MTU 20 V 4000 M73 x Operating Instructions Manual Download Page 177

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7.21.2 Engine Control Unit ECU 7 – Checking plug connections

Preconditions

☑

Engine is stopped and starting disabled.

Check plug connections on ECU
7

Check all connectors on ECU for firm seat-

ing. Ensure that clips (3) are engaged.

Check screws (2) of cable clamps on ECU

for firm seating. Ensure that cable clamps

are not faulty.

MS150046/02E 2013-07 | Task Description | 177

TIM-ID: 0000016847 - 005

Summary of Contents for 20 V 4000 M73 x

Page 1: ...Operating Instructions Diesel engine 20 V 4000 M73 x MS150046 02E...

Page 2: ...protected by copyright and may not be used in any way whether in whole or in part without the prior written permission of MTU Friedrichshafen GmbH This restriction also applies to copyright distributi...

Page 3: ...lushing from LOP optional 66 4 14 Stopping the engine 67 4 15 Stopping the engine from LOP 68 4 16 Emergency stop from LOP 69 4 17 Stopping the engine at the BlueLine automation system control stand 7...

Page 4: ...heck 166 7 17 Engine Mounting Support 167 7 17 1 Engine mounting Check 167 7 18 Auxiliary PTO 168 7 18 1 Bilge pump Relief bore check 168 7 19 Fuel Supply System 169 7 19 1 Water drain valve Check 169...

Page 5: ...on approved by the manufacturer in writ ing including engine control parameters In compliance with all safety instructions and in adherence to all warning notices in this manual In accordance with the...

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

Page 7: ...ts and monitoring units must be permanently observed with re gard to present operating status violation of limit values and warning or alarm messages Malfunctions and emergency stop The procedures for...

Page 8: ...llium containing pinion Do not blow out the interior of the flywheel housing or the starter with compressed air Clean the flywheel housing inside with a class H dust extraction device as an additional...

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

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

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

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

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

Page 14: ...trans port pallet or transport with equipment for heavy loads forklift truck Install the crankshaft locking device and the locking screws for the engine mounts prior to engine trans portation Secure t...

Page 15: ...ders on the left hand side of the engine and the letter B 3 to refer to the cylinders on the right hand side The cylinders of each bank are numbered consecutively starting with No 1 at the driving end...

Page 16: ...equential turbocharging with internal engine coolant controlled charge air cooling The right hand ex haust turbocharger is cut in and cut out on 12V and 16V engines with electronically controlled hydr...

Page 17: ...also integrated in the engine wiring har ness Functions ECU supply EMU supply Plant signals ECU7 connector X1 Bus interface 2x MCS5 CAN CAN dialog output 1xMCS5 CAN Emergency stop ECU and EMU Electric...

Page 18: ...arms when limits are violated Pushbuttons for menu control and dimming unit Combined control and display elements for local engine gear control Flashing light and horn for combined alarm in engine roo...

Page 19: ...line from fuel filter head 1 Fuel line to HP pump Lube oil system oil lines with oil pressure 1 8 bar 1 Parting line ETC oil supply free end MS150046 02E 2013 07 General Information 19 TIM ID 00000100...

Page 20: ...1 Parting line ETC oil supply driving end 1 Oil line on equipment carrier 1 Oil supply to HP pump 20 General Information MS150046 02E 2013 07 TIM ID 0000010057 003...

Page 21: ...1 Oil supply to flap control free end 1 ETC oil supply on main oil gallery 1 Switching cylinder air flap A2 MS150046 02E 2013 07 General Information 21 TIM ID 0000010057 003...

Page 22: ...A2 3 T piece flap control 1 Connection oil line to turbocharger B1 2 Switching cylinder exhaust flap tur bocharger B1 3 T piece flap control turbocharger B1 1 Switching cylinder air flap turbo charger...

Page 23: ...p turbo charger B2 4 T piece flap control turbocharger B2 1 Flap control distributor Special connections In case of leakage the following connection types are spray protected even without a cover and...

Page 24: ...has to pass the thread The pressure is so greatly reduced by this and the faulty sealing ring 1 that any leakage is not under pressure Plug in pipe connection b The sleeve 3 covers the joint to preve...

Page 25: ...ea 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 5 occurs the emerging fuel is routed to the leakage chamber The le...

Page 26: ...tic oil filter 12 HP fuel pump 13 Fuel filter 14 Centrifugal oil filter s 15 Coolant cooler Engine model designation Key to the engine model designations 20V 4000 Mxyz 20 Number of cylinders V Cylinde...

Page 27: ...2 lube oil pressure af ter filter 12 B34 2 fuel pressure be fore filter 13 B34 1 fuel pressure after filter 14 B5 3 lube oil pressure be fore filter 15 B48 fuel pressure in com mon rail 16 B4 B10 exha...

Page 28: ...ng tem perature 10 B57 2 main bearing tem perature 11 B57 3 main bearing tem perature 12 B57 4 main bearing tem perature 13 B57 5 main bearing tem perature 14 B57 6 main bearing tem perature 15 B57 7...

Page 29: ...uel level 2 B33 fuel temperature 3 B1 camshaft speed 4 B54 oil refill pump pres sure 5 B6 2 coolant tempera ture 6 B6 coolant temperature 7 Connector XD1 Dialog unit MS150046 02E 2013 07 General Infor...

Page 30: ...10 spray oil temp conrod bearing 9 B77 B9 spray oil temp conrod bearing 10 B77 B8 spray oil temp conrod bearing 11 B77 B7 spray oil temp conrod bearing 12 B77 B6 spray oil temp conrod bearing 13 B77 B...

Page 31: ...20 V 4000 M driving end 1 B13 2 crankshaft speed 2 B13 crankshaft speed 3 S37 2 safety switch 4 S37 1 safety switch MS150046 02E 2013 07 General Information 31 TIM ID 0000034733 003...

Page 32: ...temperature B9 Charge air temperature B10 Charge air pressure B13 Crankshaft speed B16 Coolant pressure B21 Raw water pressure B33 Fuel temperature B34 1 Fuel pressure after filter B34 2 Fuel pressur...

Page 33: ...rnor ECU 7 E4 X KF thermostat heating Y39A1 to Y39AX Injectors engine side A Y39B1 to Y39BX Injectors engine side B Designation Connection assignment Adaption X1 Engine Control Unit ECU X3 Engine Cont...

Page 34: ...1 7 B7 8 B10 9 B34 2 10 XY27 11 B34 1 12 B48 13 B4 23 14 F46 15 B33 16 B1 17 B4 21 18 XG03 19 B5 3 20 M8 21 X2 22 X37 23 XF33 24 B6 25 B44 4 26 B16 27 B4 24 28 B4 22 29 B49 30 Y26 31 B44 2 32 B9 33 B...

Page 35: ...3 4 Y39A4 5 Y39A5 6 Y39A6 7 Y39A7 8 Y39A8 9 Y39A9 10 Y39A10 11 X4 12 E4 1 13 E4 2 14 E4 3 15 E4 4 16 E4 5 17 Y39B9 18 Y39B10 19 Y39B8 20 Y39B7 21 Y39B6 22 Y39B5 23 Y39B4 24 Y39B3 25 Y39B2 26 Y39B1 MS1...

Page 36: ...Engine wiring harness for EIM 1 XD1 2 X1 3 X3 4 X52 5 XY1 6 X11 7 XB19 8 X37 36 General Information MS150046 02E 2013 07 TIM ID 0000034732 002...

Page 37: ...Engine wiring harness for electric starter 1 EIM terminals 2 Fuse F1 3 Starter terminals MS150046 02E 2013 07 General Information 37 TIM ID 0000034732 002...

Page 38: ...ressure mbar 1000 Site altitude above sea level m 100 Power related data power ratings are net brake power as per ISO 3046 Number of cylinders 20 Rated engine speed A rpm 1970 Fuel stop power ISO 3046...

Page 39: ...nection min during engine operation L bar 0 3 Fuel pressure at engine supply connection max when engine is starting L bar 1 5 Fuel inlet quantity to engine max R Liters min 28 GENERAL OPERATING DATA N...

Page 40: ...ns R liters 320 Oil pan capacity dipstick mark min standard oil system Option Max oper ating inclinations L liters 255 Oil pan capacity dipstick mark max standard oil system Option Max oper ating incl...

Page 41: ...bar 1000 Site altitude above sea level m 100 Power related data power ratings are net brake power as per ISO 3046 Number of cylinders 20 Rated engine speed A rpm 1970 Fuel stop power ISO 3046 A kW 320...

Page 42: ...onnection min during engine operation L bar 0 3 Fuel pressure at engine supply connection max when engine is starting L bar 1 5 Amount of flow to engine max R Liters min 28 GENERAL OPERATING DATA Numb...

Page 43: ...ns R liters 320 Oil pan capacity dipstick mark min standard oil system Option Max oper ating inclinations L liters 255 Oil pan capacity dipstick mark max standard oil system Option Max oper ating incl...

Page 44: ...mbar 1000 Site altitude above sea level m 100 Power related data power ratings are net brake power as per ISO 3046 Number of cylinders 20 Rated engine speed A rpm 2050 Fuel stop power ISO 3046 A kW 36...

Page 45: ...t connection min during engine operation L bar 0 3 Fuel pressure at engine supply connection max when engine is starting L bar 1 5 Fuel inlet quantity max R Liters min 29 GENERAL OPERATING DATA Number...

Page 46: ...ns R liters 320 Oil pan capacity dipstick mark min standard oil system Option Max oper ating inclinations L liters 255 Oil pan capacity dipstick mark max standard oil system Option Max oper ating incl...

Page 47: ...Site altitude above sea level m 100 Power related data power ratings are net brake power as per ISO 3046 Number of cylinders 20 Rated engine speed A rpm 2050 Fuel stop power ISO 3046 A kW 3600 GENERAL...

Page 48: ...t connection min during engine operation L bar 0 3 Fuel pressure at engine supply connection max when engine is starting L bar 1 5 Fuel inlet quantity max R Liters min 29 GENERAL OPERATING DATA Number...

Page 49: ...ns R liters 320 Oil pan capacity dipstick mark min standard oil system Option Max oper ating inclinations L liters 255 Oil pan capacity dipstick mark max standard oil system Option Max oper ating incl...

Page 50: ...Width B Height C 12 V 4000 M73 93 L approx 2991 mm approx 1463 mm approx 2368 mm 16 V 4000 M73 93 L approx 3583 mm approx 1463 mm approx 2368 mm 20 V 4000 M73 93 L approx 4192 mm approx 1484 mm appro...

Page 51: ...3 6 Firing order Firing order Num ber of cylin ders Firing order 20 V A1 B5 A8 B7 A5 B2 A7 B10 A2 B3 A10 B6 A3 B4 A6 B9 A4 B1 A9 B8 MS150046 02E 2013 07 Technical Data 51 TIM ID 0000035068 001...

Page 52: ...lueLine automation system Controls on LOP 6 without display Page 186 Controls on LOS or on LOP 8 with display Page 187 BlueVision automation system Controls on LOP 8 Page 187 52 Operation MS150046 02E...

Page 53: ...bove waterline Fill with water approx 3 4 liters Coolant circuit If engine is out of service for more than one year change coolant Page 157 Coolant circuit Check coolant level Page 156 Coolant circuit...

Page 54: ...required Coolant circuit Check coolant level Page 156 Coolant circuit Heat coolant with coolant preheating unit Engine control system Switch master switch to ON Press illuminated pushbutton READY FOR...

Page 55: ...sons in the en gine s danger zone WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors The engine can be started from the following points Item A...

Page 56: ...running noises and vibration Check exhaust color Page 76 Air filter Check signal ring position of service indicator Page 141 Replace air filter Page 139 if the signal ring is completely visible in th...

Page 57: ...eks Tasks after extended out of service periods 3 weeks Note Operate fuel treatment system for at least 5 minutes 1 Start up fuel treatment system Page 59 2 Shut down fuel treatment system Page 72 MS1...

Page 58: ...ves 4 Switch on fuel treatment system Page 62 5 Check direction of rotation of pump 6 Vent bypass and fuel lines of the system a Open ball valve for pressure tank b Open ball valve for overflow tank c...

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

Page 60: ...ball valve 5 at inlet to fuel treatment system Result The pressure upstream of the fuel treatment system increases until the overflow valve at the pump unit opens and fuel flows through bypass 3 and...

Page 61: ...y pump draws fuel via bypass 2 directly from tank 24 5 Check suction pressure at the engine mounted fuel delivery pump Note If the suction pressure is within the permissible limits and engine operatio...

Page 62: ...re switching on ensure that all housings are closed Before switching on ensure that no work is in progress anywhere on the entire system Fuel treatment system Switching on 1 Carry out checks prior to...

Page 63: ...the engine plant Risk of overheating damage to components Initiate emergency stop only in emergency situations Engine emergency stop at BlueLine automation system Item Measure Engine Emergency stop a...

Page 64: ...button flashes Coupling is engaged After receiving the feedback signal from coupling the COUPLING IN button is illuminated brightly Engaging coupling in ahead direction with reversing gearbox FPP WJ...

Page 65: ...OUPLING OUT button flashes Coupling is disengaged After receiving the feedback signal from coupling the COUPLING OUT button is illuminated brightly Disengaging coupling with reversing gearbox FPP WJ I...

Page 66: ...long Follow instructions of the waterjet manufacturer Flushing with reversing gearbox and flushing mode Item Measure LOP Press FLUSH illuminated pushbutton and keep pressed Page 52 FLUSH pushbutton f...

Page 67: ...4 14 Stopping the engine Stopping the engine via the automation system Refer to automation system operating instructions MS150046 02E 2013 07 Operation 67 TIM ID 0000017528 004...

Page 68: ...engine at idle speed for at least 10 minutes until engine temperatures have dropped and constant values are displayed Stopping the engine from LOP Item Measure LOP Disengage gearbox Page 52 LOP Opera...

Page 69: ...nnecting the power supply to the ECU On engines with emergency air shutoff flaps flaps close EMERGENCY STOP illuminated pushbutton flashes Horn flashing lamp etc are tripped After emergency stop from...

Page 70: ...Before shutting down disengage gear and run the engine at idle speed for at least 10 minutes until engine temperatures have dropped and constant values are displayed Stopping the engine at the BlueLi...

Page 71: ...t a suitable temperature the antifreeze concentration is insufficient for the engine room tem perature antifreeze concentration is 50 and engine room temperature is be low 40 C Raw water Drain If free...

Page 72: ...inet until water discharge from the outlet stops 2 Switch off fuel treatment system 3 Close ball valve at the inlet to the fuel treatment system 4 Close ball valve at the outlet of the fuel treatment...

Page 73: ...im compressed air gun directly at seals or electronic components such as connectors or ECUs Plant Cleaning 1 Carry out plant cleaning only in areas where an appropriate oil separator is provided envir...

Page 74: ...125 W1002 Check valve clearance Page 113 W1005 Replace air filter Page 139 W1006 Replace injectors Page 119 W1008 Replace engine oil filter at each oil change or when the time limit years is reached...

Page 75: ...ped 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 R...

Page 76: ...ode u Check fuse replace if required and re start the system by actuating the key switch Running gear blocked engine cannot be barred manually u Contact Service Engine turns but does not fire Cause Co...

Page 77: ...ndicator Page 141 Intercooler clogged u Contact Service Exhaust turbocharger defective u Contact Service Coolant leaks at intercooler Cause Corrective action Intercooler leaky major coolant discharge...

Page 78: ...st gas Cause Corrective action Engine is not at operating temperature u Run engine to reach operating temperature Intercooler leaky u Contact Service 78 Troubleshooting MS150046 02E 2013 07 TIM ID 000...

Page 79: ...1 comprises 3 digits Fault messages may also be caused by faulty sensors actuators Contact Service to have sensors actuators tested and replaced as necessary if troubleshooting as described in the ta...

Page 80: ...ilure ZKP Number 18 004 204 Cause Corrective action ETC2 could not be cut in 1 Reduce power 2 Contact Service 81 AL Rail Leakage ZKP Number 18 004 046 Cause Corrective action Pressure gradient in rail...

Page 81: ...lace as necessary 2 Error cleared after restarting the engine 202 SD T Fuel ZKP Number 18 004 572 Cause Corrective action Coolant temperature sensor faulty Short circuit or wire break 1 Check sensor a...

Page 82: ...ng B4 22 replace as necessary 208 SD P Charge Air ZKP Number 18 004 566 Cause Corrective action Charge air pressure sensor faulty Short circuit or wire break 1 Check sensor and cabling B10 replace as...

Page 83: ...sensor and cabling B48 replace as necessary 2 Error cleared after restarting the engine 216 SD T Lube Oil ZKP Number 18 004 575 Cause Corrective action Lube oil temperature sensor faulty Short circui...

Page 84: ...cleared after restarting the engine 227 SD P Lube Oil before Filter ZKP Number 18 004 620 Cause Corrective action Sensor for lube oil pressure before filter faulty Short circuit or wire break 1 Check...

Page 85: ...Error cleared after restarting the engine 233 SD Charger 2 Speed ZKP Number 13 011 129 Cause Corrective action Speed sensor of secondary turbocharger faulty Short circuit or wire break 1 Check sensor...

Page 86: ...ant lube oil pressure sensor faulty Short circuit or wire break 1 Check sensor and cabling replace as necessary 2 Error cleared after restarting the engine 301 AL Timing Cylinder A1 ZKP Number 18 004...

Page 87: ...ctive action Time of flight measuring fault of injector in cylinder A5 Time of flight measured value extremely low or extremely high u If alarm occurs frequently replace solenoid valve of injector 306...

Page 88: ...Cause Corrective action Time of flight measuring fault of injector in cylinder A10 Time of flight measured value extremely low or extremely high u If alarm occurs frequently replace solenoid valve of...

Page 89: ...Corrective action Time of flight measuring fault of injector B5 Time of flight measured value extremely low or extremely high u If alarm occurs frequently replace solenoid valve of injector 316 AL Ti...

Page 90: ...ult of injector B10 Time of flight measured value extremely low or extremely high u If alarm occurs frequently replace solenoid valve of injector 321 AL Wiring Cylinder A1 ZKP Number 18 004 520 Cause...

Page 91: ...by injector replacement 2 Error cleared after restarting the engine 326 AL Wiring Cylinder A6 ZKP Number 18 004 525 Cause Corrective action Short circuit in injector cabling to cylinder A6 Result Mis...

Page 92: ...g by injector replacement 2 Error cleared after restarting the engine 332 AL Wiring Cylinder B2 ZKP Number 18 004 531 Cause Corrective action Cabling fault in injector cabling to cylinder B2 Result Mi...

Page 93: ...by injector replacement 2 Error cleared after restarting the engine 338 AL Wiring Cylinder B8 ZKP Number 18 004 537 Cause Corrective action Cabling fault in injector cabling to cylinder B8 Result Misf...

Page 94: ...g by injector replacement 2 Error clearance After each working cycle 344 AL Open Load Cylinder A4 ZKP Number 18 004 543 Cause Corrective action Disruption fault in injector cabling to cylinder A4 Resu...

Page 95: ...by injector replacement 2 Error clearance After each working cycle 350 AL Open Load Cylinder A10 ZKP Number 18 004 549 Cause Corrective action Disruption fault in injector cabling to cylinder A10 Res...

Page 96: ...g by injector replacement 2 Error clearance After each working cycle 356 AL Open Load Cylinder B6 ZKP Number 18 004 555 Cause Corrective action Disruption fault in injector cabling to cylinder B6 Resu...

Page 97: ...t 1 1020 021 Power Stage Failure Stop Engine is set engine will be shut down as additional measure u Start ITS If the ITS diagnosis result is electronics OK note further fault messages e g cabling fau...

Page 98: ...on transistor output 1 TO 1 1 Check charger valve cabling repair as necessary 2 Replace engine governor 372 AL Wiring TO 2 ZKP Number 18 004 635 Cause Corrective action Short circuit or wire break on...

Page 99: ...Maximum deviation of lube oil pressure values from sensors 1 Check sensor and cabling replace as necessary 2 Contact Service 417 SD Level Water Fuel Prefilter ZKP Number 18 004 594 Cause Corrective a...

Page 100: ...y 1 Check signal transmitter and cabling replace as necessary 2 Replace engine governor 469 SD AUX 1 ZKP Number 18 004 590 Cause Corrective action Analog input signal for Aux 1 faulty Short circuit or...

Page 101: ...corder initialization error 1 Check setting with DiaSys 2 Contact Service 482 SD T Exhaust C ZKP Number 18 004 596 Cause Corrective action Exhaust temperature sensor on A side faulty Short circuit or...

Page 102: ...g consumer a wire break or a short circuit u Check connection between POM and starter 502 AL Open Load POM Alternator ZKP Number 14 500 902 Cause Corrective action Open load was detected at the connec...

Page 103: ...ss 519 Oillevel Calibration Error ZKP Number 10 158 921 Cause Corrective action Error when writing the calibration value into the Flash or SD memory of the level sensor associated PV AL Group 6 Mot Bi...

Page 104: ...e Oil Pan ZKP Number 10 137 900 Cause Corrective action Temperature sensor in oil pan defective Short circuit or wire break u Check sensor and cabling replace as necessary 582 AL Emergency Stop Failed...

Page 105: ...eck sensor and cabling replace as necessary 601 SD ETC1 ETC2 ZKP Number 13 011 227 Cause Corrective action SD ETC1 and ETC2 u Check sensor and cabling replace as necessary 625 SD P Fuel before Prefilt...

Page 106: ...gine s danger zone After finishing work on the engine make sure that all safety devices are put back in place and all tools removed from the engine Engine Barring manually 1 Remove guard plate Result...

Page 107: ...e automation system Starting barring procedure at LOP 8 BlueLine Operating Instructions BlueVision automation system Starting barring procedure at LOP 8 BlueLine Operating Instructions MS150046 02E 20...

Page 108: ...s First signs of marks left by lower cooling bores Running pattern seems darker No action required Dark areas with even or varying degrees of discoloration Beginning and end of the discoloration are n...

Page 109: ...Final steps 1 Install injector Page 120 2 Install cylinder head cover Page 117 MS150046 02E 2013 07 Task Description 109 TIM ID 0000000015 014...

Page 110: ...nd the liner It appears rather darker within the honed struc ture in contrast to the bright metallic running surface The honing pattern is undis turbed Discolorations extend in stroke direction and ma...

Page 111: ...tion are similar A thorough investigation and compliance with the above evaluation criteria allow an unambiguous evaluation To avoid unnecessary disassembly work it is recommended that another inspect...

Page 112: ...re parts Designation Use Part No Qty Engine oil Valve gear Lubrication 1 Remove cylinder head covers Page 117 2 Fill oil chambers of valve bridges with oil 3 Fill oil chambers of rocker arms and adjus...

Page 113: ...re parts Designation Use Part No Qty Feeler gauge Y20098771 1 Torque wrench 60 320 Nm F30452768 1 Box wrench socket 24 mm F30039526 1 Engine oil Preparatory steps 1 Remove cylinder head cover Page 117...

Page 114: ...n di rection of engine rotation until the OT A1 marking and pointer are aligned Diagram for 8V engines two crankshaft positions Diagram for 12V engines two crankshaft positions 114 Task Description MS...

Page 115: ...C 2 Check valve clearance with cold engine Inlet long rocker arm 0 2 mm 0 05 mm Exhaust short rocker arm 0 5 mm 0 05 mm 3 Check all valve clearances in two crankshaft positions firing TDC and overlap...

Page 116: ...1 with torque wrench to the specified tightening torque holding the adjusting screw 2 to prevent it from turning Name Size Type Lubricant Value Standard Locknut M16 x 1 5 Tightening torque Engine oil...

Page 117: ...r head covers 1 prior to removal 2 Remove screws 3 4 with washers 2 5 3 Take off cylinder head cover 1 with O ring 6 from cylinder head 7 Installing cylinder head cover 1 Clean mounting surface 2 Chec...

Page 118: ...G Oils oil vapors are combustible explosive Risk of fire and explosion Avoid open flames electric sparks and ignition sources Do not smoke NOTICE HP fuel pump not filled with engine oil Damage to comp...

Page 119: ...or Replacement Special tools Material Spare parts Designation Use Part No Qty Injector Spare Parts Catalog Replacing injector u Remove injector and install new injector Page 120 MS150046 02E 2013 07 T...

Page 120: ...wrench 60 320 Nm F30452768 1 Ratchet F30027341 1 Assembly paste Optimoly Paste White T 40477 1 Grease Kluthe Hakuform 30 10 Emulgier X00029933 1 Engine oil O ring Spare Parts Catalog WARNING Fuels ar...

Page 121: ...r head 7 Remove injector with installation removal tool 8 Remove installation removal tool 9 Remove sealing ring 4 from injector or use a self made hook to take it out of the cylinder head 10 Remove O...

Page 122: ...installation position of seal ing ring 4 Fit new O rings 3 included in the scope of supply of the injector O ring 2 and damping ring 1 onto the injector and coat with grease 5 Remove oil carbon from...

Page 123: ...h torque wrench to the specified tightening torque Name Size Type Lubricant Value Standard Screw M12 Tightening torque 100 Nm 10 Nm 14 Tighten adapter 3 with torque wrench to the specified tightening...

Page 124: ...screw Tightening torque 40 Nm 5 Nm 19 Fit connectors on injector Note Failure to reset drift compensation CDC will void the emissions certification 20 Reset drift compensation CDC with Dia Sys E531920...

Page 125: ...in Only run the engine at low power Keep away from the engine s danger zone WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not sm...

Page 126: ...three way cock to operating position both filters cut in 8 Replace further fuel filters in the same way 9 Vent fuel system 1 Fuel filter replacement with the engine running 1 Cut out the filter to be...

Page 127: ...differential pressure gauge 1 When installing the new filter element align adjustable pointer 2 with pressure indicating pointer 3 of pressure gauge 1 2 Check differential pressure Checking differenti...

Page 128: ...al sparks and ignition sources Do not smoke Draining fuel prefilter 1 Filter A cut out 2 Filter B cut out 1 Cut out the filter to be drained 2 Open threaded vent plug 1 of filter to be drained 3 Open...

Page 129: ...fuel emerges from the vent pipe 7 or 5 8 Close vent valve 2 or 4 9 Open rotary slide valve 6 a little by ap prox 30 and open vent valve s 2 or 4 until fuel emerges from the vent pipe 7 or 5 10 Close v...

Page 130: ...at low power Keep away from the engine s danger zone WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke WARNING High level...

Page 131: ...efilter Filling with fuel 1 Stop engine Page 67 and disable engine start 2 Remove screws securing the cover and take off cover 2 3 Fill filter housing with clean fuel 4 Place new gasket in cover 2 5 F...

Page 132: ...Diesel fuel Filter element Spare Parts Catalog Gasket Spare Parts Catalog WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke...

Page 133: ...7 Remove spring housing 4 and filter ele ment 3 8 Insert new filter element 3 and spring housing 4 9 Fill filter housing with clean fuel 10 Place new gasket in cover 2 11 Fit cover with gasket and se...

Page 134: ...rve the instructions of the cleaning agent manufacturer NOTICE Incorrect installation of components and lines Damage to component Ensure that components lines are installed so that they are never unde...

Page 135: ...ooler 5 Remove oil lines 2 6 Loosen clamp 1 7 Remove intake housing 3 with actuating cylinder 2 8 Remove coolant lines 1 from compressor housing 3 9 Remove coolant vent line 2 from com pressor housing...

Page 136: ...ssor 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 Fit new sealing rings between bearing housing compre...

Page 137: ...g 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 wre...

Page 138: ...ce mask and ear defenders Intercooler Checking conden sate drain line for coolant dis charge and obstruction 1 With the engine running verify that air emerges from the condensate drain line at driving...

Page 139: ...e parts Designation Use Part No Qty Air filter Spare Parts Catalog Replacing the air filter 1 Remove old air filter and install new air filter Page 140 2 Reset signal ring of contamination indicator P...

Page 140: ...2 Remove air filter 1 and clamp 2 from connecting 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...

Page 141: ...isabled Checking signal ring position 1 If the signal ring is completely visible in the control window 2 replace air filter Page 139 2 After installation of new filter press reset button 1 Result Enga...

Page 142: ...Part No Qty Air hose 0229979482 2 Checking air pipework from air filter to ETC Item Findings Measure Visually check outer layer of air hose Damage Deformation Cracks Cuts Brittleness Scuffing visible...

Page 143: ...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 175 MS150046 02E...

Page 144: ...or heat exchanger back to the oil pan 3 The oil level must reach mark 1 or exceed mark 1 by up to 2 cm 4 Top up with oil to mark 1 as necessary Page 145 5 Insert dipstick into guide tube up to the st...

Page 145: ...ot 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 dra...

Page 146: ...Tightening torque 100 Nm 10Nm 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 cover 1 on filler neck 4 Check engine oil level Pag...

Page 147: ...ning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor WARNING High level of engine noise when the engine is running Risk of damage to hearing Wea...

Page 148: ...arts Catalog WARNING Hot oil Oil can contain combustion residues which are harmful to health Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with ski...

Page 149: ...f spring washer and washer 9 Remove screw 4 10 Remove flushing arm 5 from screen plate 6 11 Turn filter element by 180 and use appro priate tool to push out filter candles 1 12 Turn filter insert by 1...

Page 150: ...rking steps 2 Additionally the following instructions are to be observed Replace all sealing elements Coat O rings with grease Insert O rings in grooves Observe position of cylinder screw to elongated...

Page 151: ...ing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor WARNING Compressed air gun ejects a jet of pressurized air Risk of injury to eyes and damage to hearing risk of ruptu...

Page 152: ...w part Cleaning strainer 1 Wash strainer 5 with cleaner 2 Remove stubborn deposits with soft brush 3 Blow out strainer 5 with compressed air from inside Installing strainer 1 Coat square section ring...

Page 153: ...ts Catalog WARNING Hot oil Oil can contain combustion residues which are harmful to health Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with skin...

Page 154: ...sk 8 and rotor base 10 with sealing ring 9 13 Insert new filter sleeve 6 in rotor tube 7 with the smooth paper surface facing the wall 14 Check sealing ring 5 fit new one if neces sary 15 Mount rotor...

Page 155: ...m General High Temperature Circuit 7 14 1 Venting points Coolant lines on ETC 1 Venting point Vent line Cross distributionn expansion tank 1 Venting point MS150046 02E 2013 07 Task Description 155 TIM...

Page 156: ...ure to escape 2 Continue to turn breather valve counterclockwise and remove 3 Check engine coolant level coolant must be visible at the bottom edge of the filler neck s cast eye Checking engine coolan...

Page 157: ...e Special tools Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 158 2 Fill with engine coolant Page 159 MS150046 02E 2013 07 Task Description...

Page 158: ...n expan sion tank counterclockwise to first stop and allow pressure to escape 2 Continue to turn breather valve counter clockwise and remove 3 Draw off precipitated corrosion inhibitor oil from the ex...

Page 159: ...esignation Use Part No Qty Engine coolant WARNING Coolant is hot and under pressure Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask NOTICE...

Page 160: ...until overflow edge is reached 11 When coolant temperature T Coolant of 40 C is reached increase the engine speed to 1000 rpm for approx 2 minutes 12 With the engine idling fill expansion tank until o...

Page 161: ...alve arrowed 3 Open vent points on intercooler on coolant cooler and on exhaust turbochargers Page 155 4 Ensure that the breather valve on the ex pansion tank is closed 5 Pump coolant into engine at 0...

Page 162: ...pump 13 With the expansion tank open start the en gine and run it up to nominal speed full load under load 14 Check coolant level in expansion tank If coolant level is above 50 close ex pansion tank b...

Page 163: ...o hearing Wear ear protectors Engine coolant pump Relief bore check 1 Check relief bore for oil and coolant dis charge 2 Stop engine Page 55 and disable en gine start observe general safety instruc ti...

Page 164: ...ol down Wear protective clothing gloves and goggles safety mask WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors Engine coolant Sample extrac...

Page 165: ...Risk of damage to hearing Wear ear protectors Raw water pump relief bore check 1 Check relief bore for oil and raw water dis charge 2 Stop engine Page 55 and disable en gine start observe general safe...

Page 166: ...d and starting disabled Battery charging generator drive Coupling condition check 1 Remove protective cover 2 Check resilient coupling for cracks arrow and plastic deformation 3 In case of severe defo...

Page 167: ...gine mounting Check Engine mounting Check Item Findings Action Visually inspect mounts Damage Brittleness Deformation Crack formation Swelling visible Replace contact Service MS150046 02E 2013 07 Task...

Page 168: ...ise when the engine is running Risk of damage to hearing Wear ear protectors Bilge pump Relief bore check 1 Check relief bores for oil and water dis charge 2 Stop engine Page 67 and disable en gine st...

Page 169: ...System 7 19 1 Water drain valve Check Water drain valve Check 1 Open water drain valve 2 Check water outlet for obstructions 3 Close water drain valve MS150046 02E 2013 07 Task Description 169 TIM ID...

Page 170: ...es Do not smoke Checking differential pressure gauge 1 Switch on fuel treatment system Page 62 2 Set the alarm points at the differential pressure gauge to zero Result Alarm is initiated with preset d...

Page 171: ...ect connector from water level probe 4 Immerse water level probe into a tank filled with water until water level reaches the thread 5 Switch system on Result Water drain valve opens 6 Leave water leve...

Page 172: ...k pressure at the pressure gauge in the inlet to the fuel treatment system and note down 3 Check pump pressure with reduced suction a Reduce suction pressure of pump to 0 8 bar with the shutoff valve...

Page 173: ...mponents and lines Damage to component Ensure that components lines are installed so that they are never under tension or strain Ensure correct installation position of components Coalescer filter ele...

Page 174: ...htening torque Engine oil 30 Nm 3 Nm 17 Fit gasket 10 18 Install cover 19 Install screws 1 washers 2 and nuts 9 20 Tighten nuts 9 21 Open ball valve at the inlet and outlet of the fuel treatment syste...

Page 175: ...swing freely 3 Check that cable clamps are firm tighten loose cable clamps 4 Replace faulty cable clamps 5 Visually inspect the following electrical line components for damage Connector housing Conta...

Page 176: ...on both sides of flywheel housing 2 2 Check whether both switches 3 are actu ated 3 If switches 3 and or guard plate 1 with engine support 4 is are not installed Screw on guard plate 1 with engine su...

Page 177: ...d starting disabled Check plug connections on ECU 7 1 Check all connectors on ECU for firm seat ing Ensure that clips 3 are engaged 2 Check screws 2 of cable clamps on ECU for firm seating Ensure that...

Page 178: ...ting disabled Checking EMU plug connections 1 Check both connectors on EMU 2 for firm seating Make sure that clips 3 are engag ed 2 Check screws 1 of cable clamps on EMU 2 for firm seating Make sure t...

Page 179: ...sabled Checking EIM plug connections 1 Check both Tyco plugs 62 pole 1 on EIM for firm seating Make sure that the clips 2 are engaged 2 Check screws 3 of cable clamps on EIM for firm seating Ensure th...

Page 180: ...overnor from engine 1 Note or mark assignment of cables and connectors 2 Remove all screws 2 3 Undo latches 3 of the connectors 4 Disconnect all connectors 5 Remove screws 1 6 Take off engine governor...

Page 181: ...ll screws 2 3 Undo clips 3 on connectors 4 Disconnect all connectors 5 Remove screws 1 6 Remove ECU 1 with EMU 4 Removing EMU 1 Unscrew screws on base of EMU 4 2 Remove EMU 4 from ECU 1 Installing EMU...

Page 182: ...When doing so observe correct assignment between cables and plugs 2 Check seal before installing Result Replace seal if porous or defective Downloading software 1 The new EIM still does not have appro...

Page 183: ...r operation 4 Application loader active 5 External RAM faulty 6 External FLASH faulty 7 No firmware 8 Application crashed Fuse lamp SILA A second indicator is the fuse lamp This is also integrated in...

Page 184: ...oring current path failed S8 10 Emergency stop current path failed 24V internal S9 11 ES pushbutton current path failed 24V external S10 12 Key switch current path failed S11 13 SDAF 1 2 current path...

Page 185: ...fuse S4 fail ure 1 2 second steps Note These bit sequences are transmitted constantly Information about the status of the current paths of the EIM is also provided in the CAN message Sta tus internal...

Page 186: ...ary switch has the following func tions To start Turn clockwise To stop Turn counter clockwise 2 Green POWER ON Lights up when the plant is switched on 3 Red EMERGENCY STOP An emergency stop is execut...

Page 187: ...Pressing the pushbutton engages the gearbox in the ahead direction Lit when the gearbox is engaged ahead 5 Green CLUTCH NEUTRAL Pressing the pushbutton disengages the gearbox Lit when the gearbox is d...

Page 188: ...pages alarm acknowledgment and dimming Key functions vary and are represented graphically on the display Lit as long as the pushbutton is held down 17 F2 18 F3 19 F4 20 F5 21 Green LED Operating statu...

Page 189: ...1 Briefly press illuminated pushbutton STOP Result The illuminated pushbutton STOP lights up white The automatic stopping sequence is executed The display indicates the changing operating data of the...

Page 190: ...the rotary switch clockwise back to the ON position Result The automatic stopping sequence is executed The stopping sequence is indicated on the control stand similarly to a normal engine stop Page 19...

Page 191: ...at all control stations The engine is at a standstill when the automatic stop sequence has been completed The illuminated pushbutton STOP goes out The gearbox is disengaged 2 Repeat procedure for othe...

Page 192: ...on STOP lights up white The automatic stopping sequence is executed The display indicates current engine operating data as it changes On completion of the automatic stopping sequence Illuminated pushb...

Page 193: ...display with dry cloth without applying excessive pressure 2 Remove dirt from keys using isopropyl alcohol 3 Remove heavy soiling from housing surface with isopropyl alcohol Cleaning connectors on LOP...

Page 194: ...e monitoring system EMU Engine Monitoring Unit Engine monitoring unit ETK Ersatzteilkatalog Spare Parts Catalog FPP Fixed Pitch Propeller Fixed pitch propeller GCU Gear Control Unit Gear control unit...

Page 195: ...System RL Redundancy Lost Alarm Redundant CAN bus failure SAE Society of Automotive Engineers U S standardization organization SAT Sea Acceptance Test SD Sensor Defect Alarm Sensor failure SDAF Shut D...

Page 196: ...e work in case of malfunction or changed operating conditions or for spare parts supply Your contact person in our Customer Assistance Center E mail info mtu online com Tel 49 7541 9077777 Fax 49 7541...

Page 197: ...Barring manually Page 106 Box wrench socket 24 mm Part No F30039526 Qty Used in 1 7 3 2 Valve clearance Check and adjustment Page 113 Feeler gauge Part No Y20098771 Qty Used in 1 7 3 2 Valve clearanc...

Page 198: ...r Removal and installation Page 120 MTU test kit Part No 5605892099 00 Qty Used in 1 7 12 3 Engine oil Sample extraction and analysis Page 147 Qty Used in 1 7 14 7 Engine coolant Sample extraction and...

Page 199: ...7341 Qty Used in 1 7 5 2 Injector Removal and installation Page 120 Qty Used in 1 7 12 2 Engine oil Change Page 145 Ratchet Part No F30027339 Qty Used in 1 7 19 5 Coalescer filter element Replacement...

Page 200: ...jet cleaner Part No Qty Used in 1 4 20 Plant Cleaning Page 73 Torque wrench Part No F30027337 Qty Used in 1 7 12 2 Engine oil Change Page 145 Torque wrench 0 5 5 Nm Part No 0015384230 Qty Used in 1 7...

Page 201: ...tallation Page 120 Torque wrench 4 20 Nm Part No F30044239 Qty Used in 1 7 9 2 Air filter Removal and installation Page 140 Torque wrench 6 50 Nm Part No F30027336 Qty Used in 1 7 13 3 Centrifugal oil...

Page 202: ...60 320 Nm Part No F30452768 Qty Used in 1 7 3 2 Valve clearance Check and adjustment Page 113 Qty Used in 1 7 5 2 Injector Removal and installation Page 120 202 Appendix B MS150046 02E 2013 07 DCL ID...

Page 203: ...gaging from LOP 65 E ECU 7 Installation 180 Removal 180 ECU 7 engine governor Installation 180 Removal 180 Emergency stop From LOP 69 EMU 8 Installation 181 Removal 181 Engine Overview 26 Start 55 Sto...

Page 204: ...eck 176 Local Operating Panel LOP 186 Local Operating Station LOS and Local Operating Panel LOP Controls and displays 187 LOP Cleaning 193 Connector cleaning 193 LOP controls 52 M MTU contact persons...

Page 205: ...t 14 Troubleshooting 76 Fuel treatment system 75 V Valve clearance Adjustment 113 Check 113 Valve gear Lubrication 112 Venting points 155 W Water drain valve Check 169 Water level probe 3 in 1 rod ele...

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MTU 20 V 4000 M73 x, Operating Instructions Manual

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Summary of Contents for 20 V 4000 M73 x

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