MTU 8V4000M*3 series Operating Instructions Manual Download Page 254

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Ratchet bit

Part No.:

F30027341

Qty.:
Used in:

8.5.4 Cylinder head cover – Removal and installation
(→ Page 154)

Qty.:
Used in:

1
8.14.2 Engine oil – Change (→ Page 190)

Ratchet bit

Part No.:

F30027340

Qty.:
Used in:

1
8.7.2 Injector – Removal and installation (jacketed fuel
system) (→ Page 159)

Qty.:
Used in:

1
8.15.3 Centrifugal oil filter – Cleaning and filter sleeve re-
placement (→ Page 199)

Ratchet bit

Part No.:

F30027342

Qty.:
Used in:

1
8.7.2 Injector – Removal and installation (jacketed fuel
system) (→ Page 159)

Ratchet with extension

Part No.:

F30006212

Qty.:
Used in:

1
8.2.1 Engine – Barring manually (→ Page 141)

Qty.:
Used in:

1
8.3.1 Cylinder liner – Endoscopic examination
(→ Page 144)

252 | Special Tools | MS15034/00E 2018-08

DCL-ID: 0000051756 - 001

Summary of Contents for 8V4000M*3 series

Page 1: ...Operating Instructions Diesel engine 8V4000Mx3x MS15034 00E...

Page 2: ...ight and may not be used 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 transl...

Page 3: ......

Page 4: ......

Page 5: ...Fuel treatment system Initial start up 87 5 10 Fuel treatment system Switching on 90 5 11 Fuel treatment system Shutdown 91 5 12 Stopping the engine 92 5 13 Emergency engine stop 93 5 14 After shutdo...

Page 6: ...ge 206 8 16 4 Engine coolant Draining 207 8 16 5 Engine coolant filling 208 8 16 6 HT coolant pump Relief bore check 210 8 16 7 Engine coolant Sample extraction and analysis 211 8 16 8 Engine coolant...

Page 7: ...ct 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 Noncomplianc...

Page 8: ...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 9: ...ions 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 10: ...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 11: ...ator 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 pro...

Page 12: ...ids 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 electrica...

Page 13: ...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 Ult...

Page 14: ...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 15: ...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 16: ...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 17: ...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 18: ...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 19: ...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...

Page 20: ...sport 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 Sec...

Page 21: ...nstalled heat exchanger 1 Maximum permissible diag onal pull 10 2 Center of gravity Max permissible diagonal pull must be observed Max permissible diagonal pull in longitudinal direction is 10 degrees...

Page 22: ...grees simultaneous diagonal pull in trans verse direction is impermissible Max permissible diagonal pull in transverse direction is 10 degrees simultaneous diagonal pull in longitu dinal direction is...

Page 23: ...air filter 3 Exhaust manifold 4 Cylinder head 5 Fuel filter 6 Oil filter 7 Battery charging generator option 8 HP fuel pump 9 Bilge pump option 10 Raw water pump option for engines with remote heat ex...

Page 24: ...xpansion tank 4 Oil cooler 5 Coolant pump 6 Engine mounting 7 Oil filler neck 8 Oil pan 9 Crankcase 10 Charge air line 11 Compressor housing 12 Charge air cooler 13 Exhaust turbocharger carri er housi...

Page 25: ...ifugal oil filter 4 Dry type air filter 5 Exhaust manifold 6 Cylinder head 7 Fuel filter 8 Oil filter 9 Battery charging generator option 10 HP fuel pump 11 Raw water pump 12 Heat exchanger 13 Engine...

Page 26: ...12 Air pipe to charge air cooler 13 Exhaust turbocharger carri er housing KS Driving end Engine model designation Key to engine model designation 8V 4000 Mxyz 8 Number of cylinders V Cylinder arrange...

Page 27: ...in and cut out with electronically controlled hydraulically actuated flaps Cooling system Split circuit engine cooling system with remote or engine mounted heat exchanger Heating of the charge air in...

Page 28: ...for diagnosis The engine interface comprises two parts The first section is integrated in the engine cable harness via a Tyco male connector X52 62 pin The second part refers to signals associated wi...

Page 29: ...haust lines Common Rail fuel injection and cylinder cutout allow engine operation at low load Nevertheless low load operation at engine load below 15 of the nominal rating is permitted for max 100 hou...

Page 30: ...power takes place in single ETC mode with only one exhaust turbocharger running To ensure the functionality of the control mechanism and of the ex haust flap of the turbocharger which does not run in...

Page 31: ...1 Fuel line after LP pump 1 Fuel line to fuel filter head retainer MS15034 00E 2018 08 General Information 29 TIM ID 0000010055 006...

Page 32: ...1 Fuel line from fuel filter head 1 Fuel line on HP pump 30 General Information MS15034 00E 2018 08 TIM ID 0000010055 006...

Page 33: ...line on fuel filter head Lube oil system oil lines with oil pressure 1 8 bar All lines with SOLAS compliant covers for pipe joints according to MTU standard MTN5233 are shown MS15034 00E 2018 08 Gener...

Page 34: ...charger A1 3 4 2 way valve 4 From distributor 5 Oil return from 4 2 way directional control valve 1 Oil return from 4 2 way directional control valve 2 Oil supply for 4 2 way directional con trol valv...

Page 35: ...g Comments 1 Shields A4 Exhaust turbocharger oil supply A side 2 Shields A5 2 x Exhaust turbocharger oil supply A side 1 Oil supply for exhaust turbocharger MS15034 00E 2018 08 General Information 33...

Page 36: ...Item Type of shielding Comments 1 Shields A6 Oil supply to HP pump 34 General Information MS15034 00E 2018 08 TIM ID 0000010055 006...

Page 37: ...1 Oil supply line of HP pump on equipment carrier 1 Oil supply on equipment carrier MS15034 00E 2018 08 General Information 35 TIM ID 0000010055 006...

Page 38: ...cial connections The following types of connections are spray proof in case of leakage even without covers and have been confirmed as being SOLAS compliant by GL and DnV 36 General Information MS15034...

Page 39: ...ing SOLAS compliant by DnV and GL Plugs and sensors Screwed in plugs 2 are either sealed with copper sealing rings 1 as per DIN or O rings ISO The fluid must first pass the thread in case of a loose t...

Page 40: ...ipe of HP line 19 Ball type seal area 20 Leak fuel connection The HP fuel line is sealed by the thrust ring 8 In case of leakage around the thrust ring 8 or the HP line 5 fuel escapes into the leakage...

Page 41: ...gth 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 friction coefficient tot 0 125 Threads and mating...

Page 42: ...teel 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 setscrews and nuts made of stainless s...

Page 43: ...re 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 per...

Page 44: ...en 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 For...

Page 45: ...Tightening 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...

Page 46: ...el 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...

Page 47: ...ons 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 48: ...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 49: ...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 50: ...n 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 51: ...ORFS 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 unio...

Page 52: ...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 53: ...e 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 MS15034 00E 2018...

Page 54: ...ccordance 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 55: ...engine side 8V4000Mx3 1 B44 2 N Turbocharger B 2 B4 21 T Exhaust A side 3 B10 P Charge air 4 B34 2 P Fuel before filter 5 B34 3 P Fuel before filter 6 B34 1 P Fuel after filter 7 F46 H fuel leakage MS...

Page 56: ...r only with switchable oil fil ter 4 B5 1 P Lube oil after filter 5 B5 3 P Lube oil before fil ter 6 B48 P Fuel in common rail 7 B1 N Camshaft 8 B54 P Oil refill pump 9 B6 2 T Coolant 10 B6 T Coolant...

Page 57: ...Right engine side 8V4000Mx3 1 B16 P Coolant 2 B9 T Charge Air 3 B4 22 T Exhaust B bank 4 B44 1 N Turbocharger A MS15034 00E 2018 08 General Information 55 TIM ID 0000012942 004...

Page 58: ...Driving end KS 8V4000Mx3 1 S37 1 S Safety switch 2 B13 2 N Crankshaft 3 B13 N Crankshaft 4 S37 2 safety switch 56 General Information MS15034 00E 2018 08 TIM ID 0000012942 004...

Page 59: ...control valve 2 Y26 A Air recirculation valve 3 B50 P Crankcase 4 B4 A1 B4B4 T Individual ex haust A1 A4 B1 B4 5 B49 T Charge air air recir culation valve 6 B3 T Intake air MS15034 00E 2018 08 Genera...

Page 60: ...2 N Turbocharger B 2 B4 21 T Exhaust A side 3 B10 P Charge air 4 B34 2 P Fuel before filter 5 B34 3 P Fuel before filter 6 B34 1 P Fuel after filter 7 F46 H Fuel leakage 8 B33 T Fuel in common rail 58...

Page 61: ...be oil after filter only with switchable oil fil ter 4 B5 1 P Lube oil after filter 5 B5 3 P Lube oil before of filter 6 B1 N Camshaft 7 B54 P Oil refill pump 8 B6 2 T Coolant 9 B6 T Coolant 10 Connec...

Page 62: ...engine side 8V4000Mx3 1 F33 H Coolant 2 B16 P Coolant 3 B21 P Raw water 4 B9 T Charge Air 5 B4 22 T Exhaust B bank 6 B44 1 N Turbocharger A 60 General Information MS15034 00E 2018 08 TIM ID 000001294...

Page 63: ...Driving end KS 8V4000Mx3 1 S37 1 S Safety switch 2 B13 2 N Crankshaft 3 B13 N Crankshaft 4 S37 2 S Safety switch MS15034 00E 2018 08 General Information 61 TIM ID 0000012942 004...

Page 64: ...control valve 2 B50 P Crankcase 3 B4 A1 B4B4 T Individual ex haust A1 A4 B1 B4 4 Y26 A Air recirculation valve 5 B49 T Charge air air recir culation valve 6 B3 T Intake air 62 General Information MS1...

Page 65: ...100 100 100 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylinders Engine mounted heat exchanger Remote heat ex changer Rated engine speed A rpm 1600 1600 1600 16...

Page 66: ...oil operating pressure before engine from R bar 6 3 6 3 6 3 6 3 Lube oil operating pressure before engine to R bar 5 3 5 3 5 3 5 3 Lube oil operating pressure low idle meas point before engine R bar 2...

Page 67: ...end up Option max operating in clinations L Degrees 10 10 10 10 Longitudinal inclination temporary max driving end up Option max operating in clinations L Degrees Transverse inclination continuous max...

Page 68: ...er of cylinders Engine mounted heat exchanger Remote heat ex changer Exhaust noise unsilenced BL free field sound pressure level Lp 1m distance ISO 6798 3dB A tolerance R dB A 108 108 108 108 Engine s...

Page 69: ...e must be greater than the specified value Actual value must be smaller than the specified value Insufficiently guaranteed value tolerance 10 Insufficiently guaranteed value tolerance 5 ID Product typ...

Page 70: ...IIA 97 68 EC IMO Tier I Marpol Comp IMO Tier II Marpol Comp EPA Marine T2 Comp 40CFR94 Reference conditions ID 1 2 3 4 Intake air temperature C 25 25 45 45 Charge air coolant temperature C Barometric...

Page 71: ...0 Lube oil system ID 1 2 3 4 Lube oil operating pressure before en gine from R bar 6 5 6 5 6 5 6 5 Lube oil operating pressure before en gine to R bar 5 5 5 5 5 5 5 5 Lube oil operating pressure low i...

Page 72: ...max driving end up option max operating in clinations L Degrees 17 5 17 5 17 5 17 5 Transverse inclination continuous max option max operating inclinations L Degrees 15 15 15 15 Transverse inclinatio...

Page 73: ...Lp 1m distance ISO 6798 3dB A tolerance R dB A 107 107 107 107 Engine surface noise with attenuated in take noise filter BL free field sound power level Lp 1 m distance ISO 6798 2dB A tolerance R dB A...

Page 74: ...must be greater than the specified value Actual value must be smaller than the specified value Insufficiently guaranteed value tolerance 10 Insufficiently guaranteed value tolerance 5 ID Product type...

Page 75: ...IMO Tier II Marpol convention EU Nonroad St IIIA 97 68 EC IMO Tier I Marpol Comp IMO Tier II Marpol Comp EPA Marine T2 Comp 40CFR94 Reference conditions ID 1 2 3 4 Intake air temperature C 25 25 45 45...

Page 76: ...erating pressure before en gine to R bar 5 5 5 5 5 5 5 5 Lube oil operating pressure low idle meas point before engine R bar 2 2 2 2 2 2 2 2 Fuel system ID 1 2 3 4 Fuel pressure at engine inlet connec...

Page 77: ...in clinations L Degrees 17 5 17 5 17 5 17 5 Transverse inclination continuous max option max operating inclinations L Degrees 15 15 15 15 Transverse inclination temporary max option max operating incl...

Page 78: ...l Lp 1m distance ISO 6798 3dB A tolerance R dB A 107 107 107 107 Engine surface noise with attenuated in take noise filter BL free field sound power level Lp 1 m distance ISO 6798 2dB A tolerance R dB...

Page 79: ...4 4 Firing order 8V A1 B4 A4 A2 B3 A3 B2 B1 12 V A1 B5 A5 B3 A3 B6 A6 B2 A2 B4 A4 B1 16 V A1 A7 B4 B6 A4 B8 A2 A8 B3 B5 A3 A5 B2 A6 B1 B7 MS15034 00E 2018 08 Technical Data 77 TIM ID 0000010713 002...

Page 80: ...B Height C 8V4000 M23S 23F 33S 33S 53 53R 63 approx 2386 mm approx 1613 mm approx 1959 mm Engines with engine mounted heat exchanger Engine model Length A Width B Height C 8V4000 M23S 23F 33S 33S 53...

Page 81: ...5 Operation 5 1 Controls Automation system controls Refer to automation system operating instructions MS15034 00E 2018 08 Operation 79 TIM ID 0000016959 003...

Page 82: ...gn adjustable pointer with position of pressure indicator Page 170 HP fuel pump Only for engines without oil priming pump Fill HP fuel pump with fresh engine oil Page 155 Raw water pump if located abo...

Page 83: ...Check coolant level Page 205 Coolant system Preheat coolant with preheating unit Fuel prefilter Drain Page 171 Check that suction side pressure indicated at the fuel prefilter pressure gauge is withi...

Page 84: ...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 85: ...5 5 Starting the engine Start the engine via the automation system Refer to automation system operating instructions MS15034 00E 2018 08 Operation 83 TIM ID 0000017525 003...

Page 86: ...nd exhaust color Page 100 Air filter Check signal ring position of service indicator Page 187 Replace air filter Page 185 if the signal ring is completely visible in the service indicator control wind...

Page 87: ...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 87 2 Shut down fuel treatment system Page 91 MS1...

Page 88: ...ves 4 Switch on fuel treatment system Page 90 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 89: ...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 90: ...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 91: ...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 92: ...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 93: ...binet until water discharge from the outlet stops 2 Switch off fuel treatment system 3 Close ball valve at the inlet to the fuel treatment system 4 Close ball valve at the outlet of the fuel treatment...

Page 94: ...5 12 Stopping the engine Stopping the engine via the automation system Refer to automation system operating instructions 92 Operation MS15034 00E 2018 08 TIM ID 0000017528 004...

Page 95: ...system to an extremely high load Risk of overheating damage to components Trigger an emergency stop only in emergency situations Emergency stop 1 Refer to automation system operating instructions 2 Fo...

Page 96: ...entration is insufficient for the engine room temperature antifreeze concentration is 50 and engine room temperature is below 40 C Raw water only on engines with engine mounted heat exchanger Drain if...

Page 97: ...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 98: ...place fuel injectors Page 158 W1008 X Fit new engine oil filters each time the engine oil is changed or at the latest on expiry of the time limit given in years Page 194 W1009 Check thickness of oil r...

Page 99: ...713 Injector reset drift compensation parameters CDC Page 245 W1864 X Check and clean oil indicator filter REFDM TARGET NOT FOUND Table 2 Maintenance task reference table QL1 MS15034 00E 2018 08 Maint...

Page 100: ...it new air filters Page 185 W1006 Replace fuel injectors Page 158 W1008 X Fit new engine oil filters each time the engine oil is changed or at the latest on expiry of the time limit given in years Pag...

Page 101: ...s W1675 X Fit new fuel prefilter or new fuel prefilter insert W1713 Injector reset drift compensation parameters CDC Page 245 Table 3 Maintenance task reference table QL1 MS15034 00E 2018 08 Maintenan...

Page 102: ...y and re start the system by actuating the key switch Engine blocked engine cannot be barred manually u Contact Service Engine turns on starting but does not fire Cause Corrective action Poor rotation...

Page 103: ...dicator Page 187 Intercooler dirty u Contact Service Exhaust turbocharger faulty u Contact Service Coolant leaks at intercooler Cause Corrective action Intercooler leaking major coolant discharge u Co...

Page 104: ...t gas Cause Corrective action Engine is not at operating temperature u Run engine to reach operating temperature Intercooler leaking u Contact Service 102 Troubleshooting MS15034 00E 2018 08 TIM ID 00...

Page 105: ...s equipped with an overload protection If the maximum permissible current consumption is exceeded e g in case of a blockage or dry running the motor protection relay triggers and the pump is switched...

Page 106: ...ult 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 i...

Page 107: ...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 108: ...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 109: ...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 110: ...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 111: ...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 112: ...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 113: ...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 114: ...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 115: ...510 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...

Page 116: ...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 117: ...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 118: ...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 119: ...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 120: ...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 121: ...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 122: ...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 123: ...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 124: ...essages 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 125: ...utput 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...

Page 126: ...temperature 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 I...

Page 127: ...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 128: ...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 129: ...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 Correct...

Page 130: ...ion 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 co...

Page 131: ...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 132: ...y 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...

Page 133: ...00100 2 Shield A5 735233000101 18 Shield A6 735233000102 4 Shield A7 735233000103 3 Shield A8 735233000104 4 Shield B2 735233000200 2 Shield B4 735233000202 1 Shield B6 735233000204 2 Shield E5 735233...

Page 134: ...down to ambient temperature Special tools Material Spare parts Designation Use Part No Qty Oil filter shield X00040625 5 Shield for switchable oil filter X00040625 4 Installing SOLAS shield 1 Pinpoin...

Page 135: ...nnections ensure that escaping fluid can flow out without pressure Page 140 Fuel system fuel lines with fuel pressures exceeding 1 8 bar Item Type of shielding Installation location 1 Shield A8 After...

Page 136: ...r only with great difficulty following assembly of the air pipework and or fuel filters Item Type of shielding Installation location 1 Shield E5 Fuel line on HP pump 2 Shield E5 Fuel line downstream o...

Page 137: ...sembly line This location is no longer accessible or only with great difficulty following assembly of the air pipework Lube oil system oil lines with oil pressures exceeding 1 8 bar Item Type of shiel...

Page 138: ...r air flap turbocharger A1 3 4 x shielding A5 4 2 way directional control valve Item Type of shielding Installation location 1 2 x shielding A5 Air recirculation valve 2 2 x shielding A5 1 x shielding...

Page 139: ...ielding Installation location 1 Shield A4 ETC oil supply 2 2 x shielding A5 ETC oil supply Item Type of shielding Installation location 1 Shield A4 ETC oil supply MS15034 00E 2018 08 SOLAS 137 TIM ID...

Page 140: ...tallation location 1 Shield A6 Oil supply line to HP pump To HP pump Item Type of shielding Installation location 1 Shield B4 Oil supply line to HP pump On equipment carrier 138 SOLAS MS15034 00E 2018...

Page 141: ...n location 1 Shield B2 Oil line on equipment carrier 2 Shield B2 Oil line on pressure reducing valve Item Type of shielding Installation location 1 Cover Oil easy change fuel filter MS15034 00E 2018 0...

Page 142: ...ions Note For installation positions of sealing cone un ions see REFDM TARGET NOT FOUND 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 143: ...gine parts Risk of crushing danger of parts of the body being caught or pulled in Before barring the engine make sure that there are no persons in the engine s danger zone After finishing work on the...

Page 144: ...o barring device 2 Note No resistance other than compression resist ance must be encountered 4 Rotate crankshaft in engine direction of rota tion Result If the resistance exceeds the normal com pressi...

Page 145: ...8 2 2 Barring engine with starting system Barring using the automation system Refer to automation system operating instructions MS15034 00E 2018 08 Engine 143 TIM ID 0000017532 004...

Page 146: ...top piston ring and bottom edge of carbon scraper ring First signs of marks left by top piston ring Bright mark on entire circumference Faultless even honing pattern First signs of marks left by lowe...

Page 147: ...epending on findings Do not take any action or carry out a further endoscopic examination as part of maintenance work or contact Service cylinder liner must be replaced Final steps 1 Install injector...

Page 148: ...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 149: ...ks are similar A thorough investigation and compliance with the above evaluation criteria allow an unambiguous evaluation To avoid unnecessary disassembly work it is recommended that another inspectio...

Page 150: ...are harmful to health Risk of injury and poisoning Allow the product to cool to below 50 C before beginning work Wear protective clothing protective gloves and goggles safety mask Avoid contact with s...

Page 151: ...Spare parts Designation Use Part No Qty Engine oil Valve gear Lubrication 1 Remove cylinder head covers Page 153 2 Fill oil chambers of valve bridges with oil 3 Fill oil chambers of rocker arms and ad...

Page 152: ...e wrench 60 320 Nm F30452768 1 Socket wrench 24 mm F30039526 1 Engine oil Preparatory steps 1 Remove cylinder head cover Page 153 2 Install barring device Page 141 Note The pointer 1 is in the lower o...

Page 153: ...ton is in overlap TDC when the rocker arms on cylinder A1 are loaded 2 Check valve clearance setting with engine cold Inlet long rocker arm 0 2 0 05 mm Exhaust short rocker arm 0 5 0 0 5mm 3 Check all...

Page 154: ...t just pass through the gap 4 Pull feeler gauge 3 between valve bridge and rocker arm 5 Tighten locknut 1 with torque wrench to the specified tightening torque holding the adjusting screw 2 to prevent...

Page 155: ...o screws 1 and remove with wash ers 2 3 Remove cylinder head cover 3 with gas ket 4 from cylinder head 4 Remove other cylinder head covers in the same way Installing cylinder head cover 1 Clean mating...

Page 156: ...s 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...

Page 157: ...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 158: ...box 2 Use fuel suction device to fill HP pump with 2 liters of clean engine oil 3 Screw in union 1 and use torque wrench to tighten to specified tightening torque Name Size Type Lubricant Value Standa...

Page 159: ...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 160: ...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 159 158 Injection Valve Inject...

Page 161: ...losive 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 o...

Page 162: ...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 163: ...ion 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 injecto...

Page 164: ...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 165: ...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 166: ...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 Lubri...

Page 167: ...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 168: ...fuel filter Overview 1 Storage tank 2 Day tank 3 Passive fuel prefilter with water separator 4 LP pump 5 Additional fuel filter switch able 6 Main engine filter switcha ble 166 Fuel Filter MS15034 00...

Page 169: ...re and explosion Avoid open flames electrical sparks and ignition sources Do not smoke Wear protective clothing protective gloves and safety glasses facial protection WARNING High level of engine nois...

Page 170: ...losive 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 High lev...

Page 171: ...same way 9 Vent fuel system Replacing fuel filter with the en gine running 1 Cut out the filter to be replaced B Left hand filter cut out C Right hand filter cut out 2 Unscrew cut out easy change filt...

Page 172: ...tial 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...

Page 173: ...iately do not induce vomiting Do not inhale vapors or mist Wear protective clothing protective gloves and safety glasses If contact is made with skin wash off with water and soap WARNING Fuels are com...

Page 174: ...e valve 2 a little turning to approx 30 to introduce fuel into the filter housing with the new filter element 7 Close vent valve 1 as soon as fuel emerges from vent pipe 4 8 Turn the rotary slide valv...

Page 175: ...n Seek medical attention immediately do not induce vomiting Do not inhale vapors or mist Wear protective clothing protective gloves and safety glasses If contact is made with skin wash off with water...

Page 176: ...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 177: ...hrough 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 prote...

Page 178: ...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 179: ...g with the new filter element 14 Close vent valve 1 as soon as fuel emerges from vent pipe 4 15 Turn the rotary slide valve to the upright posi tion 3 until it engages Result Both filters are cut in 1...

Page 180: ...ly 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 combust...

Page 181: ...vided in the relevant safety data sheet Wear protective gear as specified in the relevant safety data sheet NOTICE Inappropriate cleaning tool Risk of damage to component Observe manufacturer s instru...

Page 182: ...air cooler 5 Disconnect oil lines 2 from air flap actuator cylinder 6 Undo screws 3 and clamp 2 7 Remove intake housing 1 with actuating cyl inder 8 Remove coolant lines 1 on compressor cas ing 180 Ex...

Page 183: ...an compressor casing with a soft brush 2 Clean compressor wheel 2 and bearing housing 1 3 Thoroughly remove cleaning agent from all parts 4 Replace sealing rings between bearing hous ing compressor ca...

Page 184: ...m 1 Nm 3 Install coolant lines 1 on compressor cas ing 4 Install intake housing 1 with actuating cylin der 5 Align clamp 2 and tighten to specified torque using a torque wrench Name Size Type Lubrican...

Page 185: ...lines 2 8 Install air pipework 1 from exhaust turbo charger to charge air cooler 9 Install air filter Page 186 10 Fill with engine coolant Page 208 MS15034 00E 2018 08 Exhaust Turbocharger 183 TIM ID...

Page 186: ...ans Never direct air jet at people Always wear safety goggles face mask and ear defenders Checking intercooler water drain for coolant leakage and obstruction 1 With the engine running check the drain...

Page 187: ...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 186 2 Reset signal ring of contamination indicator...

Page 188: ...take housing 2 Clamp 3 Air filter 1 Loosen clamp 2 2 Remove air filter 3 and clamp 2 from flange of intake housing 1 3 Verify that there are no objects in the flange of the intake housing 1 and clean...

Page 189: ...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 190: ...ions 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 234...

Page 191: ...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 192: ...sk Avoid contact with skin Do not inhale oil vapor Oil change without semirotary hand pump Draining oil at drain plug s on oil pan 1 Provide a suitable vessel in which to collect the engine oil 2 Remo...

Page 193: ...ngine oil 100 Nm 10 Nm Filling with new engine oil 1 Open cap 1 on filler neck 2 Pour oil in at filler neck up to max mark on oil dipstick 3 Close cap on filler neck 4 Check engine oil level Page 189...

Page 194: ...rotective clothing protective gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor WARNING High level of engine noise when the engine is running Risk of damage to hearing Wea...

Page 195: ...pot test Proportion of water Fuel dilution Engine oil sample extraction and analysis engine with switchable oil filter 1 With the engine running at operating temper ature open screw on flange of centr...

Page 196: ...tective gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor NOTICE Damage to component Severe material damage For filter replacement with the engine running operate the engi...

Page 197: ...Check engine oil level Page 189 Engine oil filter with diverter option Oil filter replacement with engine running 1 To cut out the filter to be replaced set the three way cock to the corresponding pos...

Page 198: ...protective gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor WARNING Compressed air gun ejects a jet of pressurized air Risk of injury to eyes and damage to hearing risk o...

Page 199: ...er 6 with engine oil and install strainer 6 2 Coat O ring 3 with engine oil and install in filter housing 3 Install spring 4 4 Fill housing with new engine oil 5 Install cover 2 and secure with screws...

Page 200: ...aged Replace Spring Damaged Replace O ring Damaged Replace Installing strainer 1 Coat square section ring on basket strainer 5 with engine oil and install basket strainer 5 2 Coat O ring 3 with engine...

Page 201: ...ealing ring Spare Parts Catalog Sealing ring Spare Parts Catalog WARNING Oil is hot Oil can contain residue substances which are harmful to health Risk of injury and poisoning Allow the product to coo...

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

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

Page 204: ...mperature Circuit 8 16 1 Drain and vent points Coolant line to carrier housing 1 Venting point Coolant line to intercooler Arrows Vent points 202 Coolant Circuit General High Temperature Circuit MS150...

Page 205: ...line to crankcase breather 1 Venting point Coolant line to raw water cooler 1 Distribution cross 2 Venting point MS15034 00E 2018 08 Coolant Circuit General High Temperature Circuit 203 TIM ID 0000014...

Page 206: ...Coolant drain point driving end 1 Drain points Coolant drain point free end 1 Drain point 204 Coolant Circuit General High Temperature Circuit MS15034 00E 2018 08 TIM ID 0000014546 002...

Page 207: ...rst stop and allow pressure to escape 2 Continue to turn breather valve counterclockwise and remove 3 Check coolant level coolant must be visible at the bottom edge of the cast in eye in the filler ne...

Page 208: ...Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 207 2 Fill with engine coolant Page 208 206 Coolant Circuit General High Temperature Circuit...

Page 209: ...p to the 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 through filler n...

Page 210: ...oves and goggles safety mask NOTICE Cold coolant in hot engine can cause thermal stress Possible formation of cracks in the engine Fill top up coolant only into cold engine Preparatory steps 1 Turn va...

Page 211: ...and clean sealing faces if required 5 Set valve cover onto filler neck and turn until the first stop 6 Start engine Page 83 7 After 10 seconds of running the engine with out load shut down the engine...

Page 212: ...ge to hearing Wear ear protectors HT coolant pump Relief bore check 1 Check relief bore for oil and coolant dis charge 2 Stop engine Operating Instructions for Electronic System and disable engine sta...

Page 213: ...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 214: ...engine cool down Wear protective clothing gloves and goggles safety mask Engine coolant filter Replace ment 1 Remove locking device 1 2 Close shut off cock 3 3 Remove engine coolant filter 2 with filt...

Page 215: ...tection Checking operation Note The coolant temperature must correlate to the control range of the thermostat when the preheater is ready for operation 1 Check coolant preheating temperature 2 Set the...

Page 216: ...ting pump 8 ensures the circulation of the pre heated coolant through the engine The flow heater 5 incorporates a heating element When the coolant temperature has reached the value of the thermostat s...

Page 217: ...switch Number of cylinders Rated voltage frequency Heating output kW 8 V 230 V 50 Hz 4 5 400 V 50 Hz 4 5 230 V 60 Hz 4 5 440 V 60 Hz 4 5 MS15034 00E 2018 08 Coolant Circuit General High Temperature C...

Page 218: ...revents coolant from flowing through the preheating unit when the engine is running When the coolant temperature has reached the value of the thermostat setting the thermostat 5 switches off the prehe...

Page 219: ...ement 2 Close shut off valve in coolant line before and after preheater 3 Drain coolant at drain valve into a clean container 4 Clean and flush coolant circuit 5 Check hoses for cracks and other damag...

Page 220: ...n the engine is running Risk of damage to hearing Wear ear protectors Raw water pump Relief bore check 1 Check relief bore for oil and coolant dis charge 2 Stop engine Page 92 and disable engine start...

Page 221: ...ition check 1 Install barring tool Page 141 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 slow...

Page 222: ...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 223: ...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 92 and disable engi...

Page 224: ...System 8 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 222 Fuel Supply System MS15034 00E 2018 08 TIM I...

Page 225: ...Wear protective clothing protective gloves and safety glasses facial protection Checking differential pressure gage alarm function 1 Switch on fuel treatment system Page 90 2 Set the alarm points at...

Page 226: ...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 227: ...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 p...

Page 228: ...leanliness NOTICE Incorrect installation of components and lines Damage to component Ensure that components lines are installed so that they are never under tension or strain Ensure correct installati...

Page 229: ...ng torque Engine oil 30 Nm 3 Nm 17 Fit seal 10 18 Install cover 19 Install screws 1 washers 2 and nuts 9 20 Tighten nuts 9 21 Open ball valve at the inlet and outlet of the fuel treatment system Resul...

Page 230: ...e air pressure B13 Crankshaft speed B16 Coolant pressure B33 Fuel temperature B34 1 Fuel pressure after filter B34 2 Fuel pressure before filter B34 3 Fuel pressure before external filter B44 1 Exhaus...

Page 231: ...X52 EIM engine box XB19 Starting air pressure XD1 Dialog XG03 Battery charging generator XY1 Starting system Valves Y26 Charge air recirculation Y27 Exhaust turbocharger Injectors Y39A1 to Y39AX Engi...

Page 232: ...after filter B34 2 Fuel pressure before filter B34 3 Fuel pressure before exter nal filter B44 1 Exhaust turbocharger A speed B44 2 Exhaust turbocharger B speed B48 HP fuel B49 Charge air before reci...

Page 233: ...Engine wiring harness for injectors 80 Injector wiring harness MS15034 00E 2018 08 Wiring General for Engine Gearbox Unit 231 TIM ID 0000032228 002...

Page 234: ...Engine wiring harness for EIM 1 XD1 2 X1 3 X3 4 X52 5 XY1 6 X11 7 XB19 8 X37 232 Wiring General for Engine Gearbox Unit MS15034 00E 2018 08 TIM ID 0000032228 002...

Page 235: ...Engine wiring harness for electric starter 1 EIM terminals 2 Fuse FM1 3 Starter connecting termi nals MS15034 00E 2018 08 Wiring General for Engine Gearbox Unit 233 TIM ID 0000032228 002...

Page 236: ...ty cable clips 5 Check cable clamps for secure fit tighten loose clamps 6 Replace faulty cable clamps 7 Visually inspect the following electrical components for damage Connector housings Contacts Plug...

Page 237: ...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 238: ...heck 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...

Page 239: ...g EMU plug connections 1 Check both connectors on EMU 2 for firm seating Make sure that frames 3 are engag ed 2 Check screws 1 of cable clamps on EMU 2 for firm seating Make sure that cable clamps are...

Page 240: ...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 n...

Page 241: ...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 242: ...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 243: ...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 244: ...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 245: ...e 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 MS15034 00E 20...

Page 246: ...rews 2 3 Undo clips 3 on connectors 4 Remove all male connectors 5 Remove screws 1 6 Remove ECU 5 with EMU 4 Removing EMU 1 Unscrew screws on base of EMU 4 2 Remove EMU 4 from ECU 5 Installing EMU 1 P...

Page 247: ...sation CDC parameters will void the emissions certification Resetting CDC parameters with DiaSys u Dialog system DiaSys E531920 Resetting CDC parameters without DiaSys u If no DiaSys is available cont...

Page 248: ...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 249: ...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 250: ...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 251: ...c examination Page 144 Endoscope Part No Y20097353 Qty Used in 1 8 3 1 Cylinder liner Endoscopic examination Page 144 Qty Used in 1 8 18 1 Battery charging generator drive Coupling condi tion check Pa...

Page 252: ...in 1 8 16 8 Engine coolant filter Replacement Page 212 Fuel suction device Part No F30378207 Qty Used in 1 8 6 1 HP fuel pump Filling with engine oil Page 155 High pressure cleaner Part No Qty Used in...

Page 253: ...extraction and analysis Page 192 MTU test kit Part No F6798833 Qty Used in 1 8 16 7 Engine coolant Sample extraction and analysis Page 211 Ratchet adapter Part No F30027340 Qty Used in 1 8 8 7 Fuel pr...

Page 254: ...l system Page 159 Qty Used in 1 8 15 3 Centrifugal oil filter Cleaning and filter sleeve re placement Page 199 Ratchet bit Part No F30027342 Qty Used in 1 8 7 2 Injector Removal and installation jacke...

Page 255: ...F30452769 Qty Used in 1 8 6 1 HP fuel pump Filling with engine oil Page 155 Qty Used in 1 8 7 2 Injector Removal and installation jacketed fuel system Page 159 Qty Used in 1 8 8 7 Fuel prefilter with...

Page 256: ...Torque wrench 4 20 Nm Part No F30044239 Qty Used in 1 8 15 3 Centrifugal oil filter Cleaning and filter sleeve re placement Page 199 Torque wrench 60 320 Nm Part No F30452768 Qty Used in 1 8 5 2 Valve...

Page 257: ...Torque wrench 8 40 Nm Part No F30043446 Qty Used in 1 8 21 5 Coalescer filter element Replacement Page 226 MS15034 00E 2018 08 Special Tools 255 DCL ID 0000051756 001...

Page 258: ...n Instructions and comments on endoscopic and visu al examination 146 D Diagnostic lamp DILA EIM 2 241 Diagnostics EIM 2 241 Differential pressure gage Adjustment Fuel prefilter 170 Alarm function che...

Page 259: ...utdown 91 Switching on 90 Fuse lamp SILA EIM 2 241 H Hotline 248 HP pump Filling with engine oil 155 Relief bore check 157 HT coolant pump Check Relief bore 210 I Injector Installation 159 Removal 159...

Page 260: ...LAS shielding Adhesive tape application 140 Installation 132 As per MTN 5233 131 Installation locations 133 Spare parts service 248 Starter Condition check 188 T Tasks after extended out of service pe...

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MTU 8V4000M*3 series, Operating Instructions Manual

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