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MTU 8V4000Mx4, Руководство по эксплуатации

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7.23.7 EMU 8 – Removal and installation

Preconditions

☑

Engine is stopped and starting disabled.

NOTICE

Wrong engine governor installed.
Engine damage!
• When reassembling an engine, make sure that the governor with the data record for the given engine

is installed.

Remove ECU with EMU from en-
gine

1.

Note or mark assignment of cables and con-
nectors.

2.

Remove all screws (2).

3.

Undo clips (3) on connectors.

4.

Disconnect all connectors.

5.

Remove screws (1).

6.

Remove ECU (5) with EMU (4).

Removing EMU

1.

Unscrew screws on base of EMU (4).

2.

Remove EMU (4) from ECU (5).

Installing EMU

1.

Place EMU (4) on ECU (5).

2.

Screw in and tighten screws on base of EMU (4).

Installing ECU with EMU on engine

1.

Install in reverse order. Ensure correct assignment of plugs and sockets.

2.

Check resilient mount before installing.

Result:

If resilient mount is porous or defective then replace it.

MS150109/01E 2015-11

| Task Description | 261

TIM-ID: 0000044017 - 002

Содержание 8V4000Mx4

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

Страница 2: ...nd may not be used in any way whether in whole or in part without the prior writ ten consent of MTU Friedrichshafen GmbH This particularly applies to its reproduction distribution editing translation...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 20: ...ightening torques for plug screws to DIN 908 DIN 910 and DIN 7604A with short threaded end Thread Screwed into Steel gray cast iron MA Nm AI alloy MA Nm M10 x 1 15 15 M12 x 1 5 25 25 M14 x 1 5 35 30 M...

Страница 21: ...Steel gray cast iron M A Nm Al alloy MA Nm M8 x 1 10 10 M22 x 1 5 80 65 M26 x 1 5 105 90 M30 x 1 5 130 130 M38 x 1 5 140 120 M45 x 1 5 160 140 MA tightening torques Tightening torques for banjo screws...

Страница 22: ...le deviations during the tightening process Tightening torques for steel banjo screws Thread inserted in steel gray cast iron aluminum alloy MA Nm M8 x 1 10 M10 x 1 15 M12 x 1 5 20 M14 x 1 5 25 M16 x...

Страница 23: ...iled or galvanized Threads and mating faces beneath heads must be coated with engine oil prior to assembly An assembly tolerance of 10 of the figures in the table is permitted due to unavoidable devia...

Страница 24: ...on nut firmly by hand noticeable increase in force it should be tightened another 1 4 turn 90 past this point Tightening torques for spigot unions with O ring to ISO 6149 2 Thread Torque Nm 10 M8 x 1...

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

Страница 26: ...tings In contrast to the instructions for pipe unions hose fittings with sealing heads and the matching adapters must be fitted and connected as follows Hose fitting forming metallic seal with union n...

Страница 27: ...2 35 290 M52 x 2 38 42 330 Sealing head with BSP union nut BSPP thread Torque Nm G1 4 20 G3 8 34 G1 2 60 G5 8 69 G3 4 115 G1 140 G1 1 4 210 G1 1 2 290 G2 400 SAE sealing cone with union nut JIC 37 UNF...

Страница 28: ...Torque Nm 9 16 18 4 14 2 11 16 16 6 24 3 13 16 16 8 43 4 1 14 10 60 8 1 3 16 12 12 90 5 1 3 16 12 14 90 5 1 7 16 12 16 125 10 1 11 16 12 20 170 20 2 12 24 200 25 2 1 2 20 32 460 30 28 General Informa...

Страница 29: ...cordance with DIN ISO 1204 as viewed from driving end 4 For cylinder designation in accordance with DIN ISO 1204 the letter Ax refers to the cylinders on the left hand side of the engine 1 and letter...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 79: ...ves 4 Switch on fuel treatment system Page 83 5 Check direction of rotation of pump 6 Vent bypass and fuel lines of the system a Open ball valve for pressure tank b Open ball valve for overflow tank c...

Страница 80: ...drain 18 Water level electrode 19 Ball valve sample extrac tion inlet 20 Switchgear cabinet 21 Pump 22 Coarse filter 23 Fuel supply from tank 24 Tank Switching on fuel treatment system 1 Switch on fu...

Страница 81: ...speed 4 Close ball valve 5 at inlet to fuel treatment system Result The pressure upstream of the fuel treatment system increases until the overflow valve at the pump unit opens and fuel flows through...

Страница 82: ...pump draws fuel via bypass 2 directly from tank 24 5 Check suction pressure at the engine mounted fuel delivery pump Note If the suction pressure is within the admissible limits and engine operation...

Страница 83: ...ore switching on ensure that all housings are closed Before switching on ensure that no work is in progress anywhere on the entire system Fuel treatment system Switching on 1 Carry out checks prior to...

Страница 84: ...h load Risk of overheating damage to components Trigger an emergency stop only in emergency situations Emergency engine shutdown via automation system Item Measure Automation system Emergency shutdown...

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

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

Страница 87: ...for too long Follow instructions of the waterjet manufacturer Flushing with reversing gearbox and flushing mode Item Measure LOP Press and hold down FLUSH illuminated pushbutton Page 72 FLUSH illumin...

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

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

Страница 90: ...inet until water discharge from the outlet stops 2 Switch off fuel treatment system 3 Close ball valve at the inlet to the fuel treatment system 4 Close ball valve at the outlet of the fuel treatment...

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

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

Страница 93: ...y and re start the system by actuating the key switch Engine blocked engine cannot be barred manually u Contact Service Engine turns on starting but does not fire Cause Corrective action Poor rotation...

Страница 94: ...dicator Page 217 Intercooler dirty u Contact Service Exhaust turbocharger faulty u Contact Service Coolant leaks at intercooler Cause Corrective action Intercooler leaking major coolant discharge u Co...

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

Страница 96: ...s equipped with an overload protection If the maximum permissible current consumption is exceeded e g in case of a blockage or dry running the motor protection relay triggers and the pump is switched...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 172: ...parts Risk of crushing danger of parts of the body being caught or pulled in Before barring the engine make sure that there are no persons in the engine s danger zone After finishing work on the engi...

Страница 173: ...e No resistance other than compression resist ance must be encountered 4 Rotate crankshaft in engine direction of rota tion Result If the resistance exceeds the normal com pression resistance contact...

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

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

Страница 176: ...Depending on findings Do not take any action or carry out a further endoscopic examination as part of maintenance work or contact Service cylinder liner must be replaced Final steps 1 Install injecto...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 193: ...ry through swallowing risk of poisoning through inhalation irritation to eyes and skin Seek medical attention immediately do not induce vomiting Do not inhale vapors or mist Wear protective clothing p...

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

Страница 195: ...el filter Overview 1 Storage tank 2 Day tank 3 Passive fuel prefilter with water separator 4 LP pump 5 Additional fuel filter switch able 6 Main engine filter switcha ble MS150109 01E 2015 11 Task Des...

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

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

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

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

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

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

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

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

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

Страница 205: ...Risk of fatal injury through swallowing risk of poisoning through inhalation irritation to eyes and skin Seek medical attention immediately do not induce vomiting Do not inhale vapors or mist Wear pro...

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

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

Страница 208: ...do not induce vomiting Do not inhale vapors or mist Wear protective clothing protective gloves and safety glasses If contact is made with skin wash off with water and soap WARNING Fuels are combustibl...

Страница 209: ...rovided in the relevant safety data sheet Wear protective gear as specified in the relevant safety data sheet NOTICE Inappropriate cleaning tool Risk of damage to component Observe manufacturer s inst...

Страница 210: ...tercooler 5 Disconnect oil lines 2 from air flap actuator cylinder 6 Undo screws 3 and clamp 2 7 Remove intake housing 1 with actuating cyl inder 8 Remove coolant lines 1 on compressor housing 210 Tas...

Страница 211: ...n compressor housing with a soft brush 2 Clean compressor wheel 2 and bearing housing 1 3 Thoroughly remove cleaning agent from all parts 4 Replace sealing rings between bearing hous ing compressor ho...

Страница 212: ...m 1 Nm 3 Install coolant lines 1 on compressor hous ing 4 Install intake housing 1 with actuating cylin der 5 Align clamp 2 and tighten to specified torque using a torque wrench Name Size Type Lubrica...

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

Страница 214: ...Never direct air jet at people Always wear safety goggles face mask and ear defenders Checking intercooler water drain for coolant leakage and obstruction 1 With the engine running check the drain bo...

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

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

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

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

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

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

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

Страница 222: ...o not inhale oil vapor Oil change without semirotary hand pump Draining oil at drain plug s on oil pan 1 Provide a suitable vessel in which to collect the engine oil 2 Remove drain plug s and drain en...

Страница 223: ...orque Engine oil 100 Nm 10 Nm Filling with new engine oil 1 Open cap 1 on filler neck 2 Pour oil in at filler neck up to max mark on oil dipstick 3 Close cap on filler neck 4 Check engine oil level Pa...

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

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

Страница 226: ...d goggles safety mask Avoid contact with skin Do not inhale oil vapor NOTICE Damage to component Severe material damage For filter replacement with the engine running operate the engine at low engine...

Страница 227: ...9 Check engine oil level Page 219 Engine oil filter with diverter option Oil filter replacement with engine running 1 To cut out the filter to be replaced set the three way cock to the corresponding p...

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

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

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

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

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

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

Страница 234: ...oling system counterclockwise up to the first stop and allow pressure to escape 2 Continue to turn breather valve counterclockwise and remove 3 Check coolant level coolant must be visible at the botto...

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

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

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

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

Страница 239: ...Risk of damage to hearing Wear ear protectors HT coolant pump Relief bore check 1 Check relief bore for oil and coolant dis charge 2 Stop engine Operating Instructions for Electronic System and disabl...

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

Страница 241: ...ant The circulating pump 8 ensures the circulation of the pre heated coolant through the engine The flow heater 5 incorporates a heating element When the coolant temperature has reached the value of t...

Страница 242: ...ng unit 1 On Off switch Number of cylinders Rated voltage frequency Heating output kW 8 V 230 V 50 Hz 4 5 400 V 50 Hz 4 5 230 V 60 Hz 4 5 440 V 60 Hz 4 5 242 Task Description MS150109 01E 2015 11 TIM...

Страница 243: ...return flap 3 prevents coolant from flowing through the preheating unit when the engine is running When the coolant temperature has reached the value of the thermostat setting the thermostat 5 switch...

Страница 244: ...se when the engine is running Risk of damage to hearing Wear ear protectors Raw water pump Relief bore check 1 Check relief bore for oil and coolant dis charge 2 Stop engine Page 88 and disable engine...

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

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

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

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

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

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

Страница 251: ...the outlet of the fuel treatment system c Check pressure at the pressure gauge in the inlet to the fuel treatment system and note down 3 Checking pump pressure with reduced suction a Reduce suction p...

Страница 252: ...r special cleanliness NOTICE Incorrect installation of components and lines Damage to component Ensure that components lines are installed so that they are never under tension or strain Ensure correct...

Страница 253: ...Tightening torque Engine oil 30 Nm 3 Nm 17 Fit seal 10 18 Install cover 19 Install screws 1 washers 2 and nuts 9 20 Tighten nuts 9 21 Open ball valve at the inlet and outlet of the fuel treatment sys...

Страница 254: ...closed and intact 4 Replace faulty cable clips 5 Check cable clamps for secure fit tighten loose clamps 6 Replace faulty cable clamps 7 Visually inspect the following electrical components for damage...

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

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

Страница 257: ...starting disabled Check plug connections on ECU 7 1 Check all connectors on ECU for firm seating Ensure that the clips 1 are engaged 2 Check screws 2 of cable clamps on ECU for firm seating Ensure th...

Страница 258: ...tarting disabled Checking EMU plug connections 1 Check both connectors on EMU 2 for firm seating Ensure that the clips 1 are engag ed 2 Check screws 3 of cable clamps on EMU 2 for firm seating Ensure...

Страница 259: ...ng disabled Checking EIM plug connections 1 Check both Tyco plugs 62 pole 2 on EIM for firm seating Ensure that clips 3 are en gaged 2 Check screws 1 of cable clamps on EIM for firm seating Ensure tha...

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

Страница 261: ...all screws 2 3 Undo clips 3 on connectors 4 Disconnect all connectors 5 Remove screws 1 6 Remove ECU 5 with EMU 4 Removing EMU 1 Unscrew screws on base of EMU 4 2 Remove EMU 4 from ECU 5 Installing EM...

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

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

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

Страница 265: ...S1 and fuse S4 failure 1 2 second steps Note These bit patterns are continuously transmitted The CAN message Status of internal power supply also contains information on the current path states of the...

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

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

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

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

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

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

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

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

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

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

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

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

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

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