connector 2 actua tor K100 1X2 Relay 1 connector 2 actua tor B91 8 P Exhaust after SCR M60 1 X SCR Bypass Flap 1 B85 6 T Exhaust after SCR M60 2 X SCR Bypass Flap 2 B88 8 NOx after SCR 50 General Information MS150123 01E 2017 05 TIM ID 0000075361 001 ...

Page 51: ...e higher than the specified value Actual value must be lower than the specified value Value not adequately verified tolerance 10 Value not adequately verified tolerance 5 ID Product type Application Engine speed Listed output 1 16V4000M73 Marine ship s main propulsion 1B continuous opera tion variable high load 1970 1 min 2560 kW 3481 bhp Ref 25 C 25 C Heat exchanger instal led on the engine IMO T...

Page 52: ...il system ID 1 2 Lube oil operating temperature before engine from R C 72 75 Lube oil operating temperature before engine to R C 82 82 Lube oil operating pressure before engine from R bar 6 6 Lube oil operating pressure before engine to R bar 8 8 Lube oil operating pressure low idle meas point before engine R bar 2 0 2 0 Fuel system ID 1 2 Fuel pressure at engine inlet connection min when engine i...

Page 53: ...g inclinations L Degrees 14 5 14 5 Transverse inclination continuous max Option max operating inclinations L Degrees 15 15 Transverse inclination temporary max Option max operating in clinations L Degrees 22 5 22 5 Capacities ID 1 2 Engine coolant engine side with cooling system R Liters 400 400 Engine oil capacity initial filling standard oil system Option max operating inclinations R Liters 330 ...

Page 54: ...evel Lp 1 m distance ISO 6798 3 dB A tolerance R dB A 82 82 Engine surface noise with attenuated intake noise intake silenc er BL free field sound power level Lp 1 m distance ISO 6798 2 dB A tolerance R dB A 104 105 54 Technical Data MS150123 01E 2017 05 TIM ID 0000071902 002 ...

Page 55: ...ation acc to SOLAS requirements C 220 Inlet flange 2x DN300 DIN 86044 2 300 Outlet flange 1x DN450 DIN 86044 2 450 Admissible installation position Horizontal SCR catalytic converter horizontal movement mm Lateral 15 2 Axial 15 0 5 Weight of SCR box with periphery and insulation without partial flow bypass Weight of partial flow bypass kg kg 2000 300 Table 2 Design criteria of SCR catalytic conver...

Page 56: ...sions Engine Main dimensions Engine model Length A Width B Height C Height D 12V4000M73L 3021 mm 1850 mm 2071 mm 636 mm 16V4000M73L 3610 mm 1850 mm 2071 mm 636 mm 56 Technical Data MS150123 01E 2017 05 TIM ID 0000071782 001 ...

Page 57: ...SCR catalytic converter Main dimensions Width A Height B Length C Length D 1736 mm 1885 mm 307 mm 2806 mm MS150123 01E 2017 05 Technical Data 57 TIM ID 0000071782 001 ...

Page 58: ...4 4 Firing order Cylinders Firing order 12V A1 B5 A5 B3 A3 B6 A6 B2 A2 B4 A4 B1 16V A1 A7 B4 B6 A4 B8 A2 A8 B3 B5 A3 A5 B2 A6 B1 B7 58 Technical Data MS150123 01E 2017 05 TIM ID 0000023263 003 ...

Page 59: ...5 Operation 5 1 LOP controls LOP controls Item Measure LOP Start engine via the automation system Automation system Operating In structions MS150123 01E 2017 05 Operation 59 TIM ID 0000045323 001 ...

Page 60: ...ated 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 243 Coolant circuit Check coolant level Page 242 Coolant circuit Heat engine coolant with coolant preheater HP fuel pump Only for engines without oil priming pump Fill HP fuel pump with fresh engine oil Page 146 Engine Control System Switch master switch ...

Page 61: ...olant preheater Engine Control System Switch master switch to ON Press illuminated pushbutton READY FOR OPERATION Page 59 LOP Press illuminated pushbutton LAMP TEST Page 59 ECU Check plug connections Page 270 EIM Check plug connections Page 272 EMU 8 Check plug connections Page 271 Exhaust gas aftertreatment SCR system Check urea solution system for leaks Check that seal on dosing unit is gas tigh...

Page 62: ...he automation system Starting the engine via the automation system Item Task Automation system Start engine via the automation system Automation system Operating In structions 62 Operation MS150123 01E 2017 05 TIM ID 0000045316 002 ...

Page 63: ...nning noises and vibration Check exhaust color Page 84 Air filter Check signal ring position of service indicator Page 173 Replace air filter Page 171 if the signal ring is completely visible in the service indicator observation window Fuel prefilter Drain water and contaminants from fuel prefilter Page 159 Check pointer position of differential pressure gage at fuel prefilter Page 157 HT coolant ...

Page 64: ...eeks Tasks after extended out of service periods 3 weeks Note Operate fuel treatment system for at least 5 minutes 1 Start up fuel treatment system Page 67 2 Shut down fuel treatment system Page 79 64 Operation MS150123 01E 2017 05 TIM ID 0000007730 006 ...

Page 65: ...nually 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 Indicates Replace filter element Press to acknowledge 7 Switch Press to switch pump ON OFF 8 White Signal lamp Indicates Control voltage present 9 Hour meter Indicates runtime of pump 10 Master switch MS1501...

Page 66: ...lves 4 Switch on fuel treatment system Page 70 5 Check direction of rotation of pump 6 Vent bypass and fuel lines of the system a Open ball valve for pressure tank b Open ball valve for overflow tank c Close ball valve at the inlet to the fuel treatment system Result Bypass line is vented via the overflow tank d Open ball valve at the inlet to the fuel treatment system 7 Check the fuel treatment s...

Page 67: ...r drain 18 Water level electrode 19 Ball valve sample extrac tion inlet 20 Switchgear cabinet 21 Pump 22 Coarse filter 23 Fuel supply from tank 24 Tank Switching on fuel treatment system 1 Switch on fuel treatment system Page 70 2 Check differential pressure at differential pressure gage 8 Differential pressure in a new system 0 1 bar to 0 3 bar Result If no differential pressure is measured the c...

Page 68: ... 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 bypass 3 and bypass 2 5 Open ball valve 19 Result Fuel emerges If no fuel emerges Open ball valve 5 at inlet to fuel treatment system No function of bypasses 2 and 3 carry out functional test of bypa...

Page 69: ...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 admissible limits and engine operation is satisfactory 6 Operate engine at full load and monitor suction pressure Result Simulation was successful if the suction pressure is within the specified limits MS150123 01E 2017 05 Operation 69 TI...

Page 70: ...fore switching on ensure that all housings are closed Before switching on ensure that no work is in progress anywhere on the entire system Fuel treatment system Switching on 1 Carry out checks prior to start up Page 66 2 Switch on master switch on switchgear cabinet Result Signal lamp Control voltage present lights up 3 Switch on switch for pump Result Signal lamp Pump running lights up 70 Operati...

Page 71: ...uators control units OFF circulation cool ing OFF Circulation cooling contin ues to run Exhaust gas aftertreatment OFF power supply to ex haust gas aftertreatment system interrupted circula tion cooling OFF Implementation Interruption of power supply to exhaust gas aftertreat ment system implemented by shipyard as color coded ON OFF switch Comment Pumps and or actuators to supply the SCR system wi...

Page 72: ...the circulation cooling follow up time has expired up to 10 hours before actuating the Power Off SCR switch to avoid destroying the dosing units as a result of overheating 72 Operation MS150123 01E 2017 05 TIM ID 0000073589 002 ...

Page 73: ...ision and serious injury Only operate the vessel using the LOP when a second person is keeping lookout and is ready to alert the person at the LOP to any potential hazards These two persons must remain in direct voice con tact at all times e g by radio Engagement via LOP Item Task LOP Engage via LOP Automation system Operating Instructions MS150123 01E 2017 05 Operation 73 TIM ID 0000045318 002 ...

Page 74: ...sion and serious injury Only operate the vessel using the LOP when a second person is keeping lookout and is ready to alert the person at the LOP to any potential hazards These two persons must remain in direct voice con tact at all times e g by radio Disengaging from LOP Item Task LOP Disengage via LOP Automation system Operating Instructions 74 Operation MS150123 01E 2017 05 TIM ID 0000045319 00...

Page 75: ...t 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 59 FLUSH illuminated pushbutton flashes Gearbox is engaged ASTERN FLUSH illuminated pushbutton is brightly lit after receiving feedback sig nal from clutch LOP Release FLUSH illuminated pushbutton FLUSH illuminated ...

Page 76: ...ts Before shutting down disengage gear and run the engine at idle speed for at least 10 minutes until engine temperatures have dropped and constant values are displayed Engine shutdown via the automation system Item Measure Automation system Shut down engine via the automation system Automation system Operat ing Instructions 76 Operation MS150123 01E 2017 05 TIM ID 0000045327 001 ...

Page 77: ...I mode or in th event of faults Engine behavior Engine at standstill control units ate active Engine at standstill control units switch OFF when cir culation cooling is complet ed Engine running no impact on engine function Engine stop not tripped Behavior of ex haust gas after treatment sys tem SCR sys tem Circulation cooling contin ues to run Circulation cooling contin ues to run control units s...

Page 78: ...d 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 tempera ture antifreeze concentration is 50 and engine room temperature is below 40 C Raw water Drain if freezing temperatures are expected and the engine is to remain out of service for a longer period...

Page 79: ...binet until water discharge from the outlet stops 2 Switch off fuel treatment system 3 Close ball valve at the inlet to the fuel treatment system 4 Close ball valve at the outlet of the fuel treatment system 5 Open drain valve until pressure has escaped from fuel treatment system MS150123 01E 2017 05 Operation 79 TIM ID 0000007732 005 ...

Page 80: ...gun 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 tion 2 Prior to putting the cleaning unit into operation read the operating instructions of the high pressure cleaning units carefully and observe the safety precautions 3 The following requirements...

Page 81: ...ean replace filter sleeve at each engine oil change at the latest Page 239 W1011 Perform endoscopic examination Page 131 W1016 X Battery charging generator Check condition of coupling Page 258 W1055 X Crankcase breather Replace oil separator Page 135 W1207 Check valve clearance and adjust if necessary IMPORTANT First adjust ment after 1 000 operating hours on a new engine and 1 000 operating hours...

Page 82: ... SCR system Page 199 W4179 X Check insulation of housing and bypass replace as necessary Page 184 W4180 X Replace filter on pre delivery module Page 185 W4181 X Check measuring line of exhaust pressure sensor clean if necessary Page 189 W4182 X Replace SCR GECANNT insert Page 194 W4183 X Replace predelivery module Page 185 Table 3 Maintenance task reference table QL1 82 Maintenance MS150123 01E 20...

Page 83: ...ve 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 switched off u Reset motor protection relay Pre alarm Cause Corrective action The differential pressure exceeded 1 3 bar u Replace coalescer filter element Page 266 Replace filter element Cause Corre...

Page 84: ...s faulty fuse lamp on EIM flashes with relevant flashing code u Check fuse replace as necessary and re start the system by actuating the key switch Running gear blocked engine can not be barred manually 1 Check start interlock Page 269 2 Contact Service Engine turns on starting but does not fire Cause Corrective action Poor rotation by starter Battery low or faulty u Charge or replace battery see ...

Page 85: ...sive load u Reduce load Air intake temperature too high u Check fans and air supply ventilation ducts for engine room Engine coolant mixture incorrect 1 Check engine coolant level Page 242 2 Check engine coolant MTU test kit Page 249 Charge air cooler contaminated u Replace Instructions for Exchange of Sub assemblies Charge air pressure too low Cause Corrective action Air filter clogged 1 Check si...

Page 86: ...d to blow off SCR substrates soot emission possible 3 If exhaust back pressure does not fall Contact Service Blue exhaust gas Cause Corrective action Too much engine oil in the engine u Drain engine oil Page 204 Note Engine oil burns in SCR system Visually inspect SCR system for damage resulting from overheating leakage and signs of sooting Oil separator of crankcase breather contaminated u Replac...

Page 87: ...ea Pungent smell engine room Cause Corrective action Initial start up u Shut down check SCR system Reduced power due to exhaust gas temperature alarm Cause Corrective action Main flow flap faulty 1 Actuate main flow flap via handwheel 2 Repair main flow flap Back pressure too low emission fault Cause Corrective action No baffles installed u Install baffles Page 194 SCR substrate faulty u Replace S...

Page 88: ...system u Check for leakage replace as necessary Page 183 White crystals on plug connections or urea solution system Cause Corrective action Leaks cracks in urea solution system u Check for leakage replace as necessary Page 183 Yellow smoke on funnel Cause Corrective action Wrong coating DOC supplied u Install SCR module with right coating Page 194 88 Troubleshooting MS150123 01E 2017 05 TIM ID 000...

Page 89: ...9 exceeded limit value 1 Charge air temperature is too high 1 Reduce power 2 Check whether alarms 9 and 10 are signaled 3 Contact Service 6 SS T Charge Air Cause Corrective action The charge air temperature at sensor B9 exceeded limit value 2 Charge air temperature is too high 1 Reduce power 2 Check whether alarms 9 and 10 are signaled 3 Contact Service 15 LO P Lube Oil Cause Corrective action The...

Page 90: ...s description Contact Service if no DiaSys is available 22 SS T Exhaust B Cause Corrective action Exhaust temperature at sensor B4 22 exceeded limit value 2 Exhaust temperature is too high u Run injector test according to DiaSys description Contact Service if no DiaSys is available 23 LO Coolant Level Cause Corrective action Coolant level in high temperature circuit at switch F33 is too low 1 Chec...

Page 91: ...was tripped by the engine overspeed test 2 Contact Service if the emergency stop was tripped by the engine 31 HI ETC1 Overspeed Cause Corrective action The primary exhaust turbocharger speed at sensor B44 1 has exceeded limit value 1 The exhaust turbocharger speed is too high 1 Reduce power 2 Contact Service 32 SS ETC1 Overspeed Cause Corrective action The primary exhaust turbocharger speed at sen...

Page 92: ... at sensor B44 2 has exceeded limit value 2 The exhaust turbocharger speed is too high 1 Reduce power 2 Contact Service 38 AL ETC Speed Deviation Cause Corrective action The percentual deviation in exhaust turbocharger speed between the primary turbocharger and the first secondary turbocharger has exceeded the limit value The deviation in exhaust turbocharger speed is too high u Contact Service 51...

Page 93: ...Contact Service 59 SS T Coolant L3 Cause Corrective action The coolant temperature at sensor B6 exceeded limit value 3 Coolant temperature is too high 1 Check operation of cooler and fan plant 2 Check engine coolant level Page 242 3 Contact Service 60 SS T Coolant L4 Cause Corrective action The coolant temperature at sensor B6 exceeded limit value 4 Coolant temperature is too high 1 Check operatio...

Page 94: ...vel Page 242 4 Contact Service 68 SS T Coolant Cause Corrective action The coolant temperature at sensor B6 exceeded limit value 2 Coolant temperature is too high 1 Check operation of cooler and fan plant 2 Check engine coolant level Page 242 3 Contact Service 82 HI P Fuel Common Rail Cause Corrective action The fuel pressure at sensor B48 exceeded the limit value Fuel pressure is too high u Conta...

Page 95: ...sages 4 Contact Service 92 SS Starter Speed Not Reached Cause Corrective action The engine has failed to reach the defined speed threshold within the defined time 1 For hydraulic starter Check pressure supply plant of starter 2 For electric starter Check the starter power supply plant 3 Observe additional messages 4 Contact Service 93 SS T Preheat Cause Corrective action The engine coolant tempera...

Page 96: ...258 4 Contact Service 119 LOLO ECU Power Supply Voltage Cause Corrective action The ECU supply voltage went below the defined limit value 2 1 Check condition of batteries plant 2 Check plug connections to engine governor Page 270 3 Check battery charging generator Page 258 4 Contact Service 120 HI ECU Power Supply Voltage Cause Corrective action ECU supply voltage exceeded limit value 1 1 Check co...

Page 97: ...ode on CAN bus 1 has failed 1 Check engine wiring Page 268 2 Disconnect power supply then reconnect 3 Contact Service 181 AL CAN2 Node Lost Cause Corrective action Connection or communication with a node on CAN bus 2 has failed 1 Check engine wiring Page 268 2 Disconnect power supply then reconnect 3 Contact Service 182 AL CAN Wrong Parameters Cause Corrective action Incorrect parameter values ent...

Page 98: ...g connections to engine governor Page 270 2 Contact Service 188 AL CAN2 Bus Off Cause Corrective action CAN bus 2 to plant automation system e g Murphy display is disrupted or defective 1 Check connection between plant automation system and MTU automation system 2 Contact Service 189 AL CAN2 Error Passive Cause Corrective action CAN bus 2 to plant automation system e g Murphy display is disrupted ...

Page 99: ... 1 Check engine wiring Page 268 2 Contact Service 206 SD T Exhaust A Cause Corrective action The exhaust gas temperature sensor B4 21 in the exhaust pipe on A side delivers incorrect or no signal 1 Check engine wiring Page 268 2 Contact Service 207 SD T Exhaust B Cause Corrective action The charge air temperature sensor B4 22 B side is supplying a faulty or no signal 1 Check engine wiring Page 268...

Page 100: ... 215 SD P HD Cause Corrective action The signal from the rail pressure sensor B48 is faulty or missing 1 Check engine wiring Page 268 2 Contact Service 216 SD T Lube Oil Cause Corrective action The signal from the lube oil temperature sensor B7 1 is faulty or missing 1 Check engine wiring Page 268 2 Contact Service 219 SD T Intake Air Cause Corrective action The signal from the intake air temperat...

Page 101: ...D P Fuel before Filter Cause Corrective action The HP fuel sensor before the main fuel filter B34 2 supplies a faulty signal or no signal 1 Check engine wiring Page 268 2 Contact Service 229 AL Stop Camshaft Sensor Defect Cause Corrective action Emergency engine stop following failure of crankshaft sensor and camshaft sensor u Contact Service 230 SD Crankshaft Speed Cause Corrective action The sig...

Page 102: ...P Fuel Cause Corrective action The signal from the fuel pressure sensor after main fuel filter B34 1 is faulty or missing 1 Check engine wiring Page 268 2 Contact Service 241 SD T Umblasen Cause Corrective action Charge air temperature sensor B49 supplies incorrect signal or no signal 1 Check engine wiring Page 268 2 Contact Service 245 SD ECU Power Supply Voltage Cause Corrective action The signa...

Page 103: ...iring for cylinder A3 or injector is defective 1 Check wiring of affected injector Page 268 2 Replace injector Page 148 3 Contact Service 324 AL Wiring Cylinder A4 Cause Corrective action Short circuit fault in the injector wiring for cylinder A4 or injector is defective 1 Check wiring of affected injector Page 268 2 Replace injector Page 148 3 Contact Service 325 AL Wiring Cylinder A5 Cause Corre...

Page 104: ...action Short circuit fault in the injector wiring for cylinder A10 or injector is defective 1 Check wiring of affected injector Page 268 2 Replace injector Page 148 3 Contact Service 331 AL Wiring Cylinder B1 Cause Corrective action Short circuit fault in the injector wiring for cylinder B1 or injector is defective 1 Check wiring of affected injector Page 268 2 Replace injector Page 148 3 Contact ...

Page 105: ...ction Short circuit fault in the injector wiring for cylinder B7 or injector is defective 1 Check wiring of affected injector Page 268 2 Replace injector Page 148 3 Contact Service 338 AL Wiring Cylinder B8 Cause Corrective action Short circuit fault in the injector wiring for cylinder B8 or injector is defective 1 Check wiring of affected injector Page 268 2 Replace injector Page 148 3 Contact Se...

Page 106: ...der A4 1 Check wiring of affected injector Page 268 2 Contact Service 345 AL Open Load Cylinder A5 Cause Corrective action Disruption fault in injector wiring to cylinder A5 1 Check wiring of affected injector Page 268 2 Contact Service 346 AL Open Load Cylinder A6 Cause Corrective action Disruption fault in injector wiring to cylinder A6 1 Check wiring of affected injector Page 268 2 Contact Serv...

Page 107: ...ylinder B2 1 Check wiring of affected injector Page 268 2 Contact Service 353 AL Open Load Cylinder B3 Cause Corrective action Disruption fault in injector wiring cylinder B3 1 Check wiring of affected injector Page 268 2 Contact Service 354 AL Open Load Cylinder B4 Cause Corrective action Disruption fault in injector wiring cylinder B4 1 Check wiring of affected injector Page 268 2 Contact Servic...

Page 108: ... 1 Check wiring of affected injector Page 268 2 Contact Service 361 AL Power Stage Low Cause Corrective action The output stage voltage to control the injectors is too low 1 Check power supply plant 2 Contact Service 362 AL Power Stage High Cause Corrective action The output stage voltage to control the injectors is too high 1 Check power supply plant 2 Contact Service 363 AL Stop Power Stage Caus...

Page 109: ...or output 4 TO 4 1 Check engine wiring Page 268 2 Contact Service 381 AL Wiring TOP 1 Cause Corrective action Short circuit or wire break at transistor output 1 plant TOP 1 1 Check cabling Page 268 2 Contact Service 382 AL Wiring TOP 2 Cause Corrective action Short circuit or wire break at transistor output 2 plant TOP 2 1 Check cabling Page 268 2 Contact Service 383 AL Wiring TOP 3 Cause Correcti...

Page 110: ...digital input 4 of the ECU 1 Check cabling Page 268 2 Contact Service 404 AL Open Load Digital Input 5 Cause Corrective action Open load detected at digital input 5 of the ECU 1 Check cabling Page 268 2 Contact Service 405 AL Open Load Digital Input 6 Cause Corrective action Open load detected at digital input 6 of the ECU 1 Check cabling Page 268 2 Contact Service 406 AL Open Load Digital Input 7...

Page 111: ...exceeded limit value 1 1 Check power supply plant 2 Check cabling Page 268 3 Contact Service 413 HIHI U PDU Cause Corrective action The ECU voltage to control the injectors exceeded limit value 2 1 Check power supply plant 2 Check cabling Page 268 3 Contact Service 414 HI Level Water Fuel Prefilter Cause Corrective action Switch F70 in the fuel prefilter has been tripped by an excessively high wat...

Page 112: ...2 Contact Service 470 SD T ECU Cause Corrective action The signal from the temperature sensor in the ECU is faulty or missing u Contact Service 472 AL Stop SD Cause Corrective action This fault is output in case of a defective sensor which has been configured to initiate an engine stop u Contact Service 474 AL Wiring FO Cause Corrective action Short circuit or wire break at the frequency output 1 ...

Page 113: ...evice on the PCS5 CAN signals the ECU to set a red summary alarm 1 Observe additional messages 2 Contact Service 480 AL Ext Engine Protection Cause Corrective action The external engine protection function is active 1 Check plant signal 2 Contact Service 482 SD T Exhaust C Cause Corrective action The signal from the exhaust gas temperature sensor B4 23 is faulty or missing 1 Check engine wiring Pa...

Page 114: ...490 HI ETC4 Overspeed Cause Corrective action The secondary exhaust turbocharger speed at sensor B44 4 has exceeded limit value 1 The exhaust turbocharger speed is too high Cause Fault or malfunction of another turbocharger 1 Reduce power 2 Contact Service 491 SS ETC4 Overspeed Cause Corrective action The secondary exhaust turbocharger speed at sensor B44 4 has exceeded limit value 2 The exhaust t...

Page 115: ...it value 2 or the engine overspeed test was tripped Emergency engine stop was tripped u Contact Service 582 AL Emergency Stop Failed Cause Corrective action This alarm is raised if the engine fails to come to a standstill within a defined time following an emergency stop signal u Contact Service 586 LO P Oil Refill Pump Cause Corrective action The refill pump lube oil pressure measured at sensor B...

Page 116: ...nitored CAN bus devices on CAN bus 1 and CAN bus 2 1 Check engine wiring Page 268 2 Contact Service 627 AL Wiring PWM_CM9 Cause Corrective action Solenoid valve Y27 1 to cut in the A side exhaust turbocharger cannot be activated 1 Check engine wiring Page 268 2 Contact Service 836 AL Speed Demand Failure Cause Corrective action The ECU is unable to receive a speed demand signal via the CAN bus Ala...

Page 117: ...ctuators is disconnected or faulty 1 Check engine wiring Page 268 2 Contact Service 975 AL CAN3 Error Passive Cause Corrective action The first engine CAN CAN 3 for engine sensors actuators is disrupted 1 Check engine wiring Page 268 2 Contact Service 976 AL CAN4 Bus Off Cause Corrective action The second engine CAN CAN 4 for engine sensors actuators is disconnected or faulty 1 Check engine wiring...

Page 118: ... value at analog output 2 e g moving coil instrument output signal for LT circuit fan control u Contact Service 1139 AL Communication Error ECU EXU Cause Corrective action Communication error between ECU and EXU 1 Check engine wiring Page 268 2 Restart ECU 3 Contact Service 1170 AL Permanent Injection Cause Corrective action The ECU has detected continuous injection at one or more injectors based ...

Page 119: ...ly voltage is two low for successful homing of all flaps even when the engine is running 1 Check condition of batteries plant 2 Check plug connections to engine governor Page 270 3 Contact Service 1377 AL Refdrive Impossibl Eng Op Point Cause Corrective action Homing of one or more flaps before engine start was not completed successfully Homing the affected flaps is no longer possible 1 Run engine...

Page 120: ...se 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 SOLAS shielding 1 Pinpoint installation location Page 121 2 Install suitable shielding 3 Press shielding until locked 120 Task Description MS150123 01E 2017 05 TIM ID 0000071594 001 ...

Page 121: ...t possible Page 128 When affixing adhesive connections ensure that escaping fluid can flow out without pressure Page 128 Fuel system fuel lines with fuel pressure 1 8 bar Item Type of shielding Installation location 1 2 x shield A5 Fuel line to fuel filter head Item Type of shielding Installation location 1 2 x shield A8 Fuel line from to fuel filter head MS150123 01E 2017 05 SOLAS 121 TIM ID 0000...

Page 122: ...Fuel 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 ETC B1 122 SOLAS MS150123 01E 2017 05 TIM ID 0000071586 001 ...

Page 123: ... 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 MS150123 01E 2017 05 SOLAS 123 TIM ID 0000071586 001 ...

Page 124: ...g 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 main gallery These shields must be installed on the assembly line These positions can no longer be accessed after assembly intake housing 124 SOLAS MS150123 01E 2017 05 TIM ID 0000071586 001 ...

Page 125: ...ielding 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 MS150123 01E 2017 05 SOLAS 125 TIM ID 0000071586 001 ...

Page 126: ...On 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 supply 2 Shield A6 ETC oil supply 126 SOLAS MS150123 01E 2017 05 TIM ID 0000071586 001 ...

Page 127: ...eld 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 MS150123 01E 2017 05 SOLAS 127 TIM ID 0000071586 001 ...

Page 128: ...Sealing cone unions Note For installation positions of sealing cone un ions see Page 121 1 Wrap three layers of adhesive tape from the middle of the sealing cone union to area A for at least 30 mm ensuring that the adhe sive tape overlaps at least half its own width 2 Wrap three layers of adhesive tape from the middle of the sealing cone union to area B for at least 30 mm ensuring that the adhe si...

Page 129: ...that there are no persons in the engine s danger zone Barring engine manually 1 Loosen screws 1 and remove end cover 2 from flywheel housing 2 Engage barring gear 2 in ring gear of fly wheel and mount on flywheel housing 3 Fit ratchet 1 on barring gear Note No resistance other than compression resist ance must be encountered 4 Rotate crankshaft in engine direction of rota tion Result If the resist...

Page 130: ...lueLine automation system Starting barring procedure at LOP 8 BlueLine Operating Instructions BlueVision automation system Starting barring procedure at LOP 8 BlueLine Operating Instructions 130 Engine MS150123 01E 2017 05 TIM ID 0000017533 001 ...

Page 131: ...n top piston ring and bottom edge of carbon scraper ring First signs of marks left by top piston ring Bright mark on entire circumference Faultless even honing pattern First signs of marks left by lower cooling bores Running pattern seems darker No actions required Dark areas with even or varying degrees of discoloration Beginning and end of the discoloration are not sharply defined and do not cov...

Page 132: ...epending on findings Do not take any action or carry out a further endoscopic examination as part of maintenance work or contact Service cylinder liner must be replaced Final steps 1 Install injector Page 149 2 Install cylinder head cover Page 145 132 Cylinder Liner MS150123 01E 2017 05 TIM ID 0000003304 006 ...

Page 133: ... It appears rather darker within the honed struc ture in contrast to the bright metallic running surface The honing pattern is undis turbed Discolorations extend in stroke direction and may be interrupted Findings not critical Corrosion fields spots Corrosion fields spots result from moisture condensate with the valves in the overlap open position They are clearly visible due to the dark color of ...

Page 134: ...ks are similar A thorough investigation and compliance with the above evaluation criteria allow an unambiguous evaluation To avoid unnecessary disassembly work it is recommended that another inspection be carried out after further operation of the engine 134 Cylinder Liner MS150123 01E 2017 05 TIM ID 0000000014 016 ...

Page 135: ... substances which are harmful to health Risk of injury and poisoning Allow the product to cool to below 50 C before beginning work Wear protective clothing protective gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Oil mist separator Replace ment 1 Remove screws 1 and take off together with retainer 2 2 Replace oil mist separator 3 3 Replace O ring 4 if necessary 4 R...

Page 136: ...pth gage 200 mm Y20000918 1 Measuring jig 2 optional Y4350010 1 Preparatory steps 1 Remove cylinder head covers Page 145 2 Install barring tool Page 129 3 Turn crankshaft in direction of rotation using barring tool until TDC mark 1 and pointer 2 are aligned Calibrating measuring jigs 1 and 2 1 Place measuring unit 2 on calibration plate 3 136 Valve Drive MS150123 01E 2017 05 TIM ID 0000045593 010 ...

Page 137: ...er head 3 4 Turn measuring unit screws 1 into the threads provided for the cylinder head cover and tighten to specified torque using a torque wrench Name Size Type Lubricant Value Standard Screw M10 Tightening torque 20 Nm 5 Determine the values with all dial gages The valve protrusion value must be 1 5 mm If the value is 1 5 mm measure with a depth gage or optionally with measuring jig 2 6 Unscre...

Page 138: ...95 8 mm 5 Install valve bridge 6 Adjusting valve clearance Page 141 Step 2 optional Measure valve protrusion at the valve stem with measuring jig 2 1 Check TDC position of piston in cylinder A1 If rocker arms on cylinder A1 are unloaded the piston is in firing TDC If rocker arms on cylinder A1 are loaded the piston is in overlap TDC 2 Measure valve stem end to cylinder head top distance for each v...

Page 139: ...ize Type Lubricant Value Standard Screw M10 Tightening torque 20 Nm 6 Determine the values with all dial gages The valve protrusion value must be 2 mm Have the affected cylinder head replaced by expert personnel if the value is 2 mm 7 Unscrew measuring unit 2 from cylinder head 3 8 Install valve bridge 9 Adjusting valve clearance Page 141 Final steps 1 Remove barring tool Page 129 2 Install cylind...

Page 140: ...arts Designation Use Part No Qty Engine oil Valve gear Lubrication 1 Remove cylinder head covers Page 145 2 Fill oil chambers of valve bridges with oil 3 Fill oil chambers of rocker arms and adjusting screws with oil 4 Install cylinder head covers Page 145 140 Valve Drive MS150123 01E 2017 05 TIM ID 0000000921 010 ...

Page 141: ...crew 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 145 2 Install barring device Page 129 Note Pointer 1 is located in the lower opening of the flywheel housing arrow 3 Use barring device to turn crankshaft in di rection of rotation until marking OT A1 on the rear side of the flywheel housing an...

Page 142: ...meter of the flywheel 4 The additional OT A1 mark 1 if fitted on the outer perimeter of the flywheel must not be used for reference Diagram for 8V engines Two crankshaft positions Diagram for 12V engines Two crankshaft positions 142 Valve Drive MS150123 01E 2017 05 TIM ID 0000000922 015 ...

Page 143: ...rance 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 overlap TDC of cylinder A1 as per diagram 1 Cylinder A1 is in firing TDC 2 Cylinder A1 is in overlap TDC I Inlet valve X Exhaust valve 4 Use valve setting gauge or feeler gauge to determine the distance ...

Page 144: ... gauge must just pass through the gap 4 Pass valve setting gauge 3 between valve bridge and rocker arm 5 Tighten locknut 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 M16x1 5 Tightening torque Engine oil 90 Nm 9 Nm 6 Check valve clearance adjust if necessary Final steps 1 Remove barri...

Page 145: ...nder head covers 1 prior to removal 2 Remove screws 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 Coat O ring with assembly compound 4 Insert O ring in groove on cylinder head cover 1 5 Fit cylinder head cover on cylinder head 7 6 Install cylinder ...

Page 146: ...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 protective gloves and safety glasses If contact is made with skin wash off with water and soap WARNING Oils oil vapors are combustible explosive Risk of fire and explosion Avoid open flames electric sp...

Page 147: ...box 2 Use fuel suction device to fill HP pump with 2 liters of clean engine oil 3 Screw in union 1 and use torque wrench to tighten to specified tightening torque Name Size Type Lubricant Value Standard Neck M16x1 5 Tightening torque 40 Nm Final steps u Install oil line MS150123 01E 2017 05 Injection Pump HP Pump 147 TIM ID 0000001640 016 ...

Page 148: ... Replacement Special tools Material Spare parts Designation Use Part No Qty Injector Spare Parts Catalog Injector Replacement u Remove injector and install new one Page 149 148 Injector MS150123 01E 2017 05 TIM ID 0000042329 002 ...

Page 149: ...els are combustible and explosive 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 gaseous media e g fuel are poisonous Escaping vapors of highly volatile media e g fuel or ether Risk of fatal injury through swallowing risk of poisoning through inhalatio...

Page 150: ...k components for special cleanliness Preparatory steps 1 Allow HP system to cool down 2 Shut off fuel supply to engine 3 Remove cylinder head cover Page 145 Removing injector 1 Disconnect cable connector on injector Note Observe system pressure 2 Slowly release union on HP line 4 3 Remove HP fuel line 4 Note When the adapter is unscrewed the stored volume of the injector is drained 4 Remove adapte...

Page 151: ...mbly 10 Dispose of injector with O rings in place Note For repeated assembly 11 Remove O rings 3 O ring 2 and damper ring 1 from injector 12 Clean all mating and sealing surfaces 13 Cover all connections and bores or seal with suitable plugs Installing injector Note The new sealing ring is included in the scope of supply of the injector new part A multi purpose grease without solids con tent must ...

Page 152: ...P 37 Note The O rings are already in place for new as sembly 5 Fit new O rings 3 on injector 2 and apply Assembly compound Kluthe Hakuform 30 15 Note Make sure that the sealing ring does not fall into the water sleeve 6 Ensure that the sealing ring 4 is correctly seated 7 Insert injector into cylinder head ensuring that the HP line connection is correctly aligned 8 Press in injector with installat...

Page 153: ...rfectly clean 17 Coat thread and sealing cone of HP line 5 with engine oil 18 Coat O rings with Assembly compound Kluthe Hakuform 30 15 19 Thread in HP line 5 ensuring that the sealing areas are not damage 20 Tighten jacketed HP line 5 according to tightening sequence to specified torque using a torque wrench Tightening sequence 1 Adapter 4 2 Rail 6 Name Size Type Lubricant Value Standard Union nu...

Page 154: ...tion CDC 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 head cover Page 145 2 Open fuel supply to engine 154 Injector MS150123 01E 2017 05 TIM ID 0000000925 027 ...

Page 155: ...ation to eyes and skin 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 and soap WARNING Fuels are combustible and explosive Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke Wear protective clothing prot...

Page 156: ...nscrew 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 Return lever to normal position 6 and lock with locking pin 1 7 Replace other fuel filter in the same way Note Venting is omitted on changing filters with the engine running 8 Vent fuel system at fuel ve...

Page 157: ...Trailing pointer black 3 Pointer red 4 Reset button A Display area white B Display area yellow C Display area red 1 With the engine running read off at pressure gage 1 the vacuum contamination level at the filter output indicated by the red pointer 3 2 When the red pointer 3 is continuously in the yellow area B at the latest or at a high flow rate moves into the red area C a Switch over to second ...

Page 158: ...Press button on lever 2 Turn lever to desired position and engage the button The tip of the lever with the inscription always faces the filter that is in operation When the tip faces downwards both filters are in operation 158 Fuel Filter MS150123 01E 2017 05 TIM ID 0000043503 003 ...

Page 159: ...iately do not induce vomiting Do not inhale vapors or mist Wear protective clothing protective gloves and safety glasses If contact is made with skin wash off with water and soap WARNING Fuels are combustible and explosive 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 ...

Page 160: ...e valve 2 a little turning to approx 30 to introduce fuel into the filter housing with the new filter element 7 Close vent valve 1 as soon as fuel emerges from vent pipe 4 8 Turn the rotary slide valve to the upright posi tion 3 until it engages Result Both filters are cut in 9 Set differential pressure gage Page 157 160 Fuel Filter MS150123 01E 2017 05 TIM ID 0000018510 009 ...

Page 161: ...n Seek medical attention immediately do not induce vomiting Do not inhale vapors or mist Wear protective clothing protective gloves and safety glasses If contact is made with skin wash off with water and soap WARNING Fuels are combustible and explosive Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke Wear protective clothing protective gloves and saf...

Page 162: ...aded 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 emerges from vent pipe 4 7 Turn the rotary slide valve to the upright posi tion 3 until it engages Result Both filters are cut in 8 Set differential pressure gauge Page 157 162 Fuel Filter MS150123 0...

Page 163: ...ough 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 protective gloves and safety glasses If contact is made with skin wash off with water and soap WARNING Fuels are combustible and explosive Risk of fire and explosion Avoid open flames electrical sparks and i...

Page 164: ...oosen 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 Insert new O ring and turn filter housing back into position 11 Tighten screws 1 and 2 finger tight 12 Tighten screws evenly to specified torque using a torque wrench max half a turn per screw Name Size T...

Page 165: ...g with the new filter element 14 Close vent valve 1 as soon as fuel emerges from vent pipe 4 15 Turn the rotary slide valve to the upright posi tion 3 until it engages Result Both filters are cut in 16 Set differential pressure gage Page 157 MS150123 01E 2017 05 Fuel Filter 165 TIM ID 0000012750 014 ...

Page 166: ...ed 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 lines are installed so that they are never under tension or strain Ensure correct installation position of components NOTICE Inappropriate cleaning tool Risk of damage to component Observe manufactu...

Page 167: ...ler 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 MS150123 01E 2017 05 Exhaust Turbocharger 167 TIM ID 0000018669 009 ...

Page 168: ...ressor 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 compressor housing and plug in sleeves as necessary Final steps 1 Place compressor housing 2 in position 168 Exhaust Turbocharger MS150123 01E 2017 05 TIM ID 0000018669 009 ...

Page 169: ...ified torque using a torque wrench Name Size Type Lubricant Value Standard Clamp Tightening torque 15 Nm 2 Nm 6 Install oil lines 2 Tighten threaded adapter at actuating cylinder to specified torque using a torque wrench Name 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 interc...

Page 170: ...air jet at people Always wear safety goggles face mask and ear defenders Checking intercooler water drain for coolant leakage and obstruction u With the engine running verify that air emerges from the drain bores arrowed on left and right engine sides If no air emerges a Clean drain bores arrowed and blow out with compressed air b More significant coolant leakage indi cates a leaking intercooler C...

Page 171: ...al 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 172 2 Reset signal ring of contamination indicator Page 173 MS150123 01E 2017 05 Air Filter 171 TIM ID 0000005447 010 ...

Page 172: ...mp 2 2 Remove air filter 1 and clamp 2 from con necting flange of intake housing 3 3 Verify that there are no objects in the con necting flange of the intake housing 3 and clean it 4 Place new air filter 1 with clamp 2 onto in take housing 3 5 Tighten screw on clamp 2 with torque wrench to the specified tightening torque Name Size Type Lubricant Value Standard Screw Tightening torque 5 Nm 172 Air ...

Page 173: ...arting disabled Checking signal ring position 1 When the yellow piston 2 has reached the red shaded Service lettering 3 replace air filter Page 171 2 After installation of new filter press reset button 1 Result Signal ring returns to initial position MS150123 01E 2017 05 Air Intake 173 TIM ID 0000076623 001 ...

Page 174: ...lue DEF is swallowed In case of contact with urea solution e g AdBlue DEF there is a danger of skin irritation and eye in jury Risk of injury and poisoning Avoid contact with eyes or skin Do not inhale vapors or smoke When handling urea solution e g AdBlue DEF do not eat drink or smoke Wear protective clothing protective gloves and goggles safety mask WARNING Urea solution e g AdBlue DEF is hot Ri...

Page 175: ... lint free cloth Installing filter Note Only use new parts 1 Check parts of spare parts kit for Completeness Presence of housing vent in filter housing bottom 5 Presence of frost compensating dia phragm 3 and seal 4 in filter housing 5 Cleanness of sealing surface on pump housing 1 2 Fit filter element 2 via the pin on the pump housing 1 and press in until it will not go any further Note The groov...

Page 176: ... Size Type Lubricant Value Standard Filter housing 46A F Tightening torque Lubricant spray Bio lube L Spray 80 Nm 5 Nm 9 Open supply and return line from pre feed module to tank before starting engine 176 Exhaust Gas Aftertreatment MS150123 01E 2017 05 TIM ID 0000073480 002 ...

Page 177: ...ive gloves and goggles safety mask WARNING Urea solution e g AdBlue DEF is hot Risk of injury and scalding Allow product to cool down Slowly open line connections and closures When opening ensure that the separation points are covered with cloths Wear protective clothing protective gloves and safety goggles safety mask NOTICE Contamination of components Damage to component Observe manufacturer s i...

Page 178: ...tall retainer 2 on supply unit 3 2 Tighten screws 1 to specified torque using a torque wrench Name Size Type Lubricant Value Standard Screw M8 Tightening torque 17 5 Nm 3 5 Nm 3 Install supply unit 3 with retainer 2 on SCR catalytic converter 178 Exhaust Gas Aftertreatment MS150123 01E 2017 05 TIM ID 0000071313 002 ...

Page 179: ... to urea solution outlet 1 pressure line 7 Connect HDSC connector of DCM box 3 and HDSC connector of dosing unit 4 8 Check supply unit connectors for leakage af ter initial start up 9 Open supply and return line from pre feed module to tank before starting engine MS150123 01E 2017 05 Exhaust Gas Aftertreatment 179 TIM ID 0000071313 002 ...

Page 180: ...urea solution e g AdBlue DEF is swallowed In case of contact with urea solution e g AdBlue DEF there is a danger of skin irritation and eye in jury Risk of injury and poisoning Avoid contact with eyes or skin Do not inhale vapors or smoke When handling urea solution e g AdBlue DEF do not eat drink or smoke Wear protective clothing protective gloves and goggles safety mask WARNING Urea solution e g...

Page 181: ...1 from dosing unit 3 Remove urea solution supply line 3 and re turn line 2 4 Remove screws 1 2 3 5 Remove dosing unit together with insulating molding 4 Installing dosing unit 1 Fit insulating molding 1 on dosing unit 3 2 Insert plates 2 3 Turn the dosing unit a little to press the graphite ring seal flat MS150123 01E 2017 05 Exhaust Gas Aftertreatment 181 TIM ID 0000071357 002 ...

Page 182: ...ecified torque using a torque wrench Name Size Type Lubricant Value Standard Screw M6x20 Tightening torque 10 Nm 0 85 Nm 9 Install connector 1 on dosing unit 10 Remove transport closures from the urea sol ution connections 11 Install urea solution supply line 3 and return line 2 12 Open supply and return line from pre feed module to tank before starting engine 182 Exhaust Gas Aftertreatment MS1501...

Page 183: ...e that the separation points are covered with cloths Wear protective clothing protective gloves and safety goggles safety mask WARNING Slipping and falling caused by spilled liquids Risk of serious injury Immediately clean up spilled liquids with suitable cleaning agents or as defined by the manufacturer s specifications NOTICE Contamination of components Damage to component Observe manufacturer s...

Page 184: ... entire insulation and their securing elements 2 vis ually Item Findings Action Check securing elements for dam age Damaged Replace Check insulation for signs of wear abrasion deformation and con tamination with soot Wear traces Abrasion Deformation Soot Visible Replace Note The insulation complies with SOLAS requirements If the insulation is modified compliance with the SOLAS requirements can no ...

Page 185: ...void contact with eyes or skin Do not inhale vapors or smoke When handling urea solution e g AdBlue DEF do not eat drink or smoke Wear protective clothing protective gloves and goggles safety mask WARNING Urea solution e g AdBlue DEF is hot Risk of injury and scalding Allow product to cool down Slowly open line connections and closures When opening ensure that the separation points are covered wit...

Page 186: ... module 1 before opening it 4 Undo filter housing 2 with filter wrench and drain urea solution into a suitable container 5 Remove filter element by pulling it down wards 6 Replace O ring 7 Insert new filter element in filter housing 2 8 Screw in filter housing 2 up to stop then turn back a quarter turn 9 Open supply and return line from pre feed module to tank before starting engine 186 Exhaust Ga...

Page 187: ...e g AdBlue DEF there is a danger of skin irritation and eye in jury Risk of injury and poisoning Avoid contact with eyes or skin Do not inhale vapors or smoke When handling urea solution e g AdBlue DEF do not eat drink or smoke Wear protective clothing protective gloves and goggles safety mask WARNING Urea solution e g AdBlue DEF is hot Risk of injury and scalding Allow product to cool down Slowly...

Page 188: ...ections with the asso ciated transport closures 11 Remove pre feed module from SCR catalytic converter Installing pre feed module Note Coat the thread with Assembly compound Molykote P 37 1 Install pre feed module on SCR catalytic con verter 2 Remove transport closures from urea solu tion connections 3 Install tank return line on urea solution outlet 5 4 Install tank supply line on urea solution i...

Page 189: ...ter completion of work make sure that all protective devices are installed Exhaust pressure sensor Measuring lines check 1 Switch off engine and engine governor 2 Pinpoint the applicable connector on SCR catalytic converter Pressure sensor 1 is connected to SCR inlet of pipe A via measuring line 3 Pressure sensor 2 is connected to SCR outlet 3 Disconnect connectors from sensors 4 Connect test adap...

Page 190: ...ry and suffocation Avoid contact with eyes and skin Do not inhale vapors and smoke Do not eat drink smoke when working with cleaner Wear protective clothing gloves and goggles safety mask Take measures against electrostatic charging NOTICE Cleaning agents should not be left to take effect for too long Damage to components is possible Observe manufacturer s instructions Exhaust pressure sensor Meas...

Page 191: ...cancer Risk of poisoning and suffocation Keep the engine room well ventilated at all times Repair leaking exhaust pipework immediately NOTICE Deformation of housing Damage to component Do not step on the housing Note The SCR catalytic converter is fitted with fixed movable mounting with elongated holes to compensate thermal expansion The cold mount must be attached at the correct position in the h...

Page 192: ...tem mounts 6 Install foundation screws arrow and lower SCR catalytic converter until mount fully rests on foundation 7 Remove alignment jig 2 8 Loosen connecting screws lightly if alignment jig is jamming Note Recommended screw M12 10 9 ISO4017 washer DIN 433 13 400HV thread meshing length 3xD 9 Tighten foundation screws arrowed 6 pcs to specified tightening torque using a torque wrench Name Size ...

Page 193: ...ting check SCR catalytic converter Mounting check Item Findings Action Visually inspect resilient mounts Damage Deformation Crack formation Replace contact Service MS150123 01E 2017 05 Exhaust Gas Aftertreatment 193 TIM ID 0000076568 001 ...

Page 194: ...o life Use appropriate lifting devices and appliances Never stand beneath a suspended load WARNING Heavy part risk of falling or overturning due to lack of stability Risk of crushing body or limbs Use appropriate lifting gear and appliances Wear safety shoes WARNING Hot components surfaces Risk of burns Allow the engine to cool down to below 50 C before beginning work Wear suitable protective equi...

Page 195: ...can stand safely NOTICE Deformation of housing Damage to component Do not step on the housing Removing maintenance access doors Note The maintenance access doors are part of the sheet metal insulation of the SCR catalyt ic converter Removal can be done with the assistance of a mechanic 1 Unclip the clamps arrowed of maintenance access door 1 first 2 Pull maintenance access door 1 out of up per and...

Page 196: ... 6 with a lint free cloth and Cleaner Loctite 7061 to ensure that it is free from grease Note Adhesive Terokal 2444 Apply to the seal only 3 Glue seal 1 onto flange bottom 2 Note Seal 7 is already glued at the factory 4 If seal 7 becomes loose glue it manually on to the contoured bearing sealing area by wrapping it in preloaded state in two rows around the perimeter Result The joint of the two end...

Page 197: ...nto con tact after passing the perforated area B 8 Align the SCR module 3 such that the un perforated areas A longitudinal welds ar rowed are aligned with retaining pipe 1 and SCR module 3 An offset amounting to 10 of twist is still acceptable in this case Note Risk of crushing or pinching fingers especially in the perforated area 9 Push SCR module 3 into retaining pipe 4 by hand jiggling gently b...

Page 198: ...fied detail Note Make sure to establish the upper and lower clamping connections when pushing the door through the clamps into place 2 Close the clamps arrowed of maintenance access door 2 3 Push maintenance access door 1 into upper and lower clamps in the same direction of the arrow see magnified detail Note Make sure to establish the upper and lower clamping connections when pushing the door thr...

Page 199: ...beginning work Wear suitable protective equipment thermal gloves Avoid unprotected contact with hot surfaces NOTICE High voltage Risk of damage to components Switch off ignition before replacing components NOTICE Ceramic cell breakage due to shock or impact Risk of damage to components Avoid shocks and impacts Exercise extreme care when handling sensors Preparatory steps 1 Remove screws 1 and open...

Page 200: ...y including the evaluation unit 4 Loosen and disconnect connector at evalua tion unit 5 Unscrew NOx sensor 1 after SCR 6 Remove evaluation unit Installing NOx sensors before and after SCR new sensors 1 Install evaluation units before and after SCR Note Do not wipe off thread grease of manufactur er Do not apply any other lubricant 2 Only remove protective cap from thread im mediately before assemb...

Page 201: ...t does not drip or run down onto the sensor 3 Apply specified assembly compound to sen sor thread as necessary 4 Screw in sensors by hand 5 Tighten hexagon 2 to specified torque using a torque wrench Name Size Type Lubricant Value Standard Nut M20x1 5 Tightening torque Assembly compound Molykote P 37 50 Nm 10 Nm 6 Connect connector 1 to all evaluation units latch it Final steps Note Replace insula...

Page 202: ...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 268 202 Starting Equipment MS150123 01E 2017 05 TIM ID 0000000905 018 ...

Page 203: ...il 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 the minimum oil level 3 Oil level must be at least 2 cm above mark 2 4 If necessary top up with oil maximum to mark 1 Page 204 5 Insert oil dipstick into guide tube up to the stop Checking oil level im...

Page 204: ...ety 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 plug s and drain oil 3 Install drain plug s with new sealing ring Oil change using semirotary hand pump Oil extraction 1 Provide a suitable container to collect the oil 2 Extract all oil from oil p...

Page 205: ...g 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 203 5 After oil change bar engine with starting sys tem Page 130 MS150123 01E 2017 05 Lube Oil System Lube Oil Circuit 205 TIM ID 0000014100 006 ...

Page 206: ...low 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 running Risk of damage to hearing Wear ear protectors Take engine oil sample and ana lyze 1 With the engine running at operating temper ature loosen screw on automatic oil filter by 1 to 2 turns 2 Dra...

Page 207: ... 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 ring 20 Sealing ring 21 Union 22 Vent line 23 Nut 24 Screw MS150123 01E 2017 05 Oil Filtration Cooling 207 TIM ID 0000014226 007 ...

Page 208: ...lug 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 Screw 208 Oil Filtration Cooling MS150123 01E 2017 05 TIM ID 0000014226 007 ...

Page 209: ... 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 MS150123 01E 2017 05 Oil Filtration Cooling 209 TIM ID 0000014226 007 ...

Page 210: ... steps Preconditions Engine is stopped and starting disabled Automatic oil filter preparatory steps 1 Observe safety instructions 2 Remove centrifugal oil filter Page 238 210 Oil Filtration Cooling MS150123 01E 2017 05 TIM ID 0000014233 005 ...

Page 211: ...otective clothing protective gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor WARNING Oils oil vapors are combustible explosive Risk of fire and explosion Avoid open flames electric sparks and ignition sources Do not smoke NOTICE Ingress of contamination from automatic oil filter in the engine oil system Severe engine damage possible Remove the automatic oil filter be...

Page 212: ... coolant distribution housing 1 Attach automatic oil filter 1 to crane with a lightly tensioned lifting strap 2 Remove screws 2 3 Remove automatic oil filter from coolant dis tribution housing 3 4 Collect any oil that runs out 5 Remove O rings 4 6 Seal openings on coolant distribution housing with suitable covers 212 Oil Filtration Cooling MS150123 01E 2017 05 TIM ID 0000014231 011 ...

Page 213: ...ns Automatic oil filter has been removed from engine Automatic oil filter Disassembly 1 Observe safety instructions 2 Disassemble automatic oil filter as per overview drawing Page 207 MS150123 01E 2017 05 Oil Filtration Cooling 213 TIM ID 0000014232 004 ...

Page 214: ...ink smoke when working with cleaner Wear protective clothing gloves and goggles safety mask Take measures against electrostatic charging NOTICE Cleaning agents should not be left to take effect for too long Damage to components is possible Observe manufacturer s instructions Automatic oil filter Cleaning 1 Carefully clean all components and connections Clean all metallic parts with cleaner Snow Wh...

Page 215: ...p sufficiently clear off rotating parts Automatic oil filter Checking flushing arm rotation 1 Check at sight glass that plastic spinner 1 turns 2 If the plastic spinner turns irregularly or if it does not turn at all check the whole auto matic oil filter Page 207 MS150123 01E 2017 05 Oil Filtration Cooling 215 TIM ID 0000071222 001 ...

Page 216: ...ace Check gearwheel on worm gear for indentations signs of wear and damage Indentations Signs of wear Damage visible Smooth minor wear traces and damage with crocus cloth or oil stone Replace Check flushing arms on oil filter el ement for easy movement Page 232 Blow compressed air into the oil supply aperture to make the impeller rotate Flushing arms do not rotate Check worm gear and replace as ne...

Page 217: ... automatic oil filter before changing the oil filter candles Keep everything scrupulously clean when performing maintenance and repair work Cover all exposed openings when opening assemblies NOTICE Contaminated components Risk of damage to component Check components for special cleanliness and clean if necessary Assembling automatic oil filter 1 The assembly procedure is identical with that descri...

Page 218: ...nd explosion Avoid open flames electric sparks and ignition sources Do not smoke NOTICE Ingress of contamination from automatic oil filter in the engine oil system Severe engine damage possible Remove the automatic oil filter before changing the oil filter candles Keep everything scrupulously clean when performing maintenance and repair work Cover all exposed openings when opening assemblies NOTIC...

Page 219: ...ssembly compound 3 Insert O rings in ring groove 4 Attach automatic oil filter 1 with lifting strap to crane 5 Install automatic oil filter on coolant distribu tion housing 3 6 Coat screws 2 with engine oil 7 Insert and tighten screws MS150123 01E 2017 05 Oil Filtration Cooling 219 TIM ID 0000014235 010 ...

Page 220: ...filter Final steps Final steps 1 Install centrifugal oil filter Page 238 2 Check engine oil level and fill up as necessary Page 203 3 Enable engine start 220 Oil Filtration Cooling MS150123 01E 2017 05 TIM ID 0000014237 006 ...

Page 221: ...rview Oil filter candle element 1 Plastic spinner 2 Screw 3 Sealing nut 4 Spring washer 5 Washer 6 O ring 7 Upper flushing arm 8 Screw 9 O ring 10 Filter candles MS150123 01E 2017 05 Oil Filtration Cooling 221 TIM ID 0000069540 002 ...

Page 222: ... bearing 5 Grooved ball bearing 6 Connecting pipe 7 Overflow valve 8 Bottom strainer plate 9 Protective screen 1 O ring 2 Flushing arm shaft 3 Lower flushing arm 4 Gear 5 Screw 6 Screw 222 Oil Filtration Cooling MS150123 01E 2017 05 TIM ID 0000069540 002 ...

Page 223: ...y mask Avoid contact with skin Do not inhale oil vapor WARNING Oils oil vapors are combustible explosive Risk of fire and explosion Avoid open flames electric sparks and ignition sources Do not smoke Removing oil filter element 1 Remove nuts 2 from oil filter cover 1 2 Remove oil filter cover 3 Loop cable ties 2 around the flushing arm and close loosely 4 Take filter element 1 out of automatic oil...

Page 224: ... Disassembly 1 Remove screw 2 2 Pull out plastic spinner 1 with spring 3 Lock flushing arm 6 in position and remove sealing nut 3 4 Remove spring washer 4 and washer 5 5 Remove screw 8 6 Remove flushing arm from strainer plate 7 7 Remove filter element 1 from flushing arm shaft 2 224 Oil Filtration Cooling MS150123 01E 2017 05 TIM ID 0000070293 002 ...

Page 225: ...rews 1 11 Remove top strainer plate 2 12 Take off O ring 3 13 Remove protective strainer 4 from connect ing pipe 5 with bottom strainer plate attach ed 14 Remove O ring from bottom strainer plate Removing overflow valve u Unscrew overflow valves 1 and remove from connecting pipe 2 MS150123 01E 2017 05 Oil Filtration Cooling 225 TIM ID 0000070293 002 ...

Page 226: ...afety mask Take measures against electrostatic charging NOTICE Cleaning agents should not be left to take effect for too long Damage to components is possible Observe manufacturer s instructions Oil filter element Cleaning Note The outer side and the inner side of the protective strainer are installed in the filtered oil side Do not place the oil filter element on the jacket surface 1 Carefully cl...

Page 227: ...re Parts Catalog Gear Spare Parts Catalog Oil filter element Check Item Findings Measure Check grooved ball bearing on flushing arm shaft Damage Sluggish Replace Check flushing arm gap between flushing arm and strainer plate Gap 0 05 to 0 3 mm Gap incorrect Oil filter insert Replacement Check gear Indentations Signs of wear Damage visible Smooth minor wear traces and damage with crocus cloth or oi...

Page 228: ...onents for special cleanliness and clean if necessary NOTICE Ingress of contamination from automatic oil filter in the engine oil system Severe engine damage possible Remove the automatic oil filter before changing the oil filter candles Keep everything scrupulously clean when performing maintenance and repair work Cover all exposed openings when opening assemblies Installing overflow valve Note T...

Page 229: ...ainer plate 2 4 Install top strainer plate 5 Coat thread of screws 1 with screw locking compound Loctite 243 6 Insert screws 1 and tighten 7 Coat O rings 1 with assembly compound and insert in ring grooves on both ends of fil ter candles 8 Insert new filter candles 2 through top strainer plate with chamfer facing down 9 Insert flushing arm shaft 2 in filter ele ment 1 through bottom strainer plate...

Page 230: ... 14 Screw on sealing nut 5 15 Lock flushing arm 4 in position and tighten sealing nut 5 with torque wrench to the specified torque Name Size Type Lubricant Value Standard Sealing nut Tightening torque Engine oil 40 Nm Note Tolerances for gap on both sides 0 05 to 0 3 mm 16 Check gap 1 between flushing arm 4 and strainer plate 2 with feeler gauge If the tolerances are not met replace oil filter ele...

Page 231: ...ified torque using a torque wrench Name Size Type Lubricant Value Standard Screw Tightening torque Engine oil 9 Nm 19 Fit plastic spinner 2 with spring on sealing nut 1 MS150123 01E 2017 05 Oil Filtration Cooling 231 TIM ID 0000070295 003 ...

Page 232: ...mpressed air will result in airborne particles Risk of penetration of contaminants leading to component damage Disconnect the engine from the cooling water network by fitting blanking plates at the connecting flanges Seal off connecting flanges so that no dirt particles are blown into the engine NOTICE Contaminated components Risk of damage to component Check components for special cleanliness and...

Page 233: ... filter element 1 into housing 3 Insert new gasket in oil filter cover 1 4 Install oil filter cover 5 Screw on nuts 2 and tighten with torque wrench to the specified tightening torque Name Size Type Lubricant Value Standard Nut Tightening torque Engine oil 65 Nm MS150123 01E 2017 05 Oil Filtration Cooling 233 TIM ID 0000069547 003 ...

Page 234: ...nness 1 Cover opening 2 Note Constrict opening with a suitable cover 2 Blow compressed air into aperture 1 3 Check that flushing arm turns at sight glass 3 4 If flushing arm does not turn remove oil filter element disassemble check again Page 227 and replace if necessary 234 Oil Filtration Cooling MS150123 01E 2017 05 TIM ID 0000069547 003 ...

Page 235: ...es 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 to cool to below 50 C before beginning work Wear protective clothing protective gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor WARNING Compressed air gun ejects a jet ...

Page 236: ...ts from strainer as necessary 4 Blow out strainer 5 with compressed air from outside to inside Checking strainer Item Findings Action Strainer Metallic residues Clean Monitor engine operation Check strainer daily Contact Service Strainer Damaged Replace Square section ring Damaged Replace O ring Damaged Replace Installing strainer 1 Coat square section ring 4 on strainer 5 with engine oil and inst...

Page 237: ...strainer as necessary 4 Blow out strainer 5 with compressed air from outside to inside Checking strainer Item Findings Action Strainer Metallic residues Clean Monitor engine operation Check strainer daily Contact Service Strainer Damaged Replace Square section ring Damaged Replace Spring Damaged Replace O ring Damaged Replace Installing strainer 1 Coat square section ring on basket strainer 5 with...

Page 238: ...ter 1 Centrifugal oil filter 2 O ring 3 Flange 4 Washer 5 Screw 6 O ring 7 Socket pipe 8 O ring 9 Threaded adapter 10 Sealing ring 11 O ring 12 Stud 13 Flange 14 Socket pipe 15 Washer 16 Nut 238 Oil Filtration Cooling MS150123 01E 2017 05 TIM ID 0000044377 003 ...

Page 239: ...Do not inhale oil vapor WARNING Compressed air gun ejects a jet of pressurized air Risk of injury to eyes and damage to hearing risk of rupturing internal organs Never direct air jet at people Always wear safety goggles face mask and ear defenders Centrifugal oil filter Cleaning and filter sleeve replacement 1 Remove clamp 17 2 Release cover nut 2 and take off cover 1 3 Carefully lift rotor 14 all...

Page 240: ...e 7 and sealing ring 4 in rotor cover 3 9 Install rotor cover 3 and tighten nut of rotor cover 3 to specified torque using a torque wrench Name Size Type Lubricant Value Standard Nut M12 Tightening torque 80 Nm 12 Nm 10 Place rotor 14 in housing 15 and check for ease of movement 11 Check sealing ring 16 fit new one if necessary 12 Fit sealing ring 16 on housing 15 13 Fit cover 1 14 Tighten cover n...

Page 241: ...ness 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 installation position of components Removing centrifugal oil filter 1 Remove centrifugal oil filter as shown in overview drawing Page 238 2 Seal openings with suitable covers Installing centrifugal oil filter 1 Remov...

Page 242: ... stop and allow pressure to es cape 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 of the filler neck Checking coolant level at exter nal cooler 1 Check coolant level coolant must be visible at marker plate 2 Top up coolant if necessary Page 245 3 Check and clean breather valve 4 Position breather va...

Page 243: ...s Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 244 2 Fill with engine coolant Page 245 MS150123 01E 2017 05 Coolant System General High Temperature Circuit 243 TIM ID 0000000036 031 ...

Page 244: ... counterclockwise and remove 3 Draw off separated corrosion inhibitor oil in expansion tank through the filler neck 4 Open drain valves and or drain plugs and drain coolant at the following points Elbow of the engine coolant pump 2 Crankcase left and right side 1 On tee under flywheel housing At preheater 5 Tighten drain valves on elbow of engine coolant pump 2 and on crankcase 1 to specified torq...

Page 245: ...ine cool down Wear protective clothing gloves and goggles safety mask NOTICE Cold coolant in hot engine can cause thermal stress Possible formation of cracks in the engine Fill top up coolant only into cold engine Variant 1 Filling coolant through filler neck on expansion tank 1 Turn valve cover 1 on expansion tank on the left to the first lock and release pressure 2 Continue to turn valve cover c...

Page 246: ...n 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 stabilizes 15 Check coolant level in expansion tank Level 50 Close valve cover Level 50 Stop engine and fill expan sion tank until overflow edge is reached 16 Close valve cover on expansion tank and run ...

Page 247: ...uce engine speed to idle speed 11 With the engine idling fill expansion tank un til overflow edge is reached 12 Stop engine Page 76 and remove pump 13 With the expansion tank open start the en gine and run it up to nominal speed full load under load 14 Leave the engine idling for approx 5 minutes until the coolant temperature stabilizes 15 Check coolant level in expansion tank Level 50 Close valve...

Page 248: ...ar protectors Engine coolant pump Relief bore check 1 Check relief bore for oil and coolant dis charge Permissible coolant discharge up to 10 drops per hour Permissible oil discharge up to 5 drops per hour If discharge exceeds the specified limits Contact Service 2 If the relief bore is dirty stop the engine Page 76 and disable engine start observe general safety instructions for maintenance and r...

Page 249: ...engine 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 liter engine coolant Result Sampling point is clean 3 Drain approx 1 liter engine oil into a clean container 4 Tighten shut off cock arrow with torque wrench to the specified tightening torque Na...

Page 250: ...nnection 4 Connection to ship s power supply system 5 Junction box 6 ON OFF switch 7 Inlet 8 Thermostat 9 Nonmetallic cover and cap 10 Circulating pump Arrow Flow direction 250 Coolant System General High Temperature Circuit MS150123 01E 2017 05 TIM ID 0000073942 001 ...

Page 251: ...re Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Preheater Removal 1 Switch off preheater 3 at switch 4 and dis connect from power supply 2 Close shut off valves in coolant circuit be tween preheater and engine 3 Attach preheater 3 to crane with a lightly tensioned rope 4 Loosen and remove screw s on mounting plate 6 5 Loosen adapter f...

Page 252: ...erheating 7 Allow heating element to cool down 8 Remove housing cover 7 9 Remove screws of connection housing 4 and remove connection housing 4 and O ring 3 10 Loosen thermostat clip 6 11 Remove terminals on thermostat 5 from blade terminals of measuring unit 12 Replace thermostat 5 if necessary 13 Remove screws of heating element plate 2 14 Remove heating element plate 2 with heat ing element 8 f...

Page 253: ...ear safety shoes Preheater Installation 1 Remove sealing caps from flanges 1 and 5 Note Observe flow direction as marked with arrows on pump and non return flap 2 Attach preheater 3 to crane and position it on the flanges 1 and 5 3 Insert gaskets in flanges 1 and 5 4 Screw on mounting plate 6 5 Check position of non return valve 2 6 Screw on flanges 1 and 5 7 Detach preheater 3 from crane 8 Connec...

Page 254: ... preheater is ready for opera tion 1 Check coolant preheating temperature 2 Set the thermostat to the relevant temperatures if they are out of range Checking heating element s electrical u Page 255 Checking for leaks 1 Check leak tightness at coolant inlet and outlet 2 Tighten any leaking unions 254 Coolant System General High Temperature Circuit MS150123 01E 2017 05 TIM ID 0000030251 003 ...

Page 255: ... carry out one cur rent measurement per phase 2 For power consumption see electrical systems documentation or use formula I P 3 U I in Ampere P in Watt U in Volt lt is only permissible for the actual power consumption to be slightly less than the specified value No other deviations are permissible If power consumption is significantly less the heating element s must be replaced contact Service MS1...

Page 256: ...reparatory steps u Switch off preheater Replacing valve cover Note Schematic diagram Design may deviate 1 Turn valve cover 1 on coolant expansion tank counterclockwise until the first stop and release pressure 2 Continue to turn valve cover counterclock wise and remove 3 Remove chain with screw 4 and washer 3 4 Draw off separated corrosion inhibitor oil in expansion tank via filler neck 2 5 Fit ne...

Page 257: ...ger zone of the engine WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors Raw water pump Relief bore check 1 Check relief bore 1 for oil and coolant dis charge 2 Clean the relief bore with a wire if it is dirty Permissible coolant discharge Up to 10 drops hour Permissible oil discharge Up to 5 drops hour 3 If discharge exceeds the specified ...

Page 258: ...rive 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 deformation or crack for mation contact Service 5 Install protective cover 2 with screws 1 6 Use torque wrench to tighten screws 1 to specified tightening torque Name Size Type Lubricant Value Standard Screw M8x60 Tightening torque Engine...

Page 259: ... mounting Check Engine mounting Check Item Findings Action Visually inspect resilient mounts Damage Brittleness Deformation Crack formation Swelling Replace contact Service MS150123 01E 2017 05 Engine Mounting Support 259 TIM ID 0000015370 005 ...

Page 260: ...ing screws 1 to 3 2 Tighten loose screw connections 1 to specified torque using a torque wrench Name Size Type Lubricant Value Standard Screw M10x28 Control torque Engine oil 42 Nm 4 Nm 3 Tighten loose screw connections 2 to specified torque using a torque wrench Name Size Type Lubricant Value Standard Screw M20x200 Control torque Engine oil 500 Nm 50 Nm 4 Tighten loose screw connections 3 to spec...

Page 261: ...gine 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 76 and disable engine start 3 Clean relief bores with a wire if dirty Permissible water discharge up to 10 drops per hour Permissible oil discharge up to 5 drops per hour 4 If discharge exceeds the specified limits Con...

Page 262: ... System 8 22 1 Water drain valve Check Water drain valve Check 1 Open water drain valve 2 Check water outlet for obstructions 3 Close water drain valve 262 Fuel Supply System MS150123 01E 2017 05 TIM ID 0000007733 007 ...

Page 263: ... Wear protective clothing protective gloves and safety glasses facial protection Checking differential pressure gage alarm function 1 Switch on fuel treatment system Page 70 2 Set the alarm points at the differential pressure gage to zero Result Alarm is issued after preset time 3 Reset alarm points at differential pressure gage MS150123 01E 2017 05 Fuel Supply System 263 TIM ID 0000007737 007 ...

Page 264: ...rom 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 plant Result Water drain valve opens 6 Leave water level probe in tank Result Alarm must be issued after the preset time 7 Switch off the system 8 Disconnect plug from water level probe 9 Remove water l...

Page 265: ... 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 pressure of pump to 0 8 bar with the shut off valve at the pump intake side b Check pressure at the pressure gauge in the inlet to the fuel treatment system and note down c Open ball valve at inlet and...

Page 266: ...leanliness NOTICE Incorrect installation of components and lines Damage to component Ensure that components lines are installed so that they are never under tension or strain Ensure correct installation position of components Replacing coalescer filter ele ment 1 Close ball valve at the inlet and outlet of the fuel treatment system 2 Open drain ball valve 3 Drain fuel 4 Close drain ball valve 5 Re...

Page 267: ...ng torque Engine oil 30 Nm 3 Nm 17 Fit seal 10 18 Install cover 19 Install screws 1 washers 2 and nuts 9 20 Tighten nuts 9 21 Open ball valve at the inlet and outlet of the fuel treatment system Result The fuel treatment system is ready for operation MS150123 01E 2017 05 Fuel Supply System 267 TIM ID 0000007735 013 ...

Page 268: ... 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 housings Contacts Plug connectors Cables and terminals Plug in contacts Result If cable conductors are damaged contact Service Note Close connectors that are not plugged in with the protective cap sup...

Page 269: ...wheel 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 on switch 3 ensuring that the switch 3 is actuated by the guard plate 2 4 If switch 3 and guard plate 2 are installed but switch 3 is in the OFF position Make certain that the guard plate 2 at the sid...

Page 270: ...king plug connections on ECU 9 1 Check all connectors on ECU for firm seating Ensure that the clips 1 are engaged 2 Check screws of cable clamps 2 on ECU for firm seating Ensure that cable clamps are not faulty 270 Accessories for Electronic Engine Governor Control System MS150123 01E 2017 05 TIM ID 0000075262 001 ...

Page 271: ...ing plug connections on EMU 1 Check both connectors on EMU 2 for firm seating Ensure that the clips 1 are engag ed 2 Check screws of cable clamps 3 on EMU 2 for firm seating Ensure that cable clamps are not faulty MS150123 01E 2017 05 Accessories for Electronic Engine Governor Control System 271 TIM ID 0000075263 001 ...

Page 272: ... 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 not faulty 272 Accessories for Electronic Engine Governor Control System MS150123 01E 2017 05 TIM ID 0000017034 004 ...

Page 273: ...ngine 1 Note or mark assignment of cables and plugs 2 Remove all screws 2 3 Release latches 3 of male connectors 4 Remove all connectors 5 Remove screws 1 6 Take off engine governor Installing engine governor on engine 1 Install in reverse order Ensure correct assignment of plugs and sockets 2 Check resilient mount before installing Result If resilient mount is porous or defective then replace it ...

Page 274: ...rs 4 Disconnect all connectors 5 Remove screws 5 6 Remove Engine Control Unit 1 with Engine Monitoring Unit 2 Removing Engine Monitoring Unit 1 Unscrew screws on base of EMU 2 2 Remove EMU 8 2 from ECU 1 Installing Engine Monitoring Unit 1 Place EMU 8 2 on ECU 1 2 Screw in and tighten screws on base of EMU 2 Installing Engine Control Unit with Engine Monitoring Unit on engine 1 Install in reverse ...

Page 275: ...correct assignment between cables and connectors 2 Check seal before installing Result Replace seal if porous or defective Downloading software 1 The new EIM still does not have appropriate FSW and parameter descriptor module the diagnostic lamp DI LA indicates flashing code 4 when the power supply is connected Page 276 2 The FSW and the parameter descriptor module must first be downloaded from th...

Page 276: ... 4 Application loader active 5 External RAM faulty 6 External FLASH faulty 7 No firmware 8 Application crashed Fuse lamp SILA A second indicator is the fuse lamp This is also integrated in the housing of the Engine Interface Module It indicates the status of the fuses An orange LED is provided to allow diagnosis of a tripped fuse fault directly at the unit as it is often difficult to pinpoint a fa...

Page 277: ...S8 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 current path failed S13 15 Spare current path failed S14 for EIM with ECU 9 only The failed current paths are signaled consecutively following the preamble 1 LED on for 4 seconds There is a pause lastin...

Page 278: ...re 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 278 Accessories for Electronic Engine Governor Control System MS150123 01E 2017 05 TIM ID 0000075045 001 ...

Page 279: ...37 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 connectors on LOP 1 Remove dirt from connector and socket surfaces using solvent 2 Check legibility of cable labels Clean or replace illegible labels MS150123 01E 2017 05 Emergency Instrumentation Local Op...

Page 280: ... DILA Diagnostic lamp on EIM DIN Deutsches Institut für Normung e V German standardization association at the same time identifier of German standards DIN Deutsche Industrie Norm DIS Display Unit Display panel DL Default Lost Alarm Default CAN bus failure DPF Diesel Particulate Filter ECS Engine Control System Engine management system ECU Engine Control Unit Engine governor EDM Engine Data Module ...

Page 281: ...dance with DIN ISO 1204 KS Kraftseite Engine driving end in accordance with DIN ISO 1204 LCD Liquid Crystal Display Liquid Crystal Device LCU Local Control Unit LOP subassembly LED Light Emitting Diode LMU Local Monitoring Unit LOP subassembly LO Low Alarm Measured value lower than 1st minimum limit value LOLO Low Low Alarm Measured value lower than 2nd minimum limit value LOP Local Operating Pane...

Page 282: ...ional Convention for the Safety of Life at Sea SPC Spare Parts Catalog SS Safety System Safety system alarm SSK Schnellschlussklappe n German Abbreviation for SDAF SU Supply Unit T xyz Temperature xyz Temperature measuring point xyz TC Tool Catalog TD Transmitter Deviation Alarm Deviation in transmitter values UT Unterer Totpunkt Bottom Dead Center BDC VE Versorgungseinheit Supply unit SU VFM Vorf...

Page 283: ... 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 49 7541 9077778 Asia Pacific 65 6100 2688 North and Latin America 1 248 560 8000 Spare Parts Service Fast simple and correct identification of spare parts for your drive system or vehicle fleet The r...

Page 284: ...atalytic converter Mounting alignment Page 191 Angular screw driver Part No F30002815 Qty Used in 1 8 5 3 Valve clearance Check and adjustment Page 141 Barring gear Part No F6555766 Qty Used in 1 8 2 1 Engine Barring manually Page 129 284 Appendix B MS150123 01E 2017 05 DCL ID 0000043366 002 ...

Page 285: ... Page 131 Cable Part No Qty Used in 1 8 13 8 Exhaust pressure sensor Measuring lines check Page 189 Crossbeam Part No T80092210 Qty Used in 1 2 1 Transport Page 18 Crossbeam Part No T80092360 Qty Used in 1 2 1 Transport Page 18 MS150123 01E 2017 05 Special Tools 285 DCL ID 0000043366 002 ...

Page 286: ...test prods Part No Qty Used in 1 8 13 8 Exhaust pressure sensor Measuring lines check Page 189 Endoscope Part No Y20097353 Qty Used in 1 8 3 1 Cylinder liner Endoscopic examination Page 131 Feeler gage Part No Y20098771 Qty Used in 1 8 5 3 Valve clearance Check and adjustment Page 141 286 Special Tools MS150123 01E 2017 05 DCL ID 0000043366 002 ...

Page 287: ...module Filter element replacement Page 185 Fuel suction device Part No F30378207 Qty Used in 1 8 6 1 HP fuel pump Filling with engine oil Page 146 High pressure cleaner Part No Qty Used in 1 5 19 Plant Cleaning Page 80 Installation removal jig Part No F6789889 Qty Used in 1 8 7 2 Injector Removal and installation jacketed fuel system Page 149 MS150123 01E 2017 05 Special Tools 287 DCL ID 000004336...

Page 288: ...Qty Used in 1 8 5 1 Valve protrusion Measurement Page 136 Measuring jig 2 optional Part No Y4350010 Qty Used in 1 8 5 1 Valve protrusion Measurement Page 136 Milling cutter Part No F30452739 Qty Used in 1 8 7 2 Injector Removal and installation jacketed fuel system Page 149 288 Special Tools MS150123 01E 2017 05 DCL ID 0000043366 002 ...

Page 289: ...ter Replacement Page 155 Oilstone Part No F30454308 03 Qty Used in 1 8 16 7 Automatic oil filter Check Page 216 Ratchet adapter Part No F30027340 Qty Used in 1 2 3 Crankshaft transport locking device Page 22 Qty Used in 1 8 9 1 Compressor wheel Cleaning Page 166 Qty Used in 1 8 16 16 Oil filter element Assembly Page 228 Qty Used in 1 8 22 5 Coalescer filter element Replacement Page 266 MS150123 01...

Page 290: ... 1 8 8 5 Fuel prefilter with water separator Filter element replacement Page 163 Qty Used in 1 8 13 3 Dosing unit Replacement Page 180 Qty Used in 1 8 13 12 SCR modules Replacement Page 194 Ratchet bit Part No F30027341 Qty Used in 1 8 7 2 Injector Removal and installation jacketed fuel system Page 149 Qty Used in 1 8 15 2 Engine oil Change Page 204 Ratchet bit Part No F30450902 Qty Used in 1 8 13...

Page 291: ...Removal tool Part No XP52699100138 Qty Used in 1 8 16 13 Oil filter element Disassembly Page 224 Socket wrench 24 mm Part No F30039526 Qty Used in 1 8 5 3 Valve clearance Check and adjustment Page 141 Socket 46 A F Part No F30006128 Qty Used in 1 8 13 1 Supply unit Filter element replacement Page 174 MS150123 01E 2017 05 Special Tools 291 DCL ID 0000043366 002 ...

Page 292: ...r separator Filter element replacement Page 163 Qty Used in 1 8 9 1 Compressor wheel Cleaning Page 166 Qty Used in 1 8 13 13 NOx sensor Replacement Page 199 Qty Used in 1 8 16 20 Centrifugal oil filter Cleaning and filter sleeve replacement Page 239 Qty Used in 1 8 19 1 Battery charging generator drive Coupling condi tion check Page 258 Qty Used in 1 8 20 2 Engine mounting Checking securing screws...

Page 293: ... and installation jacketed fuel system Page 149 Qty Used in 1 8 13 1 Supply unit Filter element replacement Page 174 Qty Used in 1 8 13 10 SCR catalytic converter Mounting alignment Page 191 Qty Used in 1 8 15 2 Engine oil Change Page 204 Qty Used in 1 8 20 2 Engine mounting Checking securing screws for firm seating Page 260 Torque wrench 6 50 Nm Part No F30027336 Qty Used in 1 8 13 12 SCR modules...

Page 294: ...Dosing unit Replacement Page 180 Qty Used in 1 8 22 5 Coalescer filter element Replacement Page 266 Valve setting gauge Part No Y4349603 Qty Used in 1 8 5 3 Valve clearance Check and adjustment Page 141 294 Special Tools MS150123 01E 2017 05 DCL ID 0000043366 002 ...

Page 295: ...Oil mist separator Replacement 135 Crankshaft Transport locking device Installation removal 22 Cylinder Designation 25 Cylinder head cover Installation 145 Removal 145 Cylinder liner Endoscopic examination 131 Instructions and comments on endoscopic and visual examination 133 D Diagnostic lamp DILA EIM 276 Diagnostics EIM 276 Differential pressure gage Alarm function check 263 Disengaging From LOP...

Page 296: ...e Replacement 239 Firing order 58 Fuel Treatment system Switching on 70 Troubleshooting 83 treatment system Shutdown 79 Fuel filter Replacement 155 Fuel prefilter Contamination indicator check 157 Fuel prefilter with water separator Draining 159 Filter element Flushing 161 Replacement 163 Fuel treatment system Control cabinet Controls 65 Initial start up 67 Shutdown 79 Switching on 70 Fuse lamp SI...

Page 297: ...f service period 61 R Raw water pump Relief bore check 257 S Safety notices standards 17 Safety regulations Assembly work 11 Environmental protection 15 Fire prevention 15 Fluids and lubricants 15 Important provisions 6 7 Indirect materials 15 Initial start up 9 Maintenance work 11 Operation 9 Organizational requirements 8 Personnel requirements 8 Repair work 11 Safety requirements Safety notices ...

Page 298: ...Valve cover Replacement 256 Valve gear Lubrication 140 Valve protrusion Measurement 136 W Water drain valve Check 262 Water level probe 3 in 1 rod electrode Check 264 Waterjet Flushing From LOP option 75 Wiring harness Overview 44 298 Index MS150123 01E 2017 05 DCL ID 0000043366 002 ...

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MTU 16V4000M73 series, Operating Instructions Manual

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