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Operating Instructions

Diesel Engine

20V4000M93x

MS150048/05E

Содержание 20V4000M93 series

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

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

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

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

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

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

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

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

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

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 Ultr...

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 o...

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

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

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

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

Страница 25: ...orques MA are specified for screws of strength class 8 8 surface condition bare phosphatized or galvanized and 10 9 surface condition bare or phosphatized The values in the table are based on a fricti...

Страница 26: ...s for studs Thread screwed into Steel M A Nm Gray cast iron MA Nm AI alloy MA Nm M6 9 6 6 M8 11 9 10 M10 17 13 13 M12 27 23 18 M14 37 33 33 M16 55 45 MA tightening torques Tightening torques for setsc...

Страница 27: ...e based on a friction coefficient tot 0 125 Threads and mating faces of screws and nuts must be coated with engine oil prior to assembly An assembly tolerance of 10 of the figures in the table is perm...

Страница 28: ...n tightening MA tightening torques Tightening torques for plug screws as per MTN 5183 1 standard This standard applies to plug screws to DIN 908 DIN 910 and DIN 7604 with threaded end to DIN 3852 Form...

Страница 29: ...ightening torques for plug screws to DIN 908 DIN 910 and DIN 7604A with short threaded end Thread screwed into Steel gray cast iron MA Nm AI alloy MA Nm M10 x 1 15 15 M12 x 1 5 25 25 M14 x 1 5 35 30 M...

Страница 30: ...l gray cast iron M A Nm AI alloy MA Nm M8 x 1 10 10 M22 x 1 5 80 65 M26 x 1 5 105 90 M30 x 1 5 130 130 M38 x 1 5 140 120 M45 x 1 5 160 140 MA tightening torques Tightening torque for banjo screws as p...

Страница 31: ...ns during the tightening process Tightening torques for steel banjo screws Thread inserted in steel gray cast iron aluminum alloy MA Nm M8 x 1 10 M10 x 1 15 M12 x 1 5 20 M14 x 1 5 25 M16 x 1 5 25 M18...

Страница 32: ...nd oiled or galvanized Threads and mating faces beneath heads must be coated with engine oil prior to assembly An assembly tolerance of 10 of the figures in the table is permitted due to unavoidable d...

Страница 33: ...ng the union nut firmly by hand noticeable increase in force it should be tightened another 1 4 turn 90 past this point Tightening torques for spigot unions with O ring to ISO 6149 2 Thread Torque Nm...

Страница 34: ...valves see ISO 6149 47 and ISO 7789 Tightening torques for screwed plugs with O ring as per ISO 6149 3 Thread Torque Nm 10 M8 x 1 8 M10 x 1 15 M12 x 1 5 25 M14 x 1 5 35 M16 x 1 5 40 M18 x 1 5 45 M22...

Страница 35: ...RFS fittings In contrast to the instructions for pipe unions hose fittings with sealing heads and the matching adapters must be fitted and connected as follows Hose fitting metallic sealing with union...

Страница 36: ...2 35 290 M52 x 2 38 42 330 Sealing head with BSP union nut BSPP thread Torque Nm G1 4 20 G3 8 34 G1 2 60 G5 8 69 G3 4 115 G1 140 G1 1 4 210 G1 1 2 290 G2 400 SAE sealing cone with union nut JIC 37 UNF...

Страница 37: ...Torque Nm 9 16 18 4 14 2 11 16 16 6 24 3 13 16 16 8 43 4 1 14 10 60 8 1 3 16 12 12 90 5 1 3 16 12 14 90 5 1 7 16 12 16 125 10 1 11 16 12 20 170 20 2 12 24 200 25 2 1 2 20 32 460 30 MS150048 05E 2018...

Страница 38: ...cordance with DIN ISO 1204 as viewed from driving end 4 For cylinder designation in accordance with DIN ISO 1204 the letter Ax refers to the cylinders on the left hand side of the engine 1 and letter...

Страница 39: ...uantity absolute gas tightness reached Turbocharging Sequential turbocharging with internal engine coolant controlled charge air cooling The exhaust turbochargers B1 A2 and B2 are cut in and out via e...

Страница 40: ...r X1 Bus interface 2x MCS5 CAN CAN dialog output 1xMCS5 CAN Emergency stop ECU and EMU Electric starter Terminal 45 starter A B engaged Pneumatic starter Starting air pressure valve Start air pressure...

Страница 41: ...gear control Flashing light and horn for summary alarm in engine room Interface to CAN field bus for connected communicating monitoring system components SOLAS Fire safety requirements The following...

Страница 42: ...to HP pump Lube oil system oil lines with oil pressure 1 8 bar 1 Parting line ETC oil supply free end 1 Parting line ETC oil supply driving end 40 General Information MS150048 05E 2018 03 TIM ID 0000...

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

Страница 44: ...on main oil gallery 1 Switching cylinder air flap A2 1 Oil line connection 2 Switching cylinder exhaust flap turbo charger A2 3 T piece flap control 42 General Information MS150048 05E 2018 03 TIM ID...

Страница 45: ...rol turbocharger B1 1 Switching cylinder air flap turbocharg er B1 1 Connection oil line to turbocharger B2 2 Switching cylinder exhaust flap turbo charger B2 3 Switching cylinder air flap turbocharg...

Страница 46: ...with SOLAS by GL and DNV Plugs and sensors plug in pipe connections Plugs and sensors a Screwed in seal plugs 4 are sealed toward the outside either with a copper sealing ring 1 according to DIN or a...

Страница 47: ...flow bore 8 Thrust ring 9 Union nut 10 Union nut 11 Connecting piece 12 Snap ring 13 Thrust ring 14 Shims 15 Union nut 16 Thrust ring 17 External pipe of HP line 18 Internal pipe of HP line 19 Ball ty...

Страница 48: ...ng 11 HP fuel pump 12 Automatic oil filter 13 Centrifugal oil filter s 14 Fuel filter 15 Engine governor Engine model designation Key to engine model designation 20V4000Mxyz 20 Number of cylinders V C...

Страница 49: ...ylinder A10 11 B5 2 P Lube oil after filter 12 B34 2 P Fuel before filter 13 B34 1 P Fuel after filter 14 B5 3 P Lube oil before fil ter 15 B48 P Fuel in common rail 16 B4 B10 T exhaust cylinder B10 1...

Страница 50: ...P Charge air 9 B57 1 T Main bearing 10 B57 2 T Main bearing 11 B57 3 T Main bearing 12 B57 4 T Main bearing 13 B57 5 T Main bearing 14 B57 6 T Main bearing 15 B57 7 T Main bearing 16 B57 8 T Main bea...

Страница 51: ...ree end 1 F46 H Leak fuel level 2 B33 T Fuel 3 B1 N Camshaft 4 B54 P Oil level pump 5 B6 2 T Coolant 6 B6 T Coolant 7 Connector XD1 Dialog unit MS150048 05E 2018 03 General Information 49 TIM ID 00000...

Страница 52: ...bearing 9 B77 B9 T Spray oil conrod bearing 10 B77 B8 T Spray oil conrod bearing 11 B77 B7 T Spray oil conrod bearing 12 B77 B6 T Spray oil conrod bearing 13 B77 B5 T Spray oil conrod bearing 14 B77 B...

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

Страница 54: ...eed B16 Coolant pressure B21 Raw water pressure B33 Fuel temperature B34 1 Fuel pressure after filter B34 2 Fuel pressure before filter B44 1 Exhaust turbocharger speed A B44 2 Exhaust turbocharger sp...

Страница 55: ...9A1 to Y39AX Injectors engine side A Y39B1 to Y39BX Injectors engine side B Table 3 Engine wiring harness for injectors Pin assignment Designation X1 Engine Control Unit ECU X3 Engine Control Unit ECU...

Страница 56: ...1 7 B7 8 B10 9 B34 2 10 XY27 11 B34 1 12 B48 13 B4 23 14 F46 15 B33 16 B1 17 B4 21 18 XG03 19 B5 3 20 M8 21 X2 22 X37 23 XF33 24 B6 25 B44 4 26 B16 27 B4 24 28 B4 22 29 B49 30 Y26 31 B44 2 32 B9 33 B...

Страница 57: ...3 4 Y39A4 5 Y39A5 6 Y39A6 7 Y39A7 8 Y39A8 9 Y39A9 10 Y39A10 11 X4 12 E4 1 13 E4 2 14 E4 3 15 E4 4 16 E4 5 17 Y39B9 18 Y39B10 19 Y39B8 20 Y39B7 21 Y39B6 22 Y39B5 23 Y39B4 24 Y39B3 25 Y39B2 26 Y39B1 MS1...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 72: ...gth A Width B Height C 12V4000M73 93 L approx 2991 mm approx 1463 mm approx 2368 mm 16V4000M73 93 L approx 3583 mm approx 1463 mm approx 2368 mm 20V4000M73 93 L approx 4192 mm approx 1484 mm approx 23...

Страница 73: ...3 6 Firing order Number of cylinders Firing order 20V A1 B5 A8 B7 A5 B2 A7 B10 A2 B3 A10 B6 A3 B4 A6 B9 A4 B1 A9 B8 MS150048 05E 2018 03 Technical Data 71 TIM ID 0000035068 003...

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

Страница 75: ...ted above waterline Fill with water approx 3 to 4 liters Coolant circuit If engine is out of service for more than one year change coolant Page 227 Coolant circuit Check coolant level Page 225 Coolant...

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

Страница 77: ...ified or eliminated contact Service Note If an engine has been shutdown by a fault red alarm the engine may only be re started when the fault has been identified and eliminated Procedure following an...

Страница 78: ...ar protectors NOTICE Re starting the engine following an automatic safety shutdown Risk of severe engine damage Before starting the engine make sure the root cause of the safety shutdown was eliminate...

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

Страница 80: ...eks Tasks after extended out of service periods 3 weeks Note Operate fuel treatment system for at least 5 minutes 1 Start up fuel treatment system Page 80 2 Shut down fuel treatment system Page 92 78...

Страница 81: ...ves 4 Switch on fuel treatment system Page 83 5 Check direction of rotation of pump 6 Vent bypass and fuel lines of the system a Open ball valve for pressure tank b Open ball valve for overflow tank c...

Страница 82: ...drain 18 Water level electrode 19 Ball valve sample extrac tion inlet 20 Switchgear cabinet 21 Pump 22 Coarse filter 23 Fuel supply from tank 24 Tank Switching on fuel treatment system 1 Switch on fu...

Страница 83: ...speed 4 Close ball valve 5 at inlet to fuel treatment system Result The pressure upstream of the fuel treatment system increases until the overflow valve at the pump unit opens and fuel flows through...

Страница 84: ...pump draws fuel via bypass 2 directly from tank 24 5 Check suction pressure at the engine mounted fuel delivery pump Note If the suction pressure is within the admissible limits and engine operation...

Страница 85: ...ore switching on ensure that all housings are closed Before switching on ensure that no work is in progress anywhere on the entire system Fuel treatment system Switching on 1 Carry out checks prior to...

Страница 86: ...n extremely high load Risk of overheating damage to components Trigger an emergency stop only in emergency situations Emergency engine stop at BlueLine automation system Item Measure Engine Emergency...

Страница 87: ...n LOP Press illuminated pushbutton CLUTCH IN Page 72 Illuminated pushbutton CLUTCH IN flashes Clutch is engaged After receiving the feedback signal from the clutch illuminated pushbut ton CLUTCH IN li...

Страница 88: ...OUPLING OUT button flashes Coupling is disengaged After receiving the feedback signal from coupling the COUPLING OUT but ton is illuminated brightly Disengaging coupling with reversing gearbox FPP WJ...

Страница 89: ...for too long Follow instructions of the waterjet manufacturer Flushing with reversing gearbox and flushing mode Item Measure LOP Press and hold down FLUSH illuminated pushbutton Page 72 FLUSH illumin...

Страница 90: ...engine at idle speed for at least 10 minutes until engine temperatures have dropped and constant values are displayed Stopping the engine from LOP Item Measure LOP Disengage gearbox Page 72 LOP Opera...

Страница 91: ...Before shutting down disengage gear and run the engine at idle speed for at least 10 minutes until engine temperatures have dropped and constant values are displayed Stopping the engine at the BlueLi...

Страница 92: ...and if no antifreeze has been added to the coolant the engine room is not heated the coolant is not kept at a suitable temperature the antifreeze concentration is insufficient for the engine room tem...

Страница 93: ...cting the power supply to the ECU On engines with emergency air shutoff flaps the flaps close Illuminated pushbutton EMERGENCY STOP flashes Horn flashing lamp etc are tripped After an emergency stop a...

Страница 94: ...inet until water discharge from the outlet stops 2 Switch off fuel treatment system 3 Close ball valve at the inlet to the fuel treatment system 4 Close ball valve at the outlet of the fuel treatment...

Страница 95: ...un directly at seals or electronic components such as connectors or ECUs Cleaning the plant 1 Carry out plant cleaning only in areas where an appropriate oil separator is provided environmental protec...

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

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

Страница 98: ...e motor is equipped with an overload protection If the maximum permissible current consumption is exceeded e g in case of a blockage or dry running the motor protection relay triggers and the pump is...

Страница 99: ...ness faulty fuse lamp on EIM flashes with relevant flashing code u Check fuse replace as necessary and re start system by actuating key switch Engine blocked crankshaft cannot be rotated by hand 1 Che...

Страница 100: ...ure too high Cause Corrective action Engine Overload u Reduce load Air inlet temperature too high u Check fans and air supply ventilation ducts for engine room Incorrect engine coolant concentration 1...

Страница 101: ...linder compression 2 Replace cylinder head Instructions for Exchange of Sub assemblies Piston rings or cylinder liner defective 1 Check cylinder compression 2 Carry out endoscopic examination of cylin...

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

Страница 103: ...ilure ZKP Number 1 8004 204 Cause Corrective action ETC2 could not be cut in 1 Reduce power 2 Contact Service 81 AL Rail Leakage ZKP Number 1 8004 046 Cause Corrective action Pressure gradient in rail...

Страница 104: ...lace as necessary 2 Error cleared after restarting the engine 202 SD T Fuel ZKP Number 1 8004 572 Cause Corrective action Coolant temperature sensor faulty Short circuit or wire break 1 Check sensor a...

Страница 105: ...bling B4 22 replace as necessary 208 SD P Charge Air ZKP Number 1 8004 566 Cause Corrective action Charge air pressure sensor faulty Short circuit or wire break 1 Check sensor and cabling B10 replace...

Страница 106: ...Check sensor and cabling B48 replace as necessary 2 Error cleared after restarting the engine 216 SD T Lube Oil ZKP Number 1 8004 575 Cause Corrective action Lube oil temperature sensor faulty Short...

Страница 107: ...ror cleared after restarting the engine 227 SD P Lube Oil before Filter ZKP Number 1 8004 620 Cause Corrective action Sensor for lube oil pressure before filter faulty Short circuit or wire break 1 Ch...

Страница 108: ...Error cleared after restarting the engine 233 SD Charger 2 Speed ZKP Number 1 3011 129 Cause Corrective action Speed sensor of secondary turbocharger faulty Short circuit or wire break 1 Check sensor...

Страница 109: ...ed after restarting the engine 301 AL Timing Cylinder A1 ZKP Number 1 8004 500 Cause Corrective action Time of flight measuring fault of injector in cylinder A1 Time of flight measured value extremely...

Страница 110: ...ctive action Time of flight measuring fault of injector in cylinder A6 Time of flight measured value extremely low or extremely high u If alarm occurs frequently replace solenoid valve of injector 307...

Страница 111: ...10 Cause Corrective action Time of flight measuring fault of injector B1 Time of flight measured value extremely low or extremely high u If alarm occurs frequently replace solenoid valve of injector 3...

Страница 112: ...Corrective action Time of flight measuring fault of injector B6 Time of flight measured value extremely low or extremely high u If alarm occurs frequently replace solenoid valve of injector 317 AL Ti...

Страница 113: ...leared after restarting the engine 322 AL Wiring Cylinder A2 ZKP Number 1 8004 521 Cause Corrective action Short circuit in injector cabling to cylinder A2 Result Misfiring 1 Rectify injector solenoid...

Страница 114: ...by exchanging injectors 2 Error cleared after restarting the engine 328 AL Wiring Cylinder A8 ZKP Number 1 8004 527 Cause Corrective action Short circuit in injector cabling to cylinder A8 Result Misf...

Страница 115: ...by exchanging injectors 2 Error cleared after restarting the engine 334 AL Wiring Cylinder B4 ZKP Number 1 8004 533 Cause Corrective action Cabling fault in injector cabling to cylinder B4 Result Mis...

Страница 116: ...s 2 Error cleared after restarting the engine 340 AL Wiring Cylinder B10 ZKP Number 1 8004 539 Cause Corrective action Cabling fault in injector cabling to cylinder B10 Result Misfiring 1 Rectify inje...

Страница 117: ...jector replacement 2 Error clearance After each working cycle 346 AL Open Load Cylinder A6 ZKP Number 1 8004 545 Cause Corrective action Disruption fault in injector cabling to cylinder A6 Result Misf...

Страница 118: ...by replacing the injector 2 Error clearance After each working cycle 352 AL Open Load Cylinder B2 ZKP Number 1 8004 551 Cause Corrective action Disruption fault in injector cabling to cylinder B2 Res...

Страница 119: ...y replacing the injector 2 Error clearance After each working cycle 358 AL Open Load Cylinder B8 ZKP Number 1 8004 557 Cause Corrective action Disruption fault in injector cabling to cylinder B8 Resul...

Страница 120: ...ssages e g cabling faults 363 AL Stop Power Stage ZKP Number 1 8004 560 Cause Corrective action Internal electronic fault electronics possibly faulty If bit 1 1020 021 Power Stage Failure Stop Engine...

Страница 121: ...tput 3 TO 3 u Check wiring of charger valve 2 marine engine 374 AL Wiring TO 4 ZKP Number 1 8004 637 Cause Corrective action Short circuit or wire break on transistor output 4 TO 4 u Check wiring of c...

Страница 122: ...emperature sensor faulty Short circuit or wire break u Check sensor and cabling B3 replace as necessary 444 SD U PDU ZKP Number 1 8004 578 Cause Corrective action Injector power stage sensor defect In...

Страница 123: ...circuit or wire break u Check sensor and cabling replace as necessary 471 SD Coil Current ZKP Number 1 8004 592 Cause Corrective action Control of HP fuel control block faulty Short circuit or wire br...

Страница 124: ...y Short circuit or wire break u Check sensor and cabling B4 24 replace as necessary 492 AL ETC4 CutIn Failure ZKP Number 1 8004 202 Cause Corrective action ETC4 could not be cut in u Check control val...

Страница 125: ...4500 903 Cause Corrective action The battery charging generator does not charge the battery u Check battery charging generator and cabling 504 AL CAN POM node Lost ZKP Number 1 4500 904 Cause Correcti...

Страница 126: ...on Redundant lube oil pressure sensor faulty Short circuit or wire break u Check sensor and cabling replace as necessary 526 SD T Coolant R2 ZKP Number 1 8004 639 Cause Corrective action Redundant coo...

Страница 127: ...after the emergency stop signal was output u The delay between the emergency stop signal and this alarm signal is set in parameter 1 1005 4 588 SD P Oil Refill Pump ZKP Number 1 0159 910 Cause Correc...

Страница 128: ...625 SD P Fuel before Prefilter ZKP Number 1 8004 600 Cause Corrective action Analog input signal for pressure before prefilter faulty Short circuit or wire break 1 Check pressure sensor and cabling r...

Страница 129: ...y Shield A4 735233000100 3 Shield A5 735233000101 43 Shield A6 735233000102 5 Shield A7 735233000103 4 Shield A8 735233000104 6 Shield B2 735233000200 2 Shield B4 735233000202 1 Shield E5 735233000500...

Страница 130: ...possible Page 137 When affixing adhesive connections ensure that escaping fluid can flow out without pressure Page 137 Fuel system fuel lines with fuel pressure 1 8 bar Item Type of shield Installatio...

Страница 131: ...s with oil pressure 1 8 bar Item Type of shield Installation location 1 1 x shield A5 1 x shield A4 Oil line connection 2 2 x shield A5 Actuating cylinder for exhaust flap of ETC B2 3 2 x shield A5 Ac...

Страница 132: ...il line connection 2 2 x shield A5 Actuating cylinder for exhaust flap of ETC B1 3 3 x shield A5 T piece of flap control Item Type of shield Installation location 1 2 x shield A5 Actuating cylinder fo...

Страница 133: ...nder for air flap of ETC A2 Item Type of shield Installation location 1 1 x shield A5 1 x shield A4 Oil line connection 2 2 x shield A5 Actuating cylinder for exhaust flap of ETC A2 3 3 x shield A5 T...

Страница 134: ...shield Installation location 1 2 x shield A5 Air recirculation valve Item Type of shield Installation location 1 Shield A6 Oil supply line to HP pump To HP pump 132 SOLAS MS150048 05E 2018 03 TIM ID 0...

Страница 135: ...pump On equipment carrier This shield must be installed on the assembly line Assembly in this position is no longer possible after painting Item Type of shield Installation location 1 5 x shield A5 Fl...

Страница 136: ...mbly line Assembly in this position is no longer possible after painting Item Type of shield Installation location 1 1 x shield A8 Flap control to main oil gallery free end This shield must be install...

Страница 137: ...hield must be installed on the assembly line Assembly in this position is no longer possible after painting Item Type of shield Installation location 1 2 x shield A5 Connection of ETC oil supply free...

Страница 138: ...Type of shield Installation location 1 2 x shield A5 Connection of ETC oil supply driving end 2 2 x shield A6 Connection of ETC oil supply driving end 136 SOLAS MS150048 05E 2018 03 TIM ID 0000076609...

Страница 139: ...ealing cone unions Note For installation positions of sealing cone un ions see Page 128 1 Wrap three layers of adhesive tape from the middle of the sealing cone union to area A for at least 30 mm ensu...

Страница 140: ...r zone After finishing work on the engine make sure that all safety devices are put back in place and all tools are removed from the engine Engine Barring manually 1 Remove guard plate Result Safety s...

Страница 141: ...7 2 2 Barring engine with starting system Barring using the automation system Refer to automation system operating instructions MS150048 05E 2018 03 Engine 139 TIM ID 0000017532 004...

Страница 142: ...g pattern First signs of marks left by lower cooling bores Running pattern seems darker No action required Dark areas with even or varying degrees of discoloration Beginning and end of the discolorati...

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

Страница 144: ...It appears rather darker within the honed struc ture in contrast to the bright metallic running surface The honing pattern is undis turbed Discolorations extend in stroke direction and may be interrup...

Страница 145: ...s are similar A thorough investigation and compliance with the above evaluation criteria allow an unambiguous evaluation To avoid unnecessary disassembly work it is recommended that another inspection...

Страница 146: ...contain residue substances which are harmful to health Risk of injury and poisoning Allow the product to cool to below 50 C before beginning work Wear protective clothing protective gloves and goggle...

Страница 147: ...ecified tightening torque Name Size Type Lubricant Value Standard Screw Tightening torque Engine oil 10 Nm 2 Nm 6 Replace further filter elements in the same way 7 Check oil separator for leaks MS1500...

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

Страница 149: ...screw driver F30002815 1 Torque wrench 60 320 Nm F30452768 1 Socket wrench 24 mm F30039526 1 Engine oil Preparatory steps 1 Remove cylinder head covers Page 151 2 Install barring tool Page 138 Note Po...

Страница 150: ...er of the flywheel 4 The additional OT A1 mark 1 if applicable on the outer perimeter of the flywheel must not be used for reference Diagram for 8V engines Two crankshaft positions Diagram for 12V eng...

Страница 151: ...ance adjustment with cold engine Inlet valves long rocker arm 0 2 mm 0 05 mm Exhaust valves short rocker arm 0 5 mm 0 05 mm 3 Check all valve clearances in two crankshaft positions firing TDC and over...

Страница 152: ...g gauge must just pass through the gap 4 Pass valve setting gauge 3 between valve bridge and rocker arm 5 Tighten locknut 1 to specified torque using a torque wrench holding the adjusting screw 2 in p...

Страница 153: ...3 4 with washers 2 5 3 Take off cylinder head cover with O ring 6 from cylinder head 7 Installing cylinder head cover 1 Clean installation surface 2 Check O ring 6 for damage replace as necessary 3 C...

Страница 154: ...y through swallowing risk of poisoning through inhalation irritation to eyes and skin Seek medical attention immediately do not induce vomiting Do not inhale vapors or mist Wear protective clothing pr...

Страница 155: ...ox 2 Use fuel suction device to fill HP pump with 2 liters of clean engine oil 3 Screw in union 1 and use torque wrench to tighten to specified tightening torque Name Size Type Lubricant Value Standar...

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

Страница 157: ...eplacement Special tools Material Spare parts Designation Use Part No Qty Injector Spare Parts Catalog Replacing injector u Remove injector and install new injector Page 156 MS150048 05E 2018 03 Injec...

Страница 158: ...osive Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke Wear protective clothing protective gloves and safety glasses facial protection WARNING Liquid or...

Страница 159: ...of components Damage to component Observe manufacturer s instructions Check components for special cleanliness Preparatory steps 1 Allow HP system to cool down 2 Shut off fuel supply to engine 3 Remov...

Страница 160: ...on removal jig and take off hold down clamp 11 Remove installation removal jig Note The sealing ring 4 for sealing the combus tion chamber must only be used once 12 Remove sealing ring 4 from injector...

Страница 161: ...HP line only before in stallation of the adapter 3 Remove seal plug Note The damper ring is already in place for new assembly Coat damper ring with assembly compound 4 Fit damper ring 1 on injector a...

Страница 162: ...Use torque wrench to tighten screw 2 to specified tightening torque Name Size Type Lubricant Value Standard Screw M12 Tightening torque Engine oil 100 Nm 10 Nm 16 Use torque wrench to tighten adapter...

Страница 163: ...angle of rotation and without releasing the tool tighten immediately again to the specified tightening torque following the same sequence Tightening sequence 1 Adapter 4 2 Rail 6 Name Size Type Lubric...

Страница 164: ...will void the emissions certification of the engine u Reset drift compensation CDC with DiaSys Dialog system DiaSys E531920 If DiaSys is not available contact Service Final steps 1 Install cylinder he...

Страница 165: ...ry through swallowing risk of poisoning through inhalation irritation to eyes and skin Seek medical attention immediately do not induce vomiting Do not inhale vapors or mist Wear protective clothing p...

Страница 166: ...screw cut out fuel filter using an oil filter wrench 3 Clean sealing surface on filter head 4 Check sealing ring of new fuel filter and coat with fuel 5 Screw on fuel filter and tighten by hand 6 Retu...

Страница 167: ...ial pressure gage 1 When putting the new filter element into op eration Align adjustable pointer 2 with pressure indicating pointer 3 of pressure gage 1 2 Verify that differential pressure is within t...

Страница 168: ...al sparks and ignition sources Do not smoke Wear protective clothing protective gloves and safety glasses facial protection WARNING Liquid or gaseous media e g fuel are poisonous Escaping vapors of hi...

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

Страница 170: ...Seek medical attention immediately do not induce vomiting Do not inhale vapors or mist Wear protective clothing protective gloves and safety glasses If contact is made with skin wash off with water a...

Страница 171: ...ded vent plug 1 and drain valve 2 5 Open rotary slide valve 2 a little turning to approx 30 to introduce fuel into the filter housing with the new filter element 6 Close vent valves 1 as soon as fuel...

Страница 172: ...rough swallowing risk of poisoning through inhalation irritation to eyes and skin Seek medical attention immediately do not induce vomiting Do not inhale vapors or mist Wear protective clothing protec...

Страница 173: ...osen screws 1 and 2 7 Turn filter housing aside around screw 2 un til filter element is accessible 8 Remove filter element 5 with spring 6 9 Insert a new filter element in the filter hous ing 10 Inser...

Страница 174: ...with the new filter element 14 Close vent valve 1 as soon as fuel emerges from vent pipe 4 15 Turn the rotary slide valve to the upright posi tion 3 until it engages Result Both filters are cut in 16...

Страница 175: ...in the relevant safety data sheet Wear protective gear as specified in the relevant safety data sheet NOTICE Incorrect installation of components and lines Damage to component Ensure that components l...

Страница 176: ...er 5 Remove oil lines 2 6 Loosen clamp 1 7 Remove intake housing 3 with actuating cyl inder 2 8 Remove coolant lines 1 from compressor housing 3 9 Remove coolant vent line 2 from compres sor housing 3...

Страница 177: ...essor housing with a smooth paint brush or brush 2 Clean compressor wheel 2 and bearing housing 1 3 Thoroughly remove cleaner from all compo nents 4 Replace sealing rings between bearing hous ing comp...

Страница 178: ...d torque using a torque wrench Name Size Type Lubricant Value Standard Clamp Tightening torque 15 Nm 2 Nm 6 Install oil lines 2 Tighten screw fitting union at actuating cylinder to specified torque us...

Страница 179: ...rect air jet at people Always wear safety goggles face mask and ear defenders Checking condensate drain of intercooler for coolant leakage and obstruction u With the engine running check outlet of the...

Страница 180: ...tion with leak ing intercooler 1 Remove injectors Page 156 2 Bar engine manually Page 138 3 Bar engine with starting system to blow out combustion chambers Page 138 4 Install injectors Page 156 178 Ch...

Страница 181: ...l Spare parts Designation Use Part No Qty Air filter Spare Parts Catalog Replacing air filter 1 Remove old air filter and install new air filter Page 180 2 Reset signal ring of contamination indicator...

Страница 182: ...otective gloves safety goggles respiratory protection etc is to be used NOTICE Stepping or climbing on the genset to perform installation tasks is to be avoided Otherwise there is a risk of component...

Страница 183: ...r if opening of the entrance door can be prevented Only operate the engine with installed air filters Never open air carrying components during operation Ensure that the engine room is well ventilated...

Страница 184: ...l level may be up to 2 cm above mark 1 This may be caused e g by oil from oil filters and heat ex changers flowing back into the oil pan After extended standstill the oil level 2 cm above mark 2 is th...

Страница 185: ...fety mask Avoid contact with skin Do not inhale oil vapor Oil change without semirotary hand pump Draining oil via drain plug s on oil pan 1 Provide a suitable container to collect the oil 2 Remove dr...

Страница 186: ...torque 100 Nm 10 Nm Filling with new oil 1 Open cover 1 on filler neck 2 Pour oil in at filler neck up to max mark at oil dipstick 3 Close cap 1 on filler neck 4 Check engine oil level Page 182 5 Aft...

Страница 187: ...ow 50 C before beginning work Wear protective clothing protective gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor WARNING High level of engine noise when the engine is r...

Страница 188: ...6 Gasket 7 Screw fitting union 8 Gasket 9 Neck 10 Screw 11 Scavenge oil line 12 Neck 13 Gearbox flange 14 O ring 15 Screw 16 Cover 17 O ring 18 Compression spring 19 O ring 20 Strainer 21 O ring 22 In...

Страница 189: ...5 Sealing ring 6 Plug screw 7 O ring 8 Plug screw 9 O ring 10 Plug screw 11 Bypass valve 12 Sealing ring 13 O ring 14 Cover 15 Screw 16 Sealing ring 17 Screw 18 O ring 19 Cover 20 Screw MS150048 05E 2...

Страница 190: ...ng 4 Scavenge bushing 5 Sight glass 6 Flat gasket 7 O ring 8 O ring 9 Clamping ring 10 Spring washer 11 Screw 12 Worm gear 13 Grooved pin 14 Impeller 15 Washer 16 Stud 17 Nut 188 Oil Filtration Coolin...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 205: ...mask Avoid contact with skin Do not inhale oil vapor WARNING Oils oil vapors are combustible explosive Risk of fire and explosion Avoid open flames electric sparks and ignition sources Do not smoke R...

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

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

Страница 208: ...fety mask Take measures against electrostatic charging NOTICE Cleaning agents should not be left to take effect for too long Damage to components is possible Observe manufacturer s instructions Oil fi...

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

Страница 210: ...nent Check components for special cleanliness and clean if necessary NOTICE Ingress of contamination from automatic oil filter in the engine oil system Severe engine damage possible Remove the automat...

Страница 211: ...rainer plate 5 Align coiled spring pin 7 with groove 6 in connecting pipe 5 and install top strainer plate 6 Coat threads of screws 1 with screw locking compound 7 Insert screws 1 and tighten 8 Coat O...

Страница 212: ...15 Screw on sealing nut 5 16 Lock flushing arm 4 in position and tighten sealing nut 5 with torque wrench to the specified torque Name Size Type Lubricant Value Standard Sealing nut Tightening torque...

Страница 213: ...fied torque using a torque wrench Name Size Type Lubricant Value Standard Screw Tightening torque Engine oil 9 Nm 20 Fit filter indicator 2 with spring on sealing nut 1 MS150048 05E 2018 03 Oil Filtra...

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

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

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

Страница 217: ...s and goggles safety mask Take measures against electrostatic charging WARNING Oil is hot Oil can contain residue substances which are harmful to health Risk of injury and poisoning Allow the product...

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

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

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

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

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

Страница 223: ...WARNING Oil is hot Oil can contain residue substances which are harmful to health Risk of injury and poisoning Allow the product to cool to below 50 C before beginning work Wear protective clothing p...

Страница 224: ...ealing ring 9 13 Insert new filter sleeve 6 in rotor pipe 7 with the smooth paper surface facing the out er wall 14 Check sealing ring 5 replace if necessary 15 Install rotor cover 4 with sealing ring...

Страница 225: ...pecial cleanliness NOTICE Incorrect installation of components and lines Damage to component Ensure that components lines are installed so that they are never under tension or strain Ensure correct in...

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

Страница 227: ...e and remove 3 Check engine coolant level engine coolant must be visible at bottom edge of cast in eye of filler neck Checking coolant level at exter nal cooler Note Engine coolant must be visible at...

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

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

Страница 230: ...k counterclockwise to first stop and allow pressure to escape 2 Continue to turn breather valve counterclock wise and remove 3 Draw off precipitated corrosion inhibitor oil from the expansion tank thr...

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

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

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

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

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

Страница 236: ...e is running Risk of damage to hearing Wear ear protectors Engine coolant Sample extrac tion and analysis 1 Open drain valve on engine coolant pump el bow with the engine running 2 Drain off approx 1...

Страница 237: ...isk of damage to hearing Wear ear protectors Raw water pump relief bore check 1 Check relief bore for oil and raw water dis charge 2 Stop engine Page 76 and disable engine start observe general safety...

Страница 238: ...tion check 1 Install barring tool Page 138 2 Guide endoscope optics between guard plate 1 and battery charging generator car rier 2 arrow Note Seek the assistance of a second person 3 Bar engine slowl...

Страница 239: ...ife or destruction of the mounts Cover engine mounts when working with fuel or oil Remove contaminations on the rubber mounts immediately with a dry cloth and degrease them Engine mounting Check Item...

Страница 240: ...System 7 19 1 Water drain valve Check Water drain valve Check 1 Open water drain valve 2 Check water outlet for obstructions 3 Close water drain valve 238 Fuel Supply System MS150048 05E 2018 03 TIM I...

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

Страница 242: ...om water level probe 2 Unscrew water level probe 3 Disconnect plug from water level probe 4 Immerse water level probe into a tank filled with water until water level reaches the thread 5 Switch on pla...

Страница 243: ...e outlet of the fuel treatment system c Check pressure at the pressure gauge in the inlet to the fuel treatment system and note down 3 Checking pump pressure with reduced suction a Reduce suction pres...

Страница 244: ...eanliness NOTICE Incorrect installation of components and lines Damage to component Ensure that components lines are installed so that they are never under tension or strain Ensure correct installatio...

Страница 245: ...g torque Engine oil 30 Nm 3 Nm 17 Fit seal 10 18 Install cover 19 Install screws 1 washers 2 and nuts 9 20 Tighten nuts 9 21 Open ball valve at the inlet and outlet of the fuel treatment system Result...

Страница 246: ...intact 4 Replace faulty cable clips 5 Check cable clamps for secure fit tighten loose clamps 6 Replace faulty cable clamps 7 Visually inspect the following electrical components for damage Connector h...

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

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

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

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

Страница 251: ...king EMU plug connections 1 Check both connectors on EMU 2 for firm seating Ensure that the clips 1 are engag ed 2 Check screws 3 of cable clamps on EMU 2 for firm seating Ensure that cable clamps are...

Страница 252: ...EIM plug connections 1 Check both Tyco plugs 62 pole 2 on EIM for firm seating Ensure that clips 3 are en gaged 2 Check screws 1 of cable clamps on EIM for firm seating Ensure that cable clamps are no...

Страница 253: ...The contacts in the plug connection can be bent Carry out check of plug connection only with test connectors Checking plug connections at engine governor 1 Check all plug connections for secure seatin...

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

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

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

Страница 257: ...ion 4 Application loader active 5 External RAM defective 6 External FLASH defective 7 No firmware 8 Application crashed Fuse lamp SILA A second indicator is the fuse lamp This is also integrated in th...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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Содержание 20V4000M93 series

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Содержание 20V4000M93 series

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