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MTU 8V4000Mx4, Operating Instructions Manual

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MTU 8V4000Mx4 Operating Instructions Manual Download Page 4

7.6.2 Injector – Removal and installation

187

7.7 Fuel System

193

7.7.1 Fuel system – Venting

193

7.8 Fuel Filter

195

7.8.1 Additional fuel filter – Overview

195

7.8.2 Additional fuel filter – Replacement

196

7.8.3 Fuel filter – Replacement

198

7.8.4 Fuel prefilter – Differential pressure gage

check and adjustment of gage

200

7.8.5 Fuel prefilter – Draining

201

7.8.6 Fuel prefilter – Flushing

203

7.8.7 Fuel prefilter with water separator – Filter

element replacement

205

7.8.8 Fuel prefilter with water separator – O-ring

replacement in rotary slide valve

208

7.9 Exhaust Turbocharger

209

7.9.1 Compressor wheel – Cleaning

209

7.10 Charge-Air Cooling

214

7.10.1 Intercooler – Check water drain for coolant

leakage and obstruction

214

7.11 Air Filter

215

7.11.1 Air filter – Replacement

215

7.11.2 Air filter – Removal and installation

216

7.12 Air Intake

217

7.12.1 Service indicator – Signal ring position check

217

7.13 Starting Equipment

218

7.13.1 Starter – Condition check

218

7.14 Lube Oil System, Lube Oil Circuit

219

7.14.1 Engine oil – Level check

219

7.14.2 Oil indicator filter – Cleaning and check

220

7.14.3 Engine oil – Change

222

7.14.4 Engine oil – Sample extraction and analysis

224

7.15 Oil Filtration / Cooling

226

7.15.1 Engine oil filter ‒ Replacement

226

7.15.2 Automatic oil filter – Oil filter candles

replacement

228

7.15.3 Centrifugal oil filter – Cleaning and filter

sleeve replacement

231

7.16 Coolant Circuit, General, High-Temperature

Circuit

234

7.16.1 Engine coolant level – Check

234

7.16.2 Engine coolant – Change

235

7.16.3 Engine coolant – Draining

236

7.16.4 Engine coolant – Filling

237

7.16.5 HT coolant pump – Relief bore check

239

7.16.6 Engine coolant – Sample extraction and

analysis

240

7.16.7 Preheating unit

241

7.17 Raw Water Pump with Connections

244

7.17.1 Raw water pump – Relief bore check

244

7.18 Battery-Charging Generator

245

7.18.1 Battery-charging generator drive – Coupling

condition check

245

7.19 Engine Mounting / Support

246

7.19.1 Engine mounting – Check

246

7.20 Auxiliary PTO

247

7.20.1 Bilge pump – Relief bore check

247

7.21 Fuel Supply System

248

7.21.1 Water drain valve – Check

248

7.21.2 Differential pressure gauge – Check

249

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

Check

250

7.21.4 Pump capacity – Check

251

7.21.5 Coalescer filter element – Replacement

252

7.22 Wiring (General) for Engine/Gearbox/Unit

254

7.22.1 Engine cabling – Check

254

7.23 Accessories for (Electronic) Engine

Governor / Control System

255

7.23.1 Resetting CDC parameter and entering IIG

with DiaSys®

255

7.23.2 Limit switch for start interlock ‒ Check

256

7.23.3 Engine Control Unit ECU 7 – Checking plug

connections

257

7.23.4 Engine Monitoring Unit EMU 8 – Plug

connections check

258

7.23.5 Interface module EIM plug connections –

Check

259

7.23.6 Engine Control Unit ECU 7 – Removal and

installation

260

7.23.7 EMU 8 – Removal and installation

261

7.23.8 Engine Interface Module EIM – Removal and

installation

262

7.23.9 Diagnostic features on EIM

263

7.24 Emergency Instrumentation (Local

Operating Panel)

266

7.24.1 LOP and connectors – Cleaning

266

8 Appendix A

8.1 Abbreviations

267

8.2 MTU contact persons/service partners

269

9 Appendix B

9.1 Special Tools

270

9.2 Index

276

4 | Table of Contents | MS150109/01E 2015-11

DCL-ID: 0000029430 - 003

Summary of Contents for 8V4000Mx4

Page 1: ...Operating Instructions Diesel Engine 8V4000Mx4 8V4000Mx4S 8V4000Mx4R MS150109 01E...

Page 2: ...nd 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 translation...

Page 3: ...uel treatment system Initial start up 80 4 10 Fuel treatment system Switching on 83 4 11 Emergency engine shutdown via automation system 84 4 12 Engaging from LOP 85 4 13 Disengaging from LOP 86 4 14...

Page 4: ...35 7 16 3 Engine coolant Draining 236 7 16 4 Engine coolant Filling 237 7 16 5 HT coolant pump Relief bore check 239 7 16 6 Engine coolant Sample extraction and analysis 240 7 16 7 Preheating unit 241...

Page 5: ...l in particular with regard to the specified tightening torques With the exclusive use of technical personnel trained in commissioning operation maintenance and re pair By contracting only workshops a...

Page 6: ...e instructed repeatedly Personnel requirements All work on the product shall be carried out by trained and qualified personnel only Training at the Training Center of the manufacturer Technical person...

Page 7: ...ing tackle as necessary If the engine is supplied with special aluminum foil packing Lift the engine at the lifting eyes of the bearing pedestal or use a means of transportation which is appropriate f...

Page 8: ...product into operation make sure that all control and display instruments as well as the signaling and alarm systems work properly Smoking is prohibited in the area of the product Safety regulations...

Page 9: ...Follow the applicable warning instructions pertaining to such devices MS150109 01E 2015 11 Safety 9 TIM ID 0000040533 012...

Page 10: ...V belts must not be painted They may only be installed after painting the engine or must be covered before painting work is carried out The following applies to starters with copper beryllium alloy pi...

Page 11: ...in its vicinity Before starting welding work Switch off the power supply master switch Disconnect the battery cables or actuate the battery isolating switch Separate the electrical ground of electron...

Page 12: ...h sharp edges Chafing on components Contact with hot surfaces Do not secure cables on lines carrying fluids Do not use cable straps to secure cables Always use connector pliers to tighten union nuts o...

Page 13: ...ully with its handling Noise Noise can lead to an increased risk of accidents if acoustic signals warning shouts or sounds indicating dan ger are drowned Wear ear protectors in workplaces with a sound...

Page 14: ...rrying out painting work outside the spray stands provided with fume extraction systems ensure that the area is well ventilated Make sure that neighboring work areas are not adversely affected There m...

Page 15: ...NOTICE In the event of a situation involving potentially adverse effects on the product Consequences Material damage Remedial action Additional product information Warning notices 1 This manual with...

Page 16: ...ues MA are specified for screws of strength class 8 8 surface finish bare metal phosphatized or galvanized and 10 9 surface finish bare metal or phosphatized The values in the table are based on a fri...

Page 17: ...s Tightening torques for studs Thread Screwed into Steel M A Nm Gray cast iron MA Nm Al 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 Tightenin...

Page 18: ...rial and manufacture to MMN 389 standard bare metal or phosphatized The values in the table are based on a friction coefficient tot 0 125 Threads and mating faces of screws and nuts must be coated wit...

Page 19: ...1230 M30 1250 1575 Protect screw shaft from torsion when tightening MA tightening torques Tightening torques for plug screws to MTN 5183 1 standard This standard applies to plug screws to DIN 908 DIN...

Page 20: ...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 21: ...Steel gray cast iron M A Nm Al 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 torques for banjo screws...

Page 22: ...le deviations 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...

Page 23: ...iled 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 devia...

Page 24: ...on 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 10 M8 x 1...

Page 25: ...in valves see ISO 6149 47 and ISO 7789 Tightening torques for spigot unions with O ring to 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 x...

Page 26: ...tings 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 forming metallic seal with union n...

Page 27: ...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 28: ...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 28 General Informa...

Page 29: ...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 30: ...urbocharging with internal engine coolant controlled charge air cooling The left hand exhaust turbocharger is cut in and cut out with electronically controlled hydraulically actuated flaps Cooling sys...

Page 31: ...r X1 Bus interface 2x MCS5 CAN CAN dialog output 1xMCS5 CAN Emergency stop EMU and ECU Electric starter Terminal 45 starter A B engaged Pneumatic starter Start air pressure valve Start air pressure se...

Page 32: ...e for low load operation State of the art design and equipment featuring e g TE coolant circuit ETC sequencing triple walled water cooled exhaust pipes Common Rail fuel injection and cylinder cutout f...

Page 33: ...tate this type of operation Low load operation engine power up to approx 20 of rated engine power is realized in single ETC mode 1 exhaust turbocharger running We recommend running the engine with bot...

Page 34: ...is decreases significantly if an O ring 2 defect occurs The connection is confirmed as compliant with SOLAS by DNV and GL Plugs and sensors Screw in plugs 4 are sealed toward the outside either with...

Page 35: ...n fuel injector and HP accumulator 1 Support ring 2 V ring 3 Thrust ring 4 HP line 5 Thrust screw 6 Support ring 7 Thrust ring 8 V ring 9 Union nut MS150109 01E 2015 11 General Information 35 TIM ID 0...

Page 36: ...een distributor and HP accumulator 1 Union nut 2 O ring 3 Thrust ring 4 Thrust screw 5 O ring 6 O ring 7 Thrust ring 8 Pressure pipe 9 Jacket pipe 36 General Information MS150109 01E 2015 11 TIM ID 00...

Page 37: ...distributor and HP accumulator 1 Jacket pipe 2 O ring 3 O ring 4 Thrust ring 5 O ring 6 Thrust screw 7 Thrust ring 8 O ring 9 HP line 10 Pressure pipe MS150109 01E 2015 11 General Information 37 TIM I...

Page 38: ...r 4 Oil cooler 5 Coolant pump 6 Engine mounting 7 EIM Engine Interface Mod ule 8 Oil filler neck 9 Oil pan 10 Crankcase 11 Charge air line 12 Compressor housing 13 Intercooler 14 Exhaust turbocharger...

Page 39: ...ilter 7 Battery charging generator optional 8 HP fuel pump 9 Bilge pump option 10 Raw water pump optional for engines with remote heat exchanger 11 Coolant outlet from remote cooling system 12 Coolant...

Page 40: ...l cooler 5 Coolant pump 6 Engine mounting 7 EIM Engine Interface Mod ule 8 Oil filler neck 9 Oil pan 10 Crankcase 11 Charge air line 12 Compressor housing 13 Intercooler 14 Exhaust turbocharger carri...

Page 41: ...Bilge pump option 12 Raw water pump 13 Plate core heat exchanger 14 Engine management and monitoring KGS Free end Engine model designation Key to engine model designation 8V4000Mxyz 8 Number of cylind...

Page 42: ...2 B50 crankcase pressure 3 B4 A1 B4B4 cylinder ex haust temperature A1 A4 B1 B4 4 Y26 air recirculation valve 5 B49 charge air temperature from air recirculation valve 6 B3 intake air pressure 7 B5 9...

Page 43: ...ture A side 3 B10 charge air pressure 4 B34 2 fuel pressure before filter 5 B34 3 fuel pressure before filter 6 B34 1 fuel pressure after filter 7 F46 leak fuel level 8 B33 fuel temperature in common...

Page 44: ...only with reversible oil filter 4 B5 1 lube oil pressure after filter 5 B5 3 lube oil pressure be fore filter 6 B1 camshaft speed 7 B54 oil refill pump pres sure 8 B6 2 coolant temperature 9 B6 coolan...

Page 45: ...3 coolant level 2 B16 coolant pressure 3 B21 raw water pressure 4 B9 charge air temperature 5 B4 22 exhaust tempera ture B side 6 B44 1 turbocharger A speed MS150109 01E 2015 11 General Information 45...

Page 46: ...Driving end 1 S37 1 safety switch 2 B13 2 crankshaft speed 3 B13 crankshaft speed 4 S37 2 safety switch 46 General Information MS150109 01E 2015 11 TIM ID 0000045094 003...

Page 47: ...on valve 3 B50 crankcase pressure 4 B4 A1 B4B4 cylinder ex haust temperature A1 A4 B1 B4 5 B49 charge air temperature from air recirculation valve 6 B3 intake air pressure 7 B5 9 lube oil pressure be...

Page 48: ...21 exhaust tempera ture A side 3 B10 charge air pressure 4 B34 2 fuel pressure before filter 5 B34 3 fuel pressure before filter 6 B34 1 fuel pressure after filter 7 F46 leak fuel level 48 General Inf...

Page 49: ...ble oil filter 4 B5 1 lube oil pressure after filter 5 B5 3 lube oil pressure be fore filter 6 B48 fuel pressure in com mon rail 7 B1 camshaft speed 8 B54 oil refill pump pres sure 9 B6 2 coolant temp...

Page 50: ...Right engine side 1 B16 coolant pressure 2 B9 charge air temperature 3 B4 22 exhaust tempera ture B side 4 B44 1 turbocharger A speed 50 General Information MS150109 01E 2015 11 TIM ID 0000045094 003...

Page 51: ...Driving end 1 S37 1 safety switch 2 B13 2 crankshaft speed 3 B13 crankshaft speed 4 S37 2 safety switch MS150109 01E 2015 11 General Information 51 TIM ID 0000045094 003...

Page 52: ...3 Fuel pressure before external filter B44 1 Exhaust turbocharger A speed B44 2 Exhaust turbocharger B speed B48 High pressure fuel B49 Charge air before recirculation B50 Crankcase pressure B54 Refil...

Page 53: ...XY1 Starter Engine wiring harness for sensors 1 B10 2 B4 21 3 B44 2 4 B5 1 5 B7 6 B5 3 7 B33 8 B48 9 XG03 10 B34 1 11 B34 3 12 B34 2 13 F46 14 M8 15 B1 16 B6 17 X2 18 X37 19 XF33 20 B54 21 B5 8 22 B3...

Page 54: ...Engine wiring harness for injectors 1 Y39A1 2 Y39A2 3 Y39A3 4 Y39A4 5 X4 6 Y39B4 7 Y39B3 8 Y39B2 9 Y39B1 54 General Information MS150109 01E 2015 11 TIM ID 0000045095 002...

Page 55: ...Engine wiring harness for EIM 1 XD1 2 X1 3 X3 4 X52 5 XY1 6 X11 7 XB19 8 X37 MS150109 01E 2015 11 General Information 55 TIM ID 0000045095 002...

Page 56: ...Engine wiring harness for electric starter 1 Connecting terminals EIM 2 Fuse F1 3 Connecting terminals for starter 56 General Information MS150109 01E 2015 11 TIM ID 0000045095 002...

Page 57: ...arometric pressure mbar 1000 1000 1000 1000 Site altitude above sea level m 100 100 100 100 Power related data power ratings are net brake power as per ISO 3046 I Engine mounted heat exchanger Remote...

Page 58: ...ngine mounted heat exchanger Remote heat ex changer Lube oil operating temperature before engine from R C 81 87 81 87 Lube oil operating temperature before engine to R C 89 95 89 95 Lube oil operating...

Page 59: ...operating inclinations L Degrees 20 20 20 20 Longitudinal inclination temporary max driving end down Option max operating inclinations L Degrees 22 5 22 5 22 5 22 5 Longitudinal inclination continuou...

Page 60: ...hanger Remote heat ex changer Engine dry weight with standard acces sories installed w o coupling R kg 6085 6085 5680 5680 Noise I Unit Engine mounted heat exchanger Remote heat ex changer Exhaust noi...

Page 61: ...000 1000 1000 1000 Site altitude above sea level m 100 100 100 100 Power related data power ratings are net brake power as per ISO 3046 I Engine mounted heat exchanger Remote heat ex changer Rated eng...

Page 62: ...unted heat exchanger Remote heat ex changer Lube oil operating temperature before engine from R C 81 87 81 87 Lube oil operating temperature before engine to R C 89 95 89 95 Lube oil operating pressur...

Page 63: ...g inclinations L Degrees 20 20 20 20 Longitudinal inclination temporary max driving end down Option max operating inclinations L Degrees 22 5 22 5 22 5 22 5 Longitudinal inclination continuous max dri...

Page 64: ...anger Remote heat ex changer Engine dry weight with attached stand ard accessories without coupling R kg 6085 6085 5680 5680 Noise I Engine mounted heat exchanger Remote heat ex changer Exhaust noise...

Page 65: ...1000 1000 1000 1000 Site altitude above sea level m 100 100 100 100 Power related data power ratings are net brake power as per ISO 3046 I Unit Engine mounted heat exchanger Remote heat ex changer Rat...

Page 66: ...mounted heat exchanger Remote heat ex changer Lube oil operating temperature before engine from R C 81 87 81 87 Lube oil operating temperature before engine to R C 89 95 89 95 Lube oil operating press...

Page 67: ...perating inclinations L Degrees 20 20 20 20 Longitudinal inclination temporary max driving end down Option max operating inclinations L Degrees 22 5 22 5 22 5 22 5 Longitudinal inclination continuous...

Page 68: ...anger Remote heat ex changer Engine dry weight with attached stand ard accessories without coupling R kg 6085 6085 5680 5680 Noise I Unit Engine mounted heat exchanger Remote heat ex changer Exhaust n...

Page 69: ...3 4 Firing order Number of cylinders Firing order 8V A1 B4 A4 A2 B3 A3 B2 B1 MS150109 01E 2015 11 Technical Data 69 TIM ID 0000045097 002...

Page 70: ...nsions Main engine dimensions Engines with remote heat exchanger Engine model Length A Width B Height C 8V4000Mx4 approx 2386 mm approx 1613 mm approx 1959 mm 70 Technical Data MS150109 01E 2015 11 TI...

Page 71: ...Engines with engine mounted heat exchanger Engine model Length A Width B Height C 8V4000Mx4 approx 2609 mm approx 1613 mm approx 2060 mm MS150109 01E 2015 11 Technical Data 71 TIM ID 0000045096 002...

Page 72: ...4 Operation 4 1 LOP controls LOP controls Item Measure LOP Start engine via the automation system Automation system Operating In structions 72 Operation MS150109 01E 2015 11 TIM ID 0000045323 001...

Page 73: ...th position of pressure indicator Page 200 HP fuel pump Only for engines without oil priming pump Fill HP fuel pump with new engine oil Page 184 Raw water pump if located above waterline only appli ca...

Page 74: ...required Coolant circuit Check coolant level Page 234 Coolant circuit Heat coolant with coolant preheating unit Engine control system Switch master switch to ON Press illuminated pushbutton READY FOR...

Page 75: ...automation system Starting the engine via the automation system Item Measure Automation system Start engine via the automation system Automation system Operating In structions MS150109 01E 2015 11 Ope...

Page 76: ...rge air cooler Check condensate drain Page 214 Air filter Check signal ring position of service indicator Page 217 Replace air filter Page 215 if the signal ring is completely visible in the service i...

Page 77: ...eks Tasks after extended out of service periods 3 weeks Note Operate fuel treatment system for at least 5 minutes 1 Start up fuel treatment system Page 80 2 Shut down fuel treatment system Page 90 MS1...

Page 78: ...ually 4 Red Illuminated pushbutton Indicates Water alarm Press to acknowledge 5 Yellow Signal lamp Indicates Filter warning due to increased differential pressure 6 Red Illuminated pushbutton Indicate...

Page 79: ...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 80: ...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 81: ...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 82: ...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 83: ...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 84: ...h load Risk of overheating damage to components Trigger an emergency stop only in emergency situations Emergency engine shutdown via automation system Item Measure Automation system Emergency shutdown...

Page 85: ...led from the engine room Risk of accidents Only execute vessel movements on the instructions of a person who has visual contact with the area outside the vessel Engagement via LOP Item Measure LOP Eng...

Page 86: ...ed from the engine room Risk of accidents Only execute vessel movements on the instructions of a person who has visual contact with the area outside the vessel Disengaging from LOP Item Measure LOP Di...

Page 87: ...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 88: ...s Before shutting down disengage gear and run the engine at idle speed for at least 10 minutes until engine temperatures have dropped and constant values are displayed Engine shutdown via the automati...

Page 89: ...rature the antifreeze concentration is insufficient for the engine room tempera ture antifreeze concentration is 50 and engine room temperature is below 40 C Raw water only on engines with engine moun...

Page 90: ...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 91: ...ectly at seals or electronic components such as connectors or ECUs Plant Cleaning 1 Carry out plant cleaning only in areas where an appropriate oil separator is provided environmental protec tion 2 Pr...

Page 92: ...ectors Page 186 W1008 X Replace engine oil filter when changing engine oil or when the interval years is reached at the latest Page 226 W1009 X Check layer thickness of the oil residue clean out and r...

Page 93: ...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 94: ...dicator Page 217 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 95: ...t gas Cause Corrective action Engine is not at operating temperature u Run engine to reach operating temperature Intercooler leaking u Contact Service MS150109 01E 2015 11 Troubleshooting 95 TIM ID 00...

Page 96: ...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 97: ...ault code 1 comprises 3 digits Fault messages may also be caused by faulty sensors actuators Contact Service to have sensors actuators tested and replaced as necessary if troubleshooting as described...

Page 98: ...Corrective action Fuel tank may be exposed to heat u Contact Service 5 HI T charge air ZKP Number 2 0121 931 Charge air temperature too high limit value 1 Yellow alarm warning Cause Corrective action...

Page 99: ...Coolant circuit for charge air faulty 1 Check intercooler and coolant cooler 2 Contact Service 15 LO P Lube Oil ZKP Number 2 0100 921 Lube oil pressure too low limit value 1 Yellow alarm warning Caus...

Page 100: ...2 0127 931 Exhaust temperature too high B side limit value 1 Yellow alarm warning Cause Corrective action Wiring damage 1 Check air filter and wiring Page 254 2 Contact Service 22 SS T Exhaust B ZKP N...

Page 101: ...kage Fuel ZKP Number 2 0151 931 Leak off fuel level too high limit value 1 Yellow alarm warning Cause Corrective action Fuel lines leaking 1 Check fuel system 2 Contact Service 29 HI ETC Idle Speed To...

Page 102: ...0114 931 Fuel filter differential oil pressure too high limit value 1 Yellow alarm warning Cause Corrective action Fuel filter out of order 1 Replace fuel filter Page 198 2 Contact Service 34 SS P Di...

Page 103: ...8004 204 Yellow alarm warning Cause Corrective action ETC2 failed to cut in u Contact Service 44 LO Coolant Level Intercooler ZKP Number 2 0153 921 Coolant level of intercooler too low limit value 1...

Page 104: ...2 Coolant pressure too low limit value 2 Red alarm engine stop or reduced injection quantity Cause Corrective action Leak in coolant circuit 1 Check coolant level Page 234 2 Check coolant circuit 59 S...

Page 105: ...tion Crankcase exhaust system clogged or leaking 1 Reduce power 2 Replace oil mist fine separator element 3 Contact Service 64 SS P Crankcase ZKP Number 2 0106 932 Crankcase pressure too high limit va...

Page 106: ...e leaks low coolant level 1 Reduce power 2 Check coolant circuit 68 SS T Coolant ZKP Number 2 0120 932 Coolant temperature too high limit value 2 Red alarm engine shutdown Cause Corrective action Cool...

Page 107: ...vice 085 HI T Recirculation ZKP Number 2 0128 931 Recirculation temperature too high limit value 1 Cause Corrective action Charge air temperature before recirculation valve too high u Reduce power 086...

Page 108: ...ot reached Red alarm warning Cause Corrective action Starter rotates too slowly or does not rotate at all 1 Check for additional messages 2 Contact Service 93 SS T Preheat ZKP Number 2 1090 922 Prehea...

Page 109: ...em faulty Yellow alarm warning Cause Corrective action Hour meter faulty u Contact Service 118 LO ECU Power Supply Voltage ZKP Number 2 0140 921 Supply voltage too low limit value 1 Yellow alarm warni...

Page 110: ...y voltage 2 Contact Service 122 HI T ECU ZKP Number 2 0132 921 Electronics temperature too high limit value 1 Yellow alarm warning Cause Corrective action Electronics overheated 1 Reduce power 2 Impro...

Page 111: ...gine Control Unit indicated for each indiv module u Contact Service 180 AL CAN1 Node Lost ZKP Number 2 0500 680 Connection to a node on CAN bus 1 failed Yellow alarm warning Cause Corrective action Co...

Page 112: ...ntrol Unit 1 Check devices connected to CAN 2 Contact Service 184 AL CAN PU Data Flash Error ZKP Number 2 0500 684 CAN PU data flash error Cause Corrective action A program fault occurred while trying...

Page 113: ...89 AL CAN2 Error Passive ZKP Number 2 0500 689 CAN controller 2 error Yellow alarm warning Cause Corrective action Missing associated node minor disruptions or temporary bus overload 1 Check CAN bus f...

Page 114: ...rectified when engine is restarted Page 75 3 Contact Service 204 SD Level Lube Oil ZKP Number 1 8004 602 Signal error lube oil level sensor Yellow alarm warning Cause Corrective action Lube oil level...

Page 115: ...s necessary Page 254 2 Fault is rectified when engine is restarted Page 75 3 Contact Service 208 SD P Charge Air ZKP Number 1 8004 566 Signal error charge air pressure sensor Yellow alarm warning Caus...

Page 116: ...engine is restarted Page 75 3 Contact Service 214 SD P Crankcase ZKP Number 1 8004 568 Signal error crankcase pressure sensor Yellow alarm warning Cause Corrective action Crankcase pressure sensor fau...

Page 117: ...ified when engine is restarted Page 75 3 Contact Service 220 SD Level Coolant Water ZKP Number 1 8004 584 Signal error coolant level sensor Yellow alarm warning Cause Corrective action Coolant level s...

Page 118: ...ectified when engine is restarted Page 75 3 Contact Service 227 SD P Lube Oil before Filter ZKP Number 1 8004 620 Signal error lube oil pressure sensor before filter Yellow alarm warning Cause Correct...

Page 119: ...place as necessary Page 254 2 Fault is rectified when engine is restarted Page 75 3 Contact Service 231 SD Camshaft Speed ZKP Number 1 8004 499 Signal error camshaft sensor Yellow alarm warning Cause...

Page 120: ...es 240 SD P Fuel ZKP Number 1 8004 565 Signal error fuel pressure sensor Yellow alarm warning Cause Corrective action Fuel pressure sensor faulty Short circuit or wire break 1 Check sensor and wiring...

Page 121: ...re break 1 Check speed setting transmitter and wiring replace as necessary Page 254 2 Fault is rectified when engine is restarted Page 75 3 Contact Service 268 SD Spinning Value ZKP Number 2 8006 591...

Page 122: ...8004 501 Flight time measuring fault of injector Cause Corrective action Flight time value extremely low or extremely high u Replace injector if the fault message appears frequently Page 186 303 AL T...

Page 123: ...u Replace injector if the fault message appears frequently Page 186 308 AL Timing Cylinder A8 ZKP Number 1 8004 507 Flight time measuring fault of injector Cause Corrective action Flight time value ex...

Page 124: ...u Replace injector if the fault message appears frequently Page 186 314 AL Timing Cylinder B4 ZKP Number 1 8004 513 Flight time measuring fault of injector Cause Corrective action Flight time value e...

Page 125: ...or Cause Corrective action Flight time value extremely low or extremely high u Replace injector if the fault message appears frequently Page 186 320 AL Timing Cylinder B10 ZKP Number 1 8004 519 Flight...

Page 126: ...ault is rectified when engine is restarted Page 75 3 Contact Service 324 AL Wiring Cylinder A4 ZKP Number 1 8004 523 Wiring fault cylinder A4 Yellow alarm misfire Cause Corrective action Short circuit...

Page 127: ...ault is rectified when engine is restarted Page 75 3 Contact Service 328 AL Wiring Cylinder A8 ZKP Number 1 8004 527 Wiring fault cylinder A8 Yellow alarm misfire Cause Corrective action Short circuit...

Page 128: ...Fault is rectified when engine is restarted Page 75 3 Contact Service 332 AL Wiring Cylinder B2 ZKP Number 1 8004 531 Wiring fault cylinder B2 Yellow alarm misfire Cause Corrective action Short circui...

Page 129: ...ault is rectified when engine is restarted Page 75 3 Contact Service 336 AL Wiring Cylinder B6 ZKP Number 1 8004 535 Wiring fault cylinder B6 Yellow alarm misfire Cause Corrective action Short circuit...

Page 130: ...ne is restarted Page 75 3 Contact Service 340 AL Wiring Cylinder B10 ZKP Number 1 8004 539 Wiring fault cylinder B10 Yellow alarm misfire Cause Corrective action Short circuit fault in injector wiring...

Page 131: ...186 3 Fault is rectified after each working cycle 4 Contact Service 344 AL Open Load Cylinder A4 ZKP Number 1 8004 543 Injector wiring fault cylinder A4 Yellow alarm misfire Cause Corrective action D...

Page 132: ...e 186 3 Fault is rectified after each working cycle 4 Contact Service 348 AL Open Load Cylinder A8 ZKP Number 1 8004 547 Injector wiring fault cylinder A8 Yellow alarm misfire Cause Corrective action...

Page 133: ...186 3 Fault is rectified after each working cycle 4 Contact Service 352 AL Open Load Cylinder B2 ZKP Number 1 8004 551 Injector wiring fault cylinder B2 Yellow alarm misfire Cause Corrective action Di...

Page 134: ...186 3 Fault is rectified after each working cycle 4 Contact Service 356 AL Open Load Cylinder B6 ZKP Number 1 8004 555 Injector wiring fault cylinder B6 Yellow alarm misfire Cause Corrective action D...

Page 135: ...ry Page 186 3 Fault is rectified after each working cycle 4 Contact Service 360 AL Open Load Cylinder B10 ZKP Number 1 8004 559 Injector wiring fault cylinder B10 Yellow alarm misfire Cause Corrective...

Page 136: ...ctronics OK e g wiring faulty 4 Check solenoid valve wiring 5 Contact Service 365 AL Stop MV Wiring Ground ZKP Number 1 8004 561 Injector wiring fault Red alarm engine shutdown via Protection Module p...

Page 137: ...04 637 Line disruption Cause Corrective action Short circuit or wire break on transistor output 4 TO 4 u 381 AL Wiring TOP 1 ZKP Number 2 8006 638 Line disruption on digital input 1 Yellow alarm warni...

Page 138: ...er 1 1085 009 Speed limiter MCR function the maximum continuous rate was exceeded Yellow alarm engine power limited to admissible continuous power Cause Corrective action Engine was overloaded continu...

Page 139: ...r 1 0480 193 Cause Corrective action Maximum coolant temperature deviation 1 Check wiring and sensor 2 Contact Service 397 TD P Oil Sensor Deviation ZKP Number 1 0480 293 Cause Corrective action Maxim...

Page 140: ...Check wiring Page 254 2 Check target device input 3 Contact Service 403 AL Open Load Digital Input 4 ZKP Number 2 8006 628 Line disruption on digital input 4 Yellow alarm warning Cause Corrective act...

Page 141: ...ring Page 254 2 Check target device input 3 Contact Service 407 AL Open Load Digital Input 8 ZKP Number 2 8006 632 Line disruption on digital input 8 Yellow alarm warning Cause Corrective action Wirin...

Page 142: ...iring Page 254 2 Check supply 3 Acknowledge alarm 4 Contact Service 412 HI U PDU ZKP Number 2 0141 931 Injector voltage too high limit value 1 Yellow alarm warning Cause Corrective action Wiring damag...

Page 143: ...t pressure in intercooler too low limit 2 Red alarm engine shutdown Cause Corrective action Leak in coolant circuit u Top up coolant 417 SD Level Water Fuel Prefilter ZKP Number 1 8004 594 Signal erro...

Page 144: ...AL L1 T Aux 1 ZKP Number 2 0130 921 Limit value 1 Cause Corrective action Temperature signal of Aux 1 has exceeded not attained limit value 1 depending on configuration u Determine cause of limit val...

Page 145: ...ber 1 8004 580 Signal error ambient air pressure sensor Yellow alarm warning Cause Corrective action Ambient air pressure sensor faulty u Replace Engine Control Unit 446 SD P HD2 ZKP Number 1 8004 599...

Page 146: ...tact Service 454 SS Power Reduction Active ZKP Number 2 7000 011 Power reduction activated Red alarm power reduction activated Cause Corrective action Engine operation outside standard limit values Th...

Page 147: ...Exhaust EMU ZKP Number 2 8006 653 Limit value 1 Cause Corrective action EMU exhaust gas temperature value too low 1 Check wiring 2 Contact Service 462 HI T Coolant EMU ZKP Number 2 8006 654 Limit valu...

Page 148: ...signal sensor and wiring replace as necessary Fault is rectified when engine is restarted 470 SD T ECU ZKP Number 1 8004 587 Signal error Engine Control Unit temperature Yellow alarm warning Cause Co...

Page 149: ...ult on FO Yellow alarm warning Cause Corrective action Wire break or short circuit on channel FO 1 Check wiring Page 254 2 Contact Service 475 AL CR Engine Shutdown Trigger ZKP Number 1 8010 009 Crash...

Page 150: ...ion active Yellow alarm warning Cause Corrective action The external engine protection function is active Monitoring of plant signal by ECU active plant side 1 Check plant signal 2 Contact Service 482...

Page 151: ...1 Limit value 1 Cause Corrective action Exhaust gas temperature D side too high 1 Reduce power 2 Contact Service 487 SS T Exhaust D ZKP Number 20 134 932 Limit value 2 Cause Corrective action Exhaust...

Page 152: ...arger u Reduce power 491 SS ETC4 Overspeed ZKP Number 2 3015 932 Speed of the 3rd secondary turbocharger too high limit value 2 Red alarm engine shutdown Cause Corrective action Clogged charge air cir...

Page 153: ...902 Power disruption battery charging generator connection of POM Yellow alarm warning Cause Corrective action Wiring faulty or no resistance over switch u Check connection between POM and battery ch...

Page 154: ...number than expected Yellow alarm warning Cause Corrective action If alarm 504 occurs in addition the resistor in the POM wiring is missing u Check POM wiring harness 510 AL Override applied ZKP Numbe...

Page 155: ...AL Wiring PWM1 ZKP Number 1 1046 900 Red alarm Cause Corrective action Wire break or short circuit on channel PWM1 u Check wiring to mixture throttle on A side replace mixture throttle on A side as ne...

Page 156: ...er supply only after the engine has come to a standstill 551 SS Engine Overspeed Camshaft ZKP Number 22 510 933 Limit value 2 Cause Corrective action Camshaft overspeed 1 Acknowledge alarm 2 Attempt e...

Page 157: ...op command was not executed Flashing pre alarm and alarm Cause Corrective action Engine speed does not come to a standstill within a configurable period u Contact Service 584 AL CAN Start clearance fa...

Page 158: ...tive action The parameter record is used for trials The alarm remains set until a series parameter set is loaded u Contact Service 600 SD T Exhaust A B ZKP Number 1 8004 646 Signal error exhaust tempe...

Page 159: ...P Number 2 0119 001 Fuel prefilter differential pressure too high Yellow alarm warning Cause Corrective action Fuel prefilter out of order 1 Replace fuel prefilter 2 Contact Service 625 SD P Fuel b Su...

Page 160: ...921 Fuel before engine limit 1 Cause Corrective action Fuel temperature before engine too high u 760 AL L2 T Fuel b Engine ZKP Number 2 0080 922 Fuel before engine limit 2 Cause Corrective action Fue...

Page 161: ...920 Cause Corrective action ETC oil pressure sensor faulty u Check sensor and wiring replace as necessary 858 AL L1 P Lube Oil ETC B ZKP Number 1 0223 921 Limit value 1 Cause Corrective action Lube oi...

Page 162: ...9 AL L2 P Lube Oil ETC B ZKP Number 1 0223 922 Limit value 2 Cause Corrective action Lube oil pressure too low u Check ETC oil lubrication 162 Troubleshooting MS150109 01E 2015 11 TIM ID 0000045495 00...

Page 163: ...y Shield A4 735233000100 4 Shield A5 735233000101 16 Shield A6 735233000102 5 Shield A8 735233000104 4 Shield B2 735233000200 2 Shield B4 735233000202 1 Shield B6 735233000204 2 Shield E5 735233000500...

Page 164: ...ooled down to ambient temperature Special tools Material Spare parts Designation Use Part No Qty Oil filter shield X00040625 2 x Installing SOLAS shielding for oil filter 1 Pinpoint installation locat...

Page 165: ...ese shields must be installed on the assembly line These locations are no longer accessible or only with great difficulty following assembly of the air pipework and fuel filters Item Type of shielding...

Page 166: ...Shield E5 Fuel line on HP pump 2 Shield E5 Fuel line downstream of fuel filter head Item Type of shielding Comments 1 Shields A8 2 x Fuel line at fuel filter head holder 166 Task Description MS150109...

Page 167: ...x Fuel line at fuel filter head Lube oil system oil lines with oil pressure 1 8 bar Item Type of shielding Comments 1 Shields A5 2 x Air flap actuator cylinder exhaust turbocharger A1 MS150109 01E 201...

Page 168: ...m main oil gallery at distributor 5 Shield A5 Oil drain to crankcase 6 Shield A6 Oil drain from 4 2 directional con trol valve 7 Shield A5 Oil drain from air recirculation valve 8 Shields A5 2 x On ai...

Page 169: ...er oil supply A side 2 Shields A5 2 x Exhaust turbocharger oil supply A side 1 SOLAS clip on ETC Oil supply B side Item Type of shielding Comments 1 Shields A4 Oil supply exhaust turbocharger B side M...

Page 170: ...pe of shielding Comments 1 Shields A4 2 x Oil supply pressure monitor B side Item Type of shielding Comments 1 Shields A6 Oil supply to HP pump 170 Task Description MS150109 01E 2015 11 TIM ID 0000065...

Page 171: ...f shielding Comments 1 Shields B4 Oil supply of HP pump on equip ment carrier Item Type of shielding Comments 1 Shields B2 2 x Oil line on gearcase MS150109 01E 2015 11 Task Description 171 TIM ID 000...

Page 172: ...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 engi...

Page 173: ...e 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 pression resistance contact...

Page 174: ...7 2 2 Engine Barring with starting system Barring using the automation system Refer to automation system operating instructions 174 Task Description MS150109 01E 2015 11 TIM ID 0000017532 003...

Page 175: ...p piston ring and bottom edge of carbon scraper ring First signs of marks left by top piston ring Bright mark on entire circumference Faultless even honing pattern First signs of marks left by lower c...

Page 176: ...Depending 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 injecto...

Page 177: ...nd the liner It appears rather darker within the honed struc ture in contrast to the bright metallic running surface The honing pattern is undis turbed Discolorations extend in stroke direction and ma...

Page 178: ...ion are similar A thorough inves tigation and compliance with the above evaluation criteria allow an unambiguous evaluation To avoid unnec essary disassembly work it is recommended that another inspec...

Page 179: ...cylinder head covers 1 prior to removal 2 Remove screws 3 4 with washers 2 5 3 Take off cylinder head cover with O ring 6 from cylinder head 7 Installing cylinder head cover 1 Clean installation surfa...

Page 180: ...Designation Use Part No Qty Engine oil Valve gear Lubrication 1 Remove cylinder head covers Page 179 2 Fill oil chambers of valve bridges with oil 3 Fill oil chambers of rocker arms and adjusting scr...

Page 181: ...ial Spare parts Designation Use Part No Qty Feeler gage Y20010128 1 Torque wrench 60 320 Nm F30047446 1 Socket wrench 24 mm F30039526 1 Engine oil Preparatory steps 1 Remove cylinder head cover Page 1...

Page 182: ...en the rocker arms on cylinder A1 are unloaded The piston is in overlap TDC when the rocker arms on cylinder A1 are loaded 2 Check valve clearance setting with engine cold Inlet valves long rocker arm...

Page 183: ...between valve bridge and rocker arm 5 Tighten locknut 1 to specified tightening torque while holding adjusting screw 2 firmly Name Size Type Lubricant Value Standard Locknut Tightening torque Engine o...

Page 184: ...gloves and safety glasses facial protection WARNING Oils oil vapors are combustible explosive Risk of fire and explosion Avoid open flames electric sparks and ignition sources Do not smoke NOTICE HP f...

Page 185: ...e s danger zone WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors HP pump Relief bore check 1 Visually inspect relief bore 1 for fuel dis char...

Page 186: ...acement Special tools Material Spare parts Designation Use Part No Qty Injector Spare Parts Catalog Injector Replacement u Remove injector and install new one Page 187 186 Task Description MS150109 01...

Page 187: ...y Paste White T 40477 1 Assembly compound Kluthe Hakuform 30 15 X00067260 1 Engine oil O ring Spare Parts Catalog WARNING Fuels are combustible and explosive Risk of fire and explosion Avoid open flam...

Page 188: ...unscrewed 3 Provide suitable vessel to collect escaping fuel 4 Remove adapter 1 5 Remove return line 6 6 Remove screw 2 from hold down clamp 1 7 Install installation removal jig 2 on cylinder head 8 R...

Page 189: ...installation remove plug 2 Coat injector with assembly paste at the seat of the nozzle retaining nut Note A new sealing ring is included in the scope of delivery of the injector 3 Insert new sealing...

Page 190: ...w head mating face and thread 2 of hold down clamp 1 with engine oil 9 Insert screw 2 and tighten to specified initial tightening torque using a torque wrench Name Size Type Lubricant Value Standard S...

Page 191: ...dapter M18 Tightening torque Engine oil 100 Nm 10 Nm Note Ensure immaculate cleanliness 14 Coat thread and sealing cone of HP line 3 with engine oil 15 Tighten union nuts 2 5 on HP line 3 to specified...

Page 192: ...d Union M12x1 5 Tightening torque 50 Nm 19 Fit connectors on injector Note If the CDC parameters are not reset the emission certification of the engine becomes invalid 20 Reset CDC parameters and ente...

Page 193: ...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 194: ...priming pump 2 until bubble free fuel emerges from the threaded vent plugs 1 5 Close threaded vent plugs 1 6 Screw in handle by turning it clockwise 7 Verify that fuel priming pump 2 is locked Handle...

Page 195: ...el 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 MS150109 01E 2015 11 Task Des...

Page 196: ...ion irritation to eyes and skin Seek medical attention immediately do not induce vomiting Do not inhale vapors or mist Wear protective clothing protective gloves and safety glasses If contact is made...

Page 197: ...ck to normal operating position both filters cut in 8 Replace other fuel filters in the same way 9 Vent fuel system 1 Replacing fuel filter with engine running 1 Cut out the filter to be replaced 2 Un...

Page 198: ...ritation to eyes and skin Seek medical attention immediately do not induce vomiting Do not inhale vapors or mist Wear protective clothing protective gloves and safety glasses If contact is made with s...

Page 199: ...ational 7 Replace other fuel filters in the same way 8 Fuel system Venting Page 193 Replacing fuel filter with engine running 1 Cut out the filter to be replaced 1 B Left hand filter switched off C Ri...

Page 200: ...dif ferential pressure gage 1 After installation of a new filter element Align adjustable pointer 2 with pressure indicat ing pointer 3 of pressure gage 1 2 Verify that differential pressure is withi...

Page 201: ...e vomiting Do not inhale vapors or mist Wear protective clothing protective gloves and safety glasses If contact is made with skin wash off with water and soap WARNING Fuels are combustible and explos...

Page 202: ...on 1 on the suction side of the filter 7 Open vent valve 2 and fill with fuel until fuel emerges from the vent pipe 3 8 Close vent valve 2 9 Turn rotary slide valve 4 a little by approx 30 and open ve...

Page 203: ...es and skin Seek medical attention immediately do not induce vomiting Do not inhale vapors or mist Wear protective clothing protective gloves and safety glasses If contact is made with skin wash off w...

Page 204: ...filling connection 1 on the suction side of the filter 3 Open vent valve 2 and fill with fuel until fuel emerges from the vent pipe 3 4 Close vent valve 2 5 Turn rotary slide valve 4 a little by appr...

Page 205: ...Risk of fatal injury 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 pro...

Page 206: ...oosen screws 3 and screw out filter hous ing A or B 5 Remove filter element 4 6 Insert new filter element in filter housing 7 Fit O ring 8 Reinstall filter housing A or B with filter ele ment 4 9 Use...

Page 207: ...l until fuel emerges from the vent pipe 3 12 Close vent valve 2 13 Turn rotary slide valve 4 a little by approx 30 and open vent valve s 2 until fuel emerges from the vent pipe 3 14 Close vent valve s...

Page 208: ...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 combustibl...

Page 209: ...rovided 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 inst...

Page 210: ...tercooler 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 housing 210 Tas...

Page 211: ...n compressor housing 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 ho...

Page 212: ...m 1 Nm 3 Install coolant lines 1 on compressor hous 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 Lubrica...

Page 213: ...oil lines 2 8 Install air pipework 1 from exhaust turbo charger to intercooler 9 Install air filter Page 216 10 Fill with engine coolant Page 237 MS150109 01E 2015 11 Task Description 213 TIM ID 00000...

Page 214: ...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 bo...

Page 215: ...re parts Designation Use Part No Qty Air filter Spare Parts Catalog Replacing the air filter 1 Remove old air filter and install new air filter Page 216 2 Reset signal ring of contamination indicator...

Page 216: ...n the con necting flange of the intake housing 1 and clean it 4 Place new air filter 3 with clamp 2 onto in take housing 1 5 Tighten clamp 2 Removing and installing air fil ter with intake silencer 1...

Page 217: ...led Checking signal ring position 1 If the signal ring is completely visible in the control window 2 replace air filter Page 215 2 After installation of new filter press reset button 1 Result Engaged...

Page 218: ...eck Preconditions Engine is stopped and starting disabled Checking starter condition 1 Check securing screws of starter for secure seating and tighten if required 2 Check wiring Page 254 218 Task Desc...

Page 219: ...ndstill the oil level may be up to 2 cm above mark 1 This may be caused e g by oil from oil filters and heat ex changer flowing back into the oil pan 3 The oil level must reach mark 1 or exceed mark 1...

Page 220: ...protective clothing gloves and goggles safety mask Take measures against electrostatic charging WARNING Hot oil Oil can contain combustion residues which are harmful to health Risk of injury and pois...

Page 221: ...new part Square section ring Damaged Fit new part O ring Damaged Fit new part Cleaning strainer 1 Wash strainer 5 with cleaner 2 Remove stubborn deposits with soft brush 3 Blow out strainer 5 with co...

Page 222: ...o 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 Remove drain plug s and drain en...

Page 223: ...orque Engine 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 Pa...

Page 224: ...ctive clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protector...

Page 225: ...automatic oil filter 1 to 2 turns 2 Drain approx 2 liters engine oil to flush out the oil sludge 3 Drain approx 1 liter engine oil into a clean vessel 4 Close screw 1 5 Using the equipment and chemica...

Page 226: ...d 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 engine at low engine...

Page 227: ...9 Check engine oil level Page 219 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 p...

Page 228: ...WARNING Hot oil Oil can contain combustion residues which are harmful to health Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inh...

Page 229: ...ff spring washer and washer 9 Remove screw 4 10 Remove flushing arm 5 from screen plate 6 11 Turn filter element by 180 and use appropri ate tool to push out filter candles 1 12 Turn filter insert by...

Page 230: ...nally the following instructions are to be observed Replace all seals with new parts Apply assembly compound to O rings Insert O rings in grooves Observe position of fillister head screw to elongated...

Page 231: ...ing Spare Parts Catalog Sealing ring Spare Parts Catalog Sealing ring Spare Parts Catalog Sealing ring Spare Parts Catalog Sealing ring Spare Parts Catalog WARNING Hot oil Oil can contain combustion r...

Page 232: ...rotor base 10 with sealing ring 9 14 Insert new filter sleeve 6 in rotor tube 7 with the smooth paper surface facing the out er wall 15 Check sealing ring 5 fit new one as neces sary 16 Mount rotor co...

Page 233: ...ush standpipe 12 onto rotor lower sec tion 13 13 Insert new filter sleeve 9 with stiffener plate 10 into rotor cap 8 ensuring that the smooth surface of the filter sleeve 9 faces the rotor cap 8 14 Ch...

Page 234: ...oling system counterclockwise up to the first 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 botto...

Page 235: ...e Special tools Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 236 2 Fill with engine coolant Page 237 MS150109 01E 2015 11 Task Description...

Page 236: ...to the exter nal cooling system on engines with separate heat exchangers 2 Continue to turn breather valve counterclock wise and remove 3 Draw off separated corrosion inhibitor oil in expansion tank t...

Page 237: ...clothing gloves and goggles safety mask NOTICE Cold coolant in hot engine can cause thermal stress Possible formation of cracks in the engine Fill top up coolant only into cold engine Preparatory step...

Page 238: ...r valve and clean sealing faces if required 5 Set breather valve onto filler neck and turn until the first stop 6 Start engine Page 75 7 After 10 seconds of running the engine with out load shut down...

Page 239: ...Risk of damage 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 disabl...

Page 240: ...oise when the engine is running Risk of damage to hearing Wear ear protectors Engine coolant Sample extrac tion and analysis 1 Open drain valve on engine coolant pump el bow with the engine running 2...

Page 241: ...ant The circulating 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 t...

Page 242: ...ng unit 1 On Off 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 5 242 Task Description MS150109 01E 2015 11 TIM...

Page 243: ...return flap 3 prevents 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 switch...

Page 244: ...se when 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 88 and disable engine...

Page 245: ...ed Battery charging generator drive Coupling condition check 1 Remove screws 1 2 Remove protective cover 2 3 Check resilient coupling 3 for cracks and plastic deformation 4 If there is serious deforma...

Page 246: ...ine mounting Check Engine mounting Check Item Findings Action Visually inspect resilient mounts Damage Brittleness Deformation Crack formation Swelling Replace contact Service 246 Task Description MS1...

Page 247: ...ise when the engine is running Risk of damage to hearing Wear ear protectors Bilge pump Relief bore check 1 Check relief bores for oil and water dis charge 2 Stop engine Page 88 and disable engine sta...

Page 248: ...System 7 21 1 Water drain valve Check Water drain valve Check 1 Open water drain valve 2 Check water outlet for obstructions 3 Close water drain valve 248 Task Description MS150109 01E 2015 11 TIM ID...

Page 249: ...rotective clothing protective gloves and safety glasses facial protection Checking differential pressure gauge 1 Switch on fuel treatment system Page 83 2 Set the alarm points at the differential pres...

Page 250: ...l probe 2 Unscrew water level probe 3 Disconnect connector from water level probe 4 Immerse water level probe into a tank filled with water until water level reaches the thread 5 Switch on the system...

Page 251: ...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 252: ...r special 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...

Page 253: ...Tightening 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 sys...

Page 254: ...closed and 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...

Page 255: ...set the emission certification becomes invalid Resetting parameters for drift correction CDC with DiaSys 1 Use DiaSys to reset the CDC parameters Dialog system DiaSys E531920 2 If no DiaSys is availab...

Page 256: ...ng 2 2 Check whether both switches 3 are actuat ed 3 If switches 3 and or guard plate 1 with en gine support 4 is are not installed Screw on guard plate 1 with engine sup port 4 Then screw on switch 3...

Page 257: ...starting disabled Check 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 th...

Page 258: ...tarting disabled Checking 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...

Page 259: ...ng disabled Checking 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 tha...

Page 260: ...ntrol Unit from engine 1 Note or mark assignment of cables and con nectors 2 Remove all screws 3 3 Undo clips 2 on connectors 4 Remove all male connectors 5 Remove screws 1 6 Take off Engine Control U...

Page 261: ...all screws 2 3 Undo clips 3 on connectors 4 Disconnect all 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 EM...

Page 262: ...When doing so observe correct assignment between cables and plugs 2 Check seal before installing Result Replace seal if porous or defective Downloading software 1 The new EIM still does not have appro...

Page 263: ...r operation 4 Application loader active 5 External RAM faulty 6 External FLASH faulty 7 No firmware 8 Application crashed Fuse lamp SILA A second indicator is the fuse lamp This is also integrated in...

Page 264: ...ath failed S8 10 Emergency stop current path failed 24 V internal S9 11 ES pushbutton current path failed 24 V external S10 12 Key switch current path failed S11 13 SDAF 1 and 2 current path failed S1...

Page 265: ...S1 and fuse S4 failure 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...

Page 266: ...1 Cleaning LOP 1 Wipe LCD display with dry cloth without applying excessive pressure 2 Remove dirt from keys using isopropyl alcohol 3 Remove heavy soiling from housing surface with isopropyl alcohol...

Page 267: ...Engine management system ECU Engine Control Unit Engine governor EDM Engine Data Module Memory module for engine data EIM Engine Interface Module Interface to engine monitoring system EMU Engine Moni...

Page 268: ...nel PCU Propeller Control Unit PIM Peripheral Interface Module RCS Remote Control System RL Redundancy Lost Alarm Redundant CAN bus failure SAE Society of Automotive Engineers U S standardization orga...

Page 269: ...e work in case of malfunction or changed oper ating conditions or for spare parts supply Your contact person in our Customer Assistance Center E mail info mtu online com Tel 49 7541 9077777 Fax 49 754...

Page 270: ...ngine Barring manually Page 172 Barring device Part No F6792918 Qty Used in 1 7 3 1 Cylinder liner Endoscopic examination Page 175 Endoscope Part No Y20097353 Qty Used in 1 7 3 1 Cylinder liner Endosc...

Page 271: ...eplacement Page 196 Qty Used in 1 7 8 3 Fuel filter Replacement Page 198 Qty Used in 7 15 1 Engine oil filter Replacement Page 226 High pressure cleaning unit Part No Qty Used in 1 4 18 Plant Cleaning...

Page 272: ...traction and analysis Page 224 Qty Used in 1 7 16 6 Engine coolant Sample extraction and analysis Page 240 Ratchet adapter Part No F30027340 Qty Used in 1 7 8 7 Fuel prefilter with water separator Fil...

Page 273: ...gine Barring manually Page 172 Qty Used in 1 7 3 1 Cylinder liner Endoscopic examination Page 175 Socket wrench 24 mm Part No F30039526 Qty Used in 1 7 4 3 Valve clearance Check and adjustment Page 18...

Page 274: ...Used in 1 7 8 7 Fuel prefilter with water separator Filter element replacement Page 205 Torque wrench 4 20 Nm Part No F30044239 Qty Used in 1 7 9 1 Compressor wheel Cleaning Page 209 Qty Used in 1 7 1...

Page 275: ...Centrifugal oil filter Cleaning and filter sleeve re placement Page 231 Torque wrench 6 50 Nm Part No F30027336 Qty Used in 1 7 21 5 Coalescer filter element Replacement Page 252 Torque wrench 40 200...

Page 276: ...n EIM 263 Diagnostic lamp DILA On EIM 263 Differential pressure gage Adjustment Fuel prefilter 200 Check Fuel prefilter 200 Differential pressure gauge Check 249 Disengaging From LOP 86 E ECU 7 Instal...

Page 277: ...Fuel prefilter with water separator Replacement O ring in rotary slide valve 208 Fuel prefilter with water separator Filter element Replacement 205 Fuel system Venting 193 Fuel treatment system Contr...

Page 278: ...work 10 Startup 8 Safety requirements Safety notices standards 15 Sensors Overview 42 Service indicator Signal ring position check 217 Service partners 269 SOLAS Abschirmungen Installation locations...

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