MTU 20V4000M73 series Operating Instructions Manual Download Page 6

Page: 6 / 252

7.5.3 Cylinder head cover – Removal and

installation

148

7.6 Injection Pump / HP Pump

149

7.6.1 HP fuel pump – Filling with engine oil

149

7.7 Injection Valve / Injector

151

7.7.1 Injector – Replacement

151

7.7.2 Injector – Removal and installation (jacketed

fuel system)

152

7.8 Fuel Filter

159

7.8.1 Fuel filter – Replacement

159

7.8.2 Fuel prefilter – Differential pressure gage

check and adjustment

161

7.8.3 Fuel prefilter – Draining

162

7.8.4 Fuel prefilter – Flushing

164

7.8.5 Fuel prefilter with water separator – Filter

element replacement

166

7.9 Exhaust Turbocharger

169

7.9.1 Compressor wheel – Cleaning

169

7.10 Charge-Air Cooling

173

7.10.1 Intercooler – Checking condensate drain for

coolant leakage and obstruction

173

7.11 Air Filter

175

7.11.1 Air filter – Replacement

175

7.11.2 Air filter – Removal and installation

176

7.12 Air Intake

177

7.12.1 Contamination indicator – Signal ring position

check

177

7.12.2 Air pipework from air filter to ETC – Check

178

7.13 Starting Equipment

179

7.13.1 Starter – Condition check

179

7.14 Lube Oil System, Lube Oil Circuit

180

7.14.1 Engine oil level – Check

180

7.14.2 Engine oil ‒ Change

181

7.14.3 Engine oil – Sample extraction and analysis

183

7.15 Oil Filtration / Cooling

184

7.15.1 Automatic oil filter – Overview

184

7.15.2 Oil filter element – Removal

187

7.15.3 Oil filter element – Cleaning

188

7.15.4 Oil filter element – Assembly

189

7.15.5 Centrifugal oil filter – Cleaning and filter-

sleeve replacement

193

7.15.6 Oil indicator filter – Cleaning and check

195

7.16 Coolant System, General, High-Temperature

Circuit

198

7.16.1 Venting points

198

7.16.2 Engine coolant – Level check

199

7.16.3 Engine coolant – Change

201

7.16.4 Engine coolant draining

202

7.16.5 Engine coolant – Filling

203

7.16.6 Engine coolant pump – Relief bore check

206

7.16.7 Engine coolant – Sample extraction and

analysis

207

7.17 Raw Water Pump with Connections

208

7.17.1 Raw water pump – Relief bore check

208

7.18 Battery-Charging Generator

209

7.18.1 Battery-charging generator drive – Coupling

condition check

209

7.19 Engine Mounting / Support

210

7.19.1 Engine mounting – Checking resilient element

210

7.20 Auxiliary PTO

211

7.20.1 Bilge pump – Relief bore check

211

7.21 Fuel Supply System

212

7.21.1 Water drain valve – Check

212

7.21.2 Differential pressure gage – Alarm function

check

213

7.21.3 Water level probe (3-in-1 rod electrode) –

Check

214

7.21.4 Pump capacity – Check

215

7.21.5 Coalescer filter element ‒ Replacement

216

7.22 Wiring (General) for Engine/Gearbox/Unit

218

7.22.1 Engine cabling – Check

218

7.23 Accessories for (Electronic) Engine

Governor / Control System

219

7.23.1 Limit switch for start interlock – Check

219

7.23.2 Engine Control Unit ECU 7 – Checking plug

connections

220

7.23.3 Engine Monitoring Unit EMU 8 – Plug

connections check

221

7.23.4 Interface module EIM plug connections –

Check

222

7.23.5 Engine governor plug connections – Check

223

7.23.6 Engine governor ECU 7 – Removal and

installation

224

7.23.7 Engine Monitoring Unit EMU 8 – Removal and

installation

225

7.23.8 Engine Interface Module EIM 2 – Removal and

installation

226

7.23.9 Engine Interface Module EIM 2 – Diagnostic

features

227

7.24 Emergency Instrumentation (Local

Operating Panel)

230

7.24.1 Controls

230

7.24.2 Local Operating Panel LOP

231

7.24.3 Local Operating Station LOS and Local

Operating Panel LOP – Controls and displays

232

7.24.4 Engine – Shutdown

234

7.24.5 Stopping the engine

235

7.24.6 Engine shutdown

236

7.24.7 LOP and connectors – Cleaning

237

4 | Table of Contents | MS150046/03E 2018-08

DCL-ID: 0000028441 - 002

Summary of Contents for 20V4000M73 series

Page 1: ...Operating Instructions Diesel engine 20V4000M73x MS150046 03E...

Page 2: ...ine model kW cyl Application group 20V4000M73 160 kW cyl 1B continuous operation variable high load factors 20V4000M73L 180 kW cyl 1B continuous operation variable high load factors Table 1 Applicabil...

Page 3: ......

Page 4: ......

Page 5: ...t system Initial start up 77 4 10 Fuel treatment system Switching on 80 4 11 Emergency engine stop at BlueLine automation system control stand 81 4 12 Clutch Engagement at LOP 82 4 13 Coupling Disenga...

Page 6: ...4 Engine coolant draining 202 7 16 5 Engine coolant Filling 203 7 16 6 Engine coolant pump Relief bore check 206 7 16 7 Engine coolant Sample extraction and analysis 207 7 17 Raw Water Pump with Conne...

Page 7: ...8 Appendix A 8 1 List of abbreviations 238 8 2 MTU Contact Service Partners 240 9 Appendix B 9 1 Special Tools 241 9 2 Index 248 MS150046 03E 2018 08 Table of Contents 5 DCL ID 0000028441 002...

Page 8: ...s 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 particularly misuse is considered as bein...

Page 9: ...r this purpose are approved by the manufacturer Noncompliance with these specifications will invalidate the design type approval or certification issued by the emissions regulation authorities The man...

Page 10: ...s The relevant emission labels must be affixed to the spare part Emission labels shall not be transferred from the replaced part to the spare part The emission labels must be removed from the replaced...

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

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

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

Page 14: ...pallet or transport with equipment for heavy loads forklift truck Prior to transporting the engine it is imperative to install transportation locking devices for crankshaft and engine mounts Secure t...

Page 15: ...fitted Lock circuit breakers Before starting work on CaPoS if used Switch off the charging system DC DC converter Discharge the UltraCap modules using the appropriate discharger Short circuit the Ultr...

Page 16: ...ines near hot components Miscellaneous Sufficient ventilation must be guaranteed during the work Wear a breathing mask offering protection against soot dust and mineral fibers filter class P3 when wor...

Page 17: ...d the pipework at the relevant designated points For hydraulic installation screw on the jig with the piston retracted For hydraulic removal screw on the jig with the piston extended For a hydraulic i...

Page 18: ...rly prior to replacement i e protect them against moisture in particular Package faulty electronic components or assemblies properly before dispatching for repair Moisture proof Shock proof Wrapped in...

Page 19: ...sure that suitable extinguishing agents fire extinguishers are always available and that staff are familiar with their correct handling A fire can result in the creation of toxic substances Always wea...

Page 20: ...s well ventilated Make sure that neighboring work areas are not adversely affected Avoid open flames in the surrounding area No smoking Observe fire prevention regulations Always wear a mask providing...

Page 21: ...Consequences Material damage Remedial action Additional product information Warning notices 1 This manual with all safety instructions and warning notices must be issued to all personnel involved in o...

Page 22: ...orques MA are specified for screws of strength class 8 8 surface condition bare phosphatized or galvanized and 10 9 surface condition bare or phosphatized The values in the table are based on a fricti...

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

Page 24: ...e based on a friction coefficient tot 0 125 Threads and mating faces of screws and nuts must be coated with engine oil prior to assembly An assembly tolerance of 10 of the figures in the table is perm...

Page 25: ...n tightening MA tightening torques Tightening torques for plug screws as per MTN 5183 1 standard This standard applies to plug screws to DIN 908 DIN 910 and DIN 7604 with threaded end to DIN 3852 Form...

Page 26: ...ightening torques for plug screws to DIN 908 DIN 910 and DIN 7604A with short threaded end Thread screwed into Steel gray cast iron MA Nm AI alloy MA Nm M10 x 1 15 15 M12 x 1 5 25 25 M14 x 1 5 35 30 M...

Page 27: ...l gray cast iron M A Nm AI alloy MA Nm M8 x 1 10 10 M22 x 1 5 80 65 M26 x 1 5 105 90 M30 x 1 5 130 130 M38 x 1 5 140 120 M45 x 1 5 160 140 MA tightening torques Tightening torque for banjo screws as p...

Page 28: ...ns during the tightening process Tightening torques for steel banjo screws Thread inserted in steel gray cast iron aluminum alloy MA Nm M8 x 1 10 M10 x 1 15 M12 x 1 5 20 M14 x 1 5 25 M16 x 1 5 25 M18...

Page 29: ...nd oiled or galvanized Threads and mating faces beneath heads must be coated with engine oil prior to assembly An assembly tolerance of 10 of the figures in the table is permitted due to unavoidable d...

Page 30: ...ng the union nut firmly by hand noticeable increase in force it should be tightened another 1 4 turn 90 past this point Tightening torques for spigot unions with O ring to ISO 6149 2 Thread Torque Nm...

Page 31: ...valves see ISO 6149 47 and ISO 7789 Tightening torques for screwed plugs with O ring as per ISO 6149 3 Thread Torque Nm 10 M8 x 1 8 M10 x 1 15 M12 x 1 5 25 M14 x 1 5 35 M16 x 1 5 40 M18 x 1 5 45 M22...

Page 32: ...RFS fittings In contrast to the instructions for pipe unions hose fittings with sealing heads and the matching adapters must be fitted and connected as follows Hose fitting metallic sealing with union...

Page 33: ...2 35 290 M52 x 2 38 42 330 Sealing head with BSP union nut BSPP thread Torque Nm G1 4 20 G3 8 34 G1 2 60 G5 8 69 G3 4 115 G1 140 G1 1 4 210 G1 1 2 290 G2 400 SAE sealing cone with union nut JIC 37 UNF...

Page 34: ...Torque Nm 9 16 18 4 14 2 11 16 16 6 24 3 13 16 16 8 43 4 1 14 10 60 8 1 3 16 12 12 90 5 1 3 16 12 14 90 5 1 7 16 12 16 125 10 1 11 16 12 20 170 20 2 12 24 200 25 2 1 2 20 32 460 30 32 General Informa...

Page 35: ...cordance with DIN ISO 1204 as viewed from driving end 4 For cylinder designation in accordance with DIN ISO 1204 the letter Ax refers to the cylinders on the left hand side of the engine 1 and letter...

Page 36: ...uantity absolute gas tightness reached Turbocharging Sequential turbocharging with internal engine coolant controlled charge air cooling The exhaust turbochargers B1 A2 and B2 are cut in and out via e...

Page 37: ...r X1 Bus interface 2x MCS5 CAN CAN dialog output 1xMCS5 CAN Emergency stop ECU and EMU Electric starter Terminal 45 starter A B engaged Pneumatic starter Starting air pressure valve Start air pressure...

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

Page 39: ...to HP pump Lube oil system oil lines with oil pressure 1 8 bar 1 Parting line ETC oil supply free end 1 Parting line ETC oil supply driving end MS150046 03E 2018 08 General Information 37 TIM ID 0000...

Page 40: ...1 Oil line on equipment carrier 1 Oil supply to HP pump 1 Oil supply to flap control free end 38 General Information MS150046 03E 2018 08 TIM ID 0000010057 005...

Page 41: ...on main oil gallery 1 Switching cylinder air flap A2 1 Oil line connection 2 Switching cylinder exhaust flap turbo charger A2 3 T piece flap control MS150046 03E 2018 08 General Information 39 TIM ID...

Page 42: ...rol turbocharger B1 1 Switching cylinder air flap turbocharg er B1 1 Connection oil line to turbocharger B2 2 Switching cylinder exhaust flap turbo charger B2 3 Switching cylinder air flap turbocharg...

Page 43: ...with SOLAS by GL and DNV Plugs and sensors plug in pipe connections Plugs and sensors a Screwed in seal plugs 4 are sealed toward the outside either with a copper sealing ring 1 according to DIN or a...

Page 44: ...flow bore 8 Thrust ring 9 Union nut 10 Union nut 11 Connecting piece 12 Snap ring 13 Thrust ring 14 Shims 15 Union nut 16 Thrust ring 17 External pipe of HP line 18 Internal pipe of HP line 19 Ball ty...

Page 45: ...ng 11 HP fuel pump 12 Automatic oil filter 13 Centrifugal oil filter s 14 Fuel filter 15 Engine governor Engine model designation Key to engine model designation 20V4000Mxyz 20 Number of cylinders V C...

Page 46: ...ylinder A10 11 B5 2 P Lube oil after filter 12 B34 2 P Fuel before filter 13 B34 1 P Fuel after filter 14 B5 3 P Lube oil before fil ter 15 B48 P Fuel in common rail 16 B4 B10 T exhaust cylinder B10 1...

Page 47: ...P Charge air 9 B57 1 T Main bearing 10 B57 2 T Main bearing 11 B57 3 T Main bearing 12 B57 4 T Main bearing 13 B57 5 T Main bearing 14 B57 6 T Main bearing 15 B57 7 T Main bearing 16 B57 8 T Main bea...

Page 48: ...ree end 1 F46 H Leak fuel level 2 B33 T Fuel 3 B1 N Camshaft 4 B54 P Oil level pump 5 B6 2 T Coolant 6 B6 T Coolant 7 Connector XD1 Dialog unit 46 General Information MS150046 03E 2018 08 TIM ID 00000...

Page 49: ...bearing 9 B77 B9 T Spray oil conrod bearing 10 B77 B8 T Spray oil conrod bearing 11 B77 B7 T Spray oil conrod bearing 12 B77 B6 T Spray oil conrod bearing 13 B77 B5 T Spray oil conrod bearing 14 B77 B...

Page 50: ...20V4000M driving end 1 B13 2 N Crankshaft 2 B13 N Crankshaft 3 S37 2 S Safety switch 4 S37 1 S Safety switch 48 General Information MS150046 03E 2018 08 TIM ID 0000034733 006...

Page 51: ...eed B16 Coolant pressure B21 Raw water pressure B33 Fuel temperature B34 1 Fuel pressure after filter B34 2 Fuel pressure before filter B44 1 Exhaust turbocharger speed A B44 2 Exhaust turbocharger sp...

Page 52: ...9A1 to Y39AX Injectors engine side A Y39B1 to Y39BX Injectors engine side B Table 3 Engine wiring harness for injectors Pin assignment Designation X1 Engine Control Unit ECU X3 Engine Control Unit ECU...

Page 53: ...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 54: ...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 52...

Page 55: ...Engine wiring harness for EIM 1 XD1 2 X1 3 X3 4 X52 5 XY1 6 X11 7 XB19 8 X37 MS150046 03E 2018 08 General Information 53 TIM ID 0000034732 003...

Page 56: ...Engine wiring harness for electric starter 1 EIM terminals 2 Fuse F1 3 Starter connecting termi nals 54 General Information MS150046 03E 2018 08 TIM ID 0000034732 003...

Page 57: ...essure 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 58: ...ection 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 mi n 28 GENERAL OPERATING DATA N...

Page 59: ...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 60: ...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 61: ...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 mi n 28 GENERAL OPERATING DATA Num...

Page 62: ...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 63: ...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 64: ...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 mi n 29 GENERAL OPERATING DATA Number...

Page 65: ...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 66: ...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 67: ...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 mi n 29 GENERAL OPERATING DATA Number...

Page 68: ...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 69: ...gth A Width B Height C 12V4000M73 93 L approx 2991 mm approx 1463 mm approx 2368 mm 16V4000M73 93 L approx 3583 mm approx 1463 mm approx 2368 mm 20V4000M73 93 L approx 4192 mm approx 1484 mm approx 23...

Page 70: ...3 6 Firing order Number of cylinders Firing order 20V A1 B5 A8 B7 A5 B2 A7 B10 A2 B3 A10 B6 A3 B4 A6 B9 A4 B1 A9 B8 68 Technical Data MS150046 03E 2018 08 TIM ID 0000035068 003...

Page 71: ...lueLine automation system Controls on LOP 6 without display Page 231 Controls on LOS or on LOP 8 with display Page 232 BlueVision automation system Controls on LOP 8 Page 232 MS150046 03E 2018 08 Oper...

Page 72: ...ted above waterline Fill with water approx 3 to 4 liters Coolant circuit If engine is out of service for more than one year change coolant Page 201 Coolant circuit Check coolant level Page 199 Coolant...

Page 73: ...required Coolant circuit Check coolant level Page 199 Coolant circuit Heat coolant with coolant preheating unit Engine control system Switch master switch to ON Press illuminated pushbutton READY FOR...

Page 74: ...ar protectors NOTICE Re starting the engine following an automatic safety shutdown Risk of severe engine damage Before starting the engine make sure the root cause of the safety shutdown was eliminate...

Page 75: ...ified or eliminated contact Service Note If an engine has been shutdown by a fault red alarm the engine may only be re started when the fault has been identified and eliminated Procedure following an...

Page 76: ...ssures and temperatures Check engine and external lines for leaks Check for abnormal running noises and vibration Check exhaust color Page 94 Air filter Check signal ring position of service indicator...

Page 77: ...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 77 2 Shut down fuel treatment system Page 90 MS1...

Page 78: ...ves 4 Switch on fuel treatment system Page 80 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 79: ...drain 18 Water level electrode 19 Ball valve sample extrac tion inlet 20 Switchgear cabinet 21 Pump 22 Coarse filter 23 Fuel supply from tank 24 Tank Switching on fuel treatment system 1 Switch on fu...

Page 80: ...speed 4 Close ball valve 5 at inlet to fuel treatment system Result The pressure upstream of the fuel treatment system increases until the overflow valve at the pump unit opens and fuel flows through...

Page 81: ...pump draws fuel via bypass 2 directly from tank 24 5 Check suction pressure at the engine mounted fuel delivery pump Note If the suction pressure is within the admissible limits and engine operation...

Page 82: ...ore 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 83: ...n extremely high load Risk of overheating damage to components Trigger an emergency stop only in emergency situations Emergency engine stop at BlueLine automation system Item Measure Engine Emergency...

Page 84: ...n LOP Press illuminated pushbutton CLUTCH IN Page 69 Illuminated pushbutton CLUTCH IN flashes Clutch is engaged After receiving the feedback signal from the clutch illuminated pushbut ton CLUTCH IN li...

Page 85: ...OUPLING OUT button flashes Coupling is disengaged After receiving the feedback signal from coupling the COUPLING OUT but ton is illuminated brightly Disengaging coupling with reversing gearbox FPP WJ...

Page 86: ...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 69 FLUSH illumin...

Page 87: ...4 15 Stopping the engine Stopping the engine via the automation system Refer to automation system operating instructions MS150046 03E 2018 08 Operation 85 TIM ID 0000017528 004...

Page 88: ...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 69 LOP Opera...

Page 89: ...cting the power supply to the ECU On engines with emergency air shutoff flaps the flaps close Illuminated pushbutton EMERGENCY STOP flashes Horn flashing lamp etc are tripped After an emergency stop a...

Page 90: ...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 91: ...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 tem...

Page 92: ...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 93: ...un directly at seals or electronic components such as connectors or ECUs Cleaning the plant 1 Carry out plant cleaning only in areas where an appropriate oil separator is provided environmental protec...

Page 94: ...159 W1002 Check valve clearance Page 144 W1005 Replace air filter Page 175 W1006 Replace injectors Page 151 W1008 Replace engine oil filter at each oil change or when the time limit years is reached...

Page 95: ...e motor is equipped with an overload protection If the maximum permissible current consumption is exceeded e g in case of a blockage or dry running the motor protection relay triggers and the pump is...

Page 96: ...ness faulty fuse lamp on EIM flashes with relevant flashing code u Check fuse replace as necessary and re start system by actuating key switch Engine blocked crankshaft cannot be rotated by hand 1 Che...

Page 97: ...ure too high Cause Corrective action Engine Overload u Reduce load Air inlet temperature too high u Check fans and air supply ventilation ducts for engine room Incorrect engine coolant concentration 1...

Page 98: ...linder compression 2 Replace cylinder head Instructions for Exchange of Sub assemblies Piston rings or cylinder liner defective 1 Check cylinder compression 2 Carry out endoscopic examination of cylin...

Page 99: ...ault code 1 comprises 3 digits Fault messages may also be caused by faulty sensors actuators Contact Service to have sensors actuators tested and replaced as necessary if troubleshooting as described...

Page 100: ...ilure ZKP Number 1 8004 204 Cause Corrective action ETC2 could not be cut in 1 Reduce power 2 Contact Service 81 AL Rail Leakage ZKP Number 1 8004 046 Cause Corrective action Pressure gradient in rail...

Page 101: ...lace as necessary 2 Error cleared after restarting the engine 202 SD T Fuel ZKP Number 1 8004 572 Cause Corrective action Coolant temperature sensor faulty Short circuit or wire break 1 Check sensor a...

Page 102: ...bling B4 22 replace as necessary 208 SD P Charge Air ZKP Number 1 8004 566 Cause Corrective action Charge air pressure sensor faulty Short circuit or wire break 1 Check sensor and cabling B10 replace...

Page 103: ...Check sensor and cabling B48 replace as necessary 2 Error cleared after restarting the engine 216 SD T Lube Oil ZKP Number 1 8004 575 Cause Corrective action Lube oil temperature sensor faulty Short...

Page 104: ...ror cleared after restarting the engine 227 SD P Lube Oil before Filter ZKP Number 1 8004 620 Cause Corrective action Sensor for lube oil pressure before filter faulty Short circuit or wire break 1 Ch...

Page 105: ...Error cleared after restarting the engine 233 SD Charger 2 Speed ZKP Number 1 3011 129 Cause Corrective action Speed sensor of secondary turbocharger faulty Short circuit or wire break 1 Check sensor...

Page 106: ...ed after restarting the engine 301 AL Timing Cylinder A1 ZKP Number 1 8004 500 Cause Corrective action Time of flight measuring fault of injector in cylinder A1 Time of flight measured value extremely...

Page 107: ...ctive action Time of flight measuring fault of injector in cylinder A6 Time of flight measured value extremely low or extremely high u If alarm occurs frequently replace solenoid valve of injector 307...

Page 108: ...10 Cause Corrective action Time of flight measuring fault of injector B1 Time of flight measured value extremely low or extremely high u If alarm occurs frequently replace solenoid valve of injector 3...

Page 109: ...Corrective action Time of flight measuring fault of injector B6 Time of flight measured value extremely low or extremely high u If alarm occurs frequently replace solenoid valve of injector 317 AL Ti...

Page 110: ...leared after restarting the engine 322 AL Wiring Cylinder A2 ZKP Number 1 8004 521 Cause Corrective action Short circuit in injector cabling to cylinder A2 Result Misfiring 1 Rectify injector solenoid...

Page 111: ...by exchanging injectors 2 Error cleared after restarting the engine 328 AL Wiring Cylinder A8 ZKP Number 1 8004 527 Cause Corrective action Short circuit in injector cabling to cylinder A8 Result Misf...

Page 112: ...by exchanging injectors 2 Error cleared after restarting the engine 334 AL Wiring Cylinder B4 ZKP Number 1 8004 533 Cause Corrective action Cabling fault in injector cabling to cylinder B4 Result Mis...

Page 113: ...s 2 Error cleared after restarting the engine 340 AL Wiring Cylinder B10 ZKP Number 1 8004 539 Cause Corrective action Cabling fault in injector cabling to cylinder B10 Result Misfiring 1 Rectify inje...

Page 114: ...jector replacement 2 Error clearance After each working cycle 346 AL Open Load Cylinder A6 ZKP Number 1 8004 545 Cause Corrective action Disruption fault in injector cabling to cylinder A6 Result Misf...

Page 115: ...by replacing the injector 2 Error clearance After each working cycle 352 AL Open Load Cylinder B2 ZKP Number 1 8004 551 Cause Corrective action Disruption fault in injector cabling to cylinder B2 Res...

Page 116: ...y replacing the injector 2 Error clearance After each working cycle 358 AL Open Load Cylinder B8 ZKP Number 1 8004 557 Cause Corrective action Disruption fault in injector cabling to cylinder B8 Resul...

Page 117: ...ssages e g cabling faults 363 AL Stop Power Stage ZKP Number 1 8004 560 Cause Corrective action Internal electronic fault electronics possibly faulty If bit 1 1020 021 Power Stage Failure Stop Engine...

Page 118: ...tput 3 TO 3 u Check wiring of charger valve 2 marine engine 374 AL Wiring TO 4 ZKP Number 1 8004 637 Cause Corrective action Short circuit or wire break on transistor output 4 TO 4 u Check wiring of c...

Page 119: ...emperature sensor faulty Short circuit or wire break u Check sensor and cabling B3 replace as necessary 444 SD U PDU ZKP Number 1 8004 578 Cause Corrective action Injector power stage sensor defect In...

Page 120: ...circuit or wire break u Check sensor and cabling replace as necessary 471 SD Coil Current ZKP Number 1 8004 592 Cause Corrective action Control of HP fuel control block faulty Short circuit or wire br...

Page 121: ...y Short circuit or wire break u Check sensor and cabling B4 24 replace as necessary 492 AL ETC4 CutIn Failure ZKP Number 1 8004 202 Cause Corrective action ETC4 could not be cut in u Check control val...

Page 122: ...4500 903 Cause Corrective action The battery charging generator does not charge the battery u Check battery charging generator and cabling 504 AL CAN POM node Lost ZKP Number 1 4500 904 Cause Correcti...

Page 123: ...on Redundant lube oil pressure sensor faulty Short circuit or wire break u Check sensor and cabling replace as necessary 526 SD T Coolant R2 ZKP Number 1 8004 639 Cause Corrective action Redundant coo...

Page 124: ...after the emergency stop signal was output u The delay between the emergency stop signal and this alarm signal is set in parameter 1 1005 4 588 SD P Oil Refill Pump ZKP Number 1 0159 910 Cause Correc...

Page 125: ...625 SD P Fuel before Prefilter ZKP Number 1 8004 600 Cause Corrective action Analog input signal for pressure before prefilter faulty Short circuit or wire break 1 Check pressure sensor and cabling r...

Page 126: ...y Shield A4 735233000100 3 Shield A5 735233000101 43 Shield A6 735233000102 5 Shield A7 735233000103 4 Shield A8 735233000104 6 Shield B2 735233000200 2 Shield B4 735233000202 1 Shield E5 735233000500...

Page 127: ...possible Page 134 When affixing adhesive connections ensure that escaping fluid can flow out without pressure Page 134 Fuel system fuel lines with fuel pressure 1 8 bar Item Type of shield Installatio...

Page 128: ...s with oil pressure 1 8 bar Item Type of shield Installation location 1 1 x shield A5 1 x shield A4 Oil line connection 2 2 x shield A5 Actuating cylinder for exhaust flap of ETC B2 3 2 x shield A5 Ac...

Page 129: ...il line connection 2 2 x shield A5 Actuating cylinder for exhaust flap of ETC B1 3 3 x shield A5 T piece of flap control Item Type of shield Installation location 1 2 x shield A5 Actuating cylinder fo...

Page 130: ...nder for air flap of ETC A2 Item Type of shield Installation location 1 1 x shield A5 1 x shield A4 Oil line connection 2 2 x shield A5 Actuating cylinder for exhaust flap of ETC A2 3 3 x shield A5 T...

Page 131: ...shield Installation location 1 2 x shield A5 Air recirculation valve Item Type of shield Installation location 1 Shield A6 Oil supply line to HP pump To HP pump MS150046 03E 2018 08 SOLAS 129 TIM ID 0...

Page 132: ...pump 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 shield Installation location 1 5 x shield A5 Fl...

Page 133: ...mbly line Assembly in this position is no longer possible after painting Item Type of shield Installation location 1 1 x shield A8 Flap control to main oil gallery free end This shield must be install...

Page 134: ...hield must be installed on the assembly line Assembly in this position is no longer possible after painting Item Type of shield Installation location 1 2 x shield A5 Connection of ETC oil supply free...

Page 135: ...Type of shield Installation location 1 2 x shield A5 Connection of ETC oil supply driving end 2 2 x shield A6 Connection of ETC oil supply driving end MS150046 03E 2018 08 SOLAS 133 TIM ID 0000076609...

Page 136: ...ealing cone unions Note For installation positions of sealing cone un ions see Page 125 1 Wrap three layers of adhesive tape from the middle of the sealing cone union to area A for at least 30 mm ensu...

Page 137: ...r zone After finishing work on the engine make sure that all safety devices are put back in place and all tools are removed from the engine Engine Barring manually 1 Remove guard plate Result Safety s...

Page 138: ...ueLine automation system Starting barring procedure at LOP 8 BlueLine Operating Instructions BlueVision automation system Starting barring procedure at LOP 8 BlueLine Operating Instructions 136 Engine...

Page 139: ...g pattern First signs of marks left by lower cooling bores Running pattern seems darker No action required Dark areas with even or varying degrees of discoloration Beginning and end of the discolorati...

Page 140: ...Final steps 1 Install injector Page 152 2 Install cylinder head cover Page 148 138 Cylinder Liner MS150046 03E 2018 08 TIM ID 0000000015 017...

Page 141: ...It appears rather darker within the honed struc ture in contrast to the bright metallic running surface The honing pattern is undis turbed Discolorations extend in stroke direction and may be interrup...

Page 142: ...s are similar A thorough investigation and compliance with the above evaluation criteria allow an unambiguous evaluation To avoid unnecessary disassembly work it is recommended that another inspection...

Page 143: ...contain residue substances which are harmful to health Risk of injury and poisoning Allow the product to cool to below 50 C before beginning work Wear protective clothing protective gloves and goggle...

Page 144: ...ecified tightening torque Name Size Type Lubricant Value Standard Screw Tightening torque Engine oil 10 Nm 2 Nm 6 Replace further filter elements in the same way 7 Check oil separator for leaks 142 Cr...

Page 145: ...Spare parts Designation Use Part No Qty Engine oil Valve gear Lubrication 1 Remove cylinder head covers Page 148 2 Fill oil chambers of valve bridges with oil 3 Fill oil chambers of rocker arms and ad...

Page 146: ...screw driver F30002815 1 Torque wrench 60 320 Nm F30452768 1 Socket wrench 24 mm F30039526 1 Engine oil Preparatory steps 1 Remove cylinder head covers Page 148 2 Install barring tool Page 135 Note Po...

Page 147: ...er of the flywheel 4 The additional OT A1 mark 1 if applicable on the outer perimeter of the flywheel must not be used for reference Diagram for 8V engines Two crankshaft positions Diagram for 12V eng...

Page 148: ...ance adjustment with cold engine Inlet valves long rocker arm 0 2 mm 0 05 mm Exhaust valves short rocker arm 0 5 mm 0 05 mm 3 Check all valve clearances in two crankshaft positions firing TDC and over...

Page 149: ...g gauge must just pass through the gap 4 Pass valve setting gauge 3 between valve bridge and rocker arm 5 Tighten locknut 1 to specified torque using a torque wrench holding the adjusting screw 2 in p...

Page 150: ...3 4 with washers 2 5 3 Take off cylinder head cover with O ring 6 from cylinder head 7 Installing cylinder head cover 1 Clean installation surface 2 Check O ring 6 for damage replace as necessary 3 C...

Page 151: ...y through swallowing risk of poisoning through inhalation irritation to eyes and skin Seek medical attention immediately do not induce vomiting Do not inhale vapors or mist Wear protective clothing pr...

Page 152: ...ox 2 Use fuel suction device to fill HP pump with 2 liters of clean engine oil 3 Screw in union 1 and use torque wrench to tighten to specified tightening torque Name Size Type Lubricant Value Standar...

Page 153: ...eplacement Special tools Material Spare parts Designation Use Part No Qty Injector Spare Parts Catalog Replacing injector u Remove injector and install new injector Page 152 MS150046 03E 2018 08 Injec...

Page 154: ...osive Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke Wear protective clothing protective gloves and safety glasses facial protection WARNING Liquid or...

Page 155: ...of components Damage to component Observe manufacturer s instructions Check components for special cleanliness Preparatory steps 1 Allow HP system to cool down 2 Shut off fuel supply to engine 3 Remov...

Page 156: ...on removal jig and take off hold down clamp 11 Remove installation removal jig Note The sealing ring 4 for sealing the combus tion chamber must only be used once 12 Remove sealing ring 4 from injector...

Page 157: ...HP line only before in stallation of the adapter 3 Remove seal plug Note The damper ring is already in place for new assembly Coat damper ring with assembly compound 4 Fit damper ring 1 on injector a...

Page 158: ...Use torque wrench to tighten screw 2 to specified tightening torque Name Size Type Lubricant Value Standard Screw M12 Tightening torque Engine oil 100 Nm 10 Nm 16 Use torque wrench to tighten adapter...

Page 159: ...angle of rotation and without releasing the tool tighten immediately again to the specified tightening torque following the same sequence Tightening sequence 1 Adapter 4 2 Rail 6 Name Size Type Lubric...

Page 160: ...will void the emissions certification of the engine u Reset drift compensation CDC with DiaSys Dialog system DiaSys E531920 If DiaSys is not available contact Service Final steps 1 Install cylinder he...

Page 161: ...ry through swallowing risk of poisoning through inhalation irritation to eyes and skin Seek medical attention immediately do not induce vomiting Do not inhale vapors or mist Wear protective clothing p...

Page 162: ...screw cut out fuel filter using an oil filter wrench 3 Clean sealing surface on filter head 4 Check sealing ring of new fuel filter and coat with fuel 5 Screw on fuel filter and tighten by hand 6 Retu...

Page 163: ...ial pressure gage 1 When putting the new filter element into op eration Align adjustable pointer 2 with pressure indicating pointer 3 of pressure gage 1 2 Verify that differential pressure is within t...

Page 164: ...ately do not induce vomiting Do not inhale vapors or mist Wear protective clothing protective gloves and safety glasses If contact is made with skin wash off with water and soap WARNING Fuels are comb...

Page 165: ...valve 2 a little turning to approx 30 to introduce fuel into the filter housing with the new filter element 7 Close vent valve 1 as soon as fuel emerges from vent pipe 4 8 Turn the rotary slide valve...

Page 166: ...Seek medical attention immediately do not induce vomiting Do not inhale vapors or mist Wear protective clothing protective gloves and safety glasses If contact is made with skin wash off with water a...

Page 167: ...ded vent plug 1 and drain valve 2 5 Open rotary slide valve 2 a little turning to approx 30 to introduce fuel into the filter housing with the new filter element 6 Close vent valves 1 as soon as fuel...

Page 168: ...rough swallowing risk of poisoning through inhalation irritation to eyes and skin Seek medical attention immediately do not induce vomiting Do not inhale vapors or mist Wear protective clothing protec...

Page 169: ...osen screws 1 and 2 7 Turn filter housing aside around screw 2 un til filter element is accessible 8 Remove filter element 5 with spring 6 9 Insert a new filter element in the filter hous ing 10 Inser...

Page 170: ...with the new filter element 14 Close vent valve 1 as soon as fuel emerges from vent pipe 4 15 Turn the rotary slide valve to the upright posi tion 3 until it engages Result Both filters are cut in 16...

Page 171: ...in the relevant safety data sheet Wear protective gear as specified in the relevant safety data sheet NOTICE Incorrect installation of components and lines Damage to component Ensure that components l...

Page 172: ...er 5 Remove oil lines 2 6 Loosen clamp 1 7 Remove intake housing 3 with actuating cyl inder 2 8 Remove coolant lines 1 from compressor housing 3 9 Remove coolant vent line 2 from compres sor housing 3...

Page 173: ...essor housing with a smooth paint brush or brush 2 Clean compressor wheel 2 and bearing housing 1 3 Thoroughly remove cleaner from all compo nents 4 Replace sealing rings between bearing hous ing comp...

Page 174: ...d torque using a torque wrench Name Size Type Lubricant Value Standard Clamp Tightening torque 15 Nm 2 Nm 6 Install oil lines 2 Tighten screw fitting union at actuating cylinder to specified torque us...

Page 175: ...rect air jet at people Always wear safety goggles face mask and ear defenders Checking condensate drain of intercooler for coolant leakage and obstruction u With the engine running check outlet of the...

Page 176: ...tion with leak ing intercooler 1 Remove injectors Page 152 2 Bar engine manually Page 135 3 Bar engine with starting system to blow out combustion chambers Page 135 4 Install injectors Page 152 174 Ch...

Page 177: ...l Spare parts Designation Use Part No Qty Air filter Spare Parts Catalog Replacing air filter 1 Remove old air filter and install new air filter Page 176 2 Reset signal ring of contamination indicator...

Page 178: ...otective gloves safety goggles respiratory protection etc is to be used NOTICE Stepping or climbing on the genset to perform installation tasks is to be avoided Otherwise there is a risk of component...

Page 179: ...r if opening of the entrance door can be prevented Only operate the engine with installed air filters Never open air carrying components during operation Ensure that the engine room is well ventilated...

Page 180: ...se Part No Qty Air hose 0229979482 2 Checking air pipework from air filter to ETC Item Findings Measure Visually check outer layer of air hose Damage Deformation Cracks Cuts Brittleness Scuffing visib...

Page 181: ...ons Engine is stopped and starting disabled Starter Condition check 1 Check securing screws of starter and nut on cable connection for secure seating and tighten if required 2 Check cabling Page 218 M...

Page 182: ...l level may be up to 2 cm above mark 1 This may be caused e g by oil from oil filters and heat ex changers flowing back into the oil pan After extended standstill the oil level 2 cm above mark 2 is th...

Page 183: ...fety mask Avoid contact with skin Do not inhale oil vapor Oil change without semirotary hand pump Draining oil via drain plug s on oil pan 1 Provide a suitable container to collect the oil 2 Remove dr...

Page 184: ...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 180 5 Aft...

Page 185: ...ow 50 C before beginning work Wear protective clothing protective gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor WARNING High level of engine noise when the engine is r...

Page 186: ...6 Gasket 7 Screw fitting union 8 Gasket 9 Neck 10 Screw 11 Scavenge oil line 12 Neck 13 Gearbox flange 14 O ring 15 Screw 16 Cover 17 O ring 18 Compression spring 19 O ring 20 Strainer 21 O ring 22 In...

Page 187: ...5 Sealing ring 6 Plug screw 7 O ring 8 Plug screw 9 O ring 10 Plug screw 11 Bypass valve 12 Sealing ring 13 O ring 14 Cover 15 Screw 16 Sealing ring 17 Screw 18 O ring 19 Cover 20 Screw MS150046 03E 2...

Page 188: ...ng 4 Scavenge bushing 5 Sight glass 6 Flat gasket 7 O ring 8 O ring 9 Clamping ring 10 Spring washer 11 Screw 12 Worm gear 13 Grooved pin 14 Impeller 15 Washer 16 Stud 17 Nut 186 Oil Filtration Coolin...

Page 189: ...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 Re...

Page 190: ...ety 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 fil...

Page 191: ...nent Check components 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 automat...

Page 192: ...rainer plate 5 Align coiled spring pin 7 with groove 6 in connecting pipe 5 and install top strainer plate 6 Coat threads of screws 1 with screw locking compound 7 Insert screws 1 and tighten 8 Coat O...

Page 193: ...15 Screw on sealing nut 5 16 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...

Page 194: ...fied torque using a torque wrench Name Size Type Lubricant Value Standard Screw Tightening torque Engine oil 9 Nm 20 Fit filter indicator 2 with spring on sealing nut 1 192 Oil Filtration Cooling MS15...

Page 195: ...WARNING Oil is hot Oil can contain residue substances which are harmful to health Risk of injury and poisoning Allow the product to cool to below 50 C before beginning work Wear protective clothing pr...

Page 196: ...ealing ring 9 13 Insert new filter sleeve 6 in rotor pipe 7 with the smooth paper surface facing the out er wall 14 Check sealing ring 5 replace if necessary 15 Install rotor cover 4 with sealing ring...

Page 197: ...and goggles safety mask Take measures against electrostatic charging WARNING Oil is hot Oil can contain residue substances which are harmful to health Risk of injury and poisoning Allow the product t...

Page 198: ...ubborn deposits from strainer as necessary 4 Blow out strainer 6 with compressed air from outside to inside Checking strainer Item Findings Task Strainer Metallic residues Clean Monitor engine operati...

Page 199: ...strainer as necessary 4 Blow out strainer 5 with compressed air from outside to inside Checking strainer Item Findings Task Strainer Metallic residues Clean Monitor engine operation Check strainer dai...

Page 200: ...Temperature Circuit 7 16 1 Venting points Coolant line on ETC 1 Venting point Vent line Cross distribution expansion tank 1 Venting point 198 Coolant System General High Temperature Circuit MS150046 0...

Page 201: ...e and remove 3 Check engine coolant level engine coolant must be visible at bottom edge of cast in eye of filler neck Checking coolant level at exter nal cooler Note Engine coolant must be visible at...

Page 202: ...level at sight glass 1 Check coolant level coolant level must be between min and max mark 2 Top up coolant if necessary Page 203 200 Coolant System General High Temperature Circuit MS150046 03E 2018 0...

Page 203: ...Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 202 2 Fill with engine coolant Page 203 MS150046 03E 2018 08 Coolant System General High Tem...

Page 204: ...nk counterclockwise to first stop and allow pressure to escape 2 Continue to turn breather valve counterclock wise and remove 3 Draw off precipitated corrosion inhibitor oil from the expansion tank th...

Page 205: ...ne cool down Wear protective clothing gloves and goggles safety mask NOTICE Cold coolant in hot engine can cause thermal stress Possible formation of cracks in the engine Fill top up coolant only into...

Page 206: ...til overflow edge is reached 13 With the expansion tank open run the engine up to nominal speed full load under load 14 Leave the engine idling for approx 5 minutes until the coolant temperature stab...

Page 207: ...ce engine speed to idle speed 11 With the engine idling fill expansion tank un til overflow edge is reached 12 Stop engine Page 85 and remove pump 13 With the expansion tank open start the en gine and...

Page 208: ...ear ear protectors Engine coolant pump relief bore check 1 Check relief bore for oil and coolant dis charge 2 Stop engine Page 72 and disable engine start observe general safety instructions on mainte...

Page 209: ...ne is running Risk of damage to hearing Wear ear protectors Engine coolant Sample extrac tion and analysis 1 Open drain valve on engine coolant pump el bow with the engine running 2 Drain off approx 1...

Page 210: ...isk of damage to hearing Wear ear protectors Raw water pump relief bore check 1 Check relief bore for oil and raw water dis charge 2 Stop engine Page 72 and disable engine start observe general safety...

Page 211: ...tion check 1 Install barring tool Page 135 2 Guide endoscope optics between guard plate 1 and battery charging generator car rier 2 arrow Note Seek the assistance of a second person 3 Bar engine slowl...

Page 212: ...ife or destruction of the mounts Cover engine mounts when working with fuel or oil Remove contaminations on the rubber mounts immediately with a dry cloth and degrease them Engine mounting Check Item...

Page 213: ...ine noise when the engine is running Risk of damage to hearing Wear ear protectors Bilge pump Relief bore check 1 Check relief bores for oil and water dis charge 2 Stop engine Page 85 and disable engi...

Page 214: ...System 7 21 1 Water drain valve Check Water drain valve Check 1 Open water drain valve 2 Check water outlet for obstructions 3 Close water drain valve 212 Fuel Supply System MS150046 03E 2018 08 TIM I...

Page 215: ...Wear protective clothing protective gloves and safety glasses facial protection Checking differential pressure gage alarm function 1 Switch on fuel treatment system Page 80 2 Set the alarm points at t...

Page 216: ...om water level probe 2 Unscrew water level probe 3 Disconnect plug from water level probe 4 Immerse water level probe into a tank filled with water until water level reaches the thread 5 Switch on pla...

Page 217: ...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 pr...

Page 218: ...eanliness NOTICE Incorrect installation of components and lines Damage to component Ensure that components lines are installed so that they are never under tension or strain Ensure correct installatio...

Page 219: ...g torque Engine oil 30 Nm 3 Nm 17 Fit seal 10 18 Install cover 19 Install screws 1 washers 2 and nuts 9 20 Tighten nuts 9 21 Open ball valve at the inlet and outlet of the fuel treatment system Result...

Page 220: ...intact 4 Replace faulty cable clips 5 Check cable clamps for secure fit tighten loose clamps 6 Replace faulty cable clamps 7 Visually inspect the following electrical components for damage Connector h...

Page 221: ...heel housing 4 2 Check whether both switches 3 are actuat ed 3 If switches 3 and or guard plate 2 with en gine support 1 is are not installed Screw on guard plate 2 with engine sup port 1 Then screw o...

Page 222: ...eck plug connections on ECU 7 1 Check all connectors on ECU for firm seating Ensure that the clips 1 are engaged 2 Check screws 2 of cable clamps on ECU for firm seating Ensure that cable clamps are n...

Page 223: ...king EMU plug connections 1 Check both connectors on EMU 2 for firm seating Ensure that the clips 1 are engag ed 2 Check screws 3 of cable clamps on EMU 2 for firm seating Ensure that cable clamps are...

Page 224: ...EIM plug connections 1 Check both Tyco plugs 62 pole 2 on EIM for firm seating Ensure that clips 3 are en gaged 2 Check screws 1 of cable clamps on EIM for firm seating Ensure that cable clamps are no...

Page 225: ...The contacts in the plug connection can be bent Carry out check of plug connection only with test connectors Checking plug connections at engine governor 1 Check all plug connections for secure seatin...

Page 226: ...ine governor from engine 1 Note or mark assignment of cables and plugs 2 Remove all screws 3 3 Undo clips 2 on connectors 4 Remove all male connectors 5 Remove screws 1 6 Take off engine governor Inst...

Page 227: ...nect all connectors 5 Remove screws 1 6 Remove Engine Control Unit 5 with Engine Monitoring Unit 4 Removing Engine Monitoring Unit 1 Unscrew screws on base of EMU 4 2 Remove EMU 8 4 from ECU 5 Install...

Page 228: ...so observe correct assignment between cables and connectors 2 Check seal before installing Result Replace seal if porous or defective Downloading software 1 The new EIM 2 still does not have appropri...

Page 229: ...on 4 Application loader active 5 External RAM defective 6 External FLASH defective 7 No firmware 8 Application crashed Fuse lamp SILA A second indicator is the fuse lamp This is also integrated in the...

Page 230: ...10 Emergency stop current path failed 24 V internal S9 11 ES pushbutton current path failed 24 V external S10 12 Key switch current path failed S11 13 SDAF 1 and 2 current path failed S12 14 PIM curr...

Page 231: ...1 2 second steps Note These bit patterns are continuously transmitted The CAN message Status of internal power supply also contains information on the current path states of the EIM 2 MS150046 03E 20...

Page 232: ...umentation Local Operating Panel 7 24 1 Controls Automation system controls Refer to automation system operating instructions 230 Emergency Instrumentation Local Operating Panel MS150046 03E 2018 08 T...

Page 233: ...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 executed when the pushbutton is pressed Lights u...

Page 234: ...it when the gearbox is engaged ahead 5 Green CLUTCH NEUTRAL Pressing the pushbutton disengages the gearbox Lit when the gearbox is disengaged 6 Green CLUTCH ASTERN Pressing the pushbutton engages the...

Page 235: ...presented 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 status of the display LED dark Operating voltage missing LED lit Normal o...

Page 236: ...s 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 engine The eng...

Page 237: ...tch clockwise back to the ON position Result The automatic stopping sequence is executed The stopping sequence is represented on the control stand in the same way as for a normal engine stop Page 234...

Page 238: ...p 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 pushbutton STOP goes...

Page 239: ...D 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...

Page 240: ...panel DL Default Lost Alarm Default CAN bus failure ECS Engine Control System Engine management system ECU Engine Control Unit Engine governor EDM Engine Data Module Memory module for engine data EIM...

Page 241: ...OT Oberer Totpunkt Top Dead Center P xyz Pressure xyz Pressure measuring point xyz PAN Panel Control panel PCU Propeller Control Unit Propeller controller PIM Peripheral Interface Module RCS Remote C...

Page 242: ...of a malfunction for information on changes in conditions of use and for supplying spare parts Your contact person in our Customer Assistance Center E mail info mtu online com Tel 49 7541 9077777 Fax...

Page 243: ...learance Check and adjustment Page 144 Barring tool Part No F6555766 Qty Used in 1 7 2 1 Engine Barring manually Page 135 Endoscope Part No Y20097353 Qty Used in 1 7 18 1 Battery charging generator dr...

Page 244: ...suction device Part No F30378207 Qty Used in 1 7 6 1 HP fuel pump Filling with engine oil Page 149 High pressure cleaner Part No Qty Used in 1 4 21 Plant Cleaning Page 91 Installation removal jig Par...

Page 245: ...05892099 00 Qty Used in 1 7 14 3 Engine oil Sample extraction and analysis Page 183 MTU test kit Part No F6798833 Qty Used in 1 7 16 7 Engine coolant Sample extraction and analysis Page 207 Oil filter...

Page 246: ...ment Page 216 Ratchet adapter Part No F30027341 Qty Used in 1 7 14 2 Engine oil Change Page 181 Ratchet bit Part No F30027341 Qty Used in 7 5 3 Cylinder head cover Removal and installation Page 148 Ra...

Page 247: ...Part No F30006212 Qty Used in 1 7 2 1 Engine Barring manually Page 135 Rigid endoscope Part No Y20097353 Qty Used in 1 7 3 1 Cylinder liner Endoscopic examination Page 137 Socket wrench 24 mm Part No...

Page 248: ...el Cleaning Page 169 Qty Used in 1 7 15 5 Centrifugal oil filter Cleaning and filter sleeve re placement Page 193 Torque wrench 4 20 Nm Part No F30044239 Qty Used in 1 7 4 1 Crankcase breather Oil sep...

Page 249: ...filter element Assembly Page 189 Qty Used in 1 7 21 5 Coalescer filter element Replacement Page 216 Valve setting gauge Part No Y4349603 Qty Used in 1 7 5 2 Valve clearance Check and adjustment Page...

Page 250: ...separator element Replacement 141 Cylinder Designation 33 Cylinder head cover Installation 148 Removal 148 Cylinder liner Endoscopic examination 137 Endoscopic inspection Instructions and comments on...

Page 251: ...messages Engine governor ADEC ECU 7 97 Filter Fuel Replacement 159 Filter sleeve Replacement 193 Firing order 68 Fuel Treatment system Switching on 80 Troubleshooting 93 treatment system Shutdown 90 F...

Page 252: ...ntenance work 13 Operation 10 Organizational requirements 9 Personnel requirements 9 Repair work 13 Safety requirements Warning notices standards 19 Sensors Overview 44 Service partners 240 SOLAS shie...

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MTU 20V4000M73 series, Operating Instructions Manual

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Summary of Contents for 20V4000M73 series

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