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MTU 20V4000M93 series, Operating Instructions Manual

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MTU 20V4000M93 series Operating Instructions Manual Download Page 157

7.7 Injection Valve / Injector

7.7.1 Injector – 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 156).

MS150048/05E 2018-03

| Injection Valve / Injector | 155

TIM-ID: 0000000022 - 017

Summary of Contents for 20V4000M93 series

Page 1: ...Operating Instructions Diesel Engine 20V4000M93x MS150048 05E...

Page 2: ...ed in any way whether in whole or in part without the prior writ ten consent of MTU Friedrichshafen GmbH This particularly applies to its reproduction distribution editing translation micro filming an...

Page 3: ......

Page 4: ......

Page 5: ...following an automatic safety shutdown 75 4 5 Starting the engine 76 4 6 Operational checks 77 4 7 Tasks after extended out of service periods 3 weeks 78 4 8 Checks prior to start up 79 4 9 Fuel treat...

Page 6: ...ter element Disassembly 204 7 14 14 Oil filter element Cleaning 206 7 14 15 Oil filter element Check 207 7 14 16 Oil filter element Assembly 208 7 14 17 Oil filter element Installation 212 7 14 18 Oil...

Page 7: ...ngine Interface Module EIM 2 Diagnostic features 255 7 22 Emergency Instrumentation Local Operating Panel 258 7 22 1 LOP and connectors Cleaning 258 8 Appendix A 8 1 List of abbreviations 259 8 2 MTU...

Page 8: ...t are prohibited by emission regulations Emission related components must only be serviced ex changed or repaired if the components used for this purpose are approved by the manufacturer Noncompliance...

Page 9: ...sed military applications other than by US government agen cies Please note the following when replacing components with emission labels The relevant emission labels must be affixed to the spare part...

Page 10: ...ons contained in this manual in particular with regard to the specified tightening torques With the exclusive use of technical personnel trained in commissioning operation maintenance and re pair The...

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

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

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

Page 14: ...fitted Lock circuit breakers Before starting work on CaPoS if used Switch off the charging system DC DC converter Discharge the UltraCap modules using the appropriate discharger Short circuit the Ultr...

Page 15: ...ines near hot components Miscellaneous Sufficient ventilation must be guaranteed during the work Wear a breathing mask offering protection against soot dust and mineral fibers filter class P3 when wor...

Page 16: ...d the pipework at the relevant designated points For hydraulic installation screw on the jig with the piston retracted For hydraulic removal screw on the jig with the piston extended For a hydraulic i...

Page 17: ...rly prior to replacement i e protect them against moisture in particular Package faulty electronic components or assemblies properly before dispatching for repair Moisture proof Shock proof Wrapped in...

Page 18: ...sure that suitable extinguishing agents fire extinguishers are always available and that staff are familiar with their correct handling A fire can result in the creation of toxic substances Always wea...

Page 19: ...s well ventilated Make sure that neighboring work areas are not adversely affected Avoid open flames in the surrounding area No smoking Observe fire prevention regulations Always wear a mask providing...

Page 20: ...Consequences Material damage Remedial action Additional product information Warning notices 1 This manual with all safety instructions and warning notices must be issued to all personnel involved in o...

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

Page 22: ...e must be reinstalled on both engine sides accord ing to the instructions 3 If the engine is to be moved together with the generator the transport locking device for the generator must also be install...

Page 23: ...t the ring gear 4 Screw in screw 1 in bores of holder 3 until holder 3 is locked in position Note Screw 1 must be tightened stepwise and alternately on both sides of the flywheel housing 5 Tighten scr...

Page 24: ...rom the guard plates and engine supports to secure them on the engine u Install engine supports 2 on both sides with guard plates 1 washers 3 and screws 4 and tighten to specified tightening torque ti...

Page 25: ...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 26: ...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 27: ...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 28: ...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 29: ...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 30: ...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 31: ...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 32: ...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 33: ...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 34: ...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 35: ...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 36: ...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 37: ...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 MS150048 05E 2018...

Page 38: ...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 39: ...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 40: ...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 41: ...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 42: ...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 40 General Information MS150048 05E 2018 03 TIM ID 0000...

Page 43: ...1 Oil line on equipment carrier 1 Oil supply to HP pump 1 Oil supply to flap control free end MS150048 05E 2018 03 General Information 41 TIM ID 0000010057 005...

Page 44: ...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 42 General Information MS150048 05E 2018 03 TIM ID...

Page 45: ...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 46: ...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 47: ...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 48: ...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 49: ...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 50: ...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 51: ...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 MS150048 05E 2018 03 General Information 49 TIM ID 00000...

Page 52: ...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 53: ...20V4000M driving end 1 B13 2 N Crankshaft 2 B13 N Crankshaft 3 S37 2 S Safety switch 4 S37 1 S Safety switch MS150048 05E 2018 03 General Information 51 TIM ID 0000034733 006...

Page 54: ...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 55: ...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 56: ...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 57: ...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 58: ...Engine wiring harness for EIM 1 XD1 2 X1 3 X3 4 X52 5 XY1 6 X11 7 XB19 8 X37 56 General Information MS150048 05E 2018 03 TIM ID 0000034732 003...

Page 59: ...Engine wiring harness for electric starter 1 EIM terminals 2 Fuse F1 3 Starter connecting termi nals MS150048 05E 2018 03 General Information 57 TIM ID 0000034732 003...

Page 60: ...Application group 1DS Intake air temperature C 25 Raw water inlet temperature C 25 Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake powe...

Page 61: ...oil operating pressure low idle measuring point before engine R bar 2 0 FUEL SYSTEM Number of cylinders 20 Fuel pressure at engine inlet connection min during engine start L bar 0 1 Fuel pressure at...

Page 62: ...engine side with cooling system R Liters 440 Engine oil on initial filling standard oil system Option max operating inclina tions R Liters 365 Oil change quantity max standard oil system Option max op...

Page 63: ...5 Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylinders 20 Rated engine speed A rpm 2100 Fuel stop...

Page 64: ...Fuel pressure at engine inlet connection max during engine start L bar 1 5 Fuel supply rate max R liters min 30 GENERAL OPERATING DATA Number of cylinders 20 Firing speed from R rpm 80 Firing speed t...

Page 65: ...tem Option max operating incli nations R Liters 320 Oil pan capacity at dipstick mark min standard oil system Option max operating inclinations L Liters 255 Oil pan capacity at dipstick mark max stand...

Page 66: ...let temperature C 25 Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylinders 20 Rated engine speed A...

Page 67: ...Fuel pressure at engine inlet connection max during engine start L bar 1 5 Fuel supply rate max R liters min 30 GENERAL OPERATING DATA Number of cylinders 20 Firing speed from R rpm 80 Firing speed t...

Page 68: ...Liters 320 Oil pan capacity at dipstick mark min standard oil system Option max operating inclinations L Liters 255 Oil pan capacity at dipstick mark max standard oil system Option max operating incli...

Page 69: ...25 Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylinders 20 Rated engine speed A rpm 2100 Fuel stop...

Page 70: ...Fuel pressure at engine inlet connection max during engine start L bar 1 5 Fuel supply rate max R liters min 30 GENERAL OPERATING DATA Number of cylinders 20 Firing speed from R rpm 80 Firing speed t...

Page 71: ...Liters 320 Oil pan capacity at dipstick mark min standard oil system Option max operating inclinations L Liters 255 Oil pan capacity at dipstick mark max standard oil system Option max operating incli...

Page 72: ...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 73: ...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 MS150048 05E 2018 03 Technical Data 71 TIM ID 0000035068 003...

Page 74: ...4 Operation 4 1 Controls Automation system controls Refer to automation system operating instructions 72 Operation MS150048 05E 2018 03 TIM ID 0000016959 003...

Page 75: ...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 227 Coolant circuit Check coolant level Page 225 Coolant...

Page 76: ...required Coolant circuit Check coolant level Page 225 Coolant circuit Heat coolant with coolant preheating unit Engine control system Switch master switch to ON Press illuminated pushbutton READY FOR...

Page 77: ...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 78: ...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 79: ...ssures and temperatures Check engine and external lines for leaks Check for abnormal running noises and vibration Check exhaust color Page 97 Air filter Check signal ring position of service indicator...

Page 80: ...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 80 2 Shut down fuel treatment system Page 92 78...

Page 81: ...ves 4 Switch on fuel treatment system Page 83 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 82: ...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 83: ...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 84: ...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 85: ...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 86: ...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 87: ...n LOP Press illuminated pushbutton CLUTCH IN Page 72 Illuminated pushbutton CLUTCH IN flashes Clutch is engaged After receiving the feedback signal from the clutch illuminated pushbut ton CLUTCH IN li...

Page 88: ...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 89: ...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 72 FLUSH illumin...

Page 90: ...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 72 LOP Opera...

Page 91: ...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 92: ...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 93: ...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 94: ...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 95: ...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 96: ...n differential pressure gauge of fuel prefilter Page 165 W1001 Replace fuel filter or fuel filter element Page 163 W1005 Replace air filter Page 179 W1006 Replace fuel injection valves injectors Page...

Page 97: ...k general condition of engine mounting visual inspection Page 237 W1713 Injector Reset drift correction CDC param eters Page 245 Table 5 Maintenance schedule task reference table QL1 MS150048 05E 2018...

Page 98: ...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 99: ...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 100: ...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 101: ...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 102: ...lt code 1 comprises 3 digits Fault messages may also be caused by faulty sensors actuators Contact Service to have sensors actuators tested and replaced as necessary if troubleshooting as described in...

Page 103: ...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 104: ...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 105: ...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 106: ...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 107: ...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 108: ...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 109: ...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 110: ...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 111: ...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 112: ...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 113: ...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 114: ...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 115: ...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 116: ...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 117: ...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 118: ...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 119: ...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 120: ...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 121: ...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 122: ...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 123: ...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 124: ...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 125: ...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 126: ...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 127: ...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 128: ...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 129: ...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 130: ...possible Page 137 When affixing adhesive connections ensure that escaping fluid can flow out without pressure Page 137 Fuel system fuel lines with fuel pressure 1 8 bar Item Type of shield Installatio...

Page 131: ...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 132: ...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 133: ...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 134: ...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 132 SOLAS MS150048 05E 2018 03 TIM ID 0...

Page 135: ...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 136: ...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 137: ...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 138: ...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 136 SOLAS MS150048 05E 2018 03 TIM ID 0000076609...

Page 139: ...ealing cone unions Note For installation positions of sealing cone un ions see Page 128 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 140: ...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 141: ...7 2 2 Barring engine with starting system Barring using the automation system Refer to automation system operating instructions MS150048 05E 2018 03 Engine 139 TIM ID 0000017532 004...

Page 142: ...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 143: ...Final steps 1 Install injector Page 156 2 Install cylinder head cover Page 151 MS150048 05E 2018 03 Cylinder Liner 141 TIM ID 0000000015 017...

Page 144: ...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 145: ...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 146: ...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 147: ...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 MS1500...

Page 148: ...Spare parts Designation Use Part No Qty Engine oil Valve gear Lubrication 1 Remove cylinder head covers Page 151 2 Fill oil chambers of valve bridges with oil 3 Fill oil chambers of rocker arms and ad...

Page 149: ...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 151 2 Install barring tool Page 138 Note Po...

Page 150: ...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 151: ...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 152: ...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 153: ...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 154: ...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 155: ...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 156: ...oad only Keep clear of the danger zone of the engine WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors HP fuel pump checking relief bore 1 Vis...

Page 157: ...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 156 MS150048 05E 2018 03 Injec...

Page 158: ...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 159: ...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 160: ...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 161: ...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 162: ...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 163: ...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 164: ...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 165: ...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 166: ...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 167: ...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 168: ...al sparks and ignition sources Do not smoke Wear protective clothing protective gloves and safety glasses facial protection WARNING Liquid or gaseous media e g fuel are poisonous Escaping vapors of hi...

Page 169: ...Drain water and contaminants from filter until pure fuel emerges 5 Close drain valve 6 6 Remove screws for cover and take off cov er 2 7 Fill filter housing with clean fuel 8 Place new gasket in cover...

Page 170: ...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 171: ...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 172: ...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 173: ...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 174: ...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 175: ...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 176: ...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 177: ...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 178: ...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 179: ...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 180: ...tion with leak ing intercooler 1 Remove injectors Page 156 2 Bar engine manually Page 138 3 Bar engine with starting system to blow out combustion chambers Page 138 4 Install injectors Page 156 178 Ch...

Page 181: ...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 180 2 Reset signal ring of contamination indicator...

Page 182: ...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 183: ...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 184: ...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 185: ...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 186: ...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 182 5 Aft...

Page 187: ...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 188: ...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 189: ...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 MS150048 05E 2...

Page 190: ...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 188 Oil Filtration Coolin...

Page 191: ...steps Preconditions Engine is stopped and starting disabled Automatic oil filter preparatory steps 1 Observe safety instructions 2 Remove centrifugal oil filter Page 217 MS150048 05E 2018 03 Oil Filtr...

Page 192: ...to below 50 C before beginning work Wear protective clothing protective gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor WARNING Oils oil vapors are combustible explosiv...

Page 193: ...olant distribution housing 1 Attach automatic oil filter 1 to crane with a lightly tensioned lifting strap 2 Remove screws 2 3 Remove automatic oil filter 1 from coolant distribution housing 3 4 Colle...

Page 194: ...s Automatic oil filter has been removed from engine Automatic oil filter Disassembly 1 Observe safety instructions 2 Disassemble automatic oil filter as per overview drawing Page 186 192 Oil Filtratio...

Page 195: ...nk smoke when working with cleaner Wear protective clothing gloves and goggles safety mask Take measures against electrostatic charging NOTICE Cleaning agents should not be left to take effect for too...

Page 196: ...lace Check gearwheel on worm gear for indentations signs of wear and damage Indentations Wear traces Damage visible Smooth minor wear traces and damage with crocus cloth or oil stone Replace Check flu...

Page 197: ...automatic oil filter before changing the oil filter candles Keep everything scrupulously clean when performing maintenance and repair work Cover all exposed openings when opening assemblies NOTICE Con...

Page 198: ...pors are combustible explosive Risk of fire and explosion Avoid open flames electric sparks and ignition sources Do not smoke NOTICE Ingress of contamination from automatic oil filter in the engine oi...

Page 199: ...sembly compound 3 Insert O rings in ring groove 4 Attach automatic oil filter 1 with lifting strap to crane 5 Install automatic oil filter on coolant distribu tion housing 3 6 Coat screws 2 with engin...

Page 200: ...ilter Final steps Final steps 1 Install centrifugal oil filter Page 217 2 Check engine oil level and fill up as necessary Page 182 3 Enable engine start 198 Oil Filtration Cooling MS150048 05E 2018 03...

Page 201: ...p sufficiently clear off rotating parts Automatic oil filter Checking flushing arm rotation 1 Check at sight glass that plastic spinner 1 turns 2 If the plastic spinner turns irregularly or if it does...

Page 202: ...view Oil filter candle element 1 Filter indicator 2 Screw 3 Sealing nut 4 Spring washer 5 Washer 6 O ring 7 Upper flushing arm 8 Screw 9 O ring 10 Filter candles 200 Oil Filtration Cooling MS150048 05...

Page 203: ...te 3 Screw 4 Grooved ball bearing 5 Grooved ball bearing 6 Coiled spring pin 7 Connecting pipe 8 Overflow valve 9 Bottom strainer plate 10 Protective screen MS150048 05E 2018 03 Oil Filtration Cooling...

Page 204: ...1 O ring 2 Flushing arm shaft 3 Lower flushing arm 4 Spacer ring 5 Gear 6 Screw 7 Screw 202 Oil Filtration Cooling MS150048 05E 2018 03 TIM ID 0000070291 001...

Page 205: ...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 R...

Page 206: ...e sealing nut 3 4 Remove spring washer 4 and washer 5 5 Remove screw 8 6 Remove flushing arm from strainer plate 7 7 Remove filter element 1 from flushing arm shaft 2 8 Turn filter element through 180...

Page 207: ...3 13 Remove protective strainer 4 from connect ing pipe 5 with bottom strainer plate attach ed 14 Remove O ring from bottom strainer plate Removing overflow valve u Unscrew overflow valves 1 and remov...

Page 208: ...fety 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 fi...

Page 209: ...Spare Parts Catalog Gear Spare Parts Catalog Oil filter element Check Item Findings Action Check grooved ball bearing on flushing arm shaft Damage Tight Replace Check flushing arm gap between flushing...

Page 210: ...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 211: ...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 212: ...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 213: ...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 MS150048 05E 2018 03 Oil Filtra...

Page 214: ...pressed air will result in airborne particles Risk of penetration of contaminants leading to component damage Disconnect the engine from the cooling water network by fitting blanking plates at the con...

Page 215: ...filter element 1 into housing 3 Insert new gasket in oil filter cover 1 4 Install oil filter cover 5 Screw on nuts 2 and use torque wrench to tighten to specified tightening torque Name Size Type Lub...

Page 216: ...ness 1 Cover opening 2 Note Constrict opening with a suitable cover 2 Blow compressed air into opening 1 3 Check that flushing arm turns at sight glass 3 4 If flushing arm does not turn remove oil fil...

Page 217: ...s 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...

Page 218: ...maged Replace Square section ring Damaged Replace O ring Damaged Replace Cleaning strainer 1 Wash strainer 6 with cleaner 2 Remove stubborn deposits with soft brush 3 Blow out strainer 6 with compress...

Page 219: ...er 1 Centrifugal oil filter 2 O ring 3 Flange 4 Washer 5 Screw 6 O ring 7 Socket pipe 8 O ring 9 Threaded adapter 10 Sealing ring 11 O ring 12 Stud 13 Flange 14 Socket pipe 15 Washer 16 Nut MS150048 0...

Page 220: ...eparatory steps Preconditions Engine shut down and starting disabled Preparatory steps 1 Observe safety regulations 2 Drain engine oil from centrifugal oil filter 218 Oil Filtration Cooling MS150048 0...

Page 221: ...Preparatory steps have been carried out Removing centrifugal oil filter 1 Remove centrifugal oil filter as shown in overview drawing Page 217 2 Seal all openings with suitable covers MS150048 05E 2018...

Page 222: ...mely caustic Risk of injury and suffocation Avoid contact with eyes and skin Do not inhale vapors and smoke Do not eat drink smoke when working with cleaner Wear protective clothing gloves and goggles...

Page 223: ...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 p...

Page 224: ...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 225: ...pecial cleanliness 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 in...

Page 226: ...15 Coolant Circuit General High Temperature Circuit 7 15 1 Vent points Coolant line to ETC 1 Vent point 224 Coolant Circuit General High Temperature Circuit MS150048 05E 2018 03 TIM ID 0000014547 002...

Page 227: ...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 228: ...level at sight glass 1 Check coolant level coolant level must be between min and max mark 2 Top up coolant if necessary Page 229 226 Coolant Circuit General High Temperature Circuit MS150048 05E 2018...

Page 229: ...Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 228 2 Fill with engine coolant Page 229 MS150048 05E 2018 03 Coolant Circuit General High Tem...

Page 230: ...k 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 thr...

Page 231: ...nt in hot engine can cause thermal stress Possible formation of cracks in the engine Fill top up coolant only into cold engine Preparatory steps 1 Turn breather valve 1 of coolant expansion tank count...

Page 232: ...lant using a pump 1 Connect appropriate pump with hose to filling connection arrowed on A side or B side Al ternatively 230 Coolant Circuit General High Temperature Circuit MS150048 05E 2018 03 TIM ID...

Page 233: ...is 40 C T Cool ant increase engine speed to 1 000 rpm for approx 2 minutes then reduce engine speed to idle speed 12 With the engine running idle top up the ex pansion tank with coolant until the lev...

Page 234: ...edge 9 When coolant temperature is 40 C T Coolant increase engine speed to 1 000 rpm for approx 2 minutes With the engine running idle top up the expansion tank with coolant until coolant level is at...

Page 235: ...ear ear protectors Engine coolant pump relief bore check 1 Check relief bore for oil and coolant dis charge 2 Stop engine Page 76 and disable engine start observe general safety instructions on mainte...

Page 236: ...e 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 237: ...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 76 and disable engine start observe general safety...

Page 238: ...tion check 1 Install barring tool Page 138 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 239: ...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 240: ...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 238 Fuel Supply System MS150048 05E 2018 03 TIM I...

Page 241: ...Wear protective clothing protective gloves and safety glasses facial protection Checking differential pressure gage alarm function 1 Switch on fuel treatment system Page 83 2 Set the alarm points at t...

Page 242: ...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 243: ...e 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 pres...

Page 244: ...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 245: ...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 246: ...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 247: ...eset otherwise the emission certification of the engine is no longer applica ble u Reset the CDC parameters with DiaSys Manufacturer s documentation Resetting CDC parameters DiaSys is not available No...

Page 248: ...coarse dirt from housing surface using a cloth moistened with isopropyl alcohol 2 Remove dirt from the connector and cable surfaces with isopropyl alcohol 3 Check legibility of cable labels Clean or...

Page 249: ...oth switches 3 are actuat ed 3 If switches 3 and or guard plate 2 with en gine support 1 is are not installed Screw on guard plate 2 with engine sup port 1 Then screw on switch 3 ensuring that the swi...

Page 250: ...dirt from housing surface 2 Use isopropyl alcohol to remove dirt from the connector and cable surfaces 3 Check legibility of cable labels Clean or replace illegible labels Heavily contaminated connect...

Page 251: ...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 252: ...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 253: ...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 254: ...ine governor from engine 1 Note or mark assignment of cables and plugs 2 Remove all screws 3 3 Undo clips 2 on connectors 4 Remove all male connectors 5 Remove screws 1 6 Take off engine governor Inst...

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

Page 256: ...so observe correct assignment between cables and connectors 2 Check seal before installing Result Replace seal if porous or defective Downloading software 1 The new EIM 2 still does not have appropri...

Page 257: ...ion 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 th...

Page 258: ...10 Emergency stop current path failed 24 V internal S9 11 ES pushbutton current path failed 24 V external S10 12 Key switch current path failed S11 13 SDAF 1 and 2 current path failed S12 14 PIM curr...

Page 259: ...1 2 second steps Note These bit patterns are continuously transmitted The CAN message Status of internal power supply also contains information on the current path states of the EIM 2 MS150048 05E 20...

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

Page 261: ...panel DL Default Lost Alarm Default CAN bus failure ECS Engine Control System Engine management system ECU Engine Control Unit Engine governor EDM Engine Data Module Memory module for engine data EIM...

Page 262: ...OT Oberer Totpunkt Top Dead Center P xyz Pressure xyz Pressure measuring point xyz PAN Panel Control panel PCU Propeller Control Unit Propeller controller PIM Peripheral Interface Module RCS Remote C...

Page 263: ...of a malfunction for information on changes in conditions of use and for supplying spare parts Your contact person in our Customer Assistance Center E mail info mtu online com Tel 49 7541 9077777 Fax...

Page 264: ...learance Check and adjustment Page 147 Barring tool Part No F6555766 Qty Used in 1 7 2 1 Engine Barring manually Page 138 Endoscope Part No Y20097353 Qty Used in 1 7 17 1 Battery charging generator dr...

Page 265: ...lement Assembly Page 208 Fuel suction device Part No F30378207 Qty Used in 1 7 6 1 HP fuel pump Filling with engine oil Page 152 High pressure cleaner Part No Qty Used in 1 4 20 Plant Cleaning Page 93...

Page 266: ...05892099 00 Qty Used in 1 7 13 3 Engine oil Sample extraction and analysis Page 185 MTU test kit Part No F6798833 Qty Used in 1 7 15 7 Engine coolant Sample extraction and analysis Page 234 Oil filter...

Page 267: ...lter element replacement Page 170 Qty Used in 1 7 14 16 Oil filter element Assembly Page 208 Qty Used in 1 7 14 17 Oil filter element Installation Page 212 Qty Used in 1 7 19 5 Coalescer filter elemen...

Page 268: ...eaning and filter sleeve replacement Page 221 Ratchet bit Part No F30027342 Qty Used in 1 7 7 2 Injector Removal and installation jacketed fuel system Page 156 Ratchet with extension Part No F30006212...

Page 269: ...1 7 7 2 Injector Removal and installation jacketed fuel system Page 156 Qty Used in 1 7 8 5 Fuel prefilter with water separator Filter element replacement Page 170 Qty Used in 1 7 9 1 Compressor wheel...

Page 270: ...ue wrench 60 320 Nm Part No F30452768 Qty Used in 1 1 9 Crankshaft transport locking device Page 20 Qty Used in 1 7 5 2 Valve clearance Check and adjustment Page 147 Qty Used in 1 7 7 2 Injector Remov...

Page 271: ...Valve setting gauge Part No Y4349603 Qty Used in 1 7 5 2 Valve clearance Check and adjustment Page 147 MS150048 05E 2018 03 Special Tools 269 DCL ID 0000015617 003...

Page 272: ...20 221 Installation 223 Overview 217 preparatory steps 218 Removal 219 Checks Prior to start up 79 Clutch engagement At LOP 85 Coalescer filter element Replacement 242 Compressor wheel Cleaning 173 Co...

Page 273: ...ine Monitoring Unit EMU 8 Plug connections check 249 Engine mounting Check 237 Engine oil Centrifugal oil filter Cleaning 221 Change 183 Filter sleeve Replacement 221 Sample analysis 185 Sample extrac...

Page 274: ...utting the engine into operation after extended out of service periods 3 months 73 Putting the engine into operation after scheduled out of service period 74 R Raw water pump Relief bore Check 235 S S...

Page 275: ...ints 224 W Warning notices standards 18 Water drain valve Check 238 Water level probe 3 in 1 rod electrode Check 240 Waterjet Flushing From LOP option 87 MS150048 05E 2018 03 Index 273 DCL ID 00000156...

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