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Operating Instructions

Diesel engine

12V4000Mx3x
16V4000Mx3x

MS15035/00E

Содержание 12V4000M*3 series

Страница 1: ...Operating Instructions Diesel engine 12V4000Mx3x 16V4000Mx3x MS15035 00E...

Страница 2: ...yl 1A continuous operation unrestricted Table 1 Applicability 2018 Copyright MTU Friedrichshafen GmbH This publication is protected by copyright and may not be used in any way whether in whole or in p...

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Страница 5: ...ng an automatic safety shutdown 97 5 6 Stopping the engine 98 5 7 Operational checks 99 5 8 Emission label Check 100 5 9 Tasks after extended out of service periods 3 weeks 101 5 10 Checks prior to st...

Страница 6: ...eplacement 221 8 17 Coolant Circuit General High Temperature Circuit 225 8 17 1 Engine coolant level Check 225 8 17 2 Engine coolant Change 226 8 17 3 Engine coolant Draining 227 8 17 4 Engine coolant...

Страница 7: ...10 Appendix B 10 1 Special Tools 272 10 2 Index 279 MS15035 00E 2018 08 Table of Contents 5 DCL ID 0000051760 001...

Страница 8: ...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...

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

Страница 10: ...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...

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

Страница 12: ...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...

Страница 13: ...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...

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

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

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

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

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

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

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

Страница 21: ...en weight forklift truck Prior to transporting the engine genset system it is imperative to install the transport locking device for the crankshaft Prior to transporting the engine genset system it is...

Страница 22: ...ger installed vertical air intake 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...

Страница 23: ...pull must be observed Max permissible diagonal pull in longitudinal direction is 10 degrees simultaneous diagonal pull in trans verse direction is impermissible Max permissible diagonal pull in trans...

Страница 24: ...pull must be observed Max permissible diagonal pull in longitudinal direction is 10 degrees simultaneous diagonal pull in trans verse direction is impermissible Max permissible diagonal pull in transv...

Страница 25: ...ion is 10 degrees 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 d...

Страница 26: ...must be reinstalled on both engine sides accord ing to the instructions 3 If the engine is to be moved together with the generator the transport locking device for the generator must also be installe...

Страница 27: ...the ring gear 4 Screw in screw 1 in bores of holder 3 until holder 3 is locked in position Note Screw 1 must be tightened stepwise and alternately on both sides of the flywheel housing 5 Tighten scre...

Страница 28: ...om the guard plates and engine supports to secure them on the engine u Install engine supports 2 on both sides with guard plates 1 washers 3 and screws 4 and tighten to specified tightening torque tig...

Страница 29: ...torques MA are specified for screws of strength class 8 8 surface condition bare phosphatized or galvanized and 10 9 surface condition bare or phosphatized The values in the table are based on a frict...

Страница 30: ...s for studs Thread screwed into Steel M A Nm Gray cast iron MA Nm AI alloy MA Nm M6 9 6 6 M8 11 9 10 M10 17 13 13 M12 27 23 18 M14 37 33 33 M16 55 45 MA tightening torques Tightening torques for setsc...

Страница 31: ...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...

Страница 32: ...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...

Страница 33: ...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...

Страница 34: ...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...

Страница 35: ...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...

Страница 36: ...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...

Страница 37: ...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...

Страница 38: ...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...

Страница 39: ...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...

Страница 40: ...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...

Страница 41: ...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 MS15035 00E 2018...

Страница 42: ...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...

Страница 43: ...ternal engine coolant controlled charge air cooling The right hand exhaust turbocharger is cut in and cut out on 12V and 16V engines with electronically controlled hydraulically actu ated flaps Coolin...

Страница 44: ...via M threaded pins and also integrated in the engine wiring harness Functions ECU supply EMU supply Plant signals ECU7 connector X1 Bus interface 2x MCS5 CAN CAN dialog output 1xMCS5 CAN Emergency s...

Страница 45: ...on and or carbon particle deposits in the engine it is rec ommended to carry out a cleaning cycle for at least 20 minutes after extended low load operation periods During the cleaning cycle engine spe...

Страница 46: ...ead The pressure is so greatly reduced by this and the faulty sealing ring 1 that any leakage is not under pres sure Plug in pipe union b The sleeve 3 covers the joint to prevent lateral spray Only le...

Страница 47: ...ine 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 chamber Th...

Страница 48: ...7 Exhaust outlet 8 Air pipe to charge air cooler 9 Charge air cooler 10 Recirculation line 11 Exhaust manifold 12 Engine mounting 13 Charge air line 14 Oil pan 15 Oil filler neck 16 Crankcase 17 Cyli...

Страница 49: ...e air filter 9 Exhaust turbocharger 10 Exhaust outlet 11 Air pipe to charge air cooler 12 Recirculation line 13 Exhaust manifold 14 Charge air cooler 15 Charge air line 16 Engine mounting 17 Oil pan 1...

Страница 50: ...ther 7 Dry type air filter 8 Exhaust manifold 9 Recirculation line 10 Exhaust turbocharger 11 Exhaust outlet 12 Air pipe to charge air cooler 13 Charge air cooler 14 Engine mounting 15 Charge air line...

Страница 51: ...5 Charge air line 16 Engine mounting 17 Oil pan 18 Oil filler neck 19 Crankcase 20 Cylinder head 21 Fuel filter 22 Oil filter 23 HP fuel pump 24 Battery charging generator 25 Bilge pump option 26 Raw...

Страница 52: ...engine side 12V4000Mx3 1 B50 P Crankcase 2 B3 T Intake air 3 B44 1 N Turbocharger A 4 B10 P Charge air 5 B34 3 fuel pressure before filter only if supplementary fuel filter is fitted 6 B34 2 P Fuel b...

Страница 53: ...optional 4 B5 3 lube oil pressure be fore filter 5 B5 1 P Lube oil after filter 6 B48 P Fuel in common rail 7 B1 N Camshaft 8 B54 oil refill pump pres sure optional 9 B6 2 coolant temperature optiona...

Страница 54: ...Right engine side 12V4000Mx3 1 B44 2 N Turbocharger B 2 Y27 turbocharger control valve 3 B16 P Coolant 4 B9 T Charge Air 52 General Information MS15035 00E 2018 08 TIM ID 0000012941 004...

Страница 55: ...x3 1 B4 21 T Exhaust A side 2 B4 22 T Exhaust B bank 3 B13 N Crankshaft 4 S37 2 S Safety switch 5 S37 1 S Safety switch 6 B13 2 N Crankshaft speed optional MS15035 00E 2018 08 General Information 53 T...

Страница 56: ...urbocharger A 2 B49 Y26 T Charge air be fore recirculation valve recirculation valve A 3 B4 T Individual exhaust temperature A1 A6 B1 B6 optional 4 B5 9 P Lube oil before tur bocharger B 54 General In...

Страница 57: ...la tion valve recirculation valve A 3 B3 T Intake air 4 B44 1 N Turbocharger A 5 B10 P Charge air 6 B34 3 fuel pressure before filter only if supplementary fuel filter is fitted 7 B34 2 P Fuel before...

Страница 58: ...fter filter optional 4 B5 1 P Lube oil after filter 5 B5 3 P Lube oil before fil ter 6 B1 N Camshaft 7 B54 P Oil refill pump op tional 8 B6 2 T Coolant tempera ture optional 9 B6 T Coolant 10 XD1 conn...

Страница 59: ...ne side 12V4000Mx3 1 B44 2 N Turbocharger B 2 Y27 turbocharger control valve 3 B16 P Coolant 4 B21 raw water pressure optional 5 B9 T Charge Air MS15035 00E 2018 08 General Information 57 TIM ID 00000...

Страница 60: ...0Mx3 1 B4 21 T Exhaust A side 2 B4 22 T Exhaust B bank 3 B13 N Crankshaft 4 S37 2 S Safety switch 5 S37 1 S Safety switch 6 B13 2 N Crankshaft op tional 58 General Information MS15035 00E 2018 08 TIM...

Страница 61: ...B5 8 P Lube before exhaust turbocharger A 2 B4 cylinder exhaust tem perature A1 A6 B1 B6 op tional 3 F33 H Coolant 4 B5 9 P Lube oil before tur bocharger B MS15035 00E 2018 08 General Information 59...

Страница 62: ...engine side 16V4000Mx3 1 B50 P Crankcase 2 B3 T Intake air 3 B44 1 N Turbocharger A 4 B10 P Charge air 5 B34 3 fuel pressure before filter only if supplementary fuel filter is fitted 6 B34 2 P Fuel b...

Страница 63: ...ter optional 4 B5 3 P Lube oil before fil ter 5 B5 1 P Lube oil after filter 6 B48 P Fuel in common rail 7 B1 N Camshaft 8 B54 P Oil refill pump op tional 9 B6 2 T Coolant optional 10 B6 T Coolant 11...

Страница 64: ...Right engine side 16V4000Mx3 1 B44 2 N Turbocharger B 2 Y27 turbocharger control valve 3 B16 P Coolant 4 B9 T Charge Air 62 General Information MS15035 00E 2018 08 TIM ID 0000018445 005...

Страница 65: ...0Mx3 1 B4 21 T Exhaust A side 2 B4 22 T Exhaust B bank 3 B13 N Crankshaft 4 S37 2 S Safety switch 5 S37 1 S Safety switch 6 B13 2 N Crankshaft op tional MS15035 00E 2018 08 General Information 63 TIM...

Страница 66: ...turbocharger A 2 B49 Y26 T Charge air be fore recirculation valve recirculation valve A 3 B4 cylinder exhaust tem perature A1 A6 B1 B6 op tional 4 B5 9 P Lube oil before tur bocharger B 64 General Inf...

Страница 67: ...circula tion valve recirculation valve A 3 B3 T Intake air 4 B44 1 N Turbocharger A 5 B10 P Charge air 6 B34 3 fuel pressure before filter only if supplementary fuel filter is fitted 7 B34 2 P Fuel be...

Страница 68: ...e oil after filter optional 4 B5 1 P Lube oil after filter 5 B5 3 P Lube oil before fil ter 6 B1 N Camshaft 7 B54 P Oil refill pump op tional 8 B6 2 T Coolant optional 9 B6 T Coolant 10 XD1 connector...

Страница 69: ...ne side 16V4000Mx3 1 B44 2 N Turbocharger B 2 Y27 turbocharger control valve 3 B16 P Coolant 4 B21 raw water pressure optional 5 B9 T Charge Air MS15035 00E 2018 08 General Information 67 TIM ID 00000...

Страница 70: ...0Mx3 1 B4 21 T Exhaust A side 2 B4 22 T Exhaust B side 3 B13 N Crankshaft 4 S37 2 S Safety switch 5 S37 1 S Safety switch 6 B13 2 N Crankshaft op tional 68 General Information MS15035 00E 2018 08 TIM...

Страница 71: ...B5 8 P Lube before exhaust turbocharger A 2 B4 cylinder exhaust tem perature A1 A6 B1 B6 op tional 3 F33 H Coolant 4 B5 9 P Lube oil before tur bocharger B MS15035 00E 2018 08 General Information 69...

Страница 72: ...Module applies to this product type Actual value must be greater than the specified value Actual value must be smaller than the specified value Insufficiently guaranteed value tolerance 10 Insufficien...

Страница 73: ...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 4...

Страница 74: ...ating pressure before en gine to R bar 6 3 6 3 6 3 6 3 Lube oil operating pressure low idle meas point before engine R bar 2 5 2 5 2 5 2 5 Fuel system ID 1 2 3 4 Fuel pressure at engine inlet connecti...

Страница 75: ...verse inclination continuous max option max operating inclinations L Degrees 15 15 15 15 Transverse inclination temporary max option max operating inclinations L Degrees 22 5 22 5 22 5 22 5 Capacities...

Страница 76: ...p 1 m distance ISO 6798 3 dB A tolerance R dB A 106 106 106 106 Engine surface noise with attenuated in take noise filter BL free field sound power level Lp 1 m distance ISO 6798 2 dB A tolerance R dB...

Страница 77: ...plies to this product type Actual value must be greater than the specified value Actual value must be smaller than the specified value Insufficiently guaranteed value tolerance 10 Insufficiently guara...

Страница 78: ...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 4...

Страница 79: ...ine to R C 94 94 95 95 Lube oil operating pressure before en gine from R bar 5 3 5 3 5 3 5 3 Lube oil operating pressure before en gine to R bar 6 3 6 3 6 3 6 3 Lube oil operating pressure low idle me...

Страница 80: ...tions L Degrees 15 15 15 15 Longitudinal inclination temporary 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 oper...

Страница 81: ...ntenance W5 R kg 460 460 460 460 Sound ID 1 2 3 4 Exhaust noise unsilenced BL free field sound pressure level Lp 1 m distance ISO 6798 3 dB A tolerance R dB A 107 107 107 107 Engine surface noise with...

Страница 82: ...plies to this product type Actual value must be greater than the specified value Actual value must be smaller than the specified value Insufficiently guaranteed value tolerance 10 Insufficiently guara...

Страница 83: ...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 4...

Страница 84: ...ating pressure before en gine to R bar 6 3 6 3 6 3 6 3 Lube oil operating pressure low idle meas point before engine R bar 2 5 2 5 2 5 2 5 Fuel system ID 1 2 3 4 Fuel pressure at engine inlet connecti...

Страница 85: ...verse inclination continuous max option max operating inclinations L Degrees 15 15 15 15 Transverse inclination temporary max option max operating inclinations L Degrees 22 5 22 5 22 5 22 5 Capacities...

Страница 86: ...Sound ID 1 2 3 4 Exhaust noise unsilenced BL free field sound pressure level Lp 1 m distance ISO 6798 3 dB A tolerance R dB A 111 111 111 111 84 Technical Data MS15035 00E 2018 08 TIM ID 0000018491 0...

Страница 87: ...plies to this product type Actual value must be greater than the specified value Actual value must be smaller than the specified value Insufficiently guaranteed value tolerance 10 Insufficiently guara...

Страница 88: ...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 4...

Страница 89: ...ating pressure before en gine to R bar 6 3 6 3 6 3 6 3 Lube oil operating pressure low idle meas point before engine R bar 2 5 2 5 2 5 2 5 Fuel system ID 1 2 3 4 Fuel pressure at engine inlet connecti...

Страница 90: ...ransverse inclination continuous max option max operating inclinations L Degrees 15 15 15 15 Transverse inclination temporary max option max operating inclinations L Degrees 22 5 22 5 22 5 22 5 Capaci...

Страница 91: ...ound ID 1 2 3 4 Exhaust noise unsilenced BL free field sound pressure level Lp 1 m distance ISO 6798 3 dB A tolerance R dB A 110 110 110 110 MS15035 00E 2018 08 Technical Data 89 TIM ID 0000010816 003...

Страница 92: ...4 5 Firing order Cylinders Firing order 12V A1 B5 A5 B3 A3 B6 A6 B2 A2 B4 A4 B1 16V A1 A7 B4 B6 A4 B8 A2 A8 B3 B5 A3 A5 B2 A6 B1 B7 90 Technical Data MS15035 00E 2018 08 TIM ID 0000023263 003...

Страница 93: ...50 mm approx 2071 mm 16V 4000 M53 63 approx 3108 mm approx 1690 mm approx 1850 mm approx 2064 mm With engine mounted heat exchanger Engine model Length A Width B without silencer Width B with si lence...

Страница 94: ...448 mm 16V 4000 M53 63 approx 3108 mm approx 1613 mm approx 2361 mm approx 2441 mm With engine mounted heat exchanger Engine model Length A Width B Height C without silencer Height C with si lencer 12...

Страница 95: ...5 Operation 5 1 Controls Automation system controls Refer to automation system operating instructions MS15035 00E 2018 08 Operation 93 TIM ID 0000016959 003...

Страница 96: ...gn adjustable pointer with position of pressure indicator Page 189 HP fuel pump Only for engines without oil priming pump Fill HP fuel pump with fresh engine oil Page 171 Raw water pump if located abo...

Страница 97: ...Check coolant level Page 225 Coolant system Preheat coolant with preheating unit Fuel prefilter Drain Page 190 Check that suction side pressure indicated at the fuel prefilter pressure gauge is withi...

Страница 98: ...5 4 Starting the engine Start the engine via the automation system Refer to automation system operating instructions 96 Operation MS15035 00E 2018 08 TIM ID 0000017525 003...

Страница 99: ...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...

Страница 100: ...5 6 Stopping the engine Stopping the engine via the automation system Refer to automation system operating instructions 98 Operation MS15035 00E 2018 08 TIM ID 0000017528 004...

Страница 101: ...nd exhaust color Page 115 Air filter Check signal ring position of service indicator Page 209 Replace air filter Page 207 if the signal ring is completely visible in the service indicator control wind...

Страница 102: ...emission label for intactness 3 Check that emission label is fully legible 4 Check content of emission label Does the label on the engine match the label document in the Business Portal Equipment Does...

Страница 103: ...ks 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 103 2 Shut down fuel treatment system Page 107 MS...

Страница 104: ...ves 4 Switch on fuel treatment system Page 106 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...

Страница 105: ...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...

Страница 106: ...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...

Страница 107: ...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...

Страница 108: ...re switching on ensure that all housings are closed Before switching on ensure that no work is in progress anywhere on the entire system Fuel treatment system Switching on 1 Carry out checks prior to...

Страница 109: ...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...

Страница 110: ...ystem 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 Fol...

Страница 111: ...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...

Страница 112: ...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...

Страница 113: ...place fuel injectors Page 174 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 219 W1009 Check thickness of oil r...

Страница 114: ...asks W1713 Injector reset drift compensation parameters CDC Page 268 W1864 X Check and clean oil indicator filter Page 216 Table 2 Maintenance task reference table QL1 112 Maintenance MS15035 00E 2018...

Страница 115: ...005 X Fit new air filters Page 207 W1006 Replace fuel injectors Page 174 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 ye...

Страница 116: ...s W1675 X Fit new fuel prefilter or new fuel prefilter insert W1713 Injector reset drift compensation parameters CDC Page 268 Table 3 Maintenance task reference table QL1 114 Maintenance MS15035 00E 2...

Страница 117: ...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...

Страница 118: ...dicator Page 209 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...

Страница 119: ...t gas Cause Corrective action Engine is not at operating temperature u Run engine to reach operating temperature Intercooler leaking u Contact Service MS15035 00E 2018 08 Troubleshooting 117 TIM ID 00...

Страница 120: ...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...

Страница 121: ...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...

Страница 122: ...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...

Страница 123: ...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...

Страница 124: ...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...

Страница 125: ...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...

Страница 126: ...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...

Страница 127: ...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...

Страница 128: ...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...

Страница 129: ...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...

Страница 130: ...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...

Страница 131: ...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...

Страница 132: ...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...

Страница 133: ...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...

Страница 134: ...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...

Страница 135: ...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...

Страница 136: ...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...

Страница 137: ...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...

Страница 138: ...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...

Страница 139: ...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...

Страница 140: ...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...

Страница 141: ...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...

Страница 142: ...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...

Страница 143: ...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...

Страница 144: ...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...

Страница 145: ...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...

Страница 146: ...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...

Страница 147: ...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...

Страница 148: ...y Shield A5 735233000101 18 Shield A6 735233000102 2 Shield A7 735233000103 3 Shield A8 735233000104 4 Shield B2 735233000200 2 Shield B4 735233000202 1 Shield B6 735233000204 2 Shield E5 735233000500...

Страница 149: ...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...

Страница 150: ...ve connections ensure that escaping fluid can flow out without pressure Page 157 Fuel system fuel lines with fuel pressure 1 8 bar Item Type of shielding Installation location 1 Shield A8 After LP fue...

Страница 151: ...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...

Страница 152: ...mbly 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 shieldi...

Страница 153: ...ng A5 Switching cylinder air flap ETC B1 2 3 x shielding A5 T adapter for flap control ETC B1 Item Type of shielding Installation location 1 5 x shielding A5 Distributor piece 2 2 x shielding A5 Oil r...

Страница 154: ...Oil line to ETC 2 Shield A5 Oil line to flap control 3 Shield A5 Oil line to recirculation valve 4 2 x shielding E5 Oil line from main gallery These shields must be installed on the assembly line The...

Страница 155: ...lding Installation location 1 2 x shielding A5 Air recirculation valve Item Type of shielding Installation location 1 Shield A6 Oil supply line to HP pump on HP pump MS15035 00E 2018 08 SOLAS 153 TIM...

Страница 156: ...n equipment carrier This shield must be installed on the assembly line Assembly in this position is no longer possible after painting Item Type of shielding Installation location 1 Shield A6 ETC oil s...

Страница 157: ...f shielding Installation location 1 Shield B2 Oil line on equipment carrier 2 Shield B2 Oil line on pressure reducing valve This shield must be installed on the assembly line Assembly in this position...

Страница 158: ...Item Type of shielding Installation location 1 Cover Oil easy change fuel filter 156 SOLAS MS15035 00E 2018 08 TIM ID 0000069196 002...

Страница 159: ...ealing cone unions Note For installation positions of sealing cone un ions see Page 148 1 Wrap three layers of adhesive tape from the middle of the sealing cone union to area A for at least 30 mm ensu...

Страница 160: ...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...

Страница 161: ...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...

Страница 162: ...8 2 2 Barring engine with starting system Barring using the automation system Refer to automation system operating instructions 160 Engine MS15035 00E 2018 08 TIM ID 0000017532 004...

Страница 163: ...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...

Страница 164: ...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...

Страница 165: ...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...

Страница 166: ...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...

Страница 167: ...substances which are harmful to health Risk of injury and poisoning Allow the product to cool to below 50 C before beginning work Wear protective clothing protective gloves and goggles safety mask Av...

Страница 168: ...Spare parts Designation Use Part No Qty Engine oil Valve gear Lubrication 1 Remove cylinder head covers Page 170 2 Fill oil chambers of valve bridges with oil 3 Fill oil chambers of rocker arms and ad...

Страница 169: ...349603 1 Torque wrench 60 320 Nm F30452768 1 Socket wrench 24 mm F30039526 1 Engine oil Preparatory steps 1 Remove cylinder head covers Page 170 2 Install barring device Page 158 Note The pointer 1 is...

Страница 170: ...umference if applica ble 4 Additional OT A1 1 marking on the outer circumference of flywheel must not be used Diagram for 12V engines two crankshaft positions Diagram for 16V engines two crankshaft po...

Страница 171: ...d rocker arm 5 If the deviation from the reference value exceeds 0 1 mm adjust valve clearance Adjusting valve clearance 1 Loosen locknut 1 2 Insert feeler gage 3 between valve bridge and rocker arm N...

Страница 172: ...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...

Страница 173: ...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...

Страница 174: ...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...

Страница 175: ...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...

Страница 176: ...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 175 174 Injection Valve Inject...

Страница 177: ...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...

Страница 178: ...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...

Страница 179: ...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...

Страница 180: ...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...

Страница 181: ...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...

Страница 182: ...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...

Страница 183: ...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...

Страница 184: ...al 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 protective clo...

Страница 185: ...el 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 Hand...

Страница 186: ...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 184 Fuel Filter MS15035 00...

Страница 187: ...gh level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors NOTICE Damage to component Severe material damage For filter replacement with the engine running opera...

Страница 188: ...Remove the cut out oil filter 2 using an oil filter wrench 3 Clean sealing surface on filter head 4 Check sealing ring of new filter 2 and coat with fuel 5 Screw on filter 2 and tighten manually 6 Tu...

Страница 189: ...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...

Страница 190: ...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...

Страница 191: ...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...

Страница 192: ...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...

Страница 193: ...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...

Страница 194: ...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...

Страница 195: ...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...

Страница 196: ...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...

Страница 197: ...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...

Страница 198: ...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...

Страница 199: ...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...

Страница 200: ...ided 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 instruc...

Страница 201: ...5 Remove oil lines 2 6 Loosen clamp 1 7 Remove intake housing 3 with actuating cyl inder 2 8 Remove coolant lines 1 from compressor housing 3 9 Remove coolant ventilation line 2 from com pressor housi...

Страница 202: ...with a smooth paint brush or brush 2 Clean compressor wheel 2 and bearing housing 1 3 Thoroughly remove cleaner from all compo nents 4 Fit new sealing rings between bearing hous ing compressor housin...

Страница 203: ...using a torque wrench Name Size Type Lubricant Value Standard Clamp Tightening torque 15 Nm 2 Nm 6 Install oil lines 2 Tighten threaded adapter at actuating cylinder to specified torque using a torque...

Страница 204: ...lter Page 208 3 Seal all openings with suitable covers 4 Remove charge air pipework 1 from exhaust turbocharger to intercooler 5 Remove oil lines 2 6 Loosen clamp 1 7 Remove intake housing 3 with actu...

Страница 205: ...Do not use wire brushes scrapers or similar tools for cleaning 1 Clean compressor housing with a smooth paint brush or brush 2 Clean compressor wheel 2 and bearing housing 1 3 Thoroughly remove clean...

Страница 206: ...ing torque Engine oil 20 Nm 2 5 Nm 3 Install coolant ventilation line and coolant lines on compressor housing 4 Install intake housing 3 with actuating cylin der 2 5 Align clamp 1 and tighten to speci...

Страница 207: ...e Size Type Lubricant Value Standard Threaded adapter 10 G 1 4 A Tightening torque Engine oil 40 Nm 4 Nm 7 Install charge air pipework 1 between exhaust turbocharger and intercooler 8 Install air filt...

Страница 208: ...irect air jet at people Always wear safety goggles face mask and ear defenders Intercooler Checking conden sate drain for water discharge and obstruction 1 With the engine running check if air emerges...

Страница 209: ...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 208 2 Reset signal ring of contamination indicator...

Страница 210: ...e flange of the intake housing 3 and clean it 4 Attach air filter 1 with clamp 2 onto intake housing 3 5 Tighten clamp 2 Air filter with intake silencer 1 Loosen clamp 2 2 Remove air filter 1 and clam...

Страница 211: ...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...

Страница 212: ...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 257...

Страница 213: ...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...

Страница 214: ...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...

Страница 215: ...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 211...

Страница 216: ...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...

Страница 217: ...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...

Страница 218: ...l 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 skin Do not...

Страница 219: ...ubborn deposits from strainer as necessary 4 Blow out strainer 6 with compressed air from outside to inside Checking strainer Item Findings Task Strainer Metallic residues Clean Monitor engine operati...

Страница 220: ...strainer as necessary 4 Blow out strainer 5 with compressed air from outside to inside Checking strainer Item Findings Task Strainer Metallic residues Clean Monitor engine operation Check strainer dai...

Страница 221: ...e 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 engine at...

Страница 222: ...Check engine oil level Page 211 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...

Страница 223: ...leeves Spare Parts Catalog Sealing rings 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 cool to...

Страница 224: ...conical disk 8 and rotor base 13 9 Wash rotor cover 3 rotor tube 7 conical disk 8 and rotor base 13 with cold cleaner 10 Blow out with compressed air 11 Check sealing rings 9 10 12 and replace if nece...

Страница 225: ...se of movement 19 Check sealing ring 16 replace as necessary 20 Fit sealing ring 16 on housing 15 21 Fit hood 1 22 Tighten Tommy nut 2 by hand 23 Install clamp 17 and tighten to specified torque using...

Страница 226: ...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 Check sealing ri...

Страница 227: ...unterclockwise 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 bottom edge of the c...

Страница 228: ...Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 227 2 Fill with engine coolant Page 230 226 Coolant Circuit General High Temperature Circuit...

Страница 229: ...reheating unit Engine coolant Draining 1 Turn breather valve on expansion tank for engines with remote heat exchanger the expansion tank is part of the remote cooling system counterclockwise up to the...

Страница 230: ...pework driving end 1 6 Open vent valve on seawater cooler 1 or re mote heat exchanger 7 Open drain plug 1 and drain coolant at crankcase 228 Coolant Circuit General High Temperature Circuit MS15035 00...

Страница 231: ...in coolant on coolant pump elbow Final steps 1 Seal all open vent and drain points 2 Set breather valve onto filler neck and close it MS15035 00E 2018 08 Coolant Circuit General High Temperature Circu...

Страница 232: ...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 Note On engines with a separate heat...

Страница 233: ...g faces if required 5 Set breather valve onto filler neck and turn until the first stop 6 Start engine Page 96 7 After 10 seconds of running the engine with out load shut down the engine Page 98 8 Tur...

Страница 234: ...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...

Страница 235: ...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...

Страница 236: ...engine coolant The circulating pump 8 ensures the circula tion of the preheated engine coolant through the engine The continuous flow heater 5 comprises a heating element The thermostat 7 switches off...

Страница 237: ...On Off switch Cylinders Rated voltage frequency Heating power kW 12V and 16V 230 V 50 Hz 9 400 V 50 Hz 9 230 V 60 Hz 9 440 V 60 Hz 9 MS15035 00E 2018 08 Coolant Circuit General High Temperature Circui...

Страница 238: ...ement A non 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 5 the thermo...

Страница 239: ...ment 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 damage...

Страница 240: ...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...

Страница 241: ...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 98 and disable engine start...

Страница 242: ...ition check 1 Install barring tool Page 158 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...

Страница 243: ...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 98 and disable engi...

Страница 244: ...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...

Страница 245: ...System 8 22 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 MS15035 00E 2018 08 Fuel Supply System 243 TIM I...

Страница 246: ...Wear protective clothing protective gloves and safety glasses facial protection Checking differential pressure gage alarm function 1 Switch on fuel treatment system Page 106 2 Set the alarm points at...

Страница 247: ...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...

Страница 248: ...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...

Страница 249: ...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...

Страница 250: ...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...

Страница 251: ...ir 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 Rotation...

Страница 252: ...ck 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 En...

Страница 253: ...3 9 XXF33 10 B16 11 B44 2 12 Y27 13 B4 22 14 B9 15 S37 1 16 B34 3 17 B34 2 18 B34 1 19 B50 20 Y26 21 B44 1 22 B49 23 B3 24 B5 3 25 B4 21 26 B10 27 B13 28 S37 2 29 B7 30 B5 1 31 B48 32 B33 33 F46 34 XG...

Страница 254: ...4 2 9 Y27 10 F33 11 XXF33 12 B16 13 B4 22 14 B9 15 S37 1 16 B34 3 17 B34 2 18 B34 1 19 B50 20 Y26 21 B44 1 22 B49 23 B3 24 B5 3 25 B4 21 26 B10 27 B13 28 S37 2 29 B7 30 B5 1 31 B48 32 B33 33 F46 34 XG...

Страница 255: ...ess for injectors 12V engine 1 Y39A1 2 Y39A2 3 Y39A3 4 Y39A4 5 Y39A5 6 Y39A6 7 X4 8 Y39B6 9 Y39B5 10 Y39B4 11 Y39B3 12 Y39B2 13 Y39B1 MS15035 00E 2018 08 Wiring General for Engine Gearbox Unit 253 TIM...

Страница 256: ...16V engine 1 Y39A1 2 Y39A2 3 Y39A3 4 Y39A4 5 Y39A5 6 Y39A6 7 Y39A7 8 Y39A8 9 X4 10 Y39B8 11 Y39B7 12 Y39B6 13 Y39B5 14 Y39B4 15 Y39B3 16 Y39B2 17 Y39B1 254 Wiring General for Engine Gearbox Unit MS150...

Страница 257: ...Engine wiring harness for EIM 1 XD1 2 X1 3 X3 4 X52 5 XY1 6 X11 7 XB19 8 X37 MS15035 00E 2018 08 Wiring General for Engine Gearbox Unit 255 TIM ID 0000038739 003...

Страница 258: ...Engine wiring harness for electric starter 1 Connection terminals EIM 2 Fuse F1 3 Connection terminals start er 256 Wiring General for Engine Gearbox Unit MS15035 00E 2018 08 TIM ID 0000038739 003...

Страница 259: ...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...

Страница 260: ...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...

Страница 261: ...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...

Страница 262: ...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...

Страница 263: ...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...

Страница 264: ...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...

Страница 265: ...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...

Страница 266: ...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...

Страница 267: ...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...

Страница 268: ...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 2 266 Accessorie...

Страница 269: ...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...

Страница 270: ...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...

Страница 271: ...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...

Страница 272: ...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...

Страница 273: ...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...

Страница 274: ...c examination Page 161 Endoscope Part No Y20097353 Qty Used in 1 8 3 1 Cylinder liner Endoscopic examination Page 161 Qty Used in 1 8 19 1 Battery charging generator drive Coupling condi tion check Pa...

Страница 275: ...er Replacement Page 219 Fuel suction device Part No F30378207 Qty Used in 1 8 6 1 HP fuel pump Filling with engine oil Page 171 High pressure cleaner Part No Qty Used in 1 5 16 Plant Cleaning Page 110...

Страница 276: ...d in 1 8 15 3 Engine oil Sample extraction and analysis Page 214 MTU test kit Part No F6798833 Qty Used in 1 8 17 6 Engine coolant Sample extraction and analysis Page 233 Oil filter wrench Part No F30...

Страница 277: ...8 5 3 Cylinder head cover Removal and installation Page 170 Qty Used in 1 8 15 2 Engine oil Change Page 212 Ratchet bit Part No F30027340 Qty Used in 1 8 7 2 Injector Removal and installation jackete...

Страница 278: ...rt locking device Page 24 Qty Used in 1 8 6 1 HP fuel pump Filling with engine oil Page 171 Qty Used in 1 8 7 2 Injector Removal and installation jacketed fuel system Page 175 Qty Used in 1 8 9 7 Fuel...

Страница 279: ...ugal oil filter Cleaning and filter sleeve re placement Page 221 Torque wrench 60 320 Nm Part No F30452768 Qty Used in 1 2 3 Crankshaft transport locking device Page 24 Qty Used in 1 8 5 2 Valve clear...

Страница 280: ...43446 Qty Used in 1 8 22 5 Coalescer filter element Replacement Page 247 Valve setting gage Part No Y4349603 Qty Used in 1 8 5 2 Valve clearance Check and adjustment Page 167 278 Special Tools MS15035...

Страница 281: ...ement 165 Crankshaft Transport locking device Installation removal 24 Cylinder Designation 40 Cylinder head cover Installation 170 Removal 170 Cylinder liner Endoscopic examination 161 Endoscopic insp...

Страница 282: ...118 treatment system Shutdown 107 Fuel filter Replacement 187 Fuel prefilter Adjustment Differential pressure gage 189 Check Differential pressure gage 189 Fuel prefilter with water separator Drainin...

Страница 283: ...Warning notices standards 18 Sensors Overview 60 Sensors and actuators Overview 50 Service partners 271 SOLAS shielding Adhesive tape application 157 Installation 147 As per MTN 5233 146 Installation...

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