MARINE GENSET SYSTEM DOCUMENTATION

TABLE OF CONTENT Cosco N608

Order No.1107328 (2x 12V4000M33S Genset)

1 TEST REPORTS - CERTIFICATES NUMBER FOLDER INDEX

1.1 GENSET 1
1.1.1 GENSET - IDENTIFICATION PLATE 1107328/7 1 1
1.1.2 GENSET - TEST REPORT 1 1
1.1.3 GENSET - LOAD TEST 1 1
1.1.4 ENGINE - TEST REPORT 526108463 1 1
1.1.5 ENGINE - CLASS CERTIFICATE 1 1
1.1.5 GENERATOR - TEST REPORT 605809/3 1 1
1.1.7 GENERATOR - CLASS CERTIFICAT 1 1
1.2 GENSET 2
1.2.1 GENSET - IDENTIFICATION PLATE 1107328/8 1 2
1.2.2 GENSET - TEST REPORT 1 2
1.2.3 GENSET - LOAD TEST 1 2
1.2.4 ENGINE - TEST REPORT 526108466 1 2
1.2.5 ENGINE - CLASS CERTIFICATE 1 2
1.2.6 GENERATOR - TEST REPORT 605809/4 1 2
1.2.7 GENERATOR - CLASS CERTIFICAT 1 2
2 CALCULATIONS
2.1 TORSIONAL VIBRATION CALCULATION TEM 50696 1 3
2.2 CALCULATION OF THE RESILIENT MOUNTING SYSTEM TEM 50699 1 4
3 OPERATING INSTRUCTIONS
3.1 ENGINE AND AUTOMATION
3.1.1 GENSET - TECHNICAL PRODUCT DATA MG12V4000M33S 1 5
3.1.1 ENGINE - TECHNICAL PRODUCT DATA 12V4000M33S 1 5
3.1.2 ENGINE - OPERATING INSTRUCTION 1 6
3.1.3 ENGINE - FUNCTIONAL DESCRIPTION 1 7
3.1.4 EIM - FUNCTIONAL DESCRIPTION 1 8
3.1.5 GENOLINE - SYSTEM DESCRIPTION 1 9
3.1.6 GENOLINE - INSTALLATION INSTRUCTION 1 10
3.1.7 GENOLINE - DATA PROTOCOLS J1939 and CAN-open 1 11
3.2 GENERATOR
3.2.1 GENERATOR - TECHNICAL DATA Manual 605809, section 1 1 12
3.2.2 GENERATOR - SERVICE & OPERATING MANUAL Manual 605809, section 3 1 13
3.2.3 GENERATOR - LS DOCUMENTAION (COMPLETE) Manual 605809 1 14
4 FLUIDS AND LUBRICANTS
4.1 ENGINE - FLUIDS AND LUBRICANTS SPECIFICATION 2 1
4.1 ENGINE - PRESERVATION SPECIFICATION 2 1
4.2 ALTERNATOR - LUBRICANT ROLLER BEARING Manual 605809, section 1.6 2 2
5 MAINTENANCE AND SPARE PARTS
5.1 ENGINE - MAINTENANCE SCHEDULE 2 3
5.2 GENERATOR - MAINTENANCE SCHEDULE ( see also 3.2.2) Manual 605809, section 3 2 4
5.3 ENGINE - SPARE PARTS 2 5
5.4 GENERATOR - SPARE PARTS Manual 605809, section 1 2 6
6 DRAWINGS AND WIRING DIAGRAMS
6.0 DRAWING LIST 2 7
6.1 GENSET SYSTEM
6.1.1 AO GENSET XZ599001_107041 2 7
6.1.2 AO GENSET XZ599002_107041 2 7
6.2 ENGINE SYSTEM
6.2.1 ENGINE - POSITION NO FOR 2000/4000 INSTAL DRWS 5550008899 2 8
6.2.2 ENGINE - EXTERNAL COOLING, INSTALLATION DRAWING XZ59400000168 2 8
6.2.3 ENGINE - FOR EXTERNAL COOLING, ARRANGEMENT XZ59400000231 2 8
6.2.4 ENGINE - REMOVAL SPACES XZ59400000207 2 8
6.3 STARTING SYSTEM
6.3.1 AIR STARTER HOOK UP 5280040017 2 9
6.3.2 AIR STARTER LEFT XZ59317300001 2 9
6.3.3 STARTING VALVE ELECTR. OPERATED XZ59317500001 2 9
6.3.4 ARRANGEMENT METAL HOSE S4000/2000 5801700199 2 9
6.3.5 CART HOSE ARRANGEMENT 5580031120 2 9
6.3.6 PREHEATER XZ59520200233 2 9
6.3.7 STARTING SYSTEM BZ59300000015 2 9
6.4 LUBE OIL SYSTEM
6.4.1 ARRANGEMENT GEARCASE COVER OIL PRIMING 5240010018 2 10
6.4.2 INSTALLATION DRAWING VALVE NON RETURN 5591800099 2 10
6.4.3 PUMP UNIT XZ59418100013 2 10
6.4.4 SCREENING STRIP x00023728 2 10
6.4.5 LUBE OIL SYSTEM BZ59300000003 2 10
6.5 FUEL SYSTEM
6.5.1 HOSE XZ59599100144 2 11
6.5.2 FUEL PREFILTER XZ59436400011 2 11
6.5.3 FUEL SYSTEM BZ59300000005 2 11
6.6 COOLING SYSTEM
6.6.1 CAHRT BELLOWS RUBBER ARANGEMENT 5800000420 2 12
6.6.2 ARRANGEMENT RUBBER HOSE CHART 5610030020 2 12
6.6.3 PRESSURE CAP (EXPANSION TANK) 0002000017 2 12
6.6.4 ARR DWG FOR COOLANT SYSTEM INSTALLATION X00033825 2 12
6.6.5 COOLANT SYSTEM BZ59300000004 2 12
6.7 COMBUSTION AIR SYSTEM
6.7.1 AIR SYSTEM XZ59412000007 2 13
6.7.2 AIR FILTER 5240900099 2 13
6.7.3 AIR/EXHAUST SYSTEM BZ59300000006 2 13
6.8 EXHAUST SYSTEM
6.8.1 EXHASUT ELBOW XZ59414000005 2 14
6.8.2 EXH PIPE BELLOWS XZ59414500017 2 14
6.8.3 FLANGE 5260020714 2 14
6.8.4 EXHAUST GAS SILENCER DN450 XZ59514500015 2 14
6.9 ENGINE MOUNTING
6.9.1 ENGINE MOUNTING XZ52723100022 2 15
6.9.2 ENGINE MOUNTING XZ59523000001 2 15
6.9.3 ENGINE SUPPORT XZ59423100037 2 15
6.11 ENGINE MANAGEMENT SYSTEM
6.11.1 MONITOR ENGINE-SIDE BZ00E50200082 2 17
6.11.2 PRESSURE SENSOR 5205352699 2 17
6.11.3 CABLING FOR AIR START XZ00E50000441 2 17
6.11.4 CABLING FOR AIR START XZ00E50000525 2 17
6.11.5 LEVEL MONITOR XZ00E50203664 2 17
6.12 GOVERNOR
6.12.1 ALARM AND LIMIT VALUE LIST XZ59400100065 2 18
6.13 GENERATOR
6.13.1 GENERATOR - MAIN DIMENSIONS EN605809_T1+T2 2 19
6.13.2 GENERATOR - TERMINAL BOX TB605809_T1+T2 2 19
6.13.3 GENERATOR - CABLING S605809 2 19
6.14 AUTOMATION CONFIGURATION, ENGINE ROOM
6.14.1 CONTROL CONSOLE FOR ONBOARD GENSET BZ00E50200604 2 20
6.14.2 INSCRIPTION FOR CONTROL PANEL XZ00E51000137 2 20
6.14.3 TERMINAL BOX FOR ONBOARD GENSET BZ00E50200733 2 20
6.14.4 CABLING FOR ONBOARD GENSET OVERVIEW SHIP BZ599002-107328 2 20
 1107328/7
2014
1480 kWe
0,8
100
45
60
690 4530
1548 1825
2300
14000 2130
G2 1400
1850
PR149022-000 1100
14000
 1107328/8
2014
1480 kWe
0,8
100
45
60
690 4530
1548 1825
2300
14000 2130
G2 1400
1850
PR149023-000 1100
14000
TEM 50 696 Page 2

3 OPERATIONAL DATA

- Stationary operation calculated with

fuel stop power (110 %) 1716 kW within a speed range of 1800 rpm ±5 %

- Engine start and run-up calculated with

const. mean eff. pressure pme = 7.5 bar between 80 and 1800 rpm

4 DOCUMENTATION

- Centa coupling CM 18000 HTC 72Sh acc. to MTU drawing no. XZ59425200071.
An ambient temperature of 45 °C has been based for the calculation.

- Leroy Somer alternator LSA 52.2 M60/4p acc. to Leroy Somer drawing
no. P1 605 914.
Mass moment of inertia J = 50.4 kgm².
Air gap torque at short circuit acc. to DNV rules for classifications of ships and Leroy
Somer reference sheet: 605613

5 IMPORTANT NOTE

This torsional vibration calculation is a mathematical model of the power train

undertaken by MTU for the sole purpose of verifying that the torsional load levels applied
to the power train are within the permissible range. For assessment and interpretation of
the results, reasonable tolerances in the component characteristics and variations of the
exciting gas pressures have to be considered. The effects of the torsional vibrations on
the environment as well as the necessity of further analyses (e.g. whirling vibration
calculation) must be checked by the party having the system responsibility.
TEM 50 696 Page 3

6 LIST OF ILLUSTRATIONS

Fig. 1 - Mass elastic system

Fig. 2 - Resonance speeds
Fig. 3-7 - Natural modes

Stationary operation:

Fig. 8 - Crankshaft stresses Normal and 1-cyl. misfiring op. mode

Fig. 9 - Engine damper stresses Normal and 1-cyl. misfiring op. mode
Fig. 10 - Centa CM 18000 HTC 72Sh stresses Normal and 1-cyl. misfiring op. mode
Fig. 11 - Alternator shaft stresses Normal and 1-cyl. misfiring op. mode
Fig. 12 - Alternator fan angular acceleration Normal and 1-cyl. misfiring op. mode

Engine start and run-up:

Fig. 13 - Crankshaft stresses Normal and 1-cyl. misfiring op. mode

Fig. 14 - Engine damper stresses Normal and 1-cyl. misfiring op. mode
Fig. 15 - Centa CM 18000 HTC 72Sh stresses Normal and 1-cyl. misfiring op. mode
Fig. 16 - Alternator shaft stresses Normal and 1-cyl. misfiring op. mode
Fig. 17 - Alternator fan angular acceleration Normal and 1-cyl. misfiring op. mode

Torque impact due to short circuit:

Fig. 18 - Air gap torque

Fig. 19 - Crankshaft stresses
Fig. 20 - Centa CM 18000 HTC 72Sh stresses
Fig. 21 - Alternator shaft stresses
Fig. 21 - Alternator fan angular acceleration

Note: Normal operation = solid line

1-cylinder misfiring operation = dashed line

________
 12V 4000 M33S TEM 50696
Mass-Elastic-System COSCO N606
12V 4000 M33S - Centa coupling CM 18000 HTC 72Sh - Leroy Somer alternator LSA 52.2 M60/4p
MTU order number: 1107041

D44/8/2 > 0.284 D44/8/2 > 3.59

D44/8/2
0.79
< rigid

Cr.shaft end KGS > 0.29

16.3 < Cr.shaft end KGS 2

GW Cr.shaft KGS > 0.138

9.3 < Cr.shaft end KGS 1

Cyl. A6 > 0.5365

< rigid

Cyl. B6 > 0.5365

7.2 < MBJ 5-6

Cyl. A5 > 0.5365

< rigid

Cyl. B5 > 0.5365

7.2 < MBJ 4-5

Cyl. A4 > 0.5365

< rigid

Cyl. B4 > 0.5365

7.2 < MBJ 3-4

Cyl. A3 > 0.5365

< rigid

Cyl. B3 > 0.5365

7.2 < MBJ 2-3

Cyl. A2 > 0.5365

< rigid

Cyl. B2 > 0.5365

7.2 < MBJ 1-2

Cyl. A1 > 0.542

< rigid

Cyl. B1 > 0.542

9.7 < Cr.shaft end KS

Flywheel > 10.29

< Rigid

CM 18000 HTC 72Sh > 3.606

0.3016 < CM 18000 HTC 72Sh

CM 18000 HTC 72Sh > 2.232

10.484 < Alternator input shaft

Alternator Fan > 10.706

43.711 < Alternator shaft C2

Alternator Magnetic wheel > 37.975

29.36 < Alternator shaft C3

Moment of Inertia in kgm²
Alternator Exciter > 1.739 Stiffness in MNm/rad

Asare 01.07.2014 Fig. 1

 12V 4000 M33S TEM 50696
Resonance Speeds COSCO N606
12V 4000 M33S - Centa coupling CM 18000 HTC 72Sh - Leroy Somer alternator LSA 52.2 M60/4p
MTU order number: 1107041
Natural Frequencies
Frequency in 1/sec

300
F = 297.3

F = 287.9

200

5.5. Order

4.5. Order

F = 133.2

3.5. Order

100
3.0. Order

2.5. Order

F = 64.1

1.5. Order

1.0. Order

F = 20.6
0.5. Order

0 F = 3.0E-6
0 1000 2000
Rotary Speed in 1/min

Asare 01.07.2014 Fig. 2

 D44/8/2 0.01 D44/8/2

50%
50%
50%

100%
100%
100%
rigid 0.0

Cr.shaft end KGS 0.01 Cr.shaft end KGS

Cr.shaft end KGS 2 0.0

GW Cr.shaft KGS 0.0 GW Cr.shaft KGS

1890.0 1/min - 20.62 Hz

1890.0 1/min - 20.62 Hz
1890.0 1/min - 20.62 Hz
Mode Shape - X Rotation

Cr.shaft end KGS 1 0.0

Cyl. A6 0.02 Cyl. A6

rigid 0.0

Asare 01.07.2014
Kinetic Energy Distribution - X Rotation
Cyl. B6 0.02 Cyl. B6

Potential Energy Distribution - X Rotation

MBJ 5-6 0.0

Cyl. A5 0.02 Cyl. A5

rigid 0.0

Cyl. B5 0.02 Cyl. B5

MTU order number: 1107041

MBJ 4-5 0.0

Cyl. A4 0.02 Cyl. A4

rigid 0.0

Cyl. B4 0.02 Cyl. B4

MBJ 3-4 0.0

Cyl. A3 0.02 Cyl. A3

rigid 0.0

Cyl. B3 0.02 Cyl. B3

MBJ 2-3 0.01

Cyl. A2 0.01 Cyl. A2

rigid 0.0

Cyl. B2 0.01 Cyl. B2

MBJ 1-2 0.01

Cyl. A1 0.01 Cyl. A1

rigid 0.0

Cyl. B1 0.01 Cyl. B1

Natural modes
12V 4000 M33S

Cr.shaft end KS 0.01

Flywheel 0.25 Flywheel

Rigid 0.0

CM 18000 HTC 72Sh 0.09 CM 18000 HTC 72Sh

CM 18000 HTC 72Sh 0.93

CM 18000 HTC 72Sh 0.01 CM 18000 HTC 72Sh

Alternator input shaft 0.02

Alternator Fan 0.06 Alternator Fan

Alternator shaft C2 0.0

Alternator Magnetic wheel 0.23 Alternator Magnetic wheel

Alternator shaft C3 0.0

Alternator Exciter 0.01 Alternator Exciter

D44/8/2 0.13 D44/8/2

D44/8/2 0.01
12V 4000 M33S - Centa coupling CM 18000 HTC 72Sh - Leroy Somer alternator LSA 52.2 M60/4p

Fig. 3
COSCO N606
TEM 50696

D44/8/2 0.01 D44/8/2

 D44/8/2 0.0 D44/8/2

50%
50%
50%

100%
100%
100%
rigid 0.0

Cr.shaft end KGS 0.0 Cr.shaft end KGS

Cr.shaft end KGS 2 0.03

GW Cr.shaft KGS 0.0 GW Cr.shaft KGS

1890.0 1/min - 64.14 Hz

1890.0 1/min - 64.14 Hz
1890.0 1/min - 64.14 Hz
Mode Shape - X Rotation

Cr.shaft end KGS 1 0.05

Cyl. A6 0.0 Cyl. A6

rigid 0.0

Asare 01.07.2014
Kinetic Energy Distribution - X Rotation
Cyl. B6 0.0 Cyl. B6

Potential Energy Distribution - X Rotation

MBJ 5-6 0.07

Cyl. A5 0.0 Cyl. A5

rigid 0.0

Cyl. B5 0.0 Cyl. B5

MTU order number: 1107041

MBJ 4-5 0.08

Cyl. A4 0.0 Cyl. A4

rigid 0.0

Cyl. B4 0.0 Cyl. B4

MBJ 3-4 0.08

Cyl. A3 0.0 Cyl. A3

rigid 0.0

Cyl. B3 0.0 Cyl. B3

MBJ 2-3 0.07

Cyl. A2 0.0 Cyl. A2

rigid 0.0

Cyl. B2 0.0 Cyl. B2

MBJ 1-2 0.07

Cyl. A1 0.01 Cyl. A1

rigid 0.0

Cyl. B1 0.01 Cyl. B1

Natural modes
12V 4000 M33S

Cr.shaft end KS 0.04

Flywheel 0.18 Flywheel

Rigid 0.0

CM 18000 HTC 72Sh 0.06 CM 18000 HTC 72Sh

CM 18000 HTC 72Sh 0.04

CM 18000 HTC 72Sh 0.0 CM 18000 HTC 72Sh

Alternator input shaft 0.0

Alternator Fan 0.0 Alternator Fan

Alternator shaft C2 0.0

Alternator Magnetic wheel 0.0 Alternator Magnetic wheel

Alternator shaft C3 0.0

Alternator Exciter 0.0 Alternator Exciter

D44/8/2 0.71 D44/8/2

D44/8/2 0.48
12V 4000 M33S - Centa coupling CM 18000 HTC 72Sh - Leroy Somer alternator LSA 52.2 M60/4p

Fig. 4
COSCO N606
TEM 50696

D44/8/2 0.0 D44/8/2

 D44/8/2 0.05 D44/8/2

50%
50%
50%

100%
100%
100%
rigid 0.0

Cr.shaft end KGS 0.05 Cr.shaft end KGS

Cr.shaft end KGS 2 0.0

GW Cr.shaft KGS 0.03 GW Cr.shaft KGS

Mode Shape - X Rotation

1890.0 1/min - 133.18 Hz

Cr.shaft end KGS 1 0.0

1890.0 1/min - 133.18 Hz

1890.0 1/min - 133.18 Hz

Cyl. A6 0.11 Cyl. A6

rigid 0.0

Asare 01.07.2014
Kinetic Energy Distribution - X Rotation
Cyl. B6 0.11 Cyl. B6

Potential Energy Distribution - X Rotation

MBJ 5-6 0.0

Cyl. A5 0.09 Cyl. A5

rigid 0.0

Cyl. B5 0.09 Cyl. B5

MTU order number: 1107041

MBJ 4-5 0.04

Cyl. A4 0.06 Cyl. A4

rigid 0.0

Cyl. B4 0.06 Cyl. B4

MBJ 3-4 0.09

Cyl. A3 0.03 Cyl. A3

rigid 0.0

Cyl. B3 0.03 Cyl. B3

MBJ 2-3 0.15

Cyl. A2 0.01 Cyl. A2

rigid 0.0

Cyl. B2 0.01 Cyl. B2

MBJ 1-2 0.18

Cyl. A1 0.0 Cyl. A1

rigid 0.0

Cyl. B1 0.0 Cyl. B1

Natural modes
12V 4000 M33S

Cr.shaft end KS 0.13

Flywheel 0.11 Flywheel

Rigid 0.0

CM 18000 HTC 72Sh 0.04 CM 18000 HTC 72Sh

CM 18000 HTC 72Sh 0.0

CM 18000 HTC 72Sh 0.0 CM 18000 HTC 72Sh

Alternator input shaft 0.0

Alternator Fan 0.0 Alternator Fan

Alternator shaft C2 0.0

Alternator Magnetic wheel 0.0 Alternator Magnetic wheel

Alternator shaft C3 0.0

Alternator Exciter 0.0 Alternator Exciter

D44/8/2 0.11 D44/8/2

D44/8/2 0.4
12V 4000 M33S - Centa coupling CM 18000 HTC 72Sh - Leroy Somer alternator LSA 52.2 M60/4p

Fig. 5
COSCO N606
TEM 50696

D44/8/2 0.05 D44/8/2

 D44/8/2 0.09 D44/8/2

50%
50%
50%

100%
100%
100%
rigid 0.0

Cr.shaft end KGS 0.09 Cr.shaft end KGS

Cr.shaft end KGS 2 0.01

GW Cr.shaft KGS 0.03 GW Cr.shaft KGS

Mode Shape - X Rotation

1890.0 1/min - 287.92 Hz

Cr.shaft end KGS 1 0.03

1890.0 1/min - 287.92 Hz

1890.0 1/min - 287.92 Hz

Cyl. A6 0.08 Cyl. A6

rigid 0.0

Asare 01.07.2014
Kinetic Energy Distribution - X Rotation
Cyl. B6 0.08 Cyl. B6

Potential Energy Distribution - X Rotation

MBJ 5-6 0.21

Cyl. A5 0.0 Cyl. A5

rigid 0.0

Cyl. B5 0.0 Cyl. B5

MTU order number: 1107041

MBJ 4-5 0.26

Cyl. A4 0.04 Cyl. A4

rigid 0.0

Cyl. B4 0.04 Cyl. B4

MBJ 3-4 0.09

Cyl. A3 0.12 Cyl. A3

rigid 0.0

Cyl. B3 0.12 Cyl. B3

MBJ 2-3 0.0

Cyl. A2 0.11 Cyl. A2

rigid 0.0

Cyl. B2 0.11 Cyl. B2

MBJ 1-2 0.13

Cyl. A1 0.02 Cyl. A1

rigid 0.0

Cyl. B1 0.02 Cyl. B1

Natural modes
12V 4000 M33S

Cr.shaft end KS 0.19

Flywheel 0.03 Flywheel

Rigid 0.0

CM 18000 HTC 72Sh 0.01 CM 18000 HTC 72Sh

CM 18000 HTC 72Sh 0.0

CM 18000 HTC 72Sh 0.0 CM 18000 HTC 72Sh

Alternator input shaft 0.0

Alternator Fan 0.0 Alternator Fan

Alternator shaft C2 0.0

Alternator Magnetic wheel 0.0 Alternator Magnetic wheel

Alternator shaft C3 0.0

Alternator Exciter 0.0 Alternator Exciter

D44/8/2 0.0 D44/8/2

D44/8/2 0.08
12V 4000 M33S - Centa coupling CM 18000 HTC 72Sh - Leroy Somer alternator LSA 52.2 M60/4p

Fig. 6
COSCO N606
TEM 50696

D44/8/2 0.09 D44/8/2

 D44/8/2 0.0 D44/8/2

50%
50%
50%

100%
100%
100%
rigid 0.0

Cr.shaft end KGS 0.0 Cr.shaft end KGS

Cr.shaft end KGS 2 0.0

GW Cr.shaft KGS 0.0 GW Cr.shaft KGS

Mode Shape - X Rotation

1890.0 1/min - 297.28 Hz

Cr.shaft end KGS 1 0.0

1890.0 1/min - 297.28 Hz

1890.0 1/min - 297.28 Hz

Cyl. A6 0.0 Cyl. A6

rigid 0.0

Asare 01.07.2014
Kinetic Energy Distribution - X Rotation
Cyl. B6 0.0 Cyl. B6

Potential Energy Distribution - X Rotation

MBJ 5-6 0.0

Cyl. A5 0.0 Cyl. A5

rigid 0.0

Cyl. B5 0.0 Cyl. B5

MTU order number: 1107041

MBJ 4-5 0.0

Cyl. A4 0.0 Cyl. A4

rigid 0.0

Cyl. B4 0.0 Cyl. B4

MBJ 3-4 0.0

Cyl. A3 0.0 Cyl. A3

rigid 0.0

Cyl. B3 0.0 Cyl. B3

MBJ 2-3 0.0

Cyl. A2 0.0 Cyl. A2

rigid 0.0

Cyl. B2 0.0 Cyl. B2

MBJ 1-2 0.0

Cyl. A1 0.0 Cyl. A1

rigid 0.0

Cyl. B1 0.0 Cyl. B1

Natural modes
12V 4000 M33S

Cr.shaft end KS 0.0

Flywheel 0.0 Flywheel

Rigid 0.0

CM 18000 HTC 72Sh 0.0 CM 18000 HTC 72Sh

CM 18000 HTC 72Sh 0.02

CM 18000 HTC 72Sh 0.59 CM 18000 HTC 72Sh

Alternator input shaft 0.4

Alternator Fan 0.23 Alternator Fan

Alternator shaft C2 0.57

Alternator Magnetic wheel 0.17 Alternator Magnetic wheel

Alternator shaft C3 0.0

Alternator Exciter 0.01 Alternator Exciter

D44/8/2 0.0 D44/8/2

D44/8/2 0.0
12V 4000 M33S - Centa coupling CM 18000 HTC 72Sh - Leroy Somer alternator LSA 52.2 M60/4p

Fig. 7
COSCO N606
TEM 50696

D44/8/2 0.0 D44/8/2

 12V 4000 M33S TEM 50696
Normal and 1-Cyl. Misfiring Mode COSCO N606
12V 4000 M33S - Centa coupling CM 18000 HTC 72Sh - Leroy Somer alternator LSA 52.2 M60/4p
MTU order number: 1107041
Oscillating Torsional Angle at Crankshaft Free End
[mrad]

Cr.shaft end KGS

9

0
1700 1800 1900
Engine Speed in 1/min

Alternating Torsional Stress in Crankshaft

[N/mm²]

90 Cr.shaft end KS Limit

MBJ 1-2

80 MBJ 2-3
MBJ 3-4

70 MBJ 4-5
MBJ 5-6

60 Cr.shaft end KGS 1

Cr.shaft end KGS 2

50

40

30

20

10

0
1700 1800 1900
Engine Speed in 1/min

Asare 01.07.2014 Fig. 8

 12V 4000 M33S TEM 50696
Normal and 1-Cyl. Misfiring Mode COSCO N606
12V 4000 M33S - Centa coupling CM 18000 HTC 72Sh - Leroy Somer alternator LSA 52.2 M60/4p
MTU order number: 1107041
Resilient Torque in Damper D44/8/2
[kNm]

Limit
D44/8/2

10

0
1700 1800 1900
Engine Speed in 1/min

Damping Torque in Damper D44/8/2

5
[kNm]

Limit
D44/8/2

0
1700 1800 1900
Engine Speed in 1/min

Power Loss in Damper D44/8/2

[kW]

Limit
D44/8/2

10

0
1700 1800 1900
Engine Speed in 1/min

Asare 01.07.2014 Fig. 9

 12V 4000 M33S TEM 50696
Normal and 1-Cyl. Misfiring Mode COSCO N606
12V 4000 M33S - Centa coupling CM 18000 HTC 72Sh - Leroy Somer alternator LSA 52.2 M60/4p
MTU order number: 1107041
Alternating Torque in Coupling CM 18000 HTC 72Sh
[kNm]

9 CM 18000 HTC 72Sh

Limit

0
1700 1800 1900
Engine Speed in 1/min

Power Loss in Coupling CM 18000 HTC 72Sh

[kW]

CM 18000 HTC 72Sh

Limit
1

0
1700 1800 1900
Engine Speed in 1/min

Asare 01.07.2014 Fig. 10

 12V 4000 M33S TEM 50696
Normal and 1-Cyl. Misfiring Mode COSCO N606
12V 4000 M33S - Centa coupling CM 18000 HTC 72Sh - Leroy Somer alternator LSA 52.2 M60/4p
MTU order number: 1107041
Alternating Torque in Alternator Shaft
[kNm]

Alternator input shaft

10
Alternator shaft C2

Alternator shaft C3
Effective Torque

0
1700 1800 1900
Engine Speed in 1/min

Asare 01.07.2014 Fig. 11

 12V 4000 M33S TEM 50696
Normal and 1-Cyl. Misfiring Mode COSCO N606
12V 4000 M33S - Centa coupling CM 18000 HTC 72Sh - Leroy Somer alternator LSA 52.2 M60/4p
MTU order number: 1107041
Alternating Angular Acceleration of Alternator Fan
[rad/s²]

Alternator Fan
60

50

40

30

20

10

0
1700 1800 1900
Engine Speed in 1/min

Asare 01.07.2014 Fig. 12

 12V 4000 M33S TEM 50696
Normal and 1-Cyl. Misfiring Mode COSCO N606
12V 4000 M33S - Centa coupling CM 18000 HTC 72Sh - Leroy Somer alternator LSA 52.2 M60/4p
MTU order number: 1107041 - Engine start and run-up (pme = 7.5 bar)
Oscillating Torsional Angle at Crankshaft Free End
500
[mrad]

Cr.shaft end KGS

400

300

200

100

0
0 1000
Engine Speed in 1/min

Alternating Torsional Stress in Crankshaft

[N/mm²]

Cr.shaft end KS
90 Limit
MBJ 1-2

MBJ 2-3
80
MBJ 3-4

MBJ 4-5
70
MBJ 5-6

Cr.shaft end KGS 1

60
Cr.shaft end KGS 2

50

40

30

20

10

0
0 1000
Engine Speed in 1/min

Asare 01.07.2014 Fig. 13

 12V 4000 M33S TEM 50696
Normal and 1-Cyl. Misfiring Mode COSCO N606
12V 4000 M33S - Centa coupling CM 18000 HTC 72Sh - Leroy Somer alternator LSA 52.2 M60/4p
MTU order number: 1107041 - Engine start and run-up (pme = 7.5 bar)
Resilient Torque in Damper D44/8/2
[kNm]

Limit
D44/8/2

10

0
0 1000
Engine Speed in 1/min

Damping Torque in Damper D44/8/2

[kNm]

5 D44/8/2 Limit

0
0 1000
Engine Speed in 1/min

Power Loss in Damper D44/8/2

[kW]

Limit
D44/8/2

10

0
0 1000
Engine Speed in 1/min

Asare 01.07.2014 Fig. 14

 12V 4000 M33S TEM 50696
Normal and 1-Cyl. Misfiring Mode COSCO N606
12V 4000 M33S - Centa coupling CM 18000 HTC 72Sh - Leroy Somer alternator LSA 52.2 M60/4p
MTU order number: 1107041 - Engine start and run-up (pme = 7.5 bar)
Alternating Torque in Coupling CM 18000 HTC 72Sh
[kNm]

40
CM 18000 HTC 72Sh
Limit

30

20

10

0
0 1000
Engine Speed in 1/min

Power Loss in Coupling CM 18000 HTC 72Sh

[kW]

CM 18000 HTC 72Sh

10

Limit

0
0 1000
Engine Speed in 1/min

Asare 01.07.2014 Fig. 15

 12V 4000 M33S TEM 50696
Normal and 1-Cyl. Misfiring Mode COSCO N606
12V 4000 M33S - Centa coupling CM 18000 HTC 72Sh - Leroy Somer alternator LSA 52.2 M60/4p
MTU order number: 1107041 - Engine start and run-up (pme = 7.5 bar)
Alternating Torque in Alternator Shaft
[kNm]

20
Alternator input shaft

Alternator shaft C2

Alternator shaft C3

10

0
0 1000
Engine Speed in 1/min

Asare 01.07.2014 Fig. 16

 12V 4000 M33S TEM 50696
Normal and 1-Cyl. Misfiring Mode COSCO N606
12V 4000 M33S - Centa coupling CM 18000 HTC 72Sh - Leroy Somer alternator LSA 52.2 M60/4p
MTU order number: 1107041 - Engine start and run-up (pme = 7.5 bar)
Alternating Angular Acceleration of Alternator Fan
[rad/s²]

400
Alternator Fan

300

200

100

0
0 1000
Engine Speed in 1/min

Asare 01.07.2014 Fig. 17

 12V
12V4000
4000M23-M63
M33S TEM 50696

Torque
Torque
Impact
Impact
due to
dueMiss-Synchronisation
to Short Circuit Fig.
18
12V 4000 M33S - Centa coupling CM 18000 HTC 72Sh - Leroy Somer alternator LSA 52.2 M60/4p
MTU order number: 1107041 COSCO N606

Air Gap Torque

40000
Nm

30000
20000
10000
0

-10000
-20000
-30000
-40000

-50000
-60000
-70000
-80000
1 1.05 1.1 1.15
Time [s]

Asare, 2-JUL-2014
 12V
12V4000
4000M23-M63
M33S TEM 50696

Torque
Torque
Impact
Impact
due to
dueMiss-Synchronisation
to Short Circuit Fig.
19
12V 4000 M33S - Centa coupling CM 18000 HTC 72Sh - Leroy Somer alternator LSA 52.2 M60/4p
MTU order number: 1107041 COSCO N606

Torsional Stress in Crankshaft

N/mm²

80
Cr.shaft end KGS 1 permissible torsional stress +/- 90 N/mm2

60 Cr.shaft end KGS 2

40 MBJ 5-6
MBJ 4-5
20
MBJ 3-4
0
MBJ 2-3
-20 MBJ 1-2

-40 Cr.shaft end KS

-60

-80

-100
1 1.02 1.06 1.1 1.12 1.16 1.2 1.22 1.26 1.3 1.32 1.36 1.4 1.42
Time [s]

Asare, 2-JUL-2014
 12V
12V4000
4000M23-M63
M33S TEM 50696

Torque
Torque
Impact
Impact
due to
dueMiss-Synchronisation
to Short Circuit Fig.
20
12V 4000 M33S - Centa coupling CM 18000 HTC 72Sh - Leroy Somer alternator LSA 52.2 M60/4p
MTU order number: 1107041 COSCO N606

Torque in coupling CM 18000 HTC 72Sh

kNm

permissible torque +/- 40 kNm

20

15

10

1 1.05 1.1 1.15 1.2 1.25 1.3 1.35 1.4

Time [s]

Asare, 2-JUL-2014
 12V
12V4000
4000M23-M63
M33S TEM 50696

Torque
Torque
Impact
Impact
due to
dueMiss-Synchronisation
to Short Circuit Fig.
21
12V 4000 M33S - Centa coupling CM 18000 HTC 72Sh - Leroy Somer alternator LSA 52.2 M60/4p
MTU order number: 1107041 COSCO N606

Torque in Alternator Shaft

30
kNm

25
Alternator input shaft
Alternator shaft C2
20
Alternator shaft C3
15

10

-5
1 1.05 1.1 1.15 1.2 1.25 1.3 1.35 1.4
Time [s]

Angular Acceleration of Alternator Fan

1000
rad/s²

500

-500

-1000

-1500
1 1.05 1.1 1.15 1.2 1.25 1.3 1.35 1.4
Time [s]
Asare, 2-JUL-2014
TEM 50 699 Page 2
4 LOAD CASES AND CALCULATION MODEL

load class load case

dead weight DW dead weight loading −1g in v-direction
A1 vessel inclinations ±5.0° trim & ±15.0° list (simultaneously)
continuous duty loading
conditions (occurring with an A2 vessel movements in rough seas ±7.5° trim & ±22.5° list (simultaneously)
unlimited number of load A3 ±0.18g athwart & ±0.40g vertical (simultaneously)
load multiples resulting from vessel
cycles)
A4 operation in rough seas ±0.10g fore/aft & ±0.40g vertical (simultaneously)
B1 exceptional vessel movements in ±15° pitch
exceptional external loading B2 heavy seas ±45° roll
condition (occurring with a
limited number of load cycles) B3 load multiples resulting from vessel ±0.35g athwart & ±0.80g vertical (simultaneously)
B4 operation in heavy seas ±0.23g fore/aft & ±0.80g vertical (simultaneously)
C1 ±2.0g athwart
extreme external loading
C2 extreme external loads ±1.5g fore/aft
conditions (rarely occurring)
C3 ±3.0g vertical
natural frequencies NF calculation of natural frequencies and vibration modes

For the dead weight load case the buffers of the elastic mounts are not taken into account
(installation condition). For the calculation of the stresses of the elastic mounts, load cases A1-C3
are superposed with the dead weight load case.
The genset (engine with flanged-on alternator is modeled as a rigid body connected by nonlinear
spring elements of negligible mass representing the elastic mounts and their internal buffers. The
system has six degrees of freedom. For the calculation of the natural frequencies the equations
of motion are linearized around the static equilibrium (dead weight loading) and dynamic
hardening factors of the mounts’ rubber are considered. For system data see figs. 10-14.

5 CALCULATION RESULTS

5.1 Dead weight

As mentioned above the own weight of the genset is carried by eight RD 314 / RD 315 mounts.
The deflection is from 5.2 to 5.4 mm for engine mounts and 5.4 to 5.6 mm for alternator mounts
with accompanying spring forces of approximately 20.5 kN for engine mounts and 12.1 kN for
alternator mounts. Due to the dead weight deflection of the resilient mounts the auxPTO flange
travels about 5.2 mm and the alternator free end 5.6 mm downwards. This must be considered
when installing and aligning the genset in the vessel (see fig. 15).

5.2 Static stresses resulting from dead weight and loads of the groups A/B/C

5.2.1 Engine and alternator mounts

The listings of detailed results in figs. 16–48 contain stresses the conical rubber mounts and
internal vertical buffers separately. To compare the calculated and permissible stresses, the
spring forces computed for these two parts had been added up.
The following table summarizes the maximum deflections for each load case category, where the
“vertical total” values in the last column mean the stresses resulting from dead weight and buffer
forces.
TEM 50 699 Page 3
12V 4000 M33 / LSA genset loads (gs) transverse longitudinal vertical vertical total
engine mounts fatigue -Umax [mm] -1.66 -0.76 -2.93 -8.33
group A +Umax [mm] 1.66 0.76 3.27 -2.01
-Fmax [kN] -10.77 -4.94 -13.32 -34.15
+Fmax [kN] 10.76 4.90 12.94 -7.28
transient -Umax [mm] -2.94 -0.95 -4.15 -9.55
group B +Umax [mm] 2.94 0.95 4.42 -0.93
-Fmax [kN] -19.10 -6.16 -20.03 -55.99
+Fmax [kN] 19.09 6.17 17.20 9.57
extreme -Umax [mm] -5.59 -4.47 -4.41 -9.79
group C +Umax [mm] 5.59 4.46 5.17 -0.09
-Fmax [kN] -51.45 -36.02 -21.45 -83.66
+Fmax [kN] 51.45 35.88 19.98 43.08
alternator mounts fatigue -Umax [mm] -1.45 -0.57 -2.79 -8.37
group A +Umax [mm] 1.45 0.58 2.99 -2.56
-Fmax [kN] -4.15 -1.64 -6.34 -18.57
+Fmax [kN] 4.16 1.65 6.51 -5.64
transient -Umax [mm] -2.72 -0.80 -4.04 -9.62
group B +Umax [mm] 2.72 0.79 4.17 -1.37
-Fmax [kN] -7.81 -2.28 -9.23 -25.68
+Fmax [kN] 7.81 2.27 9.11 2.30
extreme -Umax [mm] -4.98 -3.74 -4.30 -9.84
group C +Umax [mm] 4.98 3.75 4.91 -0.56
-Fmax [kN] -24.65 -12.91 -9.83 -52.37
+Fmax [kN] 24.65 13.05 10.72 29.08

The permissibility of the calculated stresses for the RD 314 / RD 315 mounts is assured due to
static tests carried out by MTU, see /2/ and /3/. The permissible forces (see data sheet in fig. 5)
are considerably above the forces calculated in all cases investigated.
Note that the resilient mounting tolerates all permanent vessel inclinations of load case group A
without any buffer contact

5.2.2 Engine interfaces’ deflections

The maximum deflections for the vertical arrangement of engine exhaust outlets, horizontally
arranged combustion air intakes and engine seawater in- and outlets, the horizontally sideward
arranged coolant connections of the alternator, and the engine auxiliary output are shown in the
deflection diagrams in the figs. 7–9 as well in the table below.
The listed values for the engine exhaust outlets and the rubber bellows are permissible for all
load case categories. The MTU standard rubber bellows have to be pre-compressed with 5 mm.
The calculated displacements at the engine’s auxiliary output flange at free end and the
combustion air inlets have to be considered when installing the genset in the vessel.
TEM 50 699 Page 4
axial,
12V 4000 M33 / LSA genset loads (ps) radial axial, tension
compression
fatigue, group A [mm] 4.34 -6.68 6.67
combustion air intakes transient, group B [mm] 5.65 -10.38 10.36
extreme, group C [mm] 8.37 -15.75 15.75
fatigue, group A [mm] 8.13 -2.60 2.36
exhaust outlets transient, group B [mm] 12.51 -4.01 3.73
extreme, group C [mm] 18.47 -5.04 4.36
fatigue, group A [mm] 4.91 -0.93 0.96
seawater inlets 20.026
transient, group B [mm] 6.83 -1.29 1.27
horizontal
extreme, group C [mm] 10.65 -5.96 6.03
fatigue, group A [mm] 4.62 -0.76 0.79
seawater outlet 20.027
transient, group B [mm] 6.94 -1.41 1.39
horizontal
extreme, group C [mm] 11.19 -6.49 6.57
fatigue, group A [mm] 2.31 -0.54 0.55
engine auxPTO transient, group B [mm] 4.17 -1.09 1.08
extreme, group C [mm] 6.20 -5.07 5.10
fatigue, group A [mm] 3.99 -2.65 2.78
free alternator end transient, group B [mm] 6.46 -4.16 4.18
extreme, group C [mm] 9.96 -5.10 5.18
fatigue, group A [mm] 3.94 -7.86 7.85
alternator coolant connection
transient, group B [mm] 5.94 -12.22 12.20
(horizontal, to right or to left)
extreme, group C [mm] 8.06 -17.93 17.93

5.2.3 Maximum deflections at the outlines of the genset

The free spaces at the outlines of the genset according to the following table are to be taken into
account during the design of the unit.
12V 4000 M33 / LSA genset loads (gs) transverse longitudinal vertical
upper genset edges all load cases -Umax [mm] -6.02 -3.94 -5.10
+Umax [mm] 6.02 3.94 5.18
lower genset edges all load cases -Umax [mm] -15.49 -7.83 -6.15
+Umax [mm] 15.49 7.70 6.93
engine free end boundings all load cases -Umax [mm] -20.65 -8.25 -5.36
+Umax [mm] 20.65 8.11 5.62
alternator free end boundings all load cases -Umax [mm] -20.65 -8.25 -6.15
+Umax [mm] 20.65 8.11 6.93
left side boundings all load cases -Umax [mm] -20.65 -8.24 -6.15
+Umax [mm] 20.65 8.10 6.93
right side boundings all load cases -Umax [mm] -20.65 -8.25 -5.67
+Umax [mm] 20.65 8.11 6.47

5.3 Natural Frequencies and Vibration Modes

The natural frequencies have been computed on the basis of the mounts’ dead weight
deflections. According manufacturer’s documentation dynamic hardening factors of 1.61 (engine
mounts) and 1.66 (alternator mounts) in all directions have been considered in the calculations.
Figs. 6 and 49 show the calculated natural frequencies in form of a Campbell diagram and as a
table.
TEM 50 699 Page 5
Natural frequencies in the frequency range between 5.8 and 19.1 Hz were calculated for the
resiliently mounted genset, the tuning frequency (vibration in vertical direction) is 9.0 Hz (see fig.
49 for details). As the Campbell diagram on fig. 6 shows, no vibration mode can be excited by
main exciting engine orders at the operating engine speed of 1800 rpm. Therefore, no adverse
effects to the operational reliability of the engine are to be expected.

6 REFERENCE MATERIAL

Arrgmt. drwg. genset MTU no. XZ 599 001-107041

Arrgmt. drwg. 12V 4000 M33 MTU no. XZ 594 000 001 68
Scope of supply bellows MTU no. X 594 145 000 18
Arrgmt. drwg. LS alternator LS no. EN 605 914_T1
Table drwg. RUBBER DESIGN RD 314 mounts MTU no. XZ 526 231 00 056
Table drwg. RUBBER DESIGN RD 315 mounts MTU no. 001 237 70 12

Manufacturer documentation for

- RUBBER DESIGN RD 314 B / RD 315 HD
- STENFLEX rubber bellows for coolant and seawater
Index of source:
/1/ RUBBER DESIGN calc. report for resiliently mounted system MTU/1083/1
/2/ MTU measurement report no. EVF 26 359, Dämpfungslager RD314/315 in
Sphärogussversion, Ermittlung der Federkenndaten und Belastungsgrenzen
/3/ MTU measurement report from 05 February 2009, Dämpfungslager RD314-60,
Sach-Nr. 0022374812

7 TABLES OF FIGURES
Figure
Arrangement drawing of the genset 1
Description of the coordinate systems used 2–3
Sectional drawing for resilient mounts RUBBER DESIGN RD 314 / RD 315 4
Technical data and permissible stresses for resilient mounts 5
Campbell diagram 6
Deflections diagrams for interfaces:
exhaust gas bellows, combustion air intakes 7
bellows for seawater in-/outlets at the engine (20.026 & 20.027) 8
auxiliary PTO, alternator coolant connections 9
System data
body data 10
spring data 11–12
coordinates of interesting points 13–14
Calculation results for load cases
dead weight 15
A1, A2, A3, A4 16–27
B1, B2, B3, B4 28–39
C1, C2, C3 40–48
Natural frequencies 49
TEM 50 699 Fig. 1

Arrangement Drawing of the 12V-Genset

TEM 50 699 Fig. 2
TEM 50 699 Fig. 3
The point related coordinate system { t'i, l'i, v'i } is created from the local global coordinate system
{ ti, li, vi } by rotation with the 3 Eulerian angles (successive rotations about the 3 i-, 1''i-, 3'''i-axes).

Examples for the rotation from a local, global coordinate system { ti, li, vi }
into a local, point-related coordinate system { t'i, l'i, v'i }

Description of the rotating angles:

Phi ... 1st rotation about the original vertical axis vi (3i -axis) → { t''i, l''i, v''i }
Theta ... 2nd rotation about the newly created transverse axis t''i (1''i -axis) → { t'''i, l'''i, v'''i }
Psi ... 3rd rotation about the newly created vertical axis v'''i (3'''i -axis) → { t'i, l'i, v'i }

Example a: Engine mount at engine auxPTO, right side built-in with inclination about the longitudinal axis

coordinate system rotation new coordinate system

{ ti, li, vi } → Phi = + 90° → { t''i, l''i, v''i }

{ t''i, l''i, v''i } → Theta = - 45° → { t'''i, l'''i, v'''i }
{ t'''i, l'''i, v'''i } → Psi = - 90° → { t'i, l'i, v'i }

Example b: Exhaust bellows after exhaust Y-pipe built-in with inclination about transverse axis

coordinate system rotation new coordinate system

{ ti, li, vi } → Phi = 0° → { t''i, l''i, v''i }

{ t''i, l''i, v''i } → Theta = - 120° → { t'''i, l'''i, v'''i }
{ t'''i, l'''i, v'''i } → Psi = 0° → { t'i, l'i, v'i }

Output of Displacements and Spring Forces in a Cylindrical Coordinate System

The displacements U i / U'i and in case of evidence the spring forces F i / F'i for any point i may be
printed out according to the coordinate directions { ti, li, vi } / { t'i, l'i, v'i }. The radial / axial
displacements U'' rad / U''ax and in case of evidence the radial / axial spring forces F'' rad / F''ax may be still
printed out for individual points. They are calculated according to the following formulae:

U ''rad = ( Ut2i + Ul2i ) or ( U't2 'i + U'l2'i )

U ''ax = U vi or U'v 'i
''
Frad = ( Ft2i + Fl2i ) or ( F't2 'i + F'l2'i )
Fax'' = Fvi or F'v 'i
TEM 50 699 Fig. 4

Sectional Drawing of Mounts

pts. 3–10

pts.11–18
TEM 50 699 Fig. 5

Technical Data Sheets for Mounts

TEM 50 699 Fig. 6

TSM

Campbell Diagram Schk

02.07.2014

12V 4000 M33S on-board genset with LS alternator

mounting: engine 4 x RUBBER DESIGN RD 314 B-11MN55

alternator 4 x RUBBER DESIGN RD 315-11MN60

2nd engine order 1.5th engine order 1st engine order

20

roll

0.5th engine order

15

long
natural frequency [Hz]

yaw

10

vert

pitch

transv
5

operating speed
0
400 600 800 1000 1200 1400 1600 1800 2000
engine speed [1/min]
TEM 50 699 Fig. 7

Deflection Diagrams
TEM 50 699 Fig. 8
TEM 50 699 Fig. 9
TEM 50 699 Fig. 10

12V 4000 M33S ext. cooling, w/ flanged-on LS alternator, Appl. 3A

=================================================================

EB engine 12V 4000 M33 MTU no. XZ 594 000 001 68

AO genset MTU no. XZ 599001-107041
main dimensions alternator LS no. EN 605 914_T1

Engine mounting 4 RubberDesign RD 314B-55

MTU drwg no. XZ 526 231 000 56
Alternator mounting 4 RubberDesign RD 315-60
MTU drwg no. 001 237 70 12

Stresses Resulting from Continuous Duty & Exceptional Environmental Loading

===========================================================================

- vessel inclinations: trim ±5.0° & list ±15.0°

- g-loads resulting from athwart ±0.18g and -

vessel operation in rough seas fore and aft ±0.10g and -
- vertical ±0.40g

- vessel movements pitching ±7.5° & rolling ±22.5°

- extreme vessel movements pitching ±15° or -

in heavy seas - rolling ±45°

- max. g-loads resulting from athwart ±0.35g and -

diving of vessel hull - fore and aft ±0.23g and -
in exorbitant waves - vertical ±0.80g

- Unusual extreme external g-loads athwart ±2.00g

resulting from crashs, etc, fore and aft ±1.50g
vertical ±3.00g

design status: July 2014 Schmick / TEMA2 /

Input Record: Date: 2014.07.02 Time: 13:55

============= File: 12V_COSCO-605-606-ST_NL.DAT

System data
-----------

1 rigid body 6 degrees of freedom 16 elastic springs

Coordinates of the body centers of gravity and Euler's angles of rotation

-------------------------------------------------------------------------
of the main inertial axes of the bodies relative to the global coordinate axes
------------------------------------------------------------------------------

( T, L, V in m , PHI, THETA, PSI in degrees )

Body No. T L V PHI THETA PSI

----------------------------------------------------------------------

1 0.003 -0.078 0.207 59.33 6.08 -59.22

Masses and main mass moments of inertia of the bodies

-----------------------------------------------------

( M in kg , Jt, Jl, Jv in kg * m**2 )

Body No. M Jt Jl Jv Item

------------------------------------------------------------------------------------------

1 13284. 21959. 3002. 21154. Engine w/ alternator

TEM 50 699 Fig. 11
Data for used spring types
--------------------------

Ct, Cl, Cv .... translational stiffnesses for the 3 directions in N/m

CRt, CRl, CRv .... rotational stiffnesses about the 3 axis in Nm/rad
Fdyn .... dynamic hardening factor
So .... operating point for the vertical axis in mm

In the case of a nonlinear spring characteristic, it is written as a table, where are:

St, Sl, Sv .... edge points of spring travel in the spring characteristic in mm
Ft, Fl, Fv .... related spring forces in N
Wt, Wl, Wv .... edge points of spring angle in the spring characteristic in mrad
Mt, Ml, Mv .... related spring moments in Nm

Spring type no. 1: RD 314B-55; engine; s_0 = -5.31 mm

--------------------
_______________________________________________________________________________________
| | | | | | | | |
| Ct | Cl | Cv | CRt | CRl | CRv | Fdyn | So |
|-----------|-----------|-----------|-----------|-----------|-----------|-------|-------|
| 6.488E+06 | 6.488E+06 | 4.350E+06 | 0.000E+00 | 0.000E+00 | 0.000E+00 | 1.00 | -5.3 |
|___________|___________|___________|___________|___________|___________|_______|_______|

Spring characteristics for different directions:

____________________________________________________________________________________
| | | | | | | | | |
| St | -7.60| -5.50| -3.50| -3.00| 3.00| 3.50| 5.50| 7.60|
| Ft |-9.451E+4|-4.948E+4|-2.331E+4|-1.946E+4| 1.946E+4| 2.331E+4| 4.948E+4| 9.451E+4|
|____|_________|_________|_________|_________|_________|_________|_________|_________|
| | | | | | | | | |
| Sl | -7.60| -5.50| -3.50| -3.00| 3.00| 3.50| 5.50| 7.60|
| Fl |-9.451E+4|-4.948E+4|-2.331E+4|-1.946E+4| 1.946E+4| 2.331E+4| 4.948E+4| 9.451E+4|
|____|_________|_________|_________|_________|_________|_________|_________|_________|
| | | | | | | | | |
| Sv | -7.69| -6.69| -4.69| -2.69| -0.69| 1.31| 5.31| 6.31|
| Fv |-4.950E+4|-3.850E+4|-2.300E+4|-1.200E+4|-3.002E+3| 5.698E+3| 2.050E+4| 2.050E+4|
|____|_________|_________|_________|_________|_________|_________|_________|_________|

for dead weight calculation:

_______________________________________________________________________________________
| | | | | | | | |
| Ct | Cl | Cv | CRt | CRl | CRv | Fdyn | So |
|-----------|-----------|-----------|-----------|-----------|-----------|-------|-------|
| 6.090E+06 | 6.090E+06 | 2.700E+06 | 0.000E+00 | 0.000E+00 | 0.000E+00 | 1.00 | 0.0 |
|___________|___________|___________|___________|___________|___________|_______|_______|

Spring characteristics for different directions:

____________________________________________________________________________________
| | | | | | | | | |
| Sv | -8.50| -5.00| -4.00| -3.00| -2.00| -1.00| 0.00| 1.00|
| Fv |-3.500E+4|-1.900E+4|-1.470E+4|-1.040E+4|-6.300E+3|-2.700E+3| 0.000E+0| 0.000E+0|
|____|_________|_________|_________|_________|_________|_________|_________|_________|

for calculation of natural frequencies (including s_0 = -5.31 mm; f_dyn =1.61)

_______________________________________________________________________________________
| | | | | | | | |
| Ct | Cl | Cv | CRt | CRl | CRv | Fdyn | So |
|-----------|-----------|-----------|-----------|-----------|-----------|-------|-------|
| 1.047E+07 | 1.047E+07 | 6.926E+06 | 0.000E+00 | 0.000E+00 | 0.000E+00 | 1.00 | 0.0 |
|___________|___________|___________|___________|___________|___________|_______|_______|

Spring type no. 2: RD 315-60; alternator; s_0 = -5.50 mm

--------------------
_______________________________________________________________________________________
| | | | | | | | |
| Ct | Cl | Cv | CRt | CRl | CRv | Fdyn | So |
|-----------|-----------|-----------|-----------|-----------|-----------|-------|-------|
| 2.869E+06 | 2.869E+06 | 2.170E+06 | 0.000E+00 | 0.000E+00 | 0.000E+00 | 1.00 | -5.5 |
|___________|___________|___________|___________|___________|___________|_______|_______|

Spring characteristics for different directions:

____________________________________________________________________________________
| | | | | | | | | |
| St | -7.60| -5.50| -3.50| -3.00| 3.00| 3.50| 5.50| 7.60|
| Ft |-6.700E+4|-2.958E+4|-1.064E+4|-8.607E+3| 8.607E+3| 1.064E+4| 2.958E+4| 6.700E+4|
|____|_________|_________|_________|_________|_________|_________|_________|_________|
| | | | | | | | | |
| Sl | -7.60| -5.50| -3.50| -3.00| 3.00| 3.50| 5.50| 7.60|
| Fl |-6.700E+4|-2.958E+4|-1.064E+4|-8.607E+3| 8.607E+3| 1.064E+4| 2.958E+4| 6.700E+4|
|____|_________|_________|_________|_________|_________|_________|_________|_________|
| | | | | | | | | |
| Sv | -6.50| -5.50| -4.50| -2.50| -0.50| 1.50| 5.50| 6.50|
| Fv |-1.578E+4|-1.298E+4|-1.028E+4|-5.685E+3|-1.085E+3| 3.255E+3| 1.202E+4| 1.202E+4|
|____|_________|_________|_________|_________|_________|_________|_________|_________|
TEM 50 699 Fig. 12
for dead weight calculation:
_______________________________________________________________________________________
| | | | | | | | |
| Ct | Cl | Cv | CRt | CRl | CRv | Fdyn | So |
|-----------|-----------|-----------|-----------|-----------|-----------|-------|-------|
| 2.733E+06 | 2.733E+06 | 2.100E+06 | 0.000E+00 | 0.000E+00 | 0.000E+00 | 1.00 | 0.0 |
|___________|___________|___________|___________|___________|___________|_______|_______|

Spring characteristics for different directions:

____________________________________________________________________________________
| | | | | | | | | |
| Sv | -10.80| -9.00| -6.00| -4.00| -2.00| -1.00| 0.00| 1.00|
| Fv |-2.460E+4|-2.010E+4|-1.320E+4|-8.600E+3|-4.200E+3|-2.100E+3| 0.000E+0| 0.000E+0|
|____|_________|_________|_________|_________|_________|_________|_________|_________|

for calculation of natural frequencies (including s_0 = -5.50 mm; f_dyn =1.66)
_______________________________________________________________________________________
| | | | | | | | |
| Ct | Cl | Cv | CRt | CRl | CRv | Fdyn | So |
|-----------|-----------|-----------|-----------|-----------|-----------|-------|-------|
| 4.767E+06 | 4.767E+06 | 3.792E+06 | 0.000E+00 | 0.000E+00 | 0.000E+00 | 1.00 | 0.0 |
|___________|___________|___________|___________|___________|___________|_______|_______|

Spring type no. 3: Vertical buffer; free travel -4.0, +4.0 mm (only for static load cases)
--------------------
_______________________________________________________________________________________
| | | | | | | | |
| Ct | Cl | Cv | CRt | CRl | CRv | Fdyn | So |
|-----------|-----------|-----------|-----------|-----------|-----------|-------|-------|
| 0.000E+00 | 0.000E+00 | 0.000E+00 | 0.000E+00 | 0.000E+00 | 0.000E+00 | 1.00 | 0.0 |
|___________|___________|___________|___________|___________|___________|_______|_______|

Spring characteristics for different directions:

____________________________________________________________________________________
| | | | | | | | | |
| Sv | -5.05| -4.80| -4.40| -4.00| 4.00| 4.80| 6.00| 7.65|
| Fv |-1.750E+5|-1.060E+5|-4.050E+4| 0.000E+0| 0.000E+0| 2.500E+4| 8.500E+4| 2.000E+5|
|____|_________|_________|_________|_________|_________|_________|_________|_________|

Spring and damper data

----------------------

T, L, V ( m ) ... Spring geom. location w. resp. to global coord. system

PHI, THETA, PSI ( degree ) ... Euler's angles for the rotation of spring axes
versus the global coordinate system
K1, K2 ... Allocation of spring ends to the bodies
( for the foundation: K1 = 0 )
________________________________________________________________________________________
| | | | | | | | | |
| Spring | T | L | V | PHI | THETA | PSI | K1 | K2 |
| | | | | | | | | |
| No. | Type | | | | | | | | |
|_____|______|__________|__________|__________|__________|__________|__________|____|____|
| | | | | | | | | | |
| 1 | 1 | 0.600 | 1.353 | -0.272 | 0.000 | 0.000 | 0.000 | 0 | 1 |
| | | | | | | | | | |
| 2 | 1 | 0.600 | 0.177 | -0.272 | 0.000 | 0.000 | 0.000 | 0 | 1 |
| | | | | | | | | | |
| 3 | 2 | 0.375 | -0.990 | -0.584 | 0.000 | 0.000 | 0.000 | 0 | 1 |
| | | | | | | | | | |
| 4 | 2 | 0.375 | -1.990 | -0.584 | 0.000 | 0.000 | 0.000 | 0 | 1 |
| | | | | | | | | | |
| 5 | 1 | -0.600 | 1.353 | -0.272 | 0.000 | 0.000 | 0.000 | 0 | 1 |
| | | | | | | | | | |
| 6 | 1 | -0.600 | 0.177 | -0.272 | 0.000 | 0.000 | 0.000 | 0 | 1 |
| | | | | | | | | | |
| 7 | 2 | -0.375 | -0.990 | -0.584 | 0.000 | 0.000 | 0.000 | 0 | 1 |
| | | | | | | | | | |
| 8 | 2 | -0.375 | -1.990 | -0.584 | 0.000 | 0.000 | 0.000 | 0 | 1 |
| | | | | | | | | | |
| 9 | 3 | 0.600 | 1.353 | -0.322 | 0.000 | 0.000 | 0.000 | 0 | 1 |
| | | | | | | | | | |
| 10 | 3 | 0.600 | 0.177 | -0.322 | 0.000 | 0.000 | 0.000 | 0 | 1 |
| | | | | | | | | | |
| 11 | 3 | 0.375 | -0.990 | -0.635 | 0.000 | 0.000 | 0.000 | 0 | 1 |
| | | | | | | | | | |
| 12 | 3 | 0.375 | -1.990 | -0.635 | 0.000 | 0.000 | 0.000 | 0 | 1 |
| | | | | | | | | | |
| 13 | 3 | -0.600 | 1.353 | -0.322 | 0.000 | 0.000 | 0.000 | 0 | 1 |
| | | | | | | | | | |
| 14 | 3 | -0.600 | 0.177 | -0.322 | 0.000 | 0.000 | 0.000 | 0 | 1 |
| | | | | | | | | | |
| 15 | 3 | -0.375 | -0.990 | -0.635 | 0.000 | 0.000 | 0.000 | 0 | 1 |
| | | | | | | | | | |
| 16 | 3 | -0.375 | -1.990 | -0.635 | 0.000 | 0.000 | 0.000 | 0 | 1 |
|_____|______|__________|__________|__________|__________|__________|__________|____|____|
TEM 50 699 Fig. 13
System Response based on given Static Loads
===========================================

Displacements, forces and moments are determined relative to the bodies labeled by the indices K1 and K2
or relative to the body labeled by index K2 and the foundation.

Data for the points to be calculated

------------------------------------

T, L, V ( m ) ... Geometric location of point with respect to the global coordinate system
PHI, THETA, PSI ( degree ) ... Euler's angles for the rotation of the point-related coordinate system
versus the global coordinate system
Ct, Cl, Cv ( N/m ) ... Translational spring constants defined in the point-related coord. system
Crt, Crl, Crv ( Nm/rad ) ... Rotational spring constants defined in the point-related coord. system
K1, K2 ... Allocation numbers for the calculation of displacements and forces
relative to the bodies ( foundation: K1 = 0 )

______________________________________________________________________________________________________________
| | | | | | | | | | | |
| Point | Item | G | T | L | V | PHI | THETA | PSI | K1 | K2 |
| No. | | C | Ct | Cl | Cv | Crt | Crl | Crv | | |
|_______|______________________|___|__________|__________|__________|__________|__________|__________|____|____|
| | | | | | | | | | | |
| 1 | c/g Basic engine | G | 0.005 | 0.775 | 0.295 | 0.000 | 0.000 | 0.000 | 0 | 1 |
| | (as in EB drawing) | | | | | | | | | |
| | | | | | | | | | | |
| 2 | c/g Alternator | G | 0.000 | -1.385 | 0.096 | 0.000 | 0.000 | 0.000 | 0 | 1 |
| | | | | | | | | | | |
| 3 | Engine mount | G | 0.600 | 1.353 | -0.272 | 0.000 | 0.000 | 0.000 | 0 | 1 |
| | free end right | | | | | | | | | |
| | | | | | | | | | | |
| 4 | Engine mount | G | 0.600 | 0.177 | -0.272 | 0.000 | 0.000 | 0.000 | 0 | 1 |
| | PTO right | | | | | | | | | |
| | | | | | | | | | | |
| 5 | Alternator mount | G | 0.375 | -0.990 | -0.584 | 0.000 | 0.000 | 0.000 | 0 | 1 |
| | engineside right | | | | | | | | | |
| | | | | | | | | | | |
| 6 | Alternator mount | G | 0.375 | -1.990 | -0.584 | 0.000 | 0.000 | 0.000 | 0 | 1 |
| | free end right | | | | | | | | | |
| | | | | | | | | | | |
| 7 | Engine mount | G | -0.600 | 1.353 | -0.272 | 0.000 | 0.000 | 0.000 | 0 | 1 |
| | free end left | | | | | | | | | |
| | | | | | | | | | | |
| 8 | Engine mount | G | -0.600 | 0.177 | -0.272 | 0.000 | 0.000 | 0.000 | 0 | 1 |
| | PTO left | | | | | | | | | |
| | | | | | | | | | | |
| 9 | Alternator mount | G | -0.375 | -0.990 | -0.584 | 0.000 | 0.000 | 0.000 | 0 | 1 |
| | engineside left | | | | | | | | | |
| | | | | | | | | | | |
| 10 | Alternator mount | G | -0.375 | -1.990 | -0.584 | 0.000 | 0.000 | 0.000 | 0 | 1 |
| | free end left | | | | | | | | | |
| | | | | | | | | | | |
| 11 | eng vert buffer | G | 0.600 | 1.353 | -0.322 | 0.000 | 0.000 | 0.000 | 0 | 1 |
| | free end right | | | | | | | | | |
| | | | | | | | | | | |
| 12 | eng vert buffer | G | 0.600 | 0.177 | -0.322 | 0.000 | 0.000 | 0.000 | 0 | 1 |
| | PTO right | | | | | | | | | |
| | | | | | | | | | | |
| 13 | alt vert buffer | G | 0.375 | -0.990 | -0.635 | 0.000 | 0.000 | 0.000 | 0 | 1 |
| | engineside right | | | | | | | | | |
| | | | | | | | | | | |
| 14 | alt vert buffer | G | 0.375 | -1.990 | -0.635 | 0.000 | 0.000 | 0.000 | 0 | 1 |
| | free end right | | | | | | | | | |
| | | | | | | | | | | |
| 15 | eng vert buffer | G | -0.600 | 1.353 | -0.322 | 0.000 | 0.000 | 0.000 | 0 | 1 |
| | free end left | | | | | | | | | |
| | | | | | | | | | | |
| 16 | eng vert buffer | G | -0.600 | 0.177 | -0.322 | 0.000 | 0.000 | 0.000 | 0 | 1 |
| | PTO left | | | | | | | | | |
| | | | | | | | | | | |
| 17 | alt vert buffer | G | -0.375 | -0.990 | -0.635 | 0.000 | 0.000 | 0.000 | 0 | 1 |
| | engineside left | | | | | | | | | |
| | | | | | | | | | | |
| 18 | alt vert buffer | G | -0.375 | -1.990 | -0.635 | 0.000 | 0.000 | 0.000 | 0 | 1 |
| | free end left | | | | | | | | | |
|_______|______________________|___|__________|__________|__________|__________|__________|__________|____|____|
TEM 50 699 Fig. 14
______________________________________________________________________________________________________________
| | | | | | | | | | | |
| Point | Item | G | T | L | V | PHI | THETA | PSI | K1 | K2 |
| No. | | C | Ct | Cl | Cv | Crt | Crl | Crv | | |
|_______|______________________|___|__________|__________|__________|__________|__________|__________|____|____|
| | | | | | | | | | | |
| 19 | air inlet hor. left | G | -0.845 | 1.063 | 1.115 | -90.000 | -90.000 | 0.000 | 0 | 1 |
| | | | | | | | | | | |
| 20 | air inlet hor. right | G | 0.845 | 1.138 | 1.115 | 90.000 | -90.000 | 0.000 | 0 | 1 |
| | | | | | | | | | | |
| 21 | Exh outlet 90° left | G | -0.267 | 0.121 | 1.359 | 0.000 | 180.000 | 0.000 | 0 | 1 |
| | | | | | | | | | | |
| 22 | Exh outlet 90° right | G | 0.267 | 0.221 | 1.359 | 0.000 | 180.000 | 0.000 | 0 | 1 |
| | | | | | | | | | | |
| 23 | Water inlet 20.026 | G | 0.629 | 2.085 | 0.395 | 0.000 | 90.000 | 0.000 | 0 | 1 |
| | | | | | | | | | | |
| 24 | Water outlet 20.027 | G | 0.145 | 2.051 | 0.629 | 0.000 | 90.000 | 0.000 | 0 | 1 |
| | | | | | | | | | | |
| 25 | auxPTO flange | G | 0.000 | 1.980 | 0.000 | 0.000 | 90.000 | 0.000 | 0 | 1 |
| | | | | | | | | | | |
| 26 | alternator free end | G | 0.000 | -2.438 | 0.000 | 0.000 | 0.000 | 0.000 | 0 | 1 |
| | | | | | | | | | | |
| 27 | alt cool in | G | 0.809 | -1.111 | 0.707 | -90.000 | -90.000 | 0.000 | 0 | 1 |
| | | | | | | | | | | |
| 28 | alt cool out | G | 0.809 | -1.111 | 1.157 | -90.000 | -90.000 | 0.000 | 0 | 1 |
| | | | | | | | | | | |
| 29 | Oil pan | G | -0.325 | 1.495 | -0.636 | 0.000 | 0.000 | 0.000 | 0 | 1 |
| | (left sd., free end) | | | | | | | | | |
| | | | | | | | | | | |
| 30 | Oil pan | G | 0.311 | 1.495 | -0.636 | 0.000 | 0.000 | 0.000 | 0 | 1 |
| | (right s., free end) | | | | | | | | | |
| | | | | | | | | | | |
| 31 | Alternator bottom | G | -0.455 | -2.438 | -0.500 | 0.000 | 0.000 | 0.000 | 0 | 1 |
| | (left side) | | | | | | | | | |
| | | | | | | | | | | |
| 32 | Alternator bottom | G | 0.455 | -2.438 | -0.500 | 0.000 | 0.000 | 0.000 | 0 | 1 |
| | (right side) | | | | | | | | | |
| | | | | | | | | | | |
| 33 | Upper edge free end | G | -0.831 | 1.870 | 1.170 | 0.000 | 0.000 | 0.000 | 0 | 1 |
| | left side | | | | | | | | | |
| | | | | | | | | | | |
| 34 | Upper edge free end | G | 0.771 | 2.179 | 1.055 | 0.000 | 0.000 | 0.000 | 0 | 1 |
| | right side | | | | | | | | | |
| | | | | | | | | | | |
| 35 | Alternator top | G | -0.685 | -2.547 | 1.347 | 0.000 | 0.000 | 0.000 | 0 | 1 |
| | (left side) | | | | | | | | | |
| | | | | | | | | | | |
| 36 | Alternator top | G | 0.685 | -2.547 | 1.347 | 0.000 | 0.000 | 0.000 | 0 | 1 |
| | (right side) | | | | | | | | | |
|_______|______________________|___|__________|__________|__________|__________|__________|__________|____|____|
TEM 50 699 Fig. 15
Load case: Dead Weight
========== ===========

Maximum displacements and forces at interesting points

------------------------------------------------------

±Umax .... maximum displacements and rotations (negative and positive) in [mm, mrad]
|Urad| .... maximum radial displacement in [mm]
±Uax .... maximum axial displacements (negative and positive) in [mm]
±Fmax .... maximum spring forces and moments (negative and positive) in [N, Nm]
|Frad| .... maximum radial spring force in [N]
±Fax .... maximum axial spring forces (negative and positive) in [N]

gs .... the quantities are referenced to the global coordinate system

ps .... the quantities are referenced to a point related coordinate system

Item quantity in t-dir. in l-dir. in v-dir. ab. t-axis ab. l-axis ab. v-axis
---------------------------------------------------------------------------------------------------------------

c/g Basic engine -Umax gs : 0.03 -0.06 -5.32 0.09 0.04 0.00
(as in EB drawing) +Umax gs : 0.03 -0.06 -5.32 0.09 0.04 0.00

c/g Alternator -Umax gs : 0.03 -0.04 -5.51 0.09 0.04 0.00

+Umax gs : 0.03 -0.04 -5.51 0.09 0.04 0.00

Engine mount -Umax gs : 0.00 -0.01 -5.30 0.09 0.04 0.00

right side, free end +Umax gs : 0.00 -0.01 -5.30 0.09 0.04 0.00
-Fmax gs : -5. -37. -20366. 0. 0. 0.
+Fmax gs : -5. -37. -20366. 0. 0. 0.

Engine mount -Umax gs : 0.00 -0.01 -5.40 0.09 0.04 0.00

right side, alt. end +Umax gs : 0.00 -0.01 -5.40 0.09 0.04 0.00
-Fmax gs : 23. -37. -20827. 0. 0. 0.
+Fmax gs : 23. -37. -20827. 0. 0. 0.

Alternator mount -Umax gs : -0.01 0.02 -5.49 0.09 0.04 0.00

right side, engine +Umax gs : -0.01 0.02 -5.49 0.09 0.04 0.00
-Fmax gs : -14. 55. -12027. 0. 0. 0.
+Fmax gs : -14. 55. -12027. 0. 0. 0.

Alternator mount -Umax gs : 0.00 0.02 -5.58 0.09 0.04 0.00

right side, PTO +Umax gs : 0.00 0.02 -5.58 0.09 0.04 0.00
-Fmax gs : -4. 55. -12225. 0. 0. 0.
+Fmax gs : -4. 55. -12225. 0. 0. 0.

Engine mount -Umax gs : 0.00 -0.01 -5.25 0.09 0.04 0.00

left side, free end +Umax gs : 0.00 -0.01 -5.25 0.09 0.04 0.00
-Fmax gs : -5. -65. -20129. 0. 0. 0.
+Fmax gs : -5. -65. -20129. 0. 0. 0.

Engine mount -Umax gs : 0.00 -0.01 -5.35 0.09 0.04 0.00

left side, free end +Umax gs : 0.00 -0.01 -5.35 0.09 0.04 0.00
-Fmax gs : 23. -65. -20590. 0. 0. 0.
+Fmax gs : 23. -65. -20590. 0. 0. 0.

Alternator mount -Umax gs : -0.01 0.02 -5.46 0.09 0.04 0.00

left side, engine +Umax gs : -0.01 0.02 -5.46 0.09 0.04 0.00
-Fmax gs : -14. 47. -11953. 0. 0. 0.
+Fmax gs : -14. 47. -11953. 0. 0. 0.

Alternator mount -Umax gs : 0.00 0.02 -5.54 0.09 0.04 0.00

left side, PTO +Umax gs : 0.00 0.02 -5.54 0.09 0.04 0.00
-Fmax gs : -4. 47. -12150. 0. 0. 0.
+Fmax gs : -4. 47. -12150. 0. 0. 0.

auxPTO flange -Umax gs : 0.01 -0.03 -5.22 0.09 0.04 0.00

+Umax gs : 0.01 -0.03 -5.22 0.09 0.04 0.00

Alternator free end -Umax gs : 0.03 -0.03 -5.60 0.09 0.04 0.00
+Umax gs : 0.03 -0.03 -5.60 0.09 0.04 0.00
TEM 50 699 Fig. 16
Load case: A1 permanent vessel inclinations:
========== trim ±5.0 deg. & list ±15.0 deg.(simultaneously)

Maximum displacements and forces at interesting points

------------------------------------------------------

±Umax .... maximum displacements and rotations (negative and positive) in [mm, mrad]
|Urad| .... maximum radial displacement in [mm]
±Uax .... maximum axial displacements (negative and positive) in [mm]
±Fmax .... maximum spring forces and moments (negative and positive) in [N, Nm]
|Frad| .... maximum radial spring force in [N]
±Fax .... maximum axial spring forces (negative and positive) in [N]

gs .... the quantities are referenced to the global coordinate system

ps .... the quantities are referenced to a point related coordinate system

Item quantity in t-dir. in l-dir. in v-dir. ab. t-axis ab. l-axis ab. v-axis
---------------------------------------------------------------------------------------------------------------

c/g Basic engine -Umax gs : -2.40 -0.42 0.07 -0.17 -2.60 -0.31
(as in EB drawing) +Umax gs : 2.40 0.42 0.37 0.17 2.59 0.31

c/g Alternator -Umax gs : -2.56 -0.38 -0.01 -0.17 -2.60 -0.31

+Umax gs : 2.55 0.38 0.45 0.17 2.59 0.31

Engine mount -Umax gs : -0.75 -0.51 -1.55 -0.17 -2.60 -0.31

free end right +Umax gs : 0.75 0.50 2.02 0.17 2.59 0.31
-Fmax gs : -4885. -3288. -6884. 0. 0. 0.
+Fmax gs : 4882. 3276. 8321. 0. 0. 0.

Engine mount -Umax gs : -1.12 -0.51 -1.35 -0.17 -2.60 -0.31

PTO right +Umax gs : 1.12 0.50 1.82 0.17 2.59 0.31
-Fmax gs : -7249. -3288. -5980. 0. 0. 0.
+Fmax gs : 7247. 3276. 7572. 0. 0. 0.

Alternator mount -Umax gs : -0.67 -0.38 -0.91 -0.17 -2.60 -0.31

engineside right +Umax gs : 0.67 0.38 1.35 0.17 2.59 0.31
-Fmax gs : -1929. -1098. -2039. 0. 0. 0.
+Fmax gs : 1933. 1096. 2925. 0. 0. 0.

Alternator mount -Umax gs : -0.98 -0.38 -1.09 -0.17 -2.60 -0.31

free end right +Umax gs : 0.98 0.38 1.52 0.17 2.59 0.31
-Fmax gs : -2815. -1098. -2436. 0. 0. 0.
+Fmax gs : 2818. 1096. 3297. 0. 0. 0.

Engine mount -Umax gs : -0.75 -0.51 -1.55 -0.17 -2.60 -0.31

free end left +Umax gs : 0.75 0.50 2.02 0.17 2.59 0.31
-Fmax gs : -4885. -3283. -6891. 0. 0. 0.
+Fmax gs : 4882. 3273. 8311. 0. 0. 0.

Engine mount -Umax gs : -1.12 -0.51 -1.35 -0.17 -2.60 -0.31

PTO left +Umax gs : 1.12 0.50 1.81 0.17 2.59 0.31
-Fmax gs : -7249. -3283. -5987. 0. 0. 0.
+Fmax gs : 7247. 3273. 7561. 0. 0. 0.

Alternator mount -Umax gs : -0.67 -0.38 -0.92 -0.17 -2.60 -0.31

engineside left +Umax gs : 0.67 0.38 1.35 0.17 2.59 0.31
-Fmax gs : -1929. -1097. -2043. 0. 0. 0.
+Fmax gs : 1933. 1095. 2923. 0. 0. 0.

Alternator mount -Umax gs : -0.98 -0.38 -1.09 -0.17 -2.60 -0.31

free end left +Umax gs : 0.98 0.38 1.52 0.17 2.59 0.31
-Fmax gs : -2815. -1097. -2439. 0. 0. 0.
+Fmax gs : 2818. 1095. 3294. 0. 0. 0.
TEM 50 699 Fig. 17
Load case: A1 permanent vessel inclinations:
========== trim ±5.0 deg. & list ±15.0 deg.(simultaneously)

Maximum displacements and forces at interesting points (continuation)

------------------------------------------------------------------------

Item quantity in t-dir. in l-dir. in v-dir. ab. t-axis ab. l-axis ab. v-axis
---------------------------------------------------------------------------------------------------------------

eng vert buffer -Umax gs : -0.62 -0.50 -1.55 -0.17 -2.60 -0.31
free end right +Umax gs : 0.62 0.50 2.02 0.17 2.59 0.31
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.

eng vert buffer -Umax gs : -0.99 -0.50 -1.35 -0.17 -2.60 -0.31
PTO right +Umax gs : 0.99 0.50 1.82 0.17 2.59 0.31
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.

alt vert buffer -Umax gs : -0.54 -0.37 -0.91 -0.17 -2.60 -0.31
engineside right +Umax gs : 0.54 0.37 1.35 0.17 2.59 0.31
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.

alt vert buffer -Umax gs : -0.85 -0.37 -1.09 -0.17 -2.60 -0.31
free end right +Umax gs : 0.85 0.37 1.52 0.17 2.59 0.31
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.

eng vert buffer -Umax gs : -0.62 -0.50 -1.55 -0.17 -2.60 -0.31
free end left +Umax gs : 0.62 0.50 2.02 0.17 2.59 0.31
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.

eng vert buffer -Umax gs : -0.99 -0.50 -1.35 -0.17 -2.60 -0.31
PTO left +Umax gs : 0.99 0.50 1.81 0.17 2.59 0.31
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.

alt vert buffer -Umax gs : -0.54 -0.37 -0.92 -0.17 -2.60 -0.31
engineside left +Umax gs : 0.54 0.37 1.35 0.17 2.59 0.31
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.

alt vert buffer -Umax gs : -0.85 -0.37 -1.09 -0.17 -2.60 -0.31
free end left +Umax gs : 0.85 0.37 1.52 0.17 2.59 0.31
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.
TEM 50 699 Fig. 18
Load case: A1 permanent vessel inclinations:
========== trim ±5.0 deg. & list ±15.0 deg.(simultaneously)

Maximum displacements and forces at interesting points (continuation)

------------------------------------------------------------------------

Item quantity in t-dir. in l-dir. in v-dir. ab. t-axis ab. l-axis ab. v-axis
---------------------------------------------------------------------------------------------------------------

air inlet hor. left |Urad| ps : 2.73 -Uax ps : -4.44 +Uax ps : 4.44

air inlet hor. right |Urad| ps : 2.74 -Uax ps : -4.41 +Uax ps : 4.42

Exh outlet 90° left |Urad| ps : 5.40 -Uax ps : -0.94 +Uax ps : 0.49

Exh outlet 90° right |Urad| ps : 5.38 -Uax ps : -0.96 +Uax ps : 0.51

Water inlet 20.026 |Urad| ps : 3.16 -Uax ps : -0.63 +Uax ps : 0.63

Water outlet 20.027 |Urad| ps : 3.03 -Uax ps : -0.52 +Uax ps : 0.52

auxPTO flange |Urad| ps : 1.38 -Uax ps : -0.37 +Uax ps : 0.37

alternator free end |Urad| ps : 2.66 -Uax ps : -0.19 +Uax ps : 0.63

alt cool in |Urad| ps : 2.49 -Uax ps : -4.06 +Uax ps : 4.05

alt cool out |Urad| ps : 2.50 -Uax ps : -5.23 +Uax ps : 5.22

Oil pan -Umax gs : -0.24 -0.36 -0.87 -0.17 -2.60 -0.31

(left sd., free end) +Umax gs : 0.24 0.36 1.33 0.17 2.59 0.31

Oil pan -Umax gs : -0.24 -0.35 -0.84 -0.17 -2.60 -0.31

(right s., free end) +Umax gs : 0.24 0.35 1.29 0.17 2.59 0.31

Alternator bottom -Umax gs : -1.34 -0.42 -1.37 -0.17 -2.60 -0.31

(left side) +Umax gs : 1.34 0.42 1.80 0.17 2.59 0.31

Alternator bottom -Umax gs : -1.34 -0.42 -1.37 -0.17 -2.60 -0.31

(right side) +Umax gs : 1.34 0.42 1.80 0.17 2.59 0.31

Upper edge free end -Umax gs : -4.33 -0.83 -2.24 -0.17 -2.60 -0.31
left side +Umax gs : 4.33 0.82 2.70 0.17 2.59 0.31

Upper edge free end -Umax gs : -3.94 -0.79 -2.13 -0.17 -2.60 -0.31
right side +Umax gs : 3.93 0.78 2.61 0.17 2.59 0.31

Alternator top -Umax gs : -6.17 -0.81 -1.99 -0.17 -2.60 -0.31

(left side) +Umax gs : 6.16 0.81 2.41 0.17 2.59 0.31

Alternator top -Umax gs : -6.17 -0.81 -1.99 -0.17 -2.60 -0.31

(right side) +Umax gs : 6.16 0.81 2.41 0.17 2.59 0.31
TEM 50 699 Fig. 19
Load case: A2 vessel movements in rough seas
========== pitching ±7.5 deg. & rolling ±22.5 deg. (simul.)

Maximum displacements and forces at interesting points

------------------------------------------------------

±Umax .... maximum displacements and rotations (negative and positive) in [mm, mrad]
|Urad| .... maximum radial displacement in [mm]
±Uax .... maximum axial displacements (negative and positive) in [mm]
±Fmax .... maximum spring forces and moments (negative and positive) in [N, Nm]
|Frad| .... maximum radial spring force in [N]
±Fax .... maximum axial spring forces (negative and positive) in [N]

gs .... the quantities are referenced to the global coordinate system

ps .... the quantities are referenced to a point related coordinate system

Item quantity in t-dir. in l-dir. in v-dir. ab. t-axis ab. l-axis ab. v-axis
---------------------------------------------------------------------------------------------------------------

c/g Basic engine -Umax gs : -3.60 -0.64 0.30 -0.24 -3.92 -0.47
(as in EB drawing) +Umax gs : 3.60 0.62 0.76 0.27 3.91 0.47

c/g Alternator -Umax gs : -3.83 -0.58 0.15 -0.24 -3.92 -0.47

+Umax gs : 3.82 0.57 0.84 0.27 3.91 0.47

Engine mount -Umax gs : -1.11 -0.76 -2.14 -0.24 -3.92 -0.47

free end right +Umax gs : 1.11 0.76 3.25 0.27 3.91 0.47
-Fmax gs : -7213. -4939. -9526. 0. 0. 0.
+Fmax gs : 7209. 4901. 12869. 0. 0. 0.

Engine mount -Umax gs : -1.66 -0.76 -1.86 -0.24 -3.92 -0.47

PTO right +Umax gs : 1.66 0.76 2.93 0.27 3.91 0.47
-Fmax gs : -10765. -4939. -8253. 0. 0. 0.
+Fmax gs : 10760. 4901. 11688. 0. 0. 0.

Alternator mount -Umax gs : -0.98 -0.57 -1.21 -0.24 -3.92 -0.47

engineside right +Umax gs : 0.99 0.58 2.20 0.27 3.91 0.47
-Fmax gs : -2823. -1638. -2719. 0. 0. 0.
+Fmax gs : 2830. 1652. 4788. 0. 0. 0.

Alternator mount -Umax gs : -1.45 -0.57 -1.48 -0.24 -3.92 -0.47

free end right +Umax gs : 1.45 0.58 2.44 0.27 3.91 0.47
-Fmax gs : -4154. -1638. -3343. 0. 0. 0.
+Fmax gs : 4159. 1652. 5315. 0. 0. 0.

Engine mount -Umax gs : -1.11 -0.76 -2.14 -0.24 -3.92 -0.47

free end left +Umax gs : 1.11 0.75 3.24 0.27 3.91 0.47
-Fmax gs : -7213. -4930. -9543. 0. 0. 0.
+Fmax gs : 7209. 4898. 12846. 0. 0. 0.

Engine mount -Umax gs : -1.66 -0.76 -1.86 -0.24 -3.92 -0.47

PTO left +Umax gs : 1.66 0.75 2.92 0.27 3.91 0.47
-Fmax gs : -10765. -4930. -8270. 0. 0. 0.
+Fmax gs : 10760. 4898. 11666. 0. 0. 0.

Alternator mount -Umax gs : -0.98 -0.57 -1.21 -0.24 -3.92 -0.47

engineside left +Umax gs : 0.99 0.58 2.20 0.27 3.91 0.47
-Fmax gs : -2823. -1636. -2726. 0. 0. 0.
+Fmax gs : 2830. 1652. 4782. 0. 0. 0.

Alternator mount -Umax gs : -1.45 -0.57 -1.49 -0.24 -3.92 -0.47

free end left +Umax gs : 1.45 0.58 2.44 0.27 3.91 0.47
-Fmax gs : -4154. -1636. -3351. 0. 0. 0.
+Fmax gs : 4159. 1652. 5310. 0. 0. 0.
TEM 50 699 Fig. 20
Load case: A2 vessel movements in rough seas
========== pitching ±7.5 deg. & rolling ±22.5 deg. (simul.)

Maximum displacements and forces at interesting points (continuation)

------------------------------------------------------------------------

Item quantity in t-dir. in l-dir. in v-dir. ab. t-axis ab. l-axis ab. v-axis
---------------------------------------------------------------------------------------------------------------

eng vert buffer -Umax gs : -0.92 -0.75 -2.14 -0.24 -3.92 -0.47
free end right +Umax gs : 0.92 0.74 3.25 0.27 3.91 0.47
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.

eng vert buffer -Umax gs : -1.46 -0.75 -1.86 -0.24 -3.92 -0.47
PTO right +Umax gs : 1.46 0.74 2.93 0.27 3.91 0.47
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.

alt vert buffer -Umax gs : -0.79 -0.56 -1.21 -0.24 -3.92 -0.47
engineside right +Umax gs : 0.79 0.56 2.20 0.27 3.91 0.47
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.

alt vert buffer -Umax gs : -1.25 -0.56 -1.48 -0.24 -3.92 -0.47
free end right +Umax gs : 1.25 0.56 2.44 0.27 3.91 0.47
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.

eng vert buffer -Umax gs : -0.92 -0.75 -2.14 -0.24 -3.92 -0.47
free end left +Umax gs : 0.92 0.74 3.24 0.27 3.91 0.47
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.

eng vert buffer -Umax gs : -1.46 -0.75 -1.86 -0.24 -3.92 -0.47
PTO left +Umax gs : 1.46 0.74 2.92 0.27 3.91 0.47
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.

alt vert buffer -Umax gs : -0.79 -0.56 -1.21 -0.24 -3.92 -0.47
engineside left +Umax gs : 0.79 0.56 2.20 0.27 3.91 0.47
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.

alt vert buffer -Umax gs : -1.25 -0.56 -1.49 -0.24 -3.92 -0.47
free end left +Umax gs : 1.25 0.56 2.44 0.27 3.91 0.47
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.
TEM 50 699 Fig. 21
Load case: A2 vessel movements in rough seas
========== pitching ±7.5 deg. & rolling ±22.5 deg. (simul.)

Maximum displacements and forces at interesting points (continuation)

------------------------------------------------------------------------

Item quantity in t-dir. in l-dir. in v-dir. ab. t-axis ab. l-axis ab. v-axis
---------------------------------------------------------------------------------------------------------------

air inlet hor. left |Urad| ps : 4.31 -Uax ps : -6.68 +Uax ps : 6.67

air inlet hor. right |Urad| ps : 4.34 -Uax ps : -6.64 +Uax ps : 6.65

Exh outlet 90° left |Urad| ps : 8.13 -Uax ps : -1.60 +Uax ps : 0.56

Exh outlet 90° right |Urad| ps : 8.10 -Uax ps : -1.63 +Uax ps : 0.58

Water inlet 20.026 |Urad| ps : 4.91 -Uax ps : -0.93 +Uax ps : 0.96

Water outlet 20.027 |Urad| ps : 4.62 -Uax ps : -0.76 +Uax ps : 0.79

auxPTO flange |Urad| ps : 2.16 -Uax ps : -0.54 +Uax ps : 0.55

alternator free end |Urad| ps : 3.99 -Uax ps : -0.14 +Uax ps : 1.09

alt cool in |Urad| ps : 3.93 -Uax ps : -6.10 +Uax ps : 6.09

alt cool out |Urad| ps : 3.94 -Uax ps : -7.86 +Uax ps : 7.85

Oil pan -Umax gs : -0.38 -0.53 -1.11 -0.24 -3.92 -0.47

(left sd., free end) +Umax gs : 0.39 0.54 2.20 0.27 3.91 0.47

Oil pan -Umax gs : -0.38 -0.53 -1.06 -0.24 -3.92 -0.47

(right s., free end) +Umax gs : 0.39 0.53 2.15 0.27 3.91 0.47

Alternator bottom -Umax gs : -1.99 -0.63 -1.92 -0.24 -3.92 -0.47

(left side) +Umax gs : 1.98 0.63 2.86 0.27 3.91 0.47

Alternator bottom -Umax gs : -1.99 -0.63 -1.92 -0.24 -3.92 -0.47

(right side) +Umax gs : 1.98 0.63 2.86 0.27 3.91 0.47

Upper edge free end -Umax gs : -6.52 -1.26 -3.16 -0.24 -3.92 -0.47
left side +Umax gs : 6.51 1.21 4.29 0.27 3.91 0.47

Upper edge free end -Umax gs : -5.93 -1.20 -3.00 -0.24 -3.92 -0.47
right side +Umax gs : 5.92 1.15 4.14 0.27 3.91 0.47

Alternator top -Umax gs : -9.28 -1.24 -2.85 -0.24 -3.92 -0.47

(left side) +Umax gs : 9.26 1.18 3.77 0.27 3.91 0.47

Alternator top -Umax gs : -9.28 -1.24 -2.85 -0.24 -3.92 -0.47

(right side) +Umax gs : 9.26 1.18 3.78 0.27 3.91 0.47
TEM 50 699 Fig. 22
Load case: A3 g-loads due to fast travel in rough seas:
========== ±0.18g athwart & ±0.40g vertical (simultaneously)

Maximum displacements and forces at interesting points

------------------------------------------------------

±Umax .... maximum displacements and rotations (negative and positive) in [mm, mrad]
|Urad| .... maximum radial displacement in [mm]
±Uax .... maximum axial displacements (negative and positive) in [mm]
±Fmax .... maximum spring forces and moments (negative and positive) in [N, Nm]
|Frad| .... maximum radial spring force in [N]
±Fax .... maximum axial spring forces (negative and positive) in [N]

gs .... the quantities are referenced to the global coordinate system

ps .... the quantities are referenced to a point related coordinate system

Item quantity in t-dir. in l-dir. in v-dir. ab. t-axis ab. l-axis ab. v-axis
---------------------------------------------------------------------------------------------------------------

c/g Basic engine -Umax gs : -1.78 -0.07 -1.85 -0.08 -1.98 -0.23
(as in EB drawing) +Umax gs : 1.75 0.05 2.04 0.11 1.94 0.23

c/g Alternator -Umax gs : -1.88 -0.05 -2.08 -0.08 -1.98 -0.23

+Umax gs : 1.86 0.04 2.20 0.11 1.94 0.23

Engine mount -Umax gs : -0.53 -0.13 -2.80 -0.08 -1.98 -0.23

free end right +Umax gs : 0.52 0.14 3.18 0.11 1.94 0.23
-Fmax gs : -3407. -864. -12604. 0. 0. 0.
+Fmax gs : 3404. 937. 12614. 0. 0. 0.

Engine mount -Umax gs : -0.79 -0.13 -2.93 -0.08 -1.98 -0.23

PTO right +Umax gs : 0.79 0.14 3.27 0.11 1.94 0.23
-Fmax gs : -5140. -864. -13319. 0. 0. 0.
+Fmax gs : 5119. 937. 12943. 0. 0. 0.

Alternator mount -Umax gs : -0.48 -0.10 -2.68 -0.08 -1.98 -0.23

engineside right +Umax gs : 0.48 0.10 2.91 0.11 1.94 0.23
-Fmax gs : -1383. -297. -6089. 0. 0. 0.
+Fmax gs : 1371. 292. 6344. 0. 0. 0.

Alternator mount -Umax gs : -0.69 -0.10 -2.79 -0.08 -1.98 -0.23

free end right +Umax gs : 0.69 0.10 2.99 0.11 1.94 0.23
-Fmax gs : -1969. -297. -6344. 0. 0. 0.
+Fmax gs : 1966. 292. 6510. 0. 0. 0.

Engine mount -Umax gs : -0.53 -0.13 -2.78 -0.08 -1.98 -0.23

free end left +Umax gs : 0.52 0.15 3.15 0.11 1.94 0.23
-Fmax gs : -3407. -875. -12509. 0. 0. 0.
+Fmax gs : 3404. 950. 12520. 0. 0. 0.

Engine mount -Umax gs : -0.79 -0.13 -2.91 -0.08 -1.98 -0.23

PTO left +Umax gs : 0.79 0.15 3.24 0.11 1.94 0.23
-Fmax gs : -5140. -875. -13220. 0. 0. 0.
+Fmax gs : 5119. 950. 12852. 0. 0. 0.

Alternator mount -Umax gs : -0.48 -0.10 -2.66 -0.08 -1.98 -0.23

engineside left +Umax gs : 0.48 0.10 2.90 0.11 1.94 0.23
-Fmax gs : -1383. -293. -6063. 0. 0. 0.
+Fmax gs : 1371. 288. 6311. 0. 0. 0.

Alternator mount -Umax gs : -0.69 -0.10 -2.77 -0.08 -1.98 -0.23

free end left +Umax gs : 0.69 0.10 2.97 0.11 1.94 0.23
-Fmax gs : -1969. -293. -6316. 0. 0. 0.
+Fmax gs : 1966. 288. 6478. 0. 0. 0.
TEM 50 699 Fig. 23
Load case: A3 g-loads due to fast travel in rough seas:
========== ±0.18g athwart & ±0.40g vertical (simultaneously)

Maximum displacements and forces at interesting points (continuation)

------------------------------------------------------------------------

Item quantity in t-dir. in l-dir. in v-dir. ab. t-axis ab. l-axis ab. v-axis
---------------------------------------------------------------------------------------------------------------

eng vert buffer -Umax gs : -0.44 -0.14 -2.80 -0.08 -1.98 -0.23
free end right +Umax gs : 0.44 0.14 3.18 0.11 1.94 0.23
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.

eng vert buffer -Umax gs : -0.69 -0.14 -2.93 -0.08 -1.98 -0.23
PTO right +Umax gs : 0.69 0.14 3.27 0.11 1.94 0.23
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.

alt vert buffer -Umax gs : -0.40 -0.11 -2.68 -0.08 -1.98 -0.23
engineside right +Umax gs : 0.39 0.11 2.91 0.11 1.94 0.23
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.

alt vert buffer -Umax gs : -0.60 -0.11 -2.79 -0.08 -1.98 -0.23
free end right +Umax gs : 0.60 0.11 2.99 0.11 1.94 0.23
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.

eng vert buffer -Umax gs : -0.44 -0.13 -2.78 -0.08 -1.98 -0.23
free end left +Umax gs : 0.44 0.14 3.15 0.11 1.94 0.23
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.

eng vert buffer -Umax gs : -0.69 -0.13 -2.91 -0.08 -1.98 -0.23
PTO left +Umax gs : 0.69 0.14 3.24 0.11 1.94 0.23
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.

alt vert buffer -Umax gs : -0.40 -0.11 -2.66 -0.08 -1.98 -0.23
engineside left +Umax gs : 0.39 0.11 2.90 0.11 1.94 0.23
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.

alt vert buffer -Umax gs : -0.60 -0.11 -2.77 -0.08 -1.98 -0.23
free end left +Umax gs : 0.60 0.11 2.97 0.11 1.94 0.23
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.
TEM 50 699 Fig. 24
Load case: A3 g-loads due to fast travel in rough seas:
========== ±0.18g athwart & ±0.40g vertical (simultaneously)

Maximum displacements and forces at interesting points (continuation)

------------------------------------------------------------------------

Item quantity in t-dir. in l-dir. in v-dir. ab. t-axis ab. l-axis ab. v-axis
---------------------------------------------------------------------------------------------------------------

air inlet hor. left |Urad| ps : 3.65 -Uax ps : -3.33 +Uax ps : 3.28

air inlet hor. right |Urad| ps : 3.68 -Uax ps : -3.26 +Uax ps : 3.32

Exh outlet 90° left |Urad| ps : 4.04 -Uax ps : -2.60 +Uax ps : 2.36

Exh outlet 90° right |Urad| ps : 4.01 -Uax ps : -2.60 +Uax ps : 2.36

Water inlet 20.026 |Urad| ps : 3.59 -Uax ps : -0.20 +Uax ps : 0.21

Water outlet 20.027 |Urad| ps : 3.09 -Uax ps : -0.11 +Uax ps : 0.14

auxPTO flange |Urad| ps : 2.15 -Uax ps : -0.03 +Uax ps : 0.04

alternator free end |Urad| ps : 1.94 -Uax ps : -2.20 +Uax ps : 2.28

alt cool in |Urad| ps : 3.78 -Uax ps : -3.03 +Uax ps : 2.98

alt cool out |Urad| ps : 3.78 -Uax ps : -3.92 +Uax ps : 3.86

Oil pan -Umax gs : -0.22 -0.09 -2.31 -0.08 -1.98 -0.23

(left sd., free end) +Umax gs : 0.24 0.10 2.61 0.11 1.94 0.23

Oil pan -Umax gs : -0.22 -0.09 -2.29 -0.08 -1.98 -0.23

(right s., free end) +Umax gs : 0.24 0.09 2.60 0.11 1.94 0.23

Alternator bottom -Umax gs : -0.95 -0.11 -2.96 -0.08 -1.98 -0.23

(left side) +Umax gs : 0.94 0.11 3.16 0.11 1.94 0.23

Alternator bottom -Umax gs : -0.95 -0.12 -2.97 -0.08 -1.98 -0.23

(right side) +Umax gs : 0.94 0.11 3.18 0.11 1.94 0.23

Upper edge free end -Umax gs : -3.26 -0.34 -3.11 -0.08 -1.98 -0.23
left side +Umax gs : 3.20 0.31 3.56 0.11 1.94 0.23

Upper edge free end -Umax gs : -2.96 -0.31 -3.00 -0.08 -1.98 -0.23
right side +Umax gs : 2.91 0.28 3.46 0.11 1.94 0.23

Alternator top -Umax gs : -4.63 -0.33 -3.35 -0.08 -1.98 -0.23

(left side) +Umax gs : 4.56 0.29 3.62 0.11 1.94 0.23

Alternator top -Umax gs : -4.63 -0.33 -3.38 -0.08 -1.98 -0.23

(right side) +Umax gs : 4.56 0.29 3.64 0.11 1.94 0.23
TEM 50 699 Fig. 25
Load case: A4 g-loads due to fast travel in rough seas:
========== ±0.10g fore and aft & ±0.40g vertical (simultan.)

Maximum displacements and forces at interesting points

------------------------------------------------------

±Umax .... maximum displacements and rotations (negative and positive) in [mm, mrad]
|Urad| .... maximum radial displacement in [mm]
±Uax .... maximum axial displacements (negative and positive) in [mm]
±Fmax .... maximum spring forces and moments (negative and positive) in [N, Nm]
|Frad| .... maximum radial spring force in [N]
±Fax .... maximum axial spring forces (negative and positive) in [N]

gs .... the quantities are referenced to the global coordinate system

ps .... the quantities are referenced to a point related coordinate system

Item quantity in t-dir. in l-dir. in v-dir. ab. t-axis ab. l-axis ab. v-axis
---------------------------------------------------------------------------------------------------------------

c/g Basic engine -Umax gs : -0.01 -0.54 -2.00 -0.30 -0.02 0.00
(as in EB drawing) +Umax gs : 0.01 0.55 2.17 0.29 0.02 0.00

c/g Alternator -Umax gs : -0.01 -0.48 -2.35 -0.30 -0.02 0.00

+Umax gs : 0.01 0.49 2.46 0.29 0.02 0.00

Engine mount -Umax gs : 0.00 -0.38 -2.06 -0.30 -0.02 0.00

free end right +Umax gs : 0.00 0.38 2.25 0.29 0.02 0.00
-Fmax gs : -7. -2436. -9162. 0. 0. 0.
+Fmax gs : 7. 2439. 9181. 0. 0. 0.

Engine mount -Umax gs : 0.00 -0.38 -1.97 -0.30 -0.02 0.00

PTO right +Umax gs : 0.00 0.38 2.11 0.29 0.02 0.00
-Fmax gs : -12. -2436. -8740. 0. 0. 0.
+Fmax gs : 10. 2439. 8674. 0. 0. 0.

Alternator mount -Umax gs : 0.00 -0.32 -2.24 -0.30 -0.02 0.00

engineside right +Umax gs : 0.00 0.33 2.35 0.29 0.02 0.00
-Fmax gs : -8. -929. -5079. 0. 0. 0.
+Fmax gs : 9. 951. 5123. 0. 0. 0.

Alternator mount -Umax gs : 0.00 -0.32 -2.53 -0.30 -0.02 0.00

free end right +Umax gs : 0.00 0.33 2.65 0.29 0.02 0.00
-Fmax gs : -5. -929. -5750. 0. 0. 0.
+Fmax gs : 5. 951. 5776. 0. 0. 0.

Engine mount -Umax gs : 0.00 -0.38 -2.04 -0.30 -0.02 0.00

free end left +Umax gs : 0.00 0.38 2.23 0.29 0.02 0.00
-Fmax gs : -7. -2443. -9066. 0. 0. 0.
+Fmax gs : 7. 2448. 9087. 0. 0. 0.

Engine mount -Umax gs : 0.00 -0.38 -1.94 -0.30 -0.02 0.00

PTO left +Umax gs : 0.00 0.38 2.09 0.29 0.02 0.00
-Fmax gs : -12. -2443. -8643. 0. 0. 0.
+Fmax gs : 10. 2448. 8580. 0. 0. 0.

Alternator mount -Umax gs : 0.00 -0.32 -2.22 -0.30 -0.02 0.00

engineside left +Umax gs : 0.00 0.33 2.34 0.29 0.02 0.00
-Fmax gs : -8. -923. -5049. 0. 0. 0.
+Fmax gs : 9. 947. 5090. 0. 0. 0.

Alternator mount -Umax gs : 0.00 -0.32 -2.52 -0.30 -0.02 0.00

free end left +Umax gs : 0.00 0.33 2.64 0.29 0.02 0.00
-Fmax gs : -5. -923. -5720. 0. 0. 0.
+Fmax gs : 5. 947. 5743. 0. 0. 0.
TEM 50 699 Fig. 26
Load case: A4 g-loads due to fast travel in rough seas:
========== ±0.10g fore and aft & ±0.40g vertical (simultan.)

Maximum displacements and forces at interesting points (continuation)

------------------------------------------------------------------------

Item quantity in t-dir. in l-dir. in v-dir. ab. t-axis ab. l-axis ab. v-axis
---------------------------------------------------------------------------------------------------------------

eng vert buffer -Umax gs : 0.00 -0.36 -2.06 -0.30 -0.02 0.00
free end right +Umax gs : 0.00 0.36 2.25 0.29 0.02 0.00
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.

eng vert buffer -Umax gs : 0.00 -0.36 -1.97 -0.30 -0.02 0.00
PTO right +Umax gs : 0.00 0.36 2.11 0.29 0.02 0.00
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.

alt vert buffer -Umax gs : 0.00 -0.32 -2.24 -0.30 -0.02 0.00
engineside right +Umax gs : 0.00 0.33 2.35 0.29 0.02 0.00
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.

alt vert buffer -Umax gs : 0.00 -0.32 -2.53 -0.30 -0.02 0.00
free end right +Umax gs : 0.00 0.33 2.65 0.29 0.02 0.00
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.

eng vert buffer -Umax gs : 0.00 -0.36 -2.04 -0.30 -0.02 0.00
free end left +Umax gs : 0.00 0.36 2.23 0.29 0.02 0.00
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.

eng vert buffer -Umax gs : 0.00 -0.36 -1.94 -0.30 -0.02 0.00
PTO left +Umax gs : 0.00 0.36 2.09 0.29 0.02 0.00
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.

alt vert buffer -Umax gs : 0.00 -0.32 -2.22 -0.30 -0.02 0.00
engineside left +Umax gs : 0.00 0.33 2.34 0.29 0.02 0.00
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.

alt vert buffer -Umax gs : 0.00 -0.32 -2.52 -0.30 -0.02 0.00
free end left +Umax gs : 0.00 0.33 2.64 0.29 0.02 0.00
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.
TEM 50 699 Fig. 27
Load case: A4 g-loads due to fast travel in rough seas:
========== ±0.10g fore and aft & ±0.40g vertical (simultan.)

Maximum displacements and forces at interesting points (continuation)

------------------------------------------------------------------------

Item quantity in t-dir. in l-dir. in v-dir. ab. t-axis ab. l-axis ab. v-axis
---------------------------------------------------------------------------------------------------------------

air inlet hor. left |Urad| ps : 2.25 -Uax ps : -0.03 +Uax ps : 0.02

air inlet hor. right |Urad| ps : 2.29 -Uax ps : -0.02 +Uax ps : 0.03

Exh outlet 90° left |Urad| ps : 0.86 -Uax ps : -2.09 +Uax ps : 1.95

Exh outlet 90° right |Urad| ps : 0.86 -Uax ps : -2.11 +Uax ps : 1.96

Water inlet 20.026 |Urad| ps : 2.34 -Uax ps : -0.57 +Uax ps : 0.57

Water outlet 20.027 |Urad| ps : 2.32 -Uax ps : -0.64 +Uax ps : 0.64

auxPTO flange |Urad| ps : 2.31 -Uax ps : -0.46 +Uax ps : 0.46

alternator free end |Urad| ps : 0.46 -Uax ps : -2.65 +Uax ps : 2.78

alt cool in |Urad| ps : 2.49 -Uax ps : -0.03 +Uax ps : 0.02

alt cool out |Urad| ps : 2.53 -Uax ps : -0.03 +Uax ps : 0.03

Oil pan -Umax gs : -0.01 -0.32 -2.05 -0.30 -0.02 0.00

(left sd., free end) +Umax gs : 0.01 0.33 2.25 0.29 0.02 0.00

Oil pan -Umax gs : -0.01 -0.32 -2.07 -0.30 -0.02 0.00

(right s., free end) +Umax gs : 0.01 0.33 2.26 0.29 0.02 0.00

Alternator bottom -Umax gs : 0.00 -0.33 -2.64 -0.30 -0.02 0.00

(left side) +Umax gs : 0.00 0.34 2.77 0.29 0.02 0.00

Alternator bottom -Umax gs : 0.00 -0.33 -2.66 -0.30 -0.02 0.00

(right side) +Umax gs : 0.00 0.34 2.79 0.29 0.02 0.00

Upper edge free end -Umax gs : -0.03 -0.80 -2.07 -0.30 -0.02 0.00
left side +Umax gs : 0.02 0.81 2.28 0.29 0.02 0.00

Upper edge free end -Umax gs : -0.03 -0.76 -2.13 -0.30 -0.02 0.00
right side +Umax gs : 0.02 0.77 2.35 0.29 0.02 0.00

Alternator top -Umax gs : -0.04 -0.85 -2.67 -0.30 -0.02 0.00

(left side) +Umax gs : 0.04 0.86 2.80 0.29 0.02 0.00

Alternator top -Umax gs : -0.04 -0.85 -2.70 -0.30 -0.02 0.00

(right side) +Umax gs : 0.04 0.86 2.82 0.29 0.02 0.00
TEM 50 699 Fig. 28
Load case: B1 vessel movements in heavy seas
========== pitching ±15 degrees

Maximum displacements and forces at interesting points

------------------------------------------------------

±Umax .... maximum displacements and rotations (negative and positive) in [mm, mrad]
|Urad| .... maximum radial displacement in [mm]
±Uax .... maximum axial displacements (negative and positive) in [mm]
±Fmax .... maximum spring forces and moments (negative and positive) in [N, Nm]
|Frad| .... maximum radial spring force in [N]
±Fax .... maximum axial spring forces (negative and positive) in [N]

gs .... the quantities are referenced to the global coordinate system

ps .... the quantities are referenced to a point related coordinate system

Item quantity in t-dir. in l-dir. in v-dir. ab. t-axis ab. l-axis ab. v-axis
---------------------------------------------------------------------------------------------------------------

c/g Basic engine -Umax gs : 0.00 -1.22 -0.22 -0.51 0.00 0.00
(as in EB drawing) +Umax gs : 0.00 1.24 0.55 0.49 0.00 0.00

c/g Alternator -Umax gs : 0.00 -1.13 -0.51 -0.51 0.00 0.00

+Umax gs : 0.00 1.14 0.89 0.49 0.00 0.00

Engine mount -Umax gs : 0.00 -0.95 -0.52 -0.51 0.00 0.00

free end right +Umax gs : 0.00 0.95 0.83 0.49 0.00 0.00
-Fmax gs : -12. -6155. -2255. 0. 0. 0.
+Fmax gs : 12. 6170. 3608. 0. 0. 0.

Engine mount -Umax gs : 0.00 -0.95 0.09 -0.51 0.00 0.00

PTO right +Umax gs : 0.00 0.95 0.25 0.49 0.00 0.00
-Fmax gs : -1. -6155. 377. 0. 0. 0.
+Fmax gs : 0. 6170. 1107. 0. 0. 0.

Alternator mount -Umax gs : 0.00 -0.80 -0.32 -0.51 0.00 0.00

engineside right +Umax gs : 0.00 0.79 0.69 0.49 0.00 0.00
-Fmax gs : -3. -2282. -688. 0. 0. 0.
+Fmax gs : 5. 2266. 1492. 0. 0. 0.

Alternator mount -Umax gs : 0.00 -0.80 -0.81 -0.51 0.00 0.00

free end right +Umax gs : 0.00 0.79 1.20 0.49 0.00 0.00
-Fmax gs : -8. -2282. -1790. 0. 0. 0.
+Fmax gs : 9. 2266. 2609. 0. 0. 0.

Engine mount -Umax gs : 0.00 -0.95 -0.52 -0.51 0.00 0.00

free end left +Umax gs : 0.00 0.95 0.83 0.49 0.00 0.00
-Fmax gs : -12. -6142. -2257. 0. 0. 0.
+Fmax gs : 12. 6159. 3594. 0. 0. 0.

Engine mount -Umax gs : 0.00 -0.95 0.09 -0.51 0.00 0.00

PTO left +Umax gs : 0.00 0.95 0.25 0.49 0.00 0.00
-Fmax gs : -1. -6142. 374. 0. 0. 0.
+Fmax gs : 0. 6159. 1094. 0. 0. 0.

Alternator mount -Umax gs : 0.00 -0.79 -0.32 -0.51 0.00 0.00

engineside left +Umax gs : 0.00 0.79 0.69 0.49 0.00 0.00
-Fmax gs : -3. -2279. -692. 0. 0. 0.
+Fmax gs : 5. 2263. 1491. 0. 0. 0.

Alternator mount -Umax gs : 0.00 -0.79 -0.81 -0.51 0.00 0.00

free end left +Umax gs : 0.00 0.79 1.20 0.49 0.00 0.00
-Fmax gs : -8. -2279. -1794. 0. 0. 0.
+Fmax gs : 9. 2263. 2608. 0. 0. 0.
TEM 50 699 Fig. 29
Load case: B1 vessel movements in heavy seas
========== pitching ±15 degrees

Maximum displacements and forces at interesting points (continuation)

------------------------------------------------------------------------

Item quantity in t-dir. in l-dir. in v-dir. ab. t-axis ab. l-axis ab. v-axis
---------------------------------------------------------------------------------------------------------------

eng vert buffer -Umax gs : 0.00 -0.92 -0.52 -0.51 0.00 0.00
free end right +Umax gs : 0.00 0.93 0.83 0.49 0.00 0.00
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.

eng vert buffer -Umax gs : 0.00 -0.92 0.09 -0.51 0.00 0.00
PTO right +Umax gs : 0.00 0.93 0.25 0.49 0.00 0.00
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.

alt vert buffer -Umax gs : 0.00 -0.77 -0.32 -0.51 0.00 0.00
engineside right +Umax gs : 0.00 0.76 0.69 0.49 0.00 0.00
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.

alt vert buffer -Umax gs : 0.00 -0.77 -0.81 -0.51 0.00 0.00
free end right +Umax gs : 0.00 0.76 1.20 0.49 0.00 0.00
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.

eng vert buffer -Umax gs : 0.00 -0.92 -0.52 -0.51 0.00 0.00
free end left +Umax gs : 0.00 0.92 0.83 0.49 0.00 0.00
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.

eng vert buffer -Umax gs : 0.00 -0.92 0.09 -0.51 0.00 0.00
PTO left +Umax gs : 0.00 0.92 0.25 0.49 0.00 0.00
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.

alt vert buffer -Umax gs : 0.00 -0.77 -0.32 -0.51 0.00 0.00
engineside left +Umax gs : 0.00 0.76 0.69 0.49 0.00 0.00
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.

alt vert buffer -Umax gs : 0.00 -0.77 -0.81 -0.51 0.00 0.00
free end left +Umax gs : 0.00 0.76 1.20 0.49 0.00 0.00
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.
TEM 50 699 Fig. 30
Load case: B1 vessel movements in heavy seas
========== pitching ±15 degrees

Maximum displacements and forces at interesting points (continuation)

------------------------------------------------------------------------

Item quantity in t-dir. in l-dir. in v-dir. ab. t-axis ab. l-axis ab. v-axis
---------------------------------------------------------------------------------------------------------------

air inlet hor. left |Urad| ps : 1.76 -Uax ps : 0.00 +Uax ps : 0.00

air inlet hor. right |Urad| ps : 1.78 -Uax ps : 0.00 +Uax ps : 0.00

Exh outlet 90° left |Urad| ps : 1.79 -Uax ps : -0.22 +Uax ps : -0.11

Exh outlet 90° right |Urad| ps : 1.79 -Uax ps : -0.27 +Uax ps : -0.06

Water inlet 20.026 |Urad| ps : 1.19 -Uax ps : -1.29 +Uax ps : 1.27

Water outlet 20.027 |Urad| ps : 1.17 -Uax ps : -1.41 +Uax ps : 1.39

auxPTO flange |Urad| ps : 1.13 -Uax ps : -1.09 +Uax ps : 1.08

alternator free end |Urad| ps : 1.09 -Uax ps : -1.03 +Uax ps : 1.43

alt cool in |Urad| ps : 1.64 -Uax ps : 0.00 +Uax ps : 0.00

alt cool out |Urad| ps : 1.85 -Uax ps : -0.01 +Uax ps : 0.00

Oil pan -Umax gs : 0.00 -0.77 -0.59 -0.51 0.00 0.00

(left sd., free end) +Umax gs : 0.00 0.76 0.90 0.49 0.00 0.00

Oil pan -Umax gs : 0.00 -0.77 -0.59 -0.51 0.00 0.00

(right s., free end) +Umax gs : 0.00 0.76 0.90 0.49 0.00 0.00

Alternator bottom -Umax gs : 0.00 -0.84 -1.03 -0.51 0.00 0.00

(left side) +Umax gs : 0.00 0.83 1.43 0.49 0.00 0.00

Alternator bottom -Umax gs : 0.00 -0.84 -1.03 -0.51 0.00 0.00

(right side) +Umax gs : 0.00 0.83 1.43 0.49 0.00 0.00

Upper edge free end -Umax gs : 0.00 -1.65 -0.79 -0.51 0.00 0.00
left side +Umax gs : 0.00 1.69 1.08 0.49 0.00 0.00

Upper edge free end -Umax gs : 0.00 -1.60 -0.94 -0.51 0.00 0.00
right side +Umax gs : 0.00 1.63 1.23 0.49 0.00 0.00

Alternator top -Umax gs : -0.01 -1.74 -1.08 -0.51 0.00 0.00

(left side) +Umax gs : 0.00 1.78 1.49 0.49 0.00 0.00

Alternator top -Umax gs : -0.01 -1.74 -1.08 -0.51 0.00 0.00

(right side) +Umax gs : 0.00 1.78 1.49 0.49 0.00 0.00
TEM 50 699 Fig. 31
Load case: B2 vessel movements in heavy seas
========== rolling ±45 deg.

Maximum displacements and forces at interesting points

------------------------------------------------------

±Umax .... maximum displacements and rotations (negative and positive) in [mm, mrad]
|Urad| .... maximum radial displacement in [mm]
±Uax .... maximum axial displacements (negative and positive) in [mm]
±Fmax .... maximum spring forces and moments (negative and positive) in [N, Nm]
|Frad| .... maximum radial spring force in [N]
±Fax .... maximum axial spring forces (negative and positive) in [N]

gs .... the quantities are referenced to the global coordinate system

ps .... the quantities are referenced to a point related coordinate system

Item quantity in t-dir. in l-dir. in v-dir. ab. t-axis ab. l-axis ab. v-axis
---------------------------------------------------------------------------------------------------------------

c/g Basic engine -Umax gs : -5.81 0.15 0.76 -0.22 -5.83 -0.74
(as in EB drawing) +Umax gs : 5.80 0.15 0.81 -0.22 5.82 0.74

c/g Alternator -Umax gs : -6.24 0.10 1.27 -0.22 -5.83 -0.74

+Umax gs : 6.23 0.10 1.27 -0.22 5.82 0.74

Engine mount -Umax gs : -2.08 -0.42 -2.83 -0.22 -5.83 -0.74

free end right +Umax gs : 2.08 0.46 4.15 -0.22 5.82 0.74
-Fmax gs : -13468. -2734. -12773. 0. 0. 0.
+Fmax gs : 13470. 3008. 16222. 0. 0. 0.

Engine mount -Umax gs : -2.94 -0.42 -2.57 -0.22 -5.83 -0.74

PTO right +Umax gs : 2.94 0.46 4.42 -0.22 5.82 0.74
-Fmax gs : -19096. -2734. -11451. 0. 0. 0.
+Fmax gs : 19088. 3008. 17200. 0. 0. 0.

Alternator mount -Umax gs : -1.98 -0.33 -1.00 -0.22 -5.83 -0.74

engineside right +Umax gs : 1.98 0.23 3.37 -0.22 5.82 0.74
-Fmax gs : -5687. -934. -2229. 0. 0. 0.
+Fmax gs : 5692. 654. 7347. 0. 0. 0.

Alternator mount -Umax gs : -2.72 -0.33 -0.77 -0.22 -5.83 -0.74

free end right +Umax gs : 2.72 0.23 3.59 -0.22 5.82 0.74
-Fmax gs : -7805. -934. -1715. 0. 0. 0.
+Fmax gs : 7807. 654. 7840. 0. 0. 0.

Engine mount -Umax gs : -2.08 -0.42 -2.85 -0.22 -5.83 -0.74

free end left +Umax gs : 2.08 0.46 4.15 -0.22 5.82 0.74
-Fmax gs : -13468. -2730. -12855. 0. 0. 0.
+Fmax gs : 13470. 3013. 16216. 0. 0. 0.

Engine mount -Umax gs : -2.94 -0.42 -2.58 -0.22 -5.83 -0.74

PTO left +Umax gs : 2.94 0.46 4.42 -0.22 5.82 0.74
-Fmax gs : -19096. -2730. -11510. 0. 0. 0.
+Fmax gs : 19088. 3013. 17188. 0. 0. 0.

Alternator mount -Umax gs : -1.98 -0.32 -1.01 -0.22 -5.83 -0.74

engineside left +Umax gs : 1.98 0.23 3.37 -0.22 5.82 0.74
-Fmax gs : -5687. -932. -2248. 0. 0. 0.
+Fmax gs : 5692. 654. 7343. 0. 0. 0.

Alternator mount -Umax gs : -2.72 -0.32 -0.78 -0.22 -5.83 -0.74

free end left +Umax gs : 2.72 0.23 3.59 -0.22 5.82 0.74
-Fmax gs : -7805. -932. -1731. 0. 0. 0.
+Fmax gs : 7807. 654. 7833. 0. 0. 0.
TEM 50 699 Fig. 32
Load case: B2 vessel movements in heavy seas
========== rolling ±45 deg.

Maximum displacements and forces at interesting points (continuation)

------------------------------------------------------------------------

Item quantity in t-dir. in l-dir. in v-dir. ab. t-axis ab. l-axis ab. v-axis
---------------------------------------------------------------------------------------------------------------

eng vert buffer -Umax gs : -1.78 -0.43 -2.83 -0.22 -5.83 -0.74
free end right +Umax gs : 1.79 0.45 4.15 -0.22 5.82 0.74
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 4815. 0. 0. 0.

eng vert buffer -Umax gs : -2.65 -0.43 -2.57 -0.22 -5.83 -0.74
PTO right +Umax gs : 2.65 0.45 4.42 -0.22 5.82 0.74
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 13075. 0. 0. 0.

alt vert buffer -Umax gs : -1.68 -0.34 -1.00 -0.22 -5.83 -0.74
engineside right +Umax gs : 1.69 0.22 3.37 -0.22 5.82 0.74
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.

alt vert buffer -Umax gs : -2.42 -0.34 -0.77 -0.22 -5.83 -0.74
free end right +Umax gs : 2.42 0.22 3.59 -0.22 5.82 0.74
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.

eng vert buffer -Umax gs : -1.78 -0.43 -2.85 -0.22 -5.83 -0.74
free end left +Umax gs : 1.79 0.45 4.15 -0.22 5.82 0.74
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 4768. 0. 0. 0.

eng vert buffer -Umax gs : -2.65 -0.43 -2.58 -0.22 -5.83 -0.74
PTO left +Umax gs : 2.65 0.45 4.42 -0.22 5.82 0.74
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 12974. 0. 0. 0.

alt vert buffer -Umax gs : -1.68 -0.34 -1.01 -0.22 -5.83 -0.74
engineside left +Umax gs : 1.69 0.22 3.37 -0.22 5.82 0.74
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.

alt vert buffer -Umax gs : -2.42 -0.34 -0.78 -0.22 -5.83 -0.74
free end left +Umax gs : 2.42 0.22 3.59 -0.22 5.82 0.74
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.
TEM 50 699 Fig. 33
Load case: B2 vessel movements in heavy seas
========== rolling ±45 deg.

Maximum displacements and forces at interesting points (continuation)

------------------------------------------------------------------------

Item quantity in t-dir. in l-dir. in v-dir. ab. t-axis ab. l-axis ab. v-axis
---------------------------------------------------------------------------------------------------------------

air inlet hor. left |Urad| ps : 5.65 -Uax ps : -10.38 +Uax ps : 10.36

air inlet hor. right |Urad| ps : 5.64 -Uax ps : -10.30 +Uax ps : 10.32

Exh outlet 90° left |Urad| ps : 12.51 -Uax ps : -2.49 +Uax ps : 0.63

Exh outlet 90° right |Urad| ps : 12.42 -Uax ps : -2.47 +Uax ps : 0.64

Water inlet 20.026 |Urad| ps : 6.83 -Uax ps : -0.63 +Uax ps : 0.29

Water outlet 20.027 |Urad| ps : 6.94 -Uax ps : -0.33 +Uax ps : -0.12

auxPTO flange |Urad| ps : 3.24 -Uax ps : -0.08 +Uax ps : -0.08

alternator free end |Urad| ps : 6.46 -Uax ps : 1.51 +Uax ps : 1.51

alt cool in |Urad| ps : 5.94 -Uax ps : -9.60 +Uax ps : 9.58

alt cool out |Urad| ps : 5.93 -Uax ps : -12.22 +Uax ps : 12.20

Oil pan -Umax gs : -0.15 -0.30 -1.27 -0.22 -5.83 -0.74

(left sd., free end) +Umax gs : 0.16 0.18 2.52 -0.22 5.82 0.74

Oil pan -Umax gs : -0.15 -0.29 -1.18 -0.22 -5.83 -0.74

(right s., free end) +Umax gs : 0.16 0.17 2.44 -0.22 5.82 0.74

Alternator bottom -Umax gs : -3.54 -0.36 -1.15 -0.22 -5.83 -0.74

(left side) +Umax gs : 3.54 0.31 4.16 -0.22 5.82 0.74

Alternator bottom -Umax gs : -3.54 -0.37 -1.14 -0.22 -5.83 -0.74

(right side) +Umax gs : 3.54 0.31 4.16 -0.22 5.82 0.74

Upper edge free end -Umax gs : -10.10 -0.27 -4.31 -0.22 -5.83 -0.74
left side +Umax gs : 10.08 0.96 5.38 -0.22 5.82 0.74

Upper edge free end -Umax gs : -9.20 -0.25 -4.01 -0.22 -5.83 -0.74
right side +Umax gs : 9.19 0.89 4.97 -0.22 5.82 0.74

Alternator top -Umax gs : -14.40 -0.12 -2.46 -0.22 -5.83 -0.74

(left side) +Umax gs : 14.37 0.89 5.52 -0.22 5.82 0.74

Alternator top -Umax gs : -14.40 -0.12 -2.45 -0.22 -5.83 -0.74

(right side) +Umax gs : 14.37 0.89 5.53 -0.22 5.82 0.74
TEM 50 699 Fig. 34
Load case: B3 g-loads resulting from diving of vessel hull into exorbitant high waves:
========== ±0.35g athwart & ±0.80g vertical (simultaneously)

Maximum displacements and forces at interesting points

------------------------------------------------------

±Umax .... maximum displacements and rotations (negative and positive) in [mm, mrad]
|Urad| .... maximum radial displacement in [mm]
±Uax .... maximum axial displacements (negative and positive) in [mm]
±Fmax .... maximum spring forces and moments (negative and positive) in [N, Nm]
|Frad| .... maximum radial spring force in [N]
±Fax .... maximum axial spring forces (negative and positive) in [N]

gs .... the quantities are referenced to the global coordinate system

ps .... the quantities are referenced to a point related coordinate system

Item quantity in t-dir. in l-dir. in v-dir. ab. t-axis ab. l-axis ab. v-axis
---------------------------------------------------------------------------------------------------------------

c/g Basic engine -Umax gs : -2.32 -0.09 -2.96 -0.12 -1.97 -0.28
(as in EB drawing) +Umax gs : 2.30 0.08 3.12 0.14 1.92 0.28

c/g Alternator -Umax gs : -2.55 -0.07 -3.27 -0.12 -1.97 -0.28

+Umax gs : 2.52 0.05 3.38 0.14 1.92 0.28

Engine mount -Umax gs : -1.05 -0.18 -3.98 -0.12 -1.97 -0.28

free end right +Umax gs : 1.05 0.18 4.22 0.14 1.92 0.28
-Fmax gs : -6788. -1140. -19119. 0. 0. 0.
+Fmax gs : 6784. 1162. 16472. 0. 0. 0.

Engine mount -Umax gs : -1.38 -0.18 -4.15 -0.12 -1.97 -0.28

PTO right +Umax gs : 1.37 0.18 4.36 0.14 1.92 0.28
-Fmax gs : -8937. -1140. -20028. 0. 0. 0.
+Fmax gs : 8911. 1162. 16986. 0. 0. 0.

Alternator mount -Umax gs : -1.11 -0.13 -3.90 -0.12 -1.97 -0.28

engineside right +Umax gs : 1.11 0.13 4.06 0.14 1.92 0.28
-Fmax gs : -3190. -379. -8896. 0. 0. 0.
+Fmax gs : 3178. 382. 8851. 0. 0. 0.

Alternator mount -Umax gs : -1.38 -0.13 -4.04 -0.12 -1.97 -0.28

free end right +Umax gs : 1.38 0.13 4.17 0.14 1.92 0.28
-Fmax gs : -3967. -379. -9220. 0. 0. 0.
+Fmax gs : 3963. 382. 9110. 0. 0. 0.

Engine mount -Umax gs : -1.05 -0.18 -3.98 -0.12 -1.97 -0.28

free end left +Umax gs : 1.05 0.18 4.22 0.14 1.92 0.28
-Fmax gs : -6788. -1154. -19106. 0. 0. 0.
+Fmax gs : 6784. 1179. 16456. 0. 0. 0.

Engine mount -Umax gs : -1.38 -0.18 -4.15 -0.12 -1.97 -0.28

PTO left +Umax gs : 1.37 0.18 4.35 0.14 1.92 0.28
-Fmax gs : -8937. -1154. -20004. 0. 0. 0.
+Fmax gs : 8911. 1179. 16958. 0. 0. 0.

Alternator mount -Umax gs : -1.11 -0.13 -3.90 -0.12 -1.97 -0.28

engineside left +Umax gs : 1.11 0.13 4.06 0.14 1.92 0.28
-Fmax gs : -3190. -373. -8900. 0. 0. 0.
+Fmax gs : 3178. 378. 8851. 0. 0. 0.

Alternator mount -Umax gs : -1.38 -0.13 -4.04 -0.12 -1.97 -0.28

free end left +Umax gs : 1.38 0.13 4.17 0.14 1.92 0.28
-Fmax gs : -3967. -373. -9220. 0. 0. 0.
+Fmax gs : 3963. 378. 9104. 0. 0. 0.
TEM 50 699 Fig. 35
Load case: B3 g-loads resulting from diving of vessel hull into exorbitant high waves:
========== ±0.35g athwart & ±0.80g vertical (simultaneously)

Maximum displacements and forces at interesting points (continuation)

------------------------------------------------------------------------

Item quantity in t-dir. in l-dir. in v-dir. ab. t-axis ab. l-axis ab. v-axis
---------------------------------------------------------------------------------------------------------------

eng vert buffer -Umax gs : -0.96 -0.17 -3.98 -0.12 -1.97 -0.28
free end right +Umax gs : 0.95 0.17 4.22 0.14 1.92 0.28
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 6929. 0. 0. 0.

eng vert buffer -Umax gs : -1.28 -0.17 -4.15 -0.12 -1.97 -0.28
PTO right +Umax gs : 1.28 0.17 4.36 0.14 1.92 0.28
-Fmax gs : 0. 0. -15130. 0. 0. 0.
+Fmax gs : 0. 0. 11267. 0. 0. 0.

alt vert buffer -Umax gs : -1.02 -0.14 -3.90 -0.12 -1.97 -0.28
engineside right +Umax gs : 1.01 0.14 4.06 0.14 1.92 0.28
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 1727. 0. 0. 0.

alt vert buffer -Umax gs : -1.29 -0.14 -4.04 -0.12 -1.97 -0.28
free end right +Umax gs : 1.29 0.14 4.17 0.14 1.92 0.28
-Fmax gs : 0. 0. -3741. 0. 0. 0.
+Fmax gs : 0. 0. 5419. 0. 0. 0.

eng vert buffer -Umax gs : -0.96 -0.17 -3.98 -0.12 -1.97 -0.28
free end left +Umax gs : 0.95 0.18 4.22 0.14 1.92 0.28
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 6792. 0. 0. 0.

eng vert buffer -Umax gs : -1.28 -0.17 -4.15 -0.12 -1.97 -0.28
PTO left +Umax gs : 1.28 0.18 4.35 0.14 1.92 0.28
-Fmax gs : 0. 0. -14685. 0. 0. 0.
+Fmax gs : 0. 0. 11037. 0. 0. 0.

alt vert buffer -Umax gs : -1.02 -0.14 -3.90 -0.12 -1.97 -0.28
engineside left +Umax gs : 1.01 0.14 4.06 0.14 1.92 0.28
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 1723. 0. 0. 0.

alt vert buffer -Umax gs : -1.29 -0.14 -4.04 -0.12 -1.97 -0.28
free end left +Umax gs : 1.29 0.14 4.17 0.14 1.92 0.28
-Fmax gs : 0. 0. -3735. 0. 0. 0.
+Fmax gs : 0. 0. 5336. 0. 0. 0.
TEM 50 699 Fig. 36
Load case: B3 g-loads resulting from diving of vessel hull into exorbitant high waves:
========== ±0.35g athwart & ±0.80g vertical (simultaneously)

Maximum displacements and forces at interesting points (continuation)

------------------------------------------------------------------------

Item quantity in t-dir. in l-dir. in v-dir. ab. t-axis ab. l-axis ab. v-axis
---------------------------------------------------------------------------------------------------------------

air inlet hor. left |Urad| ps : 4.72 -Uax ps : -3.86 +Uax ps : 3.79

air inlet hor. right |Urad| ps : 4.73 -Uax ps : -3.77 +Uax ps : 3.84

Exh outlet 90° left |Urad| ps : 4.61 -Uax ps : -3.72 +Uax ps : 3.55

Exh outlet 90° right |Urad| ps : 4.58 -Uax ps : -3.70 +Uax ps : 3.53

Water inlet 20.026 |Urad| ps : 4.71 -Uax ps : -0.26 +Uax ps : 0.28

Water outlet 20.027 |Urad| ps : 4.17 -Uax ps : -0.16 +Uax ps : 0.18

auxPTO flange |Urad| ps : 3.30 -Uax ps : -0.04 +Uax ps : 0.05

alternator free end |Urad| ps : 2.66 -Uax ps : -3.42 +Uax ps : 3.50

alt cool in |Urad| ps : 4.93 -Uax ps : -3.67 +Uax ps : 3.62

alt cool out |Urad| ps : 4.92 -Uax ps : -4.56 +Uax ps : 4.48

Oil pan -Umax gs : -0.34 -0.12 -3.46 -0.12 -1.97 -0.28

(left sd., free end) +Umax gs : 0.33 0.13 3.67 0.14 1.92 0.28

Oil pan -Umax gs : -0.34 -0.12 -3.43 -0.12 -1.97 -0.28

(right s., free end) +Umax gs : 0.33 0.12 3.64 0.14 1.92 0.28

Alternator bottom -Umax gs : -1.67 -0.14 -4.24 -0.12 -1.97 -0.28

(left side) +Umax gs : 1.67 0.14 4.38 0.14 1.92 0.28

Alternator bottom -Umax gs : -1.67 -0.14 -4.25 -0.12 -1.97 -0.28

(right side) +Umax gs : 1.67 0.14 4.38 0.14 1.92 0.28

Upper edge free end -Umax gs : -3.74 -0.44 -4.33 -0.12 -1.97 -0.28
left side +Umax gs : 3.67 0.42 4.60 0.14 1.92 0.28

Upper edge free end -Umax gs : -3.42 -0.41 -4.19 -0.12 -1.97 -0.28
right side +Umax gs : 3.37 0.38 4.46 0.14 1.92 0.28

Alternator top -Umax gs : -5.34 -0.43 -4.68 -0.12 -1.97 -0.28

(left side) +Umax gs : 5.25 0.40 4.83 0.14 1.92 0.28

Alternator top -Umax gs : -5.34 -0.42 -4.69 -0.12 -1.97 -0.28

(right side) +Umax gs : 5.25 0.39 4.85 0.14 1.92 0.28
TEM 50 699 Fig. 37
Load case: B4 g-loads resulting from diving of vessel hull into exorbitant high waves:
========== ±0.23g fore and aft & ±0.80g vertical (simult.)

Maximum displacements and forces at interesting points

------------------------------------------------------

±Umax .... maximum displacements and rotations (negative and positive) in [mm, mrad]
|Urad| .... maximum radial displacement in [mm]
±Uax .... maximum axial displacements (negative and positive) in [mm]
±Fmax .... maximum spring forces and moments (negative and positive) in [N, Nm]
|Frad| .... maximum radial spring force in [N]
±Fax .... maximum axial spring forces (negative and positive) in [N]

gs .... the quantities are referenced to the global coordinate system

ps .... the quantities are referenced to a point related coordinate system

Item quantity in t-dir. in l-dir. in v-dir. ab. t-axis ab. l-axis ab. v-axis
---------------------------------------------------------------------------------------------------------------

c/g Basic engine -Umax gs : -0.01 -0.99 -3.79 -0.13 -0.01 0.00
(as in EB drawing) +Umax gs : 0.02 0.89 4.06 0.28 0.03 0.00

c/g Alternator -Umax gs : -0.01 -0.93 -3.87 -0.13 -0.01 0.00

+Umax gs : 0.02 0.86 4.06 0.28 0.03 0.00

Engine mount -Umax gs : 0.00 -0.83 -3.89 -0.13 -0.01 0.00

free end right +Umax gs : 0.00 0.82 4.12 0.28 0.03 0.00
-Fmax gs : -14. -5370. -18583. 0. 0. 0.
+Fmax gs : 11. 5290. 16089. 0. 0. 0.

Engine mount -Umax gs : 0.00 -0.83 -3.73 -0.13 -0.01 0.00

PTO right +Umax gs : 0.00 0.82 4.00 0.28 0.03 0.00
-Fmax gs : -7. -5370. -17749. 0. 0. 0.
+Fmax gs : 16. 5290. 15668. 0. 0. 0.

Alternator mount -Umax gs : 0.00 -0.78 -3.76 -0.13 -0.01 0.00

engineside right +Umax gs : 0.00 0.77 4.02 0.28 0.03 0.00
-Fmax gs : -7. -2239. -8586. 0. 0. 0.
+Fmax gs : 8. 2223. 8766. 0. 0. 0.

Alternator mount -Umax gs : 0.00 -0.78 -4.04 -0.13 -0.01 0.00

free end right +Umax gs : 0.00 0.77 4.14 0.28 0.03 0.00
-Fmax gs : -8. -2239. -9231. 0. 0. 0.
+Fmax gs : 9. 2223. 9027. 0. 0. 0.

Engine mount -Umax gs : 0.00 -0.83 -3.85 -0.13 -0.01 0.00

free end left +Umax gs : 0.00 0.81 4.11 0.28 0.03 0.00
-Fmax gs : -14. -5365. -18383. 0. 0. 0.
+Fmax gs : 11. 5267. 16057. 0. 0. 0.

Engine mount -Umax gs : 0.00 -0.83 -3.70 -0.13 -0.01 0.00

PTO left +Umax gs : 0.00 0.81 4.00 0.28 0.03 0.00
-Fmax gs : -7. -5365. -17548. 0. 0. 0.
+Fmax gs : 16. 5267. 15636. 0. 0. 0.

Alternator mount -Umax gs : 0.00 -0.78 -3.76 -0.13 -0.01 0.00

engineside left +Umax gs : 0.00 0.77 4.01 0.28 0.03 0.00
-Fmax gs : -7. -2234. -8574. 0. 0. 0.
+Fmax gs : 8. 2222. 8748. 0. 0. 0.

Alternator mount -Umax gs : 0.00 -0.78 -4.04 -0.13 -0.01 0.00

free end left +Umax gs : 0.00 0.77 4.13 0.28 0.03 0.00
-Fmax gs : -8. -2234. -9219. 0. 0. 0.
+Fmax gs : 9. 2222. 9008. 0. 0. 0.
TEM 50 699 Fig. 38
Load case: B4 g-loads resulting from diving of vessel hull into exorbitant high waves:
========== ±0.23g fore and aft & ±0.80g vertical (simult.)

Maximum displacements and forces at interesting points (continuation)

------------------------------------------------------------------------

Item quantity in t-dir. in l-dir. in v-dir. ab. t-axis ab. l-axis ab. v-axis
---------------------------------------------------------------------------------------------------------------

eng vert buffer -Umax gs : 0.00 -0.81 -3.89 -0.13 -0.01 0.00
free end right +Umax gs : 0.00 0.81 4.12 0.28 0.03 0.00
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 3693. 0. 0. 0.

eng vert buffer -Umax gs : 0.00 -0.81 -3.73 -0.13 -0.01 0.00
PTO right +Umax gs : 0.00 0.81 4.00 0.28 0.03 0.00
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 136. 0. 0. 0.

alt vert buffer -Umax gs : 0.00 -0.78 -3.76 -0.13 -0.01 0.00
engineside right +Umax gs : 0.00 0.77 4.02 0.28 0.03 0.00
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 514. 0. 0. 0.

alt vert buffer -Umax gs : 0.00 -0.78 -4.04 -0.13 -0.01 0.00
free end right +Umax gs : 0.00 0.77 4.14 0.28 0.03 0.00
-Fmax gs : 0. 0. -4228. 0. 0. 0.
+Fmax gs : 0. 0. 4235. 0. 0. 0.

eng vert buffer -Umax gs : 0.00 -0.81 -3.85 -0.13 -0.01 0.00
free end left +Umax gs : 0.00 0.81 4.11 0.28 0.03 0.00
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 3428. 0. 0. 0.

eng vert buffer -Umax gs : 0.00 -0.81 -3.70 -0.13 -0.01 0.00
PTO left +Umax gs : 0.00 0.81 4.00 0.28 0.03 0.00
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.

alt vert buffer -Umax gs : 0.00 -0.77 -3.76 -0.13 -0.01 0.00
engineside left +Umax gs : 0.00 0.77 4.01 0.28 0.03 0.00
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 251. 0. 0. 0.

alt vert buffer -Umax gs : 0.00 -0.77 -4.04 -0.13 -0.01 0.00
free end left +Umax gs : 0.00 0.77 4.13 0.28 0.03 0.00
-Fmax gs : 0. 0. -3679. 0. 0. 0.
+Fmax gs : 0. 0. 3972. 0. 0. 0.
TEM 50 699 Fig. 39
Load case: B4 g-loads resulting from diving of vessel hull into exorbitant high waves:
========== ±0.23g fore and aft & ±0.80g vertical (simult.)

Maximum displacements and forces at interesting points (continuation)

------------------------------------------------------------------------

Item quantity in t-dir. in l-dir. in v-dir. ab. t-axis ab. l-axis ab. v-axis
---------------------------------------------------------------------------------------------------------------

air inlet hor. left |Urad| ps : 4.19 -Uax ps : -0.02 +Uax ps : 0.04

air inlet hor. right |Urad| ps : 4.21 -Uax ps : -0.04 +Uax ps : 0.02

Exh outlet 90° left |Urad| ps : 1.28 -Uax ps : -3.99 +Uax ps : 3.70

Exh outlet 90° right |Urad| ps : 1.28 -Uax ps : -4.01 +Uax ps : 3.73

Water inlet 20.026 |Urad| ps : 4.19 -Uax ps : -0.90 +Uax ps : 1.01

Water outlet 20.027 |Urad| ps : 4.18 -Uax ps : -0.93 +Uax ps : 1.08

auxPTO flange |Urad| ps : 4.17 -Uax ps : -0.85 +Uax ps : 0.90

alternator free end |Urad| ps : 0.90 -Uax ps : -4.16 +Uax ps : 4.18

alt cool in |Urad| ps : 4.14 -Uax ps : -0.01 +Uax ps : 0.04

alt cool out |Urad| ps : 4.15 -Uax ps : -0.02 +Uax ps : 0.05

Oil pan -Umax gs : -0.01 -0.77 -3.88 -0.13 -0.01 0.00

(left sd., free end) +Umax gs : 0.00 0.77 4.13 0.28 0.03 0.00

Oil pan -Umax gs : -0.01 -0.78 -3.90 -0.13 -0.01 0.00

(right s., free end) +Umax gs : 0.00 0.77 4.13 0.28 0.03 0.00

Alternator bottom -Umax gs : 0.00 -0.79 -4.16 -0.13 -0.01 0.00

(left side) +Umax gs : 0.01 0.78 4.18 0.28 0.03 0.00

Alternator bottom -Umax gs : 0.00 -0.79 -4.17 -0.13 -0.01 0.00

(right side) +Umax gs : 0.01 0.79 4.19 0.28 0.03 0.00

Upper edge free end -Umax gs : -0.02 -1.23 -3.91 -0.13 -0.01 0.00
left side +Umax gs : 0.04 1.00 4.16 0.28 0.03 0.00

Upper edge free end -Umax gs : -0.02 -1.20 -4.00 -0.13 -0.01 0.00
right side +Umax gs : 0.03 0.99 4.20 0.28 0.03 0.00

Alternator top -Umax gs : -0.02 -1.28 -4.19 -0.13 -0.01 0.00

(left side) +Umax gs : 0.06 1.02 4.19 0.28 0.03 0.00

Alternator top -Umax gs : -0.02 -1.28 -4.20 -0.13 -0.01 0.00

(right side) +Umax gs : 0.06 1.02 4.21 0.28 0.03 0.00
TEM 50 699 Fig. 40
Load case: C1 g-loads resulting from crashs, etc.:
========== ±2.00g in vessel athwart direction

Maximum displacements and forces at interesting points

------------------------------------------------------

±Umax .... maximum displacements and rotations (negative and positive) in [mm, mrad]
|Urad| .... maximum radial displacement in [mm]
±Uax .... maximum axial displacements (negative and positive) in [mm]
±Fmax .... maximum spring forces and moments (negative and positive) in [N, Nm]
|Frad| .... maximum radial spring force in [N]
±Fax .... maximum axial spring forces (negative and positive) in [N]

gs .... the quantities are referenced to the global coordinate system

ps .... the quantities are referenced to a point related coordinate system

Item quantity in t-dir. in l-dir. in v-dir. ab. t-axis ab. l-axis ab. v-axis
---------------------------------------------------------------------------------------------------------------

c/g Basic engine -Umax gs : -9.54 -0.03 0.31 0.04 -7.87 -0.85
(as in EB drawing) +Umax gs : 9.54 -0.02 0.39 0.04 7.87 0.85

c/g Alternator -Umax gs : -9.82 -0.02 0.27 0.04 -7.87 -0.85

+Umax gs : 9.82 -0.02 0.27 0.04 7.87 0.85

Engine mount -Umax gs : -4.59 -0.51 -4.35 0.04 -7.87 -0.85

free end right +Umax gs : 4.59 0.51 5.09 0.04 7.87 0.85
-Fmax gs : -37580. -3340. -21141. 0. 0. 0.
+Fmax gs : 37580. 3295. 19689. 0. 0. 0.

Engine mount -Umax gs : -5.59 -0.51 -4.39 0.04 -7.87 -0.85

PTO right +Umax gs : 5.59 0.51 5.05 0.04 7.87 0.85
-Fmax gs : -51450. -3340. -21374. 0. 0. 0.
+Fmax gs : 51450. 3295. 19532. 0. 0. 0.

Alternator mount -Umax gs : -4.13 -0.31 -2.67 0.04 -7.87 -0.85

engineside right +Umax gs : 4.13 0.33 3.24 0.04 7.87 0.85
-Fmax gs : -16584. -894. -6066. 0. 0. 0.
+Fmax gs : 16584. 939. 7057. 0. 0. 0.

Alternator mount -Umax gs : -4.98 -0.31 -2.70 0.04 -7.87 -0.85

free end right +Umax gs : 4.98 0.33 3.20 0.04 7.87 0.85
-Fmax gs : -24653. -894. -6149. 0. 0. 0.
+Fmax gs : 24653. 939. 6978. 0. 0. 0.

Engine mount -Umax gs : -4.59 -0.51 -4.35 0.04 -7.87 -0.85

free end left +Umax gs : 4.59 0.51 5.09 0.04 7.87 0.85
-Fmax gs : -37580. -3340. -21141. 0. 0. 0.
+Fmax gs : 37580. 3295. 19689. 0. 0. 0.

Engine mount -Umax gs : -5.59 -0.51 -4.39 0.04 -7.87 -0.85

PTO left +Umax gs : 5.59 0.51 5.05 0.04 7.87 0.85
-Fmax gs : -51450. -3340. -21374. 0. 0. 0.
+Fmax gs : 51450. 3295. 19532. 0. 0. 0.

Alternator mount -Umax gs : -4.13 -0.31 -2.67 0.04 -7.87 -0.85

engineside left +Umax gs : 4.13 0.33 3.24 0.04 7.87 0.85
-Fmax gs : -16584. -894. -6066. 0. 0. 0.
+Fmax gs : 16584. 939. 7057. 0. 0. 0.

Alternator mount -Umax gs : -4.98 -0.31 -2.70 0.04 -7.87 -0.85

free end left +Umax gs : 4.98 0.33 3.20 0.04 7.87 0.85
-Fmax gs : -24653. -894. -6149. 0. 0. 0.
+Fmax gs : 24653. 939. 6978. 0. 0. 0.
TEM 50 699 Fig. 41
Load case: C1 g-loads resulting from crashs, etc.:
========== ±2.00g in vessel athwart direction

Maximum displacements and forces at interesting points (continuation)

------------------------------------------------------------------------

Item quantity in t-dir. in l-dir. in v-dir. ab. t-axis ab. l-axis ab. v-axis
---------------------------------------------------------------------------------------------------------------

eng vert buffer -Umax gs : -4.20 -0.51 -4.35 0.04 -7.87 -0.85
free end right +Umax gs : 4.20 0.51 5.09 0.04 7.87 0.85
-Fmax gs : 0. 0. -35612. 0. 0. 0.
+Fmax gs : 0. 0. 39554. 0. 0. 0.

eng vert buffer -Umax gs : -5.20 -0.51 -4.39 0.04 -7.87 -0.85
PTO right +Umax gs : 5.20 0.51 5.05 0.04 7.87 0.85
-Fmax gs : 0. 0. -39903. 0. 0. 0.
+Fmax gs : 0. 0. 37435. 0. 0. 0.

alt vert buffer -Umax gs : -3.73 -0.31 -2.67 0.04 -7.87 -0.85
engineside right +Umax gs : 3.73 0.33 3.24 0.04 7.87 0.85
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.

alt vert buffer -Umax gs : -4.58 -0.31 -2.70 0.04 -7.87 -0.85
free end right +Umax gs : 4.58 0.33 3.20 0.04 7.87 0.85
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.

eng vert buffer -Umax gs : -4.20 -0.51 -4.35 0.04 -7.87 -0.85
free end left +Umax gs : 4.20 0.51 5.09 0.04 7.87 0.85
-Fmax gs : 0. 0. -35612. 0. 0. 0.
+Fmax gs : 0. 0. 39554. 0. 0. 0.

eng vert buffer -Umax gs : -5.20 -0.51 -4.39 0.04 -7.87 -0.85
PTO left +Umax gs : 5.20 0.51 5.05 0.04 7.87 0.85
-Fmax gs : 0. 0. -39903. 0. 0. 0.
+Fmax gs : 0. 0. 37435. 0. 0. 0.

alt vert buffer -Umax gs : -3.73 -0.31 -2.67 0.04 -7.87 -0.85
engineside left +Umax gs : 3.73 0.33 3.24 0.04 7.87 0.85
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.

alt vert buffer -Umax gs : -4.58 -0.31 -2.70 0.04 -7.87 -0.85
free end left +Umax gs : 4.58 0.33 3.20 0.04 7.87 0.85
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.
TEM 50 699 Fig. 42
Load case: C1 g-loads resulting from crashs, etc.:
========== ±2.00g in vessel athwart direction

Maximum displacements and forces at interesting points (continuation)

------------------------------------------------------------------------

Item quantity in t-dir. in l-dir. in v-dir. ab. t-axis ab. l-axis ab. v-axis
---------------------------------------------------------------------------------------------------------------

air inlet hor. left |Urad| ps : 7.05 -Uax ps : -15.75 +Uax ps : 15.75

air inlet hor. right |Urad| ps : 7.05 -Uax ps : -15.68 +Uax ps : 15.68

Exh outlet 90° left |Urad| ps : 18.47 -Uax ps : -2.43 +Uax ps : 1.78

Exh outlet 90° right |Urad| ps : 18.39 -Uax ps : -2.43 +Uax ps : 1.77

Water inlet 20.026 |Urad| ps : 10.65 -Uax ps : -0.51 +Uax ps : 0.56

Water outlet 20.027 |Urad| ps : 11.19 -Uax ps : -0.09 +Uax ps : 0.16

auxPTO flange |Urad| ps : 6.20 -Uax ps : 0.01 +Uax ps : 0.01

alternator free end |Urad| ps : 9.96 -Uax ps : 0.23 +Uax ps : 0.23

alt cool in |Urad| ps : 6.69 -Uax ps : -14.39 +Uax ps : 14.39

alt cool out |Urad| ps : 6.69 -Uax ps : -17.93 +Uax ps : 17.93

Oil pan -Umax gs : -1.60 -0.27 -2.18 0.04 -7.87 -0.85

(left sd., free end) +Umax gs : 1.60 0.29 2.93 0.04 7.87 0.85

Oil pan -Umax gs : -1.60 -0.26 -2.07 0.04 -7.87 -0.85

(right s., free end) +Umax gs : 1.60 0.27 2.82 0.04 7.87 0.85

Alternator bottom -Umax gs : -6.02 -0.38 -3.35 0.04 -7.87 -0.85

(left side) +Umax gs : 6.02 0.39 3.81 0.04 7.87 0.85

Alternator bottom -Umax gs : -6.02 -0.38 -3.35 0.04 -7.87 -0.85

(right side) +Umax gs : 6.02 0.39 3.81 0.04 7.87 0.85

Upper edge free end -Umax gs : -15.49 -0.76 -6.15 0.04 -7.87 -0.85
left side +Umax gs : 15.49 0.65 6.93 0.04 7.87 0.85

Upper edge free end -Umax gs : -14.32 -0.71 -5.67 0.04 -7.87 -0.85
right side +Umax gs : 14.32 0.61 6.47 0.04 7.87 0.85

Alternator top -Umax gs : -20.65 -0.65 -5.16 0.04 -7.87 -0.85

(left side) +Umax gs : 20.65 0.52 5.62 0.04 7.87 0.85

Alternator top -Umax gs : -20.65 -0.65 -5.16 0.04 -7.87 -0.85

(right side) +Umax gs : 20.65 0.52 5.62 0.04 7.87 0.85
TEM 50 699 Fig. 43
Load case: C2 g-loads resulting from crashs, etc.:
========== ±1.50g in vessel fore and aft direction

Maximum displacements and forces at interesting points

------------------------------------------------------

±Umax .... maximum displacements and rotations (negative and positive) in [mm, mrad]
|Urad| .... maximum radial displacement in [mm]
±Uax .... maximum axial displacements (negative and positive) in [mm]
±Fmax .... maximum spring forces and moments (negative and positive) in [N, Nm]
|Frad| .... maximum radial spring force in [N]
±Fax .... maximum axial spring forces (negative and positive) in [N]

gs .... the quantities are referenced to the global coordinate system

ps .... the quantities are referenced to a point related coordinate system

Item quantity in t-dir. in l-dir. in v-dir. ab. t-axis ab. l-axis ab. v-axis
---------------------------------------------------------------------------------------------------------------

c/g Basic engine -Umax gs : 0.00 -5.79 -2.06 -2.25 0.00 -0.01
(as in EB drawing) +Umax gs : 0.00 5.73 2.40 2.34 0.00 0.01

c/g Alternator -Umax gs : -0.01 -5.33 -2.65 -2.25 0.00 -0.01

+Umax gs : 0.01 5.28 2.81 2.34 0.00 0.01

Engine mount -Umax gs : -0.01 -4.47 -3.36 -2.25 0.00 -0.01

free end right +Umax gs : 0.01 4.46 3.75 2.34 0.00 0.01
-Fmax gs : -57. -36018. -15673. 0. 0. 0.
+Fmax gs : 57. 35877. 14725. 0. 0. 0.

Engine mount -Umax gs : 0.00 -4.47 -0.71 -2.25 0.00 -0.01

PTO right +Umax gs : 0.00 4.46 1.01 2.34 0.00 0.01
-Fmax gs : -3. -36018. -3092. 0. 0. 0.
+Fmax gs : 4. 35877. 4372. 0. 0. 0.

Alternator mount -Umax gs : -0.01 -3.74 -1.72 -2.25 0.00 -0.01

engineside right +Umax gs : 0.01 3.75 1.92 2.34 0.00 0.01
-Fmax gs : -21. -12911. -3896. 0. 0. 0.
+Fmax gs : 20. 13054. 4177. 0. 0. 0.

Alternator mount -Umax gs : -0.01 -3.74 -4.06 -2.25 0.00 -0.01

free end right +Umax gs : 0.01 3.75 4.17 2.34 0.00 0.01
-Fmax gs : -41. -12911. -9269. 0. 0. 0.
+Fmax gs : 40. 13054. 9111. 0. 0. 0.

Engine mount -Umax gs : -0.01 -4.46 -3.35 -2.25 0.00 -0.01

free end left +Umax gs : 0.01 4.45 3.75 2.34 0.00 0.01
-Fmax gs : -57. -35909. -15658. 0. 0. 0.
+Fmax gs : 57. 35766. 14721. 0. 0. 0.

Engine mount -Umax gs : 0.00 -4.46 -0.71 -2.25 0.00 -0.01

PTO left +Umax gs : 0.00 4.45 1.00 2.34 0.00 0.01
-Fmax gs : -3. -35909. -3080. 0. 0. 0.
+Fmax gs : 4. 35766. 4366. 0. 0. 0.

Alternator mount -Umax gs : -0.01 -3.73 -1.72 -2.25 0.00 -0.01

engineside left +Umax gs : 0.01 3.75 1.92 2.34 0.00 0.01
-Fmax gs : -21. -12862. -3898. 0. 0. 0.
+Fmax gs : 20. 13004. 4180. 0. 0. 0.

Alternator mount -Umax gs : -0.01 -3.73 -4.06 -2.25 0.00 -0.01

free end left +Umax gs : 0.01 3.75 4.18 2.34 0.00 0.01
-Fmax gs : -41. -12862. -9271. 0. 0. 0.
+Fmax gs : 40. 13004. 9114. 0. 0. 0.
TEM 50 699 Fig. 44
Load case: C2 g-loads resulting from crashs, etc.:
========== ±1.50g in vessel fore and aft direction

Maximum displacements and forces at interesting points (continuation)

------------------------------------------------------------------------

Item quantity in t-dir. in l-dir. in v-dir. ab. t-axis ab. l-axis ab. v-axis
---------------------------------------------------------------------------------------------------------------

eng vert buffer -Umax gs : -0.01 -4.35 -3.36 -2.25 0.00 -0.01
free end right +Umax gs : 0.01 4.35 3.75 2.34 0.00 0.01
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.

eng vert buffer -Umax gs : 0.00 -4.35 -0.71 -2.25 0.00 -0.01
PTO right +Umax gs : 0.00 4.35 1.01 2.34 0.00 0.01
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.

alt vert buffer -Umax gs : -0.01 -3.62 -1.72 -2.25 0.00 -0.01
engineside right +Umax gs : 0.01 3.64 1.92 2.34 0.00 0.01
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.

alt vert buffer -Umax gs : -0.01 -3.62 -4.06 -2.25 0.00 -0.01
free end right +Umax gs : 0.01 3.64 4.17 2.34 0.00 0.01
-Fmax gs : 0. 0. -5884. 0. 0. 0.
+Fmax gs : 0. 0. 5435. 0. 0. 0.

eng vert buffer -Umax gs : -0.01 -4.35 -3.35 -2.25 0.00 -0.01
free end left +Umax gs : 0.01 4.34 3.75 2.34 0.00 0.01
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.

eng vert buffer -Umax gs : 0.00 -4.35 -0.71 -2.25 0.00 -0.01
PTO left +Umax gs : 0.00 4.34 1.00 2.34 0.00 0.01
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.

alt vert buffer -Umax gs : -0.01 -3.62 -1.72 -2.25 0.00 -0.01
engineside left +Umax gs : 0.01 3.63 1.92 2.34 0.00 0.01
-Fmax gs : 0. 0. 0. 0. 0. 0.
+Fmax gs : 0. 0. 0. 0. 0. 0.

alt vert buffer -Umax gs : -0.01 -3.62 -4.06 -2.25 0.00 -0.01
free end left +Umax gs : 0.01 3.63 4.18 2.34 0.00 0.01
-Fmax gs : 0. 0. -5966. 0. 0. 0.
+Fmax gs : 0. 0. 5486. 0. 0. 0.
TEM 50 699 Fig. 45
Load case: C2 g-loads resulting from crashs, etc.:
========== ±1.50g in vessel fore and aft direction

Maximum displacements and forces at interesting points (continuation)

------------------------------------------------------------------------

Item quantity in t-dir. in l-dir. in v-dir. ab. t-axis ab. l-axis ab. v-axis
---------------------------------------------------------------------------------------------------------------

air inlet hor. left |Urad| ps : 8.29 -Uax ps : 0.00 +Uax ps : 0.01

air inlet hor. right |Urad| ps : 8.37 -Uax ps : -0.01 +Uax ps : 0.00

Exh outlet 90° left |Urad| ps : 8.27 -Uax ps : -0.87 +Uax ps : 0.58

Exh outlet 90° right |Urad| ps : 8.28 -Uax ps : -1.11 +Uax ps : 0.81

Water inlet 20.026 |Urad| ps : 5.46 -Uax ps : -5.96 +Uax ps : 6.03

Water outlet 20.027 |Urad| ps : 5.38 -Uax ps : -6.49 +Uax ps : 6.57

auxPTO flange |Urad| ps : 5.21 -Uax ps : -5.07 +Uax ps : 5.10

alternator free end |Urad| ps : 5.10 -Uax ps : -5.10 +Uax ps : 5.18

alt cool in |Urad| ps : 7.05 -Uax ps : -0.01 +Uax ps : 0.01

alt cool out |Urad| ps : 8.06 -Uax ps : -0.01 +Uax ps : 0.01

Oil pan -Umax gs : -0.01 -3.61 -3.68 -2.25 0.00 -0.01

(left sd., free end) +Umax gs : 0.01 3.63 4.08 2.34 0.00 0.01

Oil pan -Umax gs : -0.01 -3.62 -3.68 -2.25 0.00 -0.01

(right s., free end) +Umax gs : 0.01 3.64 4.08 2.34 0.00 0.01

Alternator bottom -Umax gs : -0.02 -3.93 -5.10 -2.25 0.00 -0.01

(left side) +Umax gs : 0.02 3.94 5.18 2.34 0.00 0.01

Alternator bottom -Umax gs : -0.02 -3.94 -5.10 -2.25 0.00 -0.01

(right side) +Umax gs : 0.02 3.94 5.18 2.34 0.00 0.01

Upper edge free end -Umax gs : -0.01 -7.83 -4.52 -2.25 0.00 -0.01
left side +Umax gs : 0.01 7.70 4.96 2.34 0.00 0.01

Upper edge free end -Umax gs : -0.01 -7.57 -5.22 -2.25 0.00 -0.01
right side +Umax gs : 0.01 7.45 5.68 2.34 0.00 0.01

Alternator top -Umax gs : -0.02 -8.24 -5.36 -2.25 0.00 -0.01

(left side) +Umax gs : 0.02 8.10 5.43 2.34 0.00 0.01

Alternator top -Umax gs : -0.02 -8.25 -5.36 -2.25 0.00 -0.01

(right side) +Umax gs : 0.02 8.11 5.43 2.34 0.00 0.01
TEM 50 699 Fig. 46
Load case: C3 g-loads resulting from crashs, etc.:
========== ±3.00g in vessel vertical direction

Maximum displacements and forces at interesting points

------------------------------------------------------

±Umax .... maximum displacements and rotations (negative and positive) in [mm, mrad]
|Urad| .... maximum radial displacement in [mm]
±Uax .... maximum axial displacements (negative and positive) in [mm]
±Fmax .... maximum spring forces and moments (negative and positive) in [N, Nm]
|Frad| .... maximum radial spring force in [N]
±Fax .... maximum axial spring forces (negative and positive) in [N]

gs .... the quantities are referenced to the global coordinate system

ps .... the quantities are referenced to a point related coordinate system

Item quantity in t-dir. in l-dir. in v-dir. ab. t-axis ab. l-axis ab. v-axis
---------------------------------------------------------------------------------------------------------------

c/g Basic engine -Umax gs : -0.01 -0.07 -4.38 -0.05 -0.01 0.00
(as in EB drawing) +Umax gs : 0.00 0.03 5.10 0.11 0.00 0.00

c/g Alternator -Umax gs : -0.01 -0.05 -4.28 -0.05 -0.01 0.00

+Umax gs : 0.00 0.02 4.86 0.11 0.00 0.00

Engine mount -Umax gs : 0.00 -0.01 -4.41 -0.05 -0.01 0.00

free end right +Umax gs : 0.00 0.00 5.17 0.11 0.00 0.00
-Fmax gs : 0. -72. -21451. 0. 0. 0.
+Fmax gs : 1. 30. 19978. 0. 0. 0.

Engine mount -Umax gs : 0.00 -0.01 -4.36 -0.05 -0.01 0.00

PTO right +Umax gs : 0.00 0.00 5.04 0.11 0.00 0.00
-Fmax gs : -6. -72. -21159. 0. 0. 0.
+Fmax gs : 2. 30. 19497. 0. 0. 0.

Alternator mount -Umax gs : 0.00 -0.01 -4.30 -0.05 -0.01 0.00

engineside right +Umax gs : 0.00 0.02 4.91 0.11 0.00 0.00
-Fmax gs : -1. -28. -9828. 0. 0. 0.
+Fmax gs : 4. 68. 10718. 0. 0. 0.

Alternator mount -Umax gs : 0.00 -0.01 -4.26 -0.05 -0.01 0.00

free end right +Umax gs : 0.00 0.02 4.80 0.11 0.00 0.00
-Fmax gs : 0. -28. -9724. 0. 0. 0.
+Fmax gs : 1. 68. 10476. 0. 0. 0.

Engine mount -Umax gs : 0.00 -0.01 -4.40 -0.05 -0.01 0.00

free end left +Umax gs : 0.00 0.00 5.16 0.11 0.00 0.00
-Fmax gs : 0. -65. -21424. 0. 0. 0.
+Fmax gs : 1. 27. 19932. 0. 0. 0.

Engine mount -Umax gs : 0.00 -0.01 -4.35 -0.05 -0.01 0.00

PTO left +Umax gs : 0.00 0.00 5.03 0.11 0.00 0.00
-Fmax gs : -6. -65. -21132. 0. 0. 0.
+Fmax gs : 2. 27. 19451. 0. 0. 0.

Alternator mount -Umax gs : 0.00 -0.01 -4.30 -0.05 -0.01 0.00

engineside left +Umax gs : 0.00 0.02 4.90 0.11 0.00 0.00
-Fmax gs : -1. -28. -9821. 0. 0. 0.
+Fmax gs : 4. 70. 10701. 0. 0. 0.

Alternator mount -Umax gs : 0.00 -0.01 -4.25 -0.05 -0.01 0.00

free end left +Umax gs : 0.00 0.02 4.79 0.11 0.00 0.00
-Fmax gs : 0. -28. -9717. 0. 0. 0.
+Fmax gs : 1. 70. 10459. 0. 0. 0.
TEM 50 699 Fig. 47
Load case: C3 g-loads resulting from crashs, etc.:
========== ±3.00g in vessel vertical direction

Maximum displacements and forces at interesting points (continuation)

------------------------------------------------------------------------

Item quantity in t-dir. in l-dir. in v-dir. ab. t-axis ab. l-axis ab. v-axis
---------------------------------------------------------------------------------------------------------------

eng vert buffer -Umax gs : 0.00 -0.01 -4.41 -0.05 -0.01 0.00
free end right +Umax gs : 0.00 0.00 5.17 0.11 0.00 0.00
-Fmax gs : 0. 0. -41839. 0. 0. 0.
+Fmax gs : 0. 0. 43471. 0. 0. 0.

eng vert buffer -Umax gs : 0.00 -0.01 -4.36 -0.05 -0.01 0.00
PTO right +Umax gs : 0.00 0.00 5.04 0.11 0.00 0.00
-Fmax gs : 0. 0. -35950. 0. 0. 0.
+Fmax gs : 0. 0. 36967. 0. 0. 0.

alt vert buffer -Umax gs : 0.00 -0.01 -4.30 -0.05 -0.01 0.00
engineside right +Umax gs : 0.00 0.03 4.91 0.11 0.00 0.00
-Fmax gs : 0. 0. -30512. 0. 0. 0.
+Fmax gs : 0. 0. 30388. 0. 0. 0.

alt vert buffer -Umax gs : 0.00 -0.01 -4.26 -0.05 -0.01 0.00
free end right +Umax gs : 0.00 0.03 4.80 0.11 0.00 0.00
-Fmax gs : 0. 0. -25935. 0. 0. 0.
+Fmax gs : 0. 0. 24908. 0. 0. 0.

eng vert buffer -Umax gs : 0.00 0.00 -4.40 -0.05 -0.01 0.00
free end left +Umax gs : 0.00 0.00 5.16 0.11 0.00 0.00
-Fmax gs : 0. 0. -41033. 0. 0. 0.
+Fmax gs : 0. 0. 42848. 0. 0. 0.

eng vert buffer -Umax gs : 0.00 0.00 -4.35 -0.05 -0.01 0.00
PTO left +Umax gs : 0.00 0.00 5.03 0.11 0.00 0.00
-Fmax gs : 0. 0. -35451. 0. 0. 0.
+Fmax gs : 0. 0. 36345. 0. 0. 0.

alt vert buffer -Umax gs : 0.00 -0.01 -4.30 -0.05 -0.01 0.00
engineside left +Umax gs : 0.00 0.03 4.90 0.11 0.00 0.00
-Fmax gs : 0. 0. -30201. 0. 0. 0.
+Fmax gs : 0. 0. 29999. 0. 0. 0.

alt vert buffer -Umax gs : 0.00 -0.01 -4.25 -0.05 -0.01 0.00
free end left +Umax gs : 0.00 0.03 4.79 0.11 0.00 0.00
-Fmax gs : 0. 0. -25624. 0. 0. 0.
+Fmax gs : 0. 0. 24665. 0. 0. 0.
TEM 50 699 Fig. 48
Load case: C3 g-loads resulting from crashs, etc.:
========== ±3.00g in vessel vertical direction

Maximum displacements and forces at interesting points (continuation)

------------------------------------------------------------------------

Item quantity in t-dir. in l-dir. in v-dir. ab. t-axis ab. l-axis ab. v-axis
---------------------------------------------------------------------------------------------------------------

air inlet hor. left |Urad| ps : 5.12 -Uax ps : -0.01 +Uax ps : 0.01

air inlet hor. right |Urad| ps : 5.15 -Uax ps : -0.01 +Uax ps : 0.01

Exh outlet 90° left |Urad| ps : 0.19 -Uax ps : -5.02 +Uax ps : 4.35

Exh outlet 90° right |Urad| ps : 0.19 -Uax ps : -5.04 +Uax ps : 4.36

Water inlet 20.026 |Urad| ps : 5.25 -Uax ps : -0.03 +Uax ps : 0.08

Water outlet 20.027 |Urad| ps : 5.24 -Uax ps : -0.05 +Uax ps : 0.11

auxPTO flange |Urad| ps : 5.23 -Uax ps : -0.02 +Uax ps : 0.04

alternator free end |Urad| ps : 0.04 -Uax ps : -4.23 +Uax ps : 4.74

alt cool in |Urad| ps : 4.90 -Uax ps : -0.01 +Uax ps : 0.00

alt cool out |Urad| ps : 4.90 -Uax ps : -0.02 +Uax ps : 0.01

Oil pan -Umax gs : 0.00 -0.01 -4.41 -0.05 -0.01 0.00

(left sd., free end) +Umax gs : 0.00 0.03 5.18 0.11 0.00 0.00

Oil pan -Umax gs : 0.00 -0.01 -4.41 -0.05 -0.01 0.00

(right s., free end) +Umax gs : 0.00 0.03 5.18 0.11 0.00 0.00

Alternator bottom -Umax gs : 0.00 -0.01 -4.23 -0.05 -0.01 0.00

(left side) +Umax gs : 0.00 0.02 4.74 0.11 0.00 0.00

Alternator bottom -Umax gs : 0.00 -0.01 -4.24 -0.05 -0.01 0.00

(right side) +Umax gs : 0.00 0.01 4.75 0.11 0.00 0.00

Upper edge free end -Umax gs : -0.01 -0.17 -4.43 -0.05 -0.01 0.00
left side +Umax gs : 0.01 0.07 5.21 0.11 0.00 0.00

Upper edge free end -Umax gs : -0.01 -0.16 -4.45 -0.05 -0.01 0.00
right side +Umax gs : 0.01 0.06 5.26 0.11 0.00 0.00

Alternator top -Umax gs : -0.02 -0.19 -4.23 -0.05 -0.01 0.00

(left side) +Umax gs : 0.01 0.08 4.72 0.11 0.00 0.00

Alternator top -Umax gs : -0.02 -0.19 -4.23 -0.05 -0.01 0.00

(right side) +Umax gs : 0.01 0.08 4.74 0.11 0.00 0.00
TEM 50 699 Fig. 49
Natural frequencies and vibration modes
=======================================

- Dynamic hardening factors (all directions) Vh,dyn = 1.61 (engine)

1.66 (alternator)

Frequency (cy./min) 346. 441. 543. 675. 759. 1144.

Frequency ( Hz ) 5.76 7.35 9.05 11.25 12.65 19.06

Rigid body 1:
Translation transv. 0.832 -0.003 0.005 -0.102 0.001 -0.275
Translation longit. 0.001 1.000 -0.069 -0.005 1.000 0.000
Translation vertical -0.004 0.124 1.000 -0.001 0.031 0.001
Rotation ab. T-Axis -0.001 -0.930 0.036 0.004 0.653 0.001
Rotation ab. L-Axis 1.000 -0.004 0.002 -0.223 -0.001 1.000
Rotation ab. V-Axis 0.131 0.003 0.001 1.000 0.002 0.061

Modal masses and participation factors for each natural frequency

=================================================================
__________________________________________________________________________________________________
| | | | |
| No. | nat. frequency | | modal mass M [kg, kg*m**2] / participation factor P [s/m, s/rad] |
| | [Hz] | | transv. | longit. | vertical | ar. tran. | ar. long. | ar. vert. |
|_____|________________|___|___________|___________|___________|___________|___________|___________|
| | | | | | | | | |
| 1 | 5.76 | M | 9722.6 | 0.0 | 0.3 | 0.0 | 718.1 | 610.6 |
| | | P | 0.880 | 0.001 | 0.005 | 0.001 | 0.239 | 0.221 |
| | | | | | | | | |
| 2 | 7.35 | M | 0.1 | 5433.6 | 83.8 | 12838.0 | 0.0 | 0.1 |
| | | P | 0.001 | 0.409 | 0.051 | 0.629 | 0.000 | 0.002 |
| | | | | | | | | |
| 3 | 9.05 | M | 0.3 | 63.6 | 13192.0 | 45.7 | 0.0 | 0.0 |
| | | P | 0.005 | 0.069 | 0.993 | 0.058 | 0.001 | 0.001 |
| | | | | | | | | |
| 4 | 11.25 | M | 85.5 | 0.2 | 0.0 | 0.4 | 20.9 | 20869.8 |
| | | P | 0.063 | 0.003 | 0.000 | 0.004 | 0.031 | 0.987 |
| | | | | | | | | |
| 5 | 12.65 | M | 0.0 | 7784.2 | 7.5 | 9078.5 | 0.0 | 0.1 |
| | | P | 0.000 | 0.586 | 0.018 | 0.633 | 0.000 | 0.002 |
| | | | | | | | | |
| 6 | 19.06 | M | 3261.9 | 0.0 | 0.0 | 0.1 | 2207.9 | 402.8 |
| | | P | 0.894 | 0.000 | 0.003 | 0.004 | 0.735 | 0.314 |
|_____|________________|___|___________|___________|___________|___________|___________|___________|
Technical Data Sheet

MTU Order No. 1106745 Date 12.06.2014

Project Name COSCO - UT771WP Department EMSC
Genset Model MG12V4000 Name Thurner
Engine Model 12V4000M33S Reference 45°C/32°C
Customer / Shipyard Rolls-Royce MTU Data Code 39

Genset Performance
Rated Power 1480 kWe 1850 kVA
Voltage / Frequenzy 690 V 60 Hz
Engine Perrformance
Rated Power (100%) 1560 kWm
Fuel Stop Power (110%) 1716 kWm
Engine speed 1800 rpm
Reference Conditions
Raw water inlet temperature (only for engine mounted heat exchanger) °C
Site altidude above sea level 100 m

ENGINE COMBUSTION AND VENTILATION AIR SYSTEM

.06 Intake/ combustion air temperature (max.) / air is drawn out of engine room 45 °C
5.09 Combustion air volume flow (100%) 2,5 m³/s
2.01 Intake air depression (design value) 15 mbar
2.02 Intake air depression (max.) 30 mbar

6.64 Radiation and convention heat (engine) 48 kW

Alternator Radiation and convention heat (alternator*) 7,5 kW
*Air cooled alternators approx. 5% from 100% engine power / water cooled alternators approx. 0,5% from 100% engine power

EXHAUST GAS SYSTEM

5.15 Exhaust temperature after turbocharger (100%) 425 °C
5.11 Exhaust volume flow (100%) 5 m³/s
2.03 Exhaust back pressure (design value) 30 mbar
2.04 Exhaust back pressure (max.) 85 mbar

COOLING SYSTEM
6.11 Heat dissipation by engine coolant (100%) 1325 KW
7.30 Cooling equipement: coolant flow rate (engine) 32 m³/h
7.17 Coolant temperature at engine outlet to external cooling system 96 °C
7.49 Operating pressure, engine cooling system 6 bar
7.53 Operating pressure, external cooling system 3,4 bar
7.41 Pressure loss in off-engine/ external cooling system (max.) 0,7 bar
7.72 Pressure loss in off-engine/ external cooling system (min.) 0,55 bar
7.47 Breather valve (expansion tank) opening pressure (excess pressure) 1 bar
7.48 Breather valve (expansion tank) opening pressure (depression) 0,1 bar

Alternator Heat dissipation by alternator coolant (100%)** kW

Alternator Cooling equipement: coolant flow rate (alternator)** 11,5 m³/h
Alternator Coolant temperature at alternator outlet to external cooling system** 45 °C
Alternator Coolant temperature at alternator inlet to external cooling system** 40 °C
Alternator Operating pressure (max.)** 6 bar
Alternator Water pressure loss** 0,08 bar
** Values given on alternator technical data sheet/ drawing

FUEL SYSTEM
11.81 Maximum supply flow rate (100%) 11,2 liter/ min
11.85 Maximum return flow rate (100%) 4,3 liter/ min
2.06 Admissible fuel temperature 55 °C
11.01 Admissible pressure at engine start (min.) -0,1 bar
11.02 Admissible pressure at engine start (max.) 1,5 bar
11.57 Admissible pressure with engine in operation (min.) -0,3 bar
11.65 Admissible pressure with engine in operation (max.) 0,5 bar
Suction height (max.) 1 m
6.101 Heat dissipation from from fuel return flow 9 kW

STARTING SYSTEM (Compressed air)

15.05 Starting air pressure before starter motor (min.) 8 bar
15.06 Starting air pressure before starter motor (max.) 10 bar
Genset Start attempt duration Genset (first attempt)*** 5 s
Genset Start attempt duration Genset (following attempts)*** 3 s
Genset Air consumtion starter motor per second 0,6 m³/s
*** Values for Genset application higher than single engine start values in TEN-Engine

Page 1
 Technical Sales Document
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Date 6/12/2014
Name 12V4000M33S Speed[rpm] 1800
Application Group 3B Rating[KW] 1560
Dataset Ref. 45°C/35°C; Heat exchanger Rating[bhp] 2092
separate from engine (39)
Frequency[Hz] 60

IMO Tier II (Marpol-Convention);

RheinSchUO - Stage II;

Reference conditions

No. Description Index Value Unit

3 MTU data code 39 -

6 Intake air temperature 45 °C
7 Charge-air coolant temperature - °C
8 Barometric pressure 1000 mbar
9 Site altitude above sea level 100 m
10 Raw-water inlet temperature 32 °C

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0. Data-relevant engine design configuration

No. Description Index Value Unit

2 Exhaust-emissions optimized X -
(limit values see Exhaust Emissions, Chapter 21)
51 Complies with: X -
IMO Tier II (MARPOL 73/78, Annex VI,
Revised NOx Technical Code 2008)
49 Complies with: X -
RheinSchUO - Stage II
(Rheinschifffahrts-Untersuchungsordnung)
10 Cooling equipment: engine mounted - -
11 Cooling equipment: separate from engine X -
12 Engine with sequential turbocharging X -
(turbochargers with cut-in/cut-out control)
13 Engine without sequential turbocharging - -
(turbochargers without cut-in/cut-out control)

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1. Power-related data (power ratings are net brake power to ISO 3046)

No. Description Index Value Unit

1 Engine rated speed A 1800 rpm

3 Mean piston speed 12.6 m/s
4 Continuous power ISO 3046 (10% overload A 1560 kW
capability)
(design power DIN 6280, ISO 8528)
5 Fuel stop power ISO 3046 A 1716 kW
8 Mean effective pressure (MEP) 18.2 bar
(Continuous power ISO 3046)
9 Mean effective pressure (MEP) 20.0 bar
(Fuel stop power ISO 3046)

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2. General Conditions (for maximum power)

No. Description Index Value Unit

1 Intake air depression (new filter) A 15 mbar

2 Intake air depression, max. L 30 mbar
3 Exhaust back pressure A 30 mbar
4 Exhaust back pressure, max. L 85 mbar
5 Fuel temperature at fuel feed connection R 25 °C
6 Fuel temperature at fuel feed connection, max. L 55 °C

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3. Consumption

No. Description Index Value Unit

22 Specific fuel consumption (be) - 100 % CP R 210 g/kWh

w/o raw water pump (+ 5 %; EN 590; 42.8 MJ/kg)
23 Specific fuel consumption (be) - 75 % CP R 218 g/kWh
w/o raw water pump (+ 5 %; EN 590; 42.8 MJ/kg)
24 Specific fuel consumption (be) - 50 % CP R 232 g/kWh
w/o raw water pump (+ 5 %; EN 590; 42.8 MJ/kg)
25 Specific fuel consumption (be) - 25 % CP R 290 g/kWh
w/o raw water pump (+ 5 %; EN 590; 42.8 MJ/kg)
52 Specific fuel consumption (be) - FSP R 211 g/kWh
w/o raw water pump (+ 5 %; EN 590; 42.8 MJ/kg)
28 Specific fuel consumption (be) - 100 % CP R - g/kWh
with raw water pump (+ 5 %; EN 590; 42.8 MJ/kg)
29 Specific fuel consumption (be) - 75 % CP R - g/kWh
with raw water pump (+ 5 %; EN 590; 42.8 MJ/kg)
30 Specific fuel consumption (be) - 50 % CP R - g/kWh
with raw water pump (+ 5 %; EN 590; 42.8 MJ/kg)
31 Specific fuel consumption (be) - 25 % CP R - g/kWh
with raw water pump (+ 5 %; EN 590; 42.8 MJ/kg)
53 Specific fuel consumption (be) - FSP R - g/kWh
with raw water pump (+ 5 %; EN 590; 42.8 MJ/kg)
35 High-idle fuel consumption R 53 kg/h
92 Lube oil consumption after 100 h of operation R 0.3 % of B
(B = fuel consumption per hour)
Guideline value does not apply for the design
of EGA systems. Please consult the Applications
Center with regard to the layout of EGA systems.
62 Lube oil consumption after 100 h of operation, L 1.0 % of B
max.
(B = fuel consumption per hour)

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4. Model-related data (basic design)

No. Description Index Value Unit

3 Engine with exhaust turbocharger (ETC) and X -

intercooler
5 Exhaust piping, liquid-cooled X -
6 Number of cylinders 12 -
7 Cylinder configuration: V angle 90 degrees (°)
10 Bore 170 mm
11 Stroke 210 mm
12 Displacement, cylinder 4.77 liter
13 Displacement, total 57.2 liter
14 Compression ratio 17.2 -
28 Standard flywheel housing flange (engine main 00 SAE
PTO)

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5. Combustion air / exhaust gas

No. Description Index Value Unit

9 Combustion air volume flow - CP R 2.5 m³/s

10 Combustion air volume flow - FSP R 2.6 m³/s
11 Exhaust volume flow (at exhaust temperature) - R 5.0 m³/s
CP
12 Exhaust volume flow (at exhaust temperature) - R 5.4 m³/s
FSP
15 Exhaust temperature after turbocharger - CP R 425 °C
16 Exhaust temperature after turbocharger - FSP R 445 °C
78 Exhaust temperature after turbocharger - 75 % N °C
CP
79 Exhaust temperature after turbocharger - 50 % N °C
CP

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6. Heat dissipation

No. Description Index Value Unit

11 Heat dissipation by engine coolant - CP A 1325 kW

with oil heat, with charge-air heat
12 Heat dissipation by engine coolant - FSP R 1475 kW
with oil heat, with charge-air heat
15 Heat dissipated by engine coolant - CP R 860 kW
with oil heat, without charge-air heat
16 Heat dissipated by engine coolant - FSP R 950 kW
with oil heat, without charge-air heat
98 Heat dissipated from fuel return flow R - kW
Normal mode
99 Heat dissipated from fuel return flow R - kW
Failure mode (50% propeller curve)
100 Heat dissipated from fuel return flow R - kW
Failure mode (50% nominal speed curve)
101 Heat dissipated from fuel return flow - CP R 9 kW
Normal mode
102 Heat dissipated from fuel return flow - CP R 40 kW
Failure mode (50% nominal speed curve)
103 Heat dissipated from fuel return flow - FSP R 9 kW
Normal mode
104 Heat dissipated from fuel return flow - FSP R 39 kW
Failure mode (50% nominal speed curve)
64 Radiation and convection heat, engine R 48 kW
(engine room temperature = intake air
temperature,
flow velocity 2 m/s)

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7. Coolant system (high-temperature circuit)

No. Description Index Value Unit

17 Coolant temperature A 96 °C
(at engine outlet to cooling equipment)
109 Coolant temperature difference R 43 °C
via cooler, including short-circuit volume flow
25 Coolant antifreeze content, max. L 50 %
30 Cooling equipment: coolant flow rate A 32 m³/h
31 Coolant pump: pressure differential R 4.6 bar
41 Pressure loss in off-engine cooling system, max. L 0.7 bar
72 Pressure loss in off-engine cooling system, min. L 0.55 bar
47 Breather valve (expansion tank) R 1.0 bar
opening pressure (excess pressure)
53 Cooling equipment: operating pressure A 3.4 bar
50 Thermostat, starts to open R 79 °C
51 Thermostat, bypass closed R 87 °C
52 Thermostat, fully open R °C
48 Breather valve (expansion tank) R 0.1 bar
opening pressure (depression)
49 Pressure in cooling system, max. L 6.0 bar

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9. Raw water circuit (open circuit)

10. Lube oil system

No. Description Index Value Unit

7 Lube oil operating pressure before engine R 6.0 bar

(measuring block)
8 Lube oil operating press. bef. engine, from R 5.5 bar
9 Lube oil operating press. bef. engine, to R 6.5 bar
32 Lube oil fine filter (main circuit): L XZ59400100035 bar
pressure differential, max.

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11. Fuel system

No. Description Index Value Unit

1 Fuel pressure at fuel feed connection, min. L -0.1 bar

(when engine is starting)
57 Fuel pressure at fuel feed connection, min. L -0.3 bar
(when engine is running)
2 Fuel pressure at fuel feed connection, max. L 1.5 bar
(when engine is starting)
65 Fuel pressure at fuel feed connection, max. L 0.5 bar
(permanent)
74 Max. fuel supply volume R - liter/min
Normal mode
75 Max. fuel supply volume R - liter/min
Failure mode (50% propeller curve)
76 Max. fuel supply volume R - liter/min
Failure mode (50% nominal speed curve)
81 Max. fuel supply volume - CP R 11.2 liter/min
Normal mode
82 Max. fuel supply volume - CP R 17.7 liter/min
Failure mode (50% nominal speed curve)
83 Max. fuel supply volume - FSP R 11.9 liter/min
Normal mode
84 Max. fuel supply volume - FSP R 17.7 liter/min
Failure mode (50% nominal speed curve)
77 Max. fuel return volume R - liter/min
Normal mode
78 Max. fuel return volume R - liter/min
Failure mode (50% propeller curve)
79 Max. fuel return volume R - liter/min
Failure mode (50% nominal speed curve)
85 Max. fuel return volume - CP R 4.3 liter/min
Normal mode
86 Max. fuel return volume - CP R 13.6 liter/min
Failure mode (50% nominal speed curve)
87 Max. fuel return volume -FSP R 4.3 liter/min
Normal mode
88 Max. fuel return volume - FSP R 13.2 liter/min
Failure mode (50% nominal speed curve)
10 Fuel pressure at return connection on engine, L - bar
max.
89 Fuel pressure at engine return connection R 0.5 bar
Normal operation; Fault status, continuous.

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90 Fuel presssure at engine return connection, max. R 1.5 bar
Fault status, transient
12 Fuel temperature differential before/after engine R 60 °C
91 Fuel temperature difference before/after engine R 70 °C
Normal operation
92 Fuel temperature difference before/after engine R 100 °C
Fault mode
18 Fuel fine filter (main circuit): number of units A 1 -
19 Fuel fine filter (main circuit): number of elements A 2 -
per unit
20 Fuel fine filter (main circuit): particle retention A 0.01 mm

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12. General operating data

No. Description Index Value Unit

1 Cold start capability: air temperature R 10 °C

(w/o starting aid, w/o preheating) - (case A)
2 Additional condition (to case A): R 10 °C
engine coolant temperature
3 Additional condition (to case A): lube oil R 10 °C
temperature
4 Additional condition (to case A): lube oil viscosity R 30 SAE
9 Cold start capability: air temperature R -10 °C
(w/o starting aid, w/ preheating) - (case C)
10 Additional condition (to case C): R 40 °C
engine coolant temperature
11 Additional condition (to case C): lube oil R 0 °C
temperature
12 Additional condition (to case C): lube oil viscosity R 15W40 SAE
21 Coolant preheating, heater performance R 4.5 kW
(standard)
22 Coolant preheating, preheating temperature (min.) L 40 °C
28 Breakaway torque (without driven machinery) R 1500 Nm
coolant temperature +5°C
30 Breakaway torque (without driven machinery) R 1200 Nm
coolant temperature +40°C
32 Breakaway torque (without driven machinery) R 1200 Nm
coolant temperature +60°C
29 Cranking torque at firing speed (without driven R 825 Nm
machinery)
coolant temperature +5°C
31 Cranking torque at firing speed (without driven R 600 Nm
machinery)
coolant temperature +40°C
33 Cranking torque at firing speed (without driven R 525 Nm
machinery)
coolant temperature +60°C
37 High idling speed, max. (static) L 1800 rpm
38 Limit speed for overspeed alarm / emergency L 2070 rpm
shutdown
42 Firing speed, from R 80 rpm
43 Firing speed, to R 120 rpm

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44 Engine coolant temperature before starting R 60 °C
full-load operation, recommended min.
(for emergency/standby sets with coolant
preheating: at least the preheating temperature)

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13. Starting (electric)

No. Description Index Value Unit

22 Starter, rated power R 2x7.5 kW

(make PRESTOLITE) (standard design)
2 Starter, rated voltage (standard design) R 24 V=
24 Starter, power requirement max. (make R 1800 A
PRESTOLITE)
25 Starter, power requirement at firing speed R 600 A
(make PRESTOLITE)
16 Start attempt duration (engine preheated) R 3 s
17 Start attempt duration (engine not preheated) R 3 s
18 Start attempt duration, max. L 15 s

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15. Starting (pneumatic/oil pressure starter)

No. Description Index Value Unit

35 Pneumatic starter: make Gali - -

36 Pneumatic starter: make TDI X -
5 Starting air pressure before starter motor, min. R 8 bar
6 Starting air pressure before starter motor, max. R 10 bar
7 Starting air pressure before starter motor, min. L 8 bar
8 Starting air pressure before starter motor, max. L 10 bar
18 Start attempt duration (engine preheated) R <3 s
19 Start attempt duration (engine not preheated) R 3 s
114 Air consumption/start attempt R 1.1 m³n
(engine preheated)
Engine without generator
Control with engine controller
115 Air consumption/start attempt R 1.2 m³n
(engine not preheated)
Engine without generator
Control with engine controller
23 Starting air tank for 3 start attempts R 110 liter
(max. 40 bar) (engine preheated)
24 Starting air tank for 3 start attempts R 130 liter
(max. 30 bar) (engine preheated)
25 Starting air tank for 6 start attempts R 220 liter
(max. 40 bar) (engine preheated)
26 Starting air tank for 6 start attempts R 260 liter
(max. 30 bar) (engine preheated)
27 Starting air tank for 10 start attempts R 370 liter
(max. 40 bar) (engine preheated)
28 Starting air tank for 10 start attempts R 430 liter
(max. 30 bar) (engine preheated)
29 Starting air tank for 3 start attempts R 115 liter
(max. 40 bar) (engine not preheated)
30 Starting air tank for 3 start attempts R 140 liter
(max. 30 bar) (engine not preheated)
31 Starting air tank for 6 start attempts R 230 liter
(max. 40 bar) (engine not preheated)
32 Starting air tank for 6 start attempts R 280 liter
(max. 30 bar) (engine not preheated)
33 Starting air tank for 10 start attempts R 380 liter
(max. 40 bar) (engine not preheated)

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34 Starting air tank for 10 start attempts R 470 liter
(max. 30 bar) (engine not preheated)

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16. Inclinations - standard oil system (ref.: waterline)

No. Description Index Value Unit

15 Longitudinal inclination, continuous max. L 17 degrees (°)

driving end down
(Option: max. operating inclinations)
16 Longitudinal inclination, temporary max. L 19.5 degrees (°)
driving end down
(Option: max. operating inclinations)
17 Longitudinal inclination, continuous max. L 15 degrees (°)
driving end up
(Option: max. operating inclinations)
18 Longitudinal inclination, temporary max. L 17.5 degrees (°)
driving end up
(Option: max. operating inclinations)
19 Transverse inclination, continuous max. L 15 degrees (°)
(Option: max. operating inclinations)
20 Transverse inclination, temporary max. L 22.5 degrees (°)
(Option: max. operating inclinations)

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18. Capacities

No. Description Index Value Unit

1 Engine coolant capacity (without cooling R 245 liter

equipment)
2 Engine coolant capacity (with cooling equipment) R - liter
11 On-engine fuel capacity R N liter
14 Engine oil capacity, initial filling R N liter
(standard oil system)
(Option: max. operating inclinations)
20 Oil change quantity, max. R 265 liter
(standard oil system)
(Option: max. operating inclinations)
28 Oil pan capacity, dipstick mark min. L 195 liter
(standard oil system)
(Option: max. operating inclinations)
29 Oil pan capacity, dipstick mark max. L 235 liter
(standard oil system)
(Option: max. operating inclinations)

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19. Weights / dimensions

No. Description Index Value Unit

1 Engine dry weight (basic engine) R N kg

2 Engine dry weight (with engine-mounted R 7370 kg
standard accessories incl. coupling)
7 Engine dry weight (with engine-mounted R 7240 kg
standard accessories, without coupling)
12 Engine weight, wet R 7800 kg
(with engine-mounted standard accessories,
without coupling)
8 Heaviest component to be lifted during R 460 kg
maintenance level W5

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21. Exhaust emissions

No. Description Index Value Unit

1942 Emissions data sheet: EDS40000143 -

IMO Tier II
1946 Emissions data sheet: EDS40000144 -
RheinSchUO - stage II

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22. Acoustics

No. Description Index Value Unit

101 Exhaust noise, unsilenced - CP R 107 dB(A)

(free-field sound-pressure level Lp, 1m distance,
ISO 6798, +3dB(A) tolerance)
201 Exhaust noise, unsilenced - CP R 120 dB(A)
(sound power level LW, ISO 6798, +3dB(A)
tolerance)
103 Exhaust noise, unsilenced - FSP R 735499e -
(free-field sound-pressure level Lp, 1m distance,
ISO 6798)
Spectrum No.
113 Engine surface noise with attenuated R 103 dB(A)
intake noise (intake silencer) - CP
(free-field sound-pressure level Lp, 1m distance,
ISO 6798, +2dB(A) tolerance)
213 Engine surface noise with attenuated R 121 dB(A)
intake noise (intake silencer) - CP
(sound power level LW,
ISO 6798, +2dB(A) tolerance)
115 Engine surface noise with attenuated R 735512e -
intake noise (intake silencer) - CP
(free-field sound-pressure level Lp, 1m distance,
ISO 6798) Spectrum No.

Please consider the explanations on the last page. 22/24

 Technical Sales Document
- Product Data -

Date 6/12/2014

23. TBO and load profile (case A)

No. Description Index Value Unit

1 TBO (Time between Overhaul) L 18000 h

(related to standard load profile (Pn,tn))
22 P1 (percent load related to CP) R 100 %
3 t1 (percentage of operating time) R 20 %
24 P2 (percent load related to CP) R 70 %
5 t2 (percentage of operating time) R 65 %
26 P3 (percent load related to CP) R <15 %
7 t3 (percentage of operating time) R 15 %
11 Mean utilization rate (percentage of rated power) R 68 %
12 1XPEHURIORDGFKDQJHVKRXUW\SH, R <0.3 -
"WR"ORDG
13 1XPEHURIORDGFKDQJHVKRXUW\SH,, R <0.3 -
"WREHWZHHQDQGORDG

Please consider the explanations on the last page. 23/24

 Technical Sales Document
- Product Data -

Date 6/12/2014

Description:

CP = Ref. value: Continuous power

FSP = Ref. value: Fuel stop power

A = Design value

R = Guideline value

L = limit value

N = Not yet defined value

- = Not applicable

X = Applicable

Please consider the explanations on the last page. 24/24

Operating Instructions
Diesel Engine
12 V 4000 M33F
12 V 4000 M33S
16 V 4000 M33F
16 V 4000 M33S
16 V 4000 M43S

MS150069/02E
Printed in Germany
© 2014 Copyright MTU Friedrichshafen GmbH
This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior
written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, mi-
crofilming and storage or processing on electronic systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage
during operation.
Subject to alterations and amendments.
 Table of Contents
1 Safety 3.6 Tasks after extended out-of-service periods
(>3 weeks) 81
1.1 Important provisions for all products 5 3.7 Checks prior to start-up 82
1.2 Personnel and organizational requirements 6 3.8 Fuel treatment system – Putting into
1.3 Transport 7 operation 83
1.4 Safety regulations for startup and operation 8 3.9 Fuel treatment system – Switching on 86
1.5 Safety regulations for maintenance and 3.10 Fuel treatment system – Shutdown 87
repair work 9 3.11 Stopping the engine 88
1.6 Fire prevention and environmental 3.12 Emergency engine stop 89
protection, fluids and lubricants, auxiliary 3.13 After stopping the engine 90
materials 12 3.14 Plant – Cleaning 91
1.7 Standards for safety notices in the text 14
4 Maintenance
2 Product Summary
4.1 Maintenance task reference table [QL1] 92
2.1 Engine Layout 15
2.1.1 Product description 15
2.1.2 Engine layout 27
5 Troubleshooting
2.1.3 Overview of sensors and actuators 31
5.1 Troubleshooting 94
2.2 Engine Side and Cylinder Designations 51 5.2 Fuel treatment system – Troubleshooting 97
2.2.1 Engine side and cylinder designations 51 5.3 Engine governor ADEC (ECU 7) fault
messages for Series 4000 engines, marine
2.3 Main Engine Dimensions 52
2.3.1 Engine – Main dimensions 52 application 98
5.4 Engine governor ADEC (ECU 7) – Fault
2.4 Firing Sequence 54 codes 99
2.4.1 Firing order 54

2.5 Technical Data 55 6 Task Description

2.5.1 ENGINE DATA 12V 4000 M33F, RheinSchUO
Stage II, IMO Tier II 55 6.1 Engine 164
2.5.2 ENGINE DATA 12V 4000 M33S, RheinSchUO 6.1.1 Engine – Barring manually 164
Stage II, IMO Tier II 58 6.1.2 Engine – Barring with starting system 166
2.5.3 ENGINE DATA 12V 4000 M33S, IMO Tier II, 6.2 Cylinder Liner 167
EPA Tier 2 61 6.2.1 Cylinder liner – Endoscopic examination 167
2.5.4 ENGINE DATA 16V 4000 M33F, RheinSchUO 6.2.2 Instructions and comments on endoscopic and
Stage II, IMO Tier II 64 visual examination of cylinder liners 169
2.5.5 ENGINE DATA 16V 4000 M33S, RheinSchUO
Stage II, IMO Tier II 67 6.3 Crankcase Breather 171
2.5.6 ENGINE DATA 16V 4000 M33S, IMO Tier II, 6.3.1 Crankcase breather – Overview 171
EPA Tier 2 70 6.3.2 Crankcase breather – Oil mist fine separator
2.5.7 Engine data 16V 4000 M43S, IMO Tier II, EPA replacement 173
Tier 2 73
6.4 Valve Drive 174
6.4.1 Valve gear – Lubrication 174
DCL-ID: 0000030904 - 001

3 Operation 6.4.2 Valve clearance – Check and adjustment 175

6.4.3 Cylinder head cover – Removal and
3.1 Controls 76 installation 178
3.2 Putting the engine into operation after 6.5 Injection Pump / HP Pump 179
extended out-of-service periods (>3 months) 77 6.5.1 HP pump – Filling with engine oil 179
3.3 Putting the engine into operation after 6.5.2 HP pump – Relief bore check 180
scheduled out-of-service-period 78
3.4 Starting the engine 79 6.6 Injector 181
6.6.1 Injector – Replacement 181
3.5 Operational checks 80
6.6.2 Injector – Removal and installation 182

MS150069/02E 2014-03 | Table of Contents | 3

 6.15.10 Preheater – Overhaul 242
6.7 Fuel Filter 187 6.15.11 Preheater – Function and leak-tightness check 243
6.7.1 Supplementary fuel filter – Overview 187
6.7.2 Additional fuel filter – Replacement 188 6.16 Raw Water Pump with Connections 244
6.7.3 Fuel filter – Replacement 189 6.16.1 Raw water pump – Relief bore check 244
6.7.4 Fuel system – Venting 191
6.7.5 Fuel prefilter – Differential pressure check
6.17 Engine Mounting / Support 245
6.17.1 Engine mounting – Check 245
and adjustment of gauge 192
6.7.6 Fuel prefilter – Draining 193 6.18 Battery-Charging Generator 246
6.7.7 Fuel prefilter – Flushing 195 6.18.1 Battery-charging generator drive – Coupling
6.7.8 Fuel prefilter with water separator – Filter condition check 246
element replacement 197
6.7.9 Fuel prefilter with water separator – O-ring 6.19 Auxiliary PTO 247
replacement in rotary slide valve 199 6.19.1 Bilge pump – Relief bore check 247

6.8 Exhaust Turbocharger 200 6.20 Fuel Supply System 248

6.8.1 Compressor wheel – Cleaning 200 6.20.1 Water drain valve – Check 248
6.20.2 Differential pressure gauge – Check 249
6.9 Charge-Air Cooling 208 6.20.3 Water level probe (3-in-1 rod electrode) –
6.9.1 Intercooler – Checking condensate drain for Check 250
water discharge and obstruction 208 6.20.4 Pump capacity – Check 251
6.20.5 Coalescer filter element – Replacement 252
6.10 Air Filter 209
6.10.1 Air filter – Replacement 209 6.21 Wiring (General) for Engine/Gearbox/Unit 254
6.10.2 Air filter – Removal and installation 210 6.21.1 Engine wiring harness – Overview 254
6.21.2 Engine wiring – Check 260
6.11 Air Intake 211
6.11.1 Service indicator – Signal ring position check 6.22 Accessories for (Electronic) Engine
(optional) 211 Governor / Control System 261
6.12 Starting Equipment 212 6.22.1 CDC parameters – Reset 261
6.12.1 Starter – Condition check 212 6.22.2 Limit switch for start interlock ‒ Check 262
6.22.3 Engine Control Unit ECU 7 – Checking plug
6.13 Lube Oil System, Lube Oil Circuit 213 connections 263
6.13.1 Engine oil – Level check 213 6.22.4 Engine Monitoring Unit EMU 7 – Plug
6.13.2 Engine oil – Change 214 connection check 264
6.13.3 Engine oil – Sample extraction and analysis 216 6.22.5 Interface module EIM plug connections –
Check 265
6.14 Oil Filtration / Cooling 218
6.22.6 Engine Control Unit ECU 7 – Removal and
6.14.1 Engine oil filter ‒ Replacement 218
installation 266
6.14.2 Oil indicator filter – Cleaning and check 220
6.22.7 EMU 7 – Removal and installation 267
6.14.3 Centrifugal oil filter – Cleaning and filter
6.22.8 Engine Interface Module EIM – Removal and
sleeve replacement 222
installation 268
6.15 Coolant Circuit, General, High-Temperature 6.22.9 Diagnostic features of EIM 269
Circuit 225
6.15.1 Drain and vent points 225
6.15.2 Engine coolant level – Check 229
7 Appendix A
6.15.3 Engine coolant – Change 230
7.1 Abbreviations 272
6.15.4 Engine coolant – Draining 231
7.2 MTU contact persons/service partners 274
6.15.5 Engine coolant – Filling 234
DCL-ID: 0000030904 - 001

6.15.6 HT coolant pump – Relief bore check 236

6.15.7 Engine coolant – Sample extraction and 8 Appendix B
analysis 237
6.15.8 Engine coolant filter – Replacement 238
8.1 Special Tools 275
6.15.9 Preheating unit 239 8.2 Index 280

4 | Table of Contents | MS150069/02E 2014-03

 1 Safety
1.1 Important provisions for all products
Nameplate
The product is identified by nameplate, model designation or serial number and must match with the
information on the title page of this manual.
Nameplate, model designation or serial number can be found on the product.

General information
This product may pose a risk of injury or damage in the following cases:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Modifications or conversions
• Noncompliance with the safety instructions and warning notices

Correct use
The product is intended exclusively for the application specified in the contract or defined at the time of
delivery.
This means that the equipment must be operated:
• Within the permissible operating parameters in accordance with the (→ Technical data)
• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubri-
cants Specifications of the manufacturer)
• With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU
contact/Service partner)
• In the original as-delivered configuration or in a configuration approved by the manufacturer in writ-
ing (including engine control/parameters)
• In compliance with all safety regulations and in adherence with all warning notices in this manual
• In accordance with the maintenance requirements over the entire service life of the product (→ Main-
tenance Schedule)
• In compliance with the maintenance and repair instructions 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
repair
• By contracting only workshops authorized by the manufacturer to carry out repair and overhaul
Any other use is considered improper use and increases the risk of personnel injury or material damage
in product operation. The manufacturer will accept no liability for such damage.

Modifications or conversions
Unauthorized modifications to the product compromise safety.
TIM-ID: 0000040530 - 003

The manufacturer will accept no liability or warranty claims for any damage caused by unauthorized
modifications or conversions.

Spare parts
Only genuine spare parts must be used to replace components or assemblies.
The manufacturer will accept no liability or warranty claims for any damage caused by the use of other
spare parts.

MS150069/02E 2014-03 | Safety | 5

 1.2 Personnel and organizational requirements
Organizational measures of the operator
This manual must be issued to all personnel involved in operation, maintenance, repair or transporta-
tion.
Keep this manual handy in the vicinity of the product such that it is accessible to operating, mainte-
nance, repair and transport personnel at all times.
Use this manual as a basis for instructing personnel on product operation and repair, whereby the safe-
ty-relevant instructions, in particular, must be read and understood.
This is particularly important in the case of personnel who only occasionally perform work on or around
the product. This personnel must be 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
• Qualified personnel specialized in mechanical and plant engineering
The operator must define the responsibilities of the personnel involved in operation, maintenance, re-
pair and transport.

Working clothes and personal protective equipment

Wear proper protective clothing for all work.
When working, always wear the necessary personal protective equipment (e.g. ear protectors, protec-
tive gloves, goggles, breathing protection). Observe the information on personal protective equipment
in the respective activity description.

TIM-ID: 0000040531 - 002

6 | Safety | MS150069/02E 2014-03

 1.3 Transport
Transport

Attach the engine at the lifting eyes provided only.

The lifting eyes are designed for engine transport only, not for the transport of propulsion units (engine
and gearbox).
Use only the transport and lifting gear approved by MTU.
The engine must only be transported in installation position, max. permissible diagonal pull 10°.
Take note of the engine center of gravity.
In the case of special packaging with aluminum foil, suspend the engine on the lifting eyes of the trans-
port 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 the engine against tilting during transportation. The engine must be especially secured against
slipping or tilting when going up or down inclines and ramps.
TIM-ID: 0000002621 - 004

Setting the engine down after transport

Place the engine only on an even, firm surface.
Ensure appropriate consistency and load-bearing capacity of the ground or support surface.
Never place an engine on the oil pan, unless expressively authorized by MTU on a case-to-case basis to
do so.

MS150069/02E 2014-03 | Safety | 7

 1.4 Safety regulations for startup and operation
Safety regulations for startup
Install the product correctly and carry out acceptance in accordance with the manufacturer's specifica-
tions before putting the product into service.
Before the product is put into operation for the first time, all official authorizations must be available
and commissioning preconditions met.
When putting the product into operation, always ensure that
• All maintenance and repair work has been completed.
• All loose parts have been removed from rotating machine components.
• All personnel is clear of the danger zone surrounding moving parts of the machine.
• No persons wearing pacemakers or any other technical body aids are present.
• The service room is adequately ventilated.
• The exhaust system is leak-tight and that the gases are vented to atmosphere.
• Protect battery terminals, generator terminals or cables against accidental contact.
Immediately after putting the product into operation, make sure that all control and display instruments
as well as the monitoring, signaling and alarm systems are working properly.

Safety regulations for operation

The operator must be familiar with the controls and displays.
The operator must be familiar with the consequences of any operations performed.
During operation, the display instruments and monitoring units must be permanently observed with re-
gard to present operating status, violation of limit values and warning or alarm messages.

Malfunctions and emergency stop

The procedures for emergencies, in particular, emergency stop, must be practiced regularly.
The following steps must be taken if a malfunction of the system is detected or reported by the system:
• Inform supervisor(s) in charge.
• Analyze the message.
• If required, carry out emergency operations e.g. emergency stop.

Operation
Do not remain in the operating room when the product is running for any longer than absolutely neces-
sary.
Keep a safe distance away from the product if possible. Do not touch the product unless expressly in-
structed to do so following a written procedure.
Do not inhale the exhaust gases of the product.
The following requirements must be fulfilled before the product is started:
• Wear ear protectors.
• Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binder
TIM-ID: 0000040533 - 004

agent.

Operation of electrical equipment

When electrical equipment is in operation, certain components of these appliances are electrically live.
Observe the safety instructions for these devices.

8 | Safety | MS150069/02E 2014-03

 1.5 Safety regulations for maintenance and repair work
Safety regulations prior to maintenance and repair work
Have maintenance or repair work carried out by qualified and authorized personnel only.
Allow the product to cool down to below 50°C before starting maintenance work (risk of explosion of oil
vapors, fluids and lubricants, risk of burning).
Before starting work, relieve pressure in systems and compressed-air lines which are to be opened. Use
suitable containers of adequate capacity to catch fluids and lubricants.
When changing the oil or working on the fuel system, ensure that the service room is adequately venti-
lated.
Never carry out maintenance and repair work with the product in operation, unless:
• It is expressly permitted to do so following a written procedure.
• The product is running in the low load range and only for as long as absolutely necessary.
Secure the product against unintentional starting, e.g. with start interlock.
Attach “Do not operate” sign in the operating area or to control equipment.
Disconnect the battery. Lock contactors.
Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic
starters are fitted.
Disconnect the control equipment from the product.
The following applies to starters with copper-beryllium alloy pinions:
• Wear breathing protection of filter class P3 during maintenance work. Do not blow out the interior of
the flywheel housing or the starter with compressed air. Clean the flywheel housing inside with a
class H dust extraction device.
• Observe the safety data sheet.

Safety regulations during maintenance and repair work

Take special care when removing ventilation or plug screws from the product. Cover the screw or plug
with a rag to prevent fluids escaping under pressure.
Take care when draining hot fluids and lubricants (risk of burning).
Use only proper and calibrated tools. Observe the specified tightening torques during assembly or dis-
assembly.
Carry out work only on assemblies or plants which are properly secured.
Never use lines for climbing.
Keep fuel injection lines and connections clean.
Always seal connections with caps or covers if a line is removed or opened.
Take care not to damage lines, in particular fuel lines, during maintenance and repair work.
Ensure that all retainers and dampers are installed correctly.
TIM-ID: 0000040535 - 004

Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent
contact with other components. Do not place fuel or oil lines near hot components.
Do not touch elastomer seals if they have carbonized or resinous appearance unless hands are properly
protected.
Note cooling time for components which are heated for installation or removal (risk of burning).
When working high on the equipment, always use suitable ladders and work platforms. Make sure com-
ponents or assemblies are placed on stable surfaces.

MS150069/02E 2014-03 | Safety | 9

 Ensure particular cleanness during maintenance and repair work on the product. After completion of
maintenance and repair work, make sure that no unattached parts are in/on the product (e.g. cloths
and cable ties).

Safety regulations after completion of maintenance and repair work

Before barring, make sure that nobody is standing in the danger zone of the product.
After working on the product, check that all openings opened for work are closed again.
Check that all guards have been reinstalled and that all tools and loose parts have been removed after
working on the product (in particular, the barring tool).

Welding work
Welding operations on the product or mounted units are not permitted. Cover the product when welding
in its vicinity.
Before starting welding work:
• Switch off the power supply master switch.
• Disconnect the battery.
• Separate the electrical ground of electronic equipment from the ground of the unit.
No other maintenance or repair work must be carried out in the vicinity of the product while welding is
going on. Risk of explosion or fire due to oil vapors and highly flammable fluids and lubricants.
Do not use product as ground terminal.
Never position the welding power supply cable adjacent to, or crossing wiring harnesses of the product.
The welding current may otherwise induce an interference voltage in the wiring harnesses which could
conceivably damage the electrical system.
Remove parts (e.g. exhaust pipes) which are to be welded from the product beforehand.

Hydraulic installation and removal

Check satisfactory function and safe operating condition of tools, jigs and fixtures to be used. Use only
the specified jigs and fixtures for hydraulic removal/installation procedures.
Observe the max. permissible force-on pressure specified for the jig/fixture.
Do not attempt to bend or apply force to lines.
Before starting work, pay attention to the following:
• Vent the hydraulic installation/removal jig, the pumps and the lines at the relevant points for the
equipment to be used (e.g. open vent plugs, pump until bubble-free air emerges, close vent plugs).
• 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 installation/removal jig with central expansion pressure supply, screw spindle into shaft
end until correct sealing is established.
During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of
the component to be installed/removed.
TIM-ID: 0000040535 - 004

Working with batteries

Observe the safety instructions of the battery manufacturer when working with batteries.
Gases emanating from the battery are explosive. Avoid sparks and naked flames.
Do not allow electrolyte to come in contact with skin or clothing.
Wear goggles and protective gloves.
Never place tools on the battery.
Before connecting the cable to the battery, check the battery polarity. Battery pole reversal may lead to
injury through the sudden discharge of acid or bursting of the battery body.

10 | Safety | MS150069/02E 2014-03

 Working on electrical and electronic assemblies
Always obtain the permission of the person in charge before commencing maintenance and repair work
or switching off any part of the electronic system required to do so.
De-energize the appropriate areas prior to working on assemblies.
Do not damage cabling during removal work. When reinstalling ensure that wiring is not damaged dur-
ing operation by contact with sharp objects, by rubbing against other components or by a hot surface.
Do not secure cables on lines carrying fluids.
Do not use cable straps to secure cables.
Always use connector pliers to tighten union nuts on connectors.
Subject the device as well as the product to a function check on completion of all repair work. In partic-
ular, check the function of the engine emergency stop feature.
Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Pack
defective electronic components and assemblies in a suitable manner when dispatched for repair, i.e.
protected, in particular, against moisture and impact and wrapped in anti-static foil if necessary.

Working with laser equipment

When working with laser equipment, always wear special laser-protection goggles (hazard due to heavi-
ly focused radiation).
Laser equipment must be equipped with the protective devices necessary for safe operation according
to type and application.
For conducting light-beam procedures and measurement work, only the following laser devices must be
used:
• Laser devices of classes 1, 2 or 3A.
• Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700
nm), a maximum output of 5 mW, and in which the beam axis and surface are designed to prevent
any risk to the eyes.
TIM-ID: 0000040535 - 004

MS150069/02E 2014-03 | Safety | 11

 1.6 Fire prevention and environmental protection, fluids and
lubricants, auxiliary materials
Fire prevention
Rectify any fuel or oil leaks immediately. Oil or fuel on hot components can cause fires – therefore al-
ways keep the product in a clean condition. Do not leave rags saturated with fluids and lubricants on
the product. Do not store combustible materials near the product.
Do not carry out welding work on pipes and components carrying oil or fuel. Before welding, clean with
a nonflammable fluid.
When starting the engine with an external power source, connect the ground lead last and remove it
first. To avoid sparks in the vicinity of the battery, connect the ground lead from the external power
source to the ground lead of the engine or to the ground terminal of the starter.
Always keep suitable firefighting equipment (fire extinguishers) at hand and familiarize yourself with
their use.

Noise
Noise can lead to an increased risk of accidents if it makes it more difficult to hear audible signals,
warning calls or noises indicating danger.
Wear ear protectors in workplaces with a sound pressure level in excess of 85dB (A).

Environmental protection and disposal

Modification or removal of any mechanical/electronic components or the installation of additional com-
ponents including the execution of calibration processes that might affect the emission characteristics
of the product are prohibited by emission regulations. Emission control units/systems may only be
maintained, exchanged or repaired if the components used for this purpose are approved by the manu-
facturer. Noncompliance with these guidelines will invalidate the design type approval issued by the
emissions regulation authorities. The manufacturer does not accept any liability for violations of the
emission regulations. The maintenance schedules of the manufacturer must be observed over the entire
life cycle of the product.
Dispose of used fluids, lubricants and filters in accordance with local regulations.
Within the EU, batteries can be returned free of charge to the manufacturer where they will be properly
recycled.

Fluids and lubricants and auxiliary materials

The Fluids and Lubricants Specifications will be amended or supplemented as necessary. Prior to opera-
tion, make sure that the latest version is used. The latest version can be found on the website on the
"Technical Info" or "Spare Parts and Service" tabs at http://www.mtu-online.com.
Consumable fluids and materials may also be hazardous or toxic. When using fluids, lubricants, consum-
ables and other chemical substances, follow the safety regulations that apply to the product. Take spe-
cial care when using hot, chilled or caustic substances. When using flammable materials, prevent them
TIM-ID: 0000040536 - 005

coming into contact with ignition sources and do not smoke.

Used oil
Used oil contains combustion residues that are harmful to health.
Rub barrier cream into hands.
Wash hands after contact with used oil.

12 | Safety | MS150069/02E 2014-03

 Lead
• Adopt suitable measures to avoid the formation of lead dust.
• Switch on extraction system.
• When working with lead or pastes that contain lead, avoid direct contact with the skin. Do not inhale
lead vapors.
• Wash hands after contact with lead or lead-containing substances.

Compressed air
Observe special safety precautions when working with compressed air:
• Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII and B) out of
containers, risks causing an explosion.
• Wear goggles when blowing dirt off workpieces or blowing away swarf.
• Blowing compressed air into thin-walled containers (e.g. containers made of sheet metal, plastic or
glass) for drying purposes or to check for leaks risks bursting them.
• Pay special attention to the pressure in the compressed air system or pressure vessel.
• Assemblies or products to be connected must either be designed for that pressure, or, if the permis-
sible pressure is lower than the system pressure, a pressure reducing valve and safety valve (set to
the permissible pressure) must be connected between the assemblies/products and the system.
• Hose couplings and connections must be securely attached.
• Provide the snout of the air nozzle with a protective disk (e.g. rubber disk).
• First shut off compressed air lines before compressed air device is disconnected from the supply
line, or before device or tool is to be replaced.
• Carry out leak test in accordance with the specifications.

Paints and varnishes

• Observe the relevant safety data sheet for all materials.
• When painting in areas other than spray booths equipped with extractors, ensure good ventilation.
Make sure that neighboring work areas are not adversely affected.
• There must be no naked flames in the vicinity.
• No smoking.
• Observe fire prevention regulations.
• Always wear a mask providing protection against paint and solvent vapors.

Liquid nitrogen
• Observe the relevant safety data sheet for all materials.
• Work with liquid nitrogen may be carried out only by qualified personnel.
• Store liquid nitrogen only in small quantities and always in regulation containers (without gas-tight
caps).
• Avoid body contact (eyes, hands).
• Wear protective clothing, protective gloves, closed shoes and safety goggles.
• Make sure that working area is well ventilated.
• Avoid knocking or jolting the containers, valves and fittings or workpieces in any way.

Acids/alkaline solutions/urea (AdBlue®, DEF)

TIM-ID: 0000040536 - 005

• Observe the relevant safety data sheet for all materials.

• When working with acids and alkaline solutions, wear goggles or face mask, gloves and protective
clothing.
• Do not inhale vapors.
• If urea solution is swallowed, rinse out mouth and drink plenty of water.
• If spilled onto clothing, remove the affected clothing immediately.
• After contact with skin, rinse affected parts of the body with plenty of water.
• Rinse eyes immediately with eye drops or clean tap water. Seek medical attention as soon as possi-
ble.

MS150069/02E 2014-03 | Safety | 13

 1.7 Standards for safety notices in the text
DANGER
In the event of immediate danger.
Consequences: Death, serious or permanent injury!
• Remedial action.

WARNING
In the event of a situation involving potential danger.
Consequences: Death, serious or permanent injury!
• Remedial action.

CAUTION
In the event of a situation involving potential danger.
Consequences: Minor or moderate injuries!
• Remedial action.

NOTICE
In the event of a situation involving potentially adverse effects on the product.
Consequences: Material damage!
• Remedial action.
• Additional product information.

Safety notices
u This manual with all safety instructions and safety notices must be issued to all personnel involved in
operation, maintenance, repair or transportation.

TIM-ID: 0000040578 - 002

14 | Safety | MS150069/02E 2014-03

 2 Product Summary
2.1 Engine Layout
2.1.1 Product description
Description of the engine
Engine
The engine is a liquid-cooled four-stroke diesel engine, rotating counterclockwise (seen from driving
end), with direct injection, sequential turbocharging and charge air cooling.
The engine is monitored by an engine control and monitoring system (ADEC).

Fuel system
Electronically controlled common-rail-injection system with HP pump, pressure accumulator (rail) and
single injectors with integrated individual store.
The electronic control unit controls
• Injection start
• Injection quantity
• Injection pressure

Exhaust system
The exhaust system is equipped with triple-walled, water-cooled exhaust lines.
The triple-walled design permits
• low surface temperature,
• reduced amount of heat to be dissipated by the coolant,
• absolute gas-tightness.

Turbocharging
Sequential turbocharging with internal, engine-coolant-controlled charge air cooling. The right-hand ex-
haust turbocharger is cut-in and cut-out on 12V and 16V engines with electronically-controlled, hydraul-
ically-actuated flaps.

Cooling system
Split-circuit engine cooling system with remote or engine-mounted heat exchanger.
Heating of the charge air in idle and low-load operation prevents white smoke formation.
Seawater flows only through engine coolant cooler and fuel cooler as well as the raw water pump (if
fitted).
TIM-ID: 0000010054 - 009

Service block
The service components are mounted at the auxiliary PTO end.
The layout permits easy access for maintenance.
Service-components:
• Raw water pump (if fitted), coolant pump
• Centrifugal lube oil filter
• Coolant expansion tank (only on engines with engine-mounted heat exchanger)
• Coolant filter

MS150069/02E 2014-03 | Product Summary | 15

 Intermittent oil priming for marine genset engines (M23-M43)
The standard configuration of these engines comprises intermittent oil priming.
Oil priming is activated every 30 minutes. The oil priming process ends as soon as oil pressure in the
main oil gallery reaches 0.4 bar or after 180 seconds, at the latest.
If a pressure of at least 0.2 bar is not attained after 180 seconds, an alarm is output.
To avoid engine damage from a hydraulic lock due to excessive oil supply to the combustion chambers,
the engine must be started at least once a month.

Electronic system
Electronic control and monitoring system with integrated safety and test system with interfaces to Re-
mote Control System (RCS) and to Monitoring and Control System (MCS).

Engine Interface Module (EIM)

The Engine Interface Module (EIM) is the central connection box on the engine. It covers the complete
minimum scope of a marine engine. It does not comprise controls of components requiring mainte-
nance.
Functions:
• Starter control (start repetition, tooth alignment, starter protection)
• Monitoring of the battery-charging generator
• Open bus interface to the plant (SAE J1939)
• Emergency stop function with line break monitoring
• Redundant supply voltage input
• Emergency air-shutoff flap control (option)
• Key switch logic
• Interface to ECU and EMU
• MCS5 dialog interface
• Control of an MTU lube-oil priming pump (power components in separate MTU PPC Box)
• Connection facility for an MTU Local Operating Station (LOS)

Serial RS422 interface for diagnosis

The engine interface comprises two parts. The first part of signals is integrated in the engine wiring har-
ness with a 62-pole Tyco connector X52. The second part refers to signals associated with higher cur-
rents. These signals are led out via M threaded pins and also integrated in the engine wiring harness.
Functions
• ECU supply
• EMU supply
• Plant signals (ECU7 connector X1)
• Bus interface (2x MCS5 CAN)
• CAN dialog output (1xMCS5 CAN)
• Emergency stop from EMU and ECU
• Electric starter
• Terminal 45 starter A/B (engaged)
• Pneumatic starter
TIM-ID: 0000010054 - 009

• Starting-air pressure valve

• Start-air pressure sensor
• Barring gear (1 and 2)
• Battery-charging generator (with exciter control)
• Optional emergency-air shutoff flaps
• Activation signal to air shut-off flaps 1+2
• Feedback signal from air shut-off flaps 1+2

16 | Product Summary | MS150069/02E 2014-03

 Electronic engine governor (ECU)
Functions:
• Engine speed control with fuel and speed limitation dependent on engine status and operating condi-
tions
• Control of sequential turbocharging, cylinder bank cut-out and air recirculation function
• Data processing logistics for analog and binary signals
• Interface for data transfer to CAN field bus for remote control and ship-side monitoring

Electronic Engine Monitoring Unit (EMU)

Functions:
• Data processing logistics for analog and binary signals
• Interface for data transfer to CAN field bus for remote control and ship-side monitoring

Low-load operation
12/16V4000M53R/M53/M63R/M63/M63L engines

1 Low-load operation 2 Cleaning cycle 3 ditto

MTU marine engine Series 4000M53R to …M93L may be operated in low-load operation. State-of-the-
art design and equipment features, e.g. TE coolant circuit, sequential turbocharging, jacketed, coolant-
TIM-ID: 0000010054 - 009

cooled exhaust lines, Common Rail fuel injection and cylinder cutout allow engine operation at low load.
Nevertheless, low-load operation at engine load below 15% of the nominal rating is permitted for max.
100 hours. In order to avoid inadmissible oil carbon and/or carbon particle deposits in the engine, it is
recommended to carry out a cleaning cycle for at least 20 minutes after extended low-load operation
periods. During the cleaning cycle, engine speed (power) must be increased step by step until all ex-
haust turbochargers are running. The figure shows the basic speed/power run-up procedure for the
cleaning cycle to be carried out.

MS150069/02E 2014-03 | Product Summary | 17

 12/16V4000M23S/M23F/M33S/M33F/M43S engines

A Engine power B Engine speed ETC Exhaust turbocharger

MTU marine genset engine Series 4000M23/M33/M43 may be operated in low-load operation. State-
of-the-art design and equipment features e.g. TE coolant circuit, jacketed, coolant-cooled exhaust lines,
Common Rail fuel injection and cylinder cutout allow engine operation at low load.
Low-load operation (engine power up to approx. 20% of rated power) takes place in single-ETC mode
(with only one exhaust turbocharger running). To ensure the functionality of the control mechanism and
of the exhaust flap of the turbocharger which does not run in low-load operation, it is recommended to
operate the engine with both exhaust turbochargers running after 100 operating hours in low-load oper-
ation, at the latest.

SOLAS – Fire protection specifications

Fuel system, fuel lines with fuel pressure >1.8 bar
All lines with SOLAS-compliant covers for pipe connections, according to MTU standard MTN5233, are
shown.
TIM-ID: 0000010054 - 009

18 | Product Summary | MS150069/02E 2014-03

 1 SOLAS clip on the fuel line: after LP
pump

1 SOLAS clip on the fuel line: on fuel

filter head retainer

1 SOLAS clip on the fuel line: on HP

pump
2 SOLAS clip on the fuel line: after fuel
filter head
TIM-ID: 0000010054 - 009

MS150069/02E 2014-03 | Product Summary | 19

 1 SOLAS clips on the fuel line: on fuel
filter head retainer

1 SOLAS clips on the fuel line: on fuel

filter head

Lube oil system, oil lines with oil pressure >1.8 bar
All lines with SOLAS-compliant covers for pipe connections, according to MTU standard MTN5233, are
shown.
TIM-ID: 0000010054 - 009

20 | Product Summary | MS150069/02E 2014-03

 1 SOLAS clips on exhaust flap switch-
ing cylinder ETC B1

1 SOLAS clips on air flap switching

cylinder ETC B1
2 SOLAS clips on flap control T adapt-
er ETC B1

1 SOLAS clips on distributor element

2 SOLAS clips on oil return
TIM-ID: 0000010054 - 009

MS150069/02E 2014-03 | Product Summary | 21

 1 SOLAS clip on oil return

1 SOLAS clip on oil line to ETC

2 SOLAS clip on oil line to flap control
3 SOLAS clip on oil line to recircula-
tion valve
4 SOLAS clips on oil line from main
gallery

1 SOLAS clips on recirculation valve TIM-ID: 0000010054 - 009

22 | Product Summary | MS150069/02E 2014-03

 1 SOLAS clip on HP pump oil supply:
on HP pump

1 SOLAS clip on HP pump oil supply:

on equipment carrier

1 SOLAS clip on ETC oil supply

2 SOLAS clip on ETC oil supply
TIM-ID: 0000010054 - 009

MS150069/02E 2014-03 | Product Summary | 23

 1 SOLAS clips of oil line on equipment
carrier

1 Cover on oil filter cartridge

Special connections
The following types of union are spray-proof in case of leakage even without covers and have been con-
firmed as being SOLAS-compliant by GL and DNV.
TIM-ID: 0000010054 - 009

24 | Product Summary | MS150069/02E 2014-03

 Plugs and sensors (a)
Screw-in plugs (4) are sealed toward the outside either with a copper sealing ring (1), according to DIN,
or an O-ring (ISO).
In case of a loose thread or a defective sealing ring (1), the liquid first has to pass the thread.
The pressure is so greatly reduced by this and the faulty sealing ring (1) that any leakage is not under
pressure.

Plug-in pipe union (b)

The sleeve (3) covers the joint to prevent lateral spray.
Only leak-off along the line is possible, the pressure is decreases significantly if an O-ring (2) defect
occurs.
The union is confirmed as being SOLAS-compliant by DNV and GL.
TIM-ID: 0000010054 - 009

MS150069/02E 2014-03 | Product Summary | 25

 HP connections

1 Jacket pipe 8 Thrust ring 15 Union nut

2 HP fuel line 9 Union nut 16 Thrust ring
3 O-ring 10 Union nut 17 HP line outer pipe
4 Union nut 11 Connecting piece 18 Internal pipe of HP line
5 Recess for O-ring 12 Snap ring 19 Ball-type seal area
6 Thrust ring 13 Thrust ring 20 Leak-fuel connection
7 Leakage overflow bore 14 Shim washers
The HP fuel line is sealed by the thrust ring (8).
If leakage in the area of the thrust ring (8) or the HP line (2) occurs, the emerging fuel is routed to the
leakage chamber.
The leaking fuel is drained off without pressure via the leakage overflow-bore (7). The leakage chamber
is sealed toward the outside by the O-rings (3).
This prevents leakage egress.
The union is confirmed as being SOLAS-compliant by DNV and GL.
TIM-ID: 0000010054 - 009

26 | Product Summary | MS150069/02E 2014-03

 2.1.2 Engine layout
Engines with remote heat exchanger and horizontal air intake

1 Engine management and 10 Recirculation line 19Battery-charging generator

monitoring 11 Exhaust manifold 20HP fuel pump
2 Oil cooler 12 Engine mounts 21Oil filter
3 Centrifugal oil filter 13 Charge-air line 22Bilge pump (option)
4 Crankcase breather 14 Oil pan 23Coolant outlet to remote
5 Dry-type air filter 15 Oil filler neck cooling system
6 Exhaust turbocharger 16 Crankcase 24 Coolant inlet from remote
7 Exhaust outlet 17 Cylinder head cooling system
8 Air pipe to intercooler 18 Fuel filter KGS Free end
9 Intercooler
TIM-ID: 0000009990 - 007

MS150069/02E 2014-03 | Product Summary | 27

 Engines with engine-mounted heat exchanger and horizontal air intake

1 Raw-water outlet 10 Exhaust outlet 19 Cylinder head

2 Engine management and 11 Air pipe to intercooler 20 Crankcase
monitoring 12 Recirculation line 21 Fuel filter
3 Plate-core heat exchanger 13 Exhaust manifold 22 Battery-charging generator
4 Oil cooler 14 Intercooler 23 HP fuel pump
5 Coolant expansion tank 15 Charge-air line 24 Oil filter
6 Centrifugal oil filter 16 Engine mounts 25 Bilge pump (option)
7 Crankcase breather 17 Oil pan 26 Raw-water inlet
8 Dry-type air filter 18 Oil filler neck KGS Free end
9 Exhaust turbocharger
TIM-ID: 0000009990 - 007

28 | Product Summary | MS150069/02E 2014-03

 Engines with remote heat exchanger and vertical air intake

1 Coolant outlet to remote 10 Exhaust turbocharger 19 Cylinder head

cooling system 11 Exhaust outlet 20 Fuel filter
2 Coolant inlet from remote 12 Air pipe to intercooler 21 Oil filter
cooling system 13 Intercooler 22 HP fuel pump
3 Engine management and 14 Engine mounts 23 Battery-charging generator
monitoring 15 Charge-air line 24 Bilge pump (option)
4 Oil cooler 16 Oil pan KGS Free end
5 Centrifugal oil filter 17 Oil filler neck
6 Crankcase breather 18 Crankcase
7 Dry-type air filter
8 Exhaust manifold
9 Recirculation line
Overview drawing is also valid for 16V engines.
TIM-ID: 0000009990 - 007

MS150069/02E 2014-03 | Product Summary | 29

 Engines with engine-mounted heat exchanger and vertical air intake

1 Raw-water outlet 10 Recirculation line 19 Crankcase

2 Engine management and 11 Exhaust turbocharger 20 Cylinder head
monitoring 12 Exhaust outlet 21 Fuel filter
3 Oil cooler 13 Air pipe to intercooler 22 Oil filter
4 Plate-core heat exchanger 14 Intercooler 23 HP fuel pump
5 Coolant expansion tank 15 Charge-air line 24 Battery-charging generator
6 Centrifugal oil filter 16 Engine mounts 25 Bilge pump (option)
7 Crankcase breather 17 Oil pan 26 Raw-water inlet
8 Dry-type air filter 18 Oil filler neck KGS Free end
9 Exhaust manifold
Overview drawing is also valid for 16V engines.

Engine model designation

Key to the engine model designations 12/16V 4000 Mxy z
12, 16 Number of cylinders
V Cylinder arrangement: V-engine
4000 Series
TIM-ID: 0000009990 - 007

M Application (M= Marine)

x Application load profile (0, 1, 2, 3...9)
y Design index (0, 1, 2, 3...9)
z R (power / speed reduction)
L (enhanced power / speed)
S (60 Hz)
F (50 Hz)

30 | Product Summary | MS150069/02E 2014-03

 2.1.3 Overview of sensors and actuators
Top view of 12V 4000 M with external cooling

1 B49 (charge-air temp., air 2 B4.A1-B4.B6 (single ex- 3 B33 (fuel temperature in
recirculation valve) haust temp., A1-A6, B1- common rail)
Y26 (air recirculation valve B6)
A)
TIM-ID: 0000038758 - 002

MS150069/02E 2014-03 | Product Summary | 31

 Aux. PTO end, 12V 4000 M, external cooling

1 B7 (engine oil temp.) 4 B33 (fuel temperature in 7 B54 (oil refill pump pres-
2 B5.3 (oil pressure up- common rail) sure)
stream of filter) 5 B48 (fuel pressure in com- 8 B6.2 (coolant tempera-
3 B5.1 (oil pressure down- mon rail) ture)
stream of filter) 6 B1 (camshaft speed) 9 B6 (coolant temperature)

TIM-ID: 0000038758 - 002

32 | Product Summary | MS150069/02E 2014-03

 Main PTO end, 12V 4000 M, external cooling

1 B4.21 (exhaust tempera- 3 B13 (crankshaft speed) 5 S37.1 (safety switch)

ture, A bank) 4 S37.2 (safety switch) 6 B13.2 (crankshaft speed)
2 B4.22 (exhaust tempera-
ture, B bank)
TIM-ID: 0000038758 - 002

MS150069/02E 2014-03 | Product Summary | 33

 Left side of engine, 12V 4000 M, external cooling

1 B50 (crankcase pressure) 4 B10 (charge-air pressure) 7 B34.1 (fuel pressure down-
2 B3 (intake air temperature) 5 B34.3 (fuel pressure up- stream of filter)
3 B44.1 (turbocharger A stream of filter) 8 F46 (fuel overflow level)
speed) 6 B34.2 (fuel pressure up-
stream of filter)

TIM-ID: 0000038758 - 002

34 | Product Summary | MS150069/02E 2014-03

 Right side of engine, 12V 4000 M, external cooling

1 B44.2 (turbocharger B 3 B16 (coolant pressure)

speed) 4 B9 (charge-air tempera-
2 Y27 (turbocharger control ture)
valve)
TIM-ID: 0000038758 - 002

MS150069/02E 2014-03 | Product Summary | 35

 Top view, 12V 4000 M, integral cooling

1 B4.A1-B4.B6 (single ex- 2 B33 (fuel temperature in 3 F33 (coolant level)

haust temp., A1-A6, B1- common rail)
B6)

TIM-ID: 0000038758 - 002

36 | Product Summary | MS150069/02E 2014-03

 Aux. PTO end, 12V 4000 M, integral cooling

1 B7 (engine oil temp.) 4 B33 (fuel temperature in 7 B54 (oil refill pump pres-
2 B5.3 (oil pressure up- common rail) sure)
stream of filter) 5 B48 (fuel pressure in com- 8 B6.2 (coolant tempera-
3 B5.1 (oil pressure down- mon rail) ture)
stream of filter) 6 B1 (camshaft speed) 9 B6 (coolant temperature)
TIM-ID: 0000038758 - 002

MS150069/02E 2014-03 | Product Summary | 37

 Main PTO end, 12V 4000 M, integral cooling

1 B4.21 (exhaust tempera- 3 B13 (crankshaft speed) 5 S37.1 (safety switch)

ture, A bank) 4 S37.2 (safety switch) 6 B13.2 (crankshaft speed)
2 B4.22 (exhaust tempera-
ture, B bank)

TIM-ID: 0000038758 - 002

38 | Product Summary | MS150069/02E 2014-03

 Left side of engine, 12V 4000 M, integral cooling

1 B50 (crankcase pressure) 4 B44.1 (turbocharger A 7 B34.2 (fuel pressure up-

2 B49 (charge-air temp., air speed) stream of filter)
recirculation valve) 5 B10 (charge-air pressure) 8 B34.1 (fuel pressure down-
Y26 (air recirculation valve 6 B34.3 (fuel pressure up- stream of filter)
A) stream of filter) 9 F46 (fuel overflow level)
3 B3 (intake air temperature)
TIM-ID: 0000038758 - 002

MS150069/02E 2014-03 | Product Summary | 39

 Right side of engine, 12V 4000 M, integral cooling

1 B44.2 (turbocharger B 3 B16 (coolant pressure) 5 B9 (charge-air tempera-

speed) 4 B21 (raw water pressure) ture)
2 Y27 (turbocharger control
valve)

TIM-ID: 0000038758 - 002

40 | Product Summary | MS150069/02E 2014-03

 Top view of 16V 4000 M with external cooling

1 B49 (charge-air temp., air 2 B4.A1-B4.B8 (single ex- 3 B33 (fuel temperature in
recirculation valve) haust temp., A1-A8, B1- common rail)
Y26 (air recirculation valve B8)
A)
TIM-ID: 0000038758 - 002

MS150069/02E 2014-03 | Product Summary | 41

 Aux. PTO end, 16V 4000 M, external cooling

1 B7 (engine oil temp.) 4 B33 (fuel temperature in 7 B54 (oil refill pump pres-
2 B5.3 (oil pressure up- common rail) sure)
stream of filter) 5 B48 (fuel pressure in com- 8 B6.2 (coolant tempera-
3 B5.1 (oil pressure down- mon rail) ture)
stream of filter) 6 B1 (camshaft speed) 9 B6 (coolant temperature)

TIM-ID: 0000038758 - 002

42 | Product Summary | MS150069/02E 2014-03

 Main PTO end, 16V 4000 M, external cooling

1 B4.21 (exhaust tempera- 3 B13 (crankshaft speed) 5 S37.1 (safety switch)

ture, A bank) 4 S37.2 (safety switch) 6 B13.2 (crankshaft speed)
2 B4.22 (exhaust tempera-
ture, B bank)
TIM-ID: 0000038758 - 002

MS150069/02E 2014-03 | Product Summary | 43

 Left side of engine, 16V 4000 M, external cooling

1 B50 (crankcase pressure) 4 B10 (charge-air pressure) 7 B34.1 (fuel pressure down-
2 B3 (intake air temperature) 5 B34.3 (fuel pressure up- stream of filter)
3 B44.1 (turbocharger A stream of filter) 8 F46 (fuel overflow level)
speed) 6 B34.2 (fuel pressure up-
stream of filter)

TIM-ID: 0000038758 - 002

44 | Product Summary | MS150069/02E 2014-03

 Right side of engine, 16V 4000 M, external cooling

1 B44.2 (turbocharger B 3 B16 (coolant pressure)

speed) 4 B9 (charge-air tempera-
2 Y27 (turbocharger control ture)
valve)
TIM-ID: 0000038758 - 002

MS150069/02E 2014-03 | Product Summary | 45

 Top view, 16V 4000 M, integral cooling

1 B4.A1-B4.B8 (single ex- 2 B33 (fuel temperature in 3 F33 (coolant level)

haust temp., A1-A8, B1- common rail)
B8)

TIM-ID: 0000038758 - 002

46 | Product Summary | MS150069/02E 2014-03

 Aux. PTO end, 16V 4000 M, integral cooling

1 B7 (engine oil temp.) 4 B33 (fuel temperature in 7 B54 (oil refill pump pres-
2 B5.3 (oil pressure up- common rail) sure)
stream of filter) 5 B48 (fuel pressure in com- 8 B6.2 (coolant tempera-
3 B5.1 (oil pressure down- mon rail) ture)
stream of filter) 6 B1 (camshaft speed) 9 B6 (coolant temperature)
TIM-ID: 0000038758 - 002

MS150069/02E 2014-03 | Product Summary | 47

 Main PTO end, 16V 4000 M, integral cooling

1 B4.21 (exhaust tempera- 3 B13 (crankshaft speed) 5 S37.1 (safety switch)

ture, A bank) 4 S37.2 (safety switch) 6 B13.2 (crankshaft speed)
2 B4.22 (exhaust tempera-
ture, B bank)

TIM-ID: 0000038758 - 002

48 | Product Summary | MS150069/02E 2014-03

 Left side of engine, 16V 4000 M, integral cooling

1 B50 (crankcase pressure) 4 B44.1 (turbocharger A 7 B34.2 (fuel pressure up-

2 B49 (charge-air temp., air speed) stream of filter)
recirculation valve) 5 B10 (charge-air pressure) 8 B34.1 (fuel pressure down-
Y26 (air recirculation valve 6 B34.3 (fuel pressure up- stream of filter)
A) stream of filter) 9 F46 (fuel overflow level)
3 B3 (intake air temperature)
TIM-ID: 0000038758 - 002

MS150069/02E 2014-03 | Product Summary | 49

 Right side of engine, 16V 4000 M, integral cooling

1 B44.2 (turbocharger B 3 B16 (coolant pressure) 5 B9 (charge-air tempera-

speed) 4 B21 (raw water pressure) ture)
2 Y27 (turbocharger control
valve)

TIM-ID: 0000038758 - 002

50 | Product Summary | MS150069/02E 2014-03

 2.2 Engine Side and Cylinder Designations
2.2.1 Engine side and cylinder designations
Engine sides are always designated as viewed from the driving end (KS).
The cylinders of the left engine side are designated “A” and those of the right side “B" (as per DIN ISO
1204). The cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end.
The numbering of other engine components is also from the driving end, starting with no. 1.

1 Left-hand side of engine, 3 Right-hand side of engine,

A-side B-side
2 KGS = Engine free end, 4 KS = Engine driving end,
Engine free end in accord- Engine driving end in ac-
ance with DIN ISO 1204 cordance with
DIN ISO 1204
TIM-ID: 0000043249 - 001

MS150069/02E 2014-03 | Product Summary | 51

 2.3 Main Engine Dimensions
2.3.1 Engine – Main dimensions

Engines with horizontal air intake

With remote heat exchanger
Engine model Length (A) Width (B) without Width (B) with si- Height (C)
silencer lencer
16V 4000 approx. 3108 mm approx. 1690 mm approx. 1850 mm approx. 2064 mm
M23S/23F/33S/33F/
TIM-ID: 0000010043 - 004

43S
16V 4000 M53R/
53/63R/63/63L

With engine-mounted heat exchanger

Engine model Length (A) Width (B) without Width (B) with si- Height (C)
silencer lencer
16V 4000 approx. 3388 mm approx. 1690 mm approx. 1850 mm approx. 2064 mm
M23S/23F/33S/33F/
43S

52 | Product Summary | MS150069/02E 2014-03

 Engine model Length (A) Width (B) without Width (B) with si- Height (C)
silencer lencer
16V 4000 M53R/
53/63R/63/63L

Engines with vertical air intake

With remote heat exchanger
Engine model Length (A) Width (B) Height (C) without Height (C) with si-
silencer lencer
12V 4000 approx. 2628 mm approx. 1602 mm approx. 2368 mm approx. 2448 mm
M23S/23F/33S/
33F
12V 4000 M53R/
53/63
16V 4000 approx. 3108 mm approx. 1602 mm approx. 2361 mm approx. 2441 mm
M23S/23F/33S/33F/
43S
16V 4000 M53R/
53/63R/63/63L

With engine-mounted heat exchanger

Engine model Length (A) Width (B) Height (C) without Height (C) with si-
silencer lencer
12V 4000 approx. 2857 mm approx. 1602 mm approx. 2368 mm approx. 2448 mm
M23S/23F/33S/
33F
12V 4000 M53R/
53/63
16V 4000 approx. 3388 mm approx. 1602 mm approx. 2361 mm approx. 2441 mm
M23S/23F/33S/33F/
43S
16V 4000 M53R/
53/63R/63/63L
TIM-ID: 0000010043 - 004

MS150069/02E 2014-03 | Product Summary | 53

 2.4 Firing Sequence
2.4.1 Firing order
8V A1-B4-A4-A2-B3-A3-B2-B1
12 V A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1
16 V A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B7

TIM-ID: 0000010713 - 002

54 | Product Summary | MS150069/02E 2014-03

 2.5 Technical Data
2.5.1 ENGINE DATA 12V 4000 M33F, RheinSchUO Stage II, IMO Tier II
Explanation:
DL Ref. value: Continuous power
BL Ref. value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power setting)
N Not yet defined value
- Not applicable
X Applicable

Heat exchanger Heat exchanger

installed separate
Application group 3B 3B 3B 3B
Intake air temperature °C 25 32 25 32
Charge-air coolant temperature °C - - - -
Raw water inlet temperature °C 25 45 25 45
Barometric 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)
Heat exchanger Heat exchanger
installed separate
Rated engine speed A rpm 1500 1500 1500 1500
Continuous power ISO 3046 (10% over- A kW 1320 1320 1320 1320
load capability, design power DIN 6280,
ISO 8528)

GENERAL CONDITIONS (for maximum power)

Heat exchanger Heat exchanger
installed separate
Intake depression (new filter) A mbar 15 15 15 15
Intake depression, max. L mbar 30 30 30 30

MODEL-RELATED DATA (basic design)

TIM-ID: 0000022938 - 001

Heat exchanger Heat exchanger

installed separate
Cylinder arrangement: V angle Degrees 90 90 90 90
(°)
Bore mm 170 170 170 170
Stroke mm 210 210 210 210
Cylinder displacement Liters 4.77 4.77 4.77 4.77
Displacement, total Liters 57.2 57.2 57.2 57.2

MS150069/02E 2014-03 | Product Summary | 55

 Heat exchanger Heat exchanger
installed separate
Inlet valves per cylinder 2 2 2 2
Exhaust valves per cylinder 2 2 2 2

RAW WATER CIRCUIT (open circuit)

Heat exchanger Heat exchanger
installed separate
Raw water pump: Inlet pressure, min. L bar -0.4 -0.4 -- --
Raw water pump: inlet pressure, max. L bar 1.0 1.0 -- --
Pressure loss in engine-external raw water L bar N N -- --
system, max.

LUBE OIL SYSTEM

Heat exchanger Heat exchanger
installed separate
Lube oil operating temperature before en- R °C 82 82 82 82
gine, from
Lube-oil operating temperature before en- R °C 90 90 90 90
gine, to
Lube oil operating pressure upstream of R bar 5.0 5.0 5.0 5.0
engine, from
Lube-oil operating pressure before engine, R bar 6.0 6.0 6.0 6.0
to
Lube oil operating pressure (low idle) R bar
(meas. point: before engine)

FUEL SYSTEM
Heat exchanger Heat exchanger
installed separate
Fuel pressure at engine inlet connection, L bar -0.1 -0.1 -0.1 -0.1
min. (when engine is starting)
Fuel pressure at supply connection to en- L bar -0.3 -0.3 -0.3 -0.3
gine, min. (when engine is running),
Fuel pressure at supply connection to en- L bar 1.5 1.5 1.5 1.5
gine (when engine is starting), max.
Fuel supply flow, max. A Liters/
min
TIM-ID: 0000022938 - 001

GENERAL OPERATING DATA

Heat exchanger Heat exchanger
installed separate
Firing speed, from R rpm 80 80 80 80
Firing speed, to R rpm 120 120 120 120

56 | Product Summary | MS150069/02E 2014-03

 STARTER (electric)
Heat exchanger Heat exchanger
installed separate
Rated starter voltage (standard design) R V= 24 24 24 24

STARTING (with compressed air/hydraulic starter)

Heat exchanger Heat exchanger
installed separate
Starting-air pressure before starter motor, R bar 8 8 8 8
min.
Starting-air pressure before starter, max. R bar 10 10 10 10

CAPACITIES
Heat exchanger Heat exchanger
installed separate
Engine coolant, engine side (with cooling R Liters 305 305 -- --
system)
Total engine oil capacity at initial filling R Liters N N N N
(standard oil system) (option: max. operat-
ing inclinations)
Oil change quantity, max. (standard oil R Liters 265 265 265 265
system) (option: max. operating inclina-
tions)
Oil pan capacity at dipstick mark “min.” L Liters 195 195 195 195
(standard oil system) (option: max. operat-
ing inclinations)
Oil pan capacity at dipstick mark “max.” L Liters 235 235 235 235
(standard oil system) (option: max. operat-
ing inclinations)

WEIGHTS / MAIN DIMENSIONS

Heat exchanger Heat exchanger
installed separate
Engine dry weight (with attached standard R kg 7640 7640 7240 7240
accessories, without coupling)

ACOUSTICS
Heat exchanger Heat exchanger
installed separate
TIM-ID: 0000022938 - 001

Exhaust noise, unsilenced - DL (free-field R dB(A) 105 105 105 105

sound pressure level Lp, 1m distance, ISO
6798, +3dB(A) tolerance)

MS150069/02E 2014-03 | Product Summary | 57

 2.5.2 ENGINE DATA 12V 4000 M33S, RheinSchUO Stage II, IMO Tier II
Explanation:
DL Ref. value: Continuous power
BL Ref. value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power setting)
N Not yet defined value
- Not applicable
X Applicable

Heat exchanger Heat exchanger

installed separate
Application group 3B 3B 3B 3B
Intake air temperature °C 25 45 25 45
Charge-air coolant temperature °C - - - -
Raw water inlet temperature °C 25 32 25 32
Barometric 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)
Heat exchanger Heat exchanger
installed separate
Rated engine speed A rpm 1800 1800 1800 1800
Continuous power ISO 3046 (10% over- A kW 1560 1560 1560 1560
load capability, design power DIN 6280,
ISO 8528)

GENERAL CONDITIONS (for maximum power)

Heat exchanger Heat exchanger
installed separate
Intake depression (new filter) A mbar 15 15 15 15
Intake depression, max. L mbar 30 30 30 30

MODEL-RELATED DATA (basic design)

Heat exchanger Heat exchanger
installed separate
TIM-ID: 0000022940 - 001

Cylinder arrangement: V angle Degrees 90 90 90 90

(°)
Bore mm 170 170 170 170
Stroke mm 210 210 210 210
Cylinder displacement Liters 4.77 4.77 4.77 4.77
Displacement, total Liters 57.2 57.2 57.2 57.2
Inlet valves per cylinder 2 2 2 2
Exhaust valves per cylinder 2 2 2 2

58 | Product Summary | MS150069/02E 2014-03

 RAW WATER CIRCUIT (open circuit)
Heat exchanger Heat exchanger
installed separate
Raw water pump: inlet pressure, min. L bar -0.4 -0.4 -- --
Raw water pump: inlet pressure, max. L bar 1.0 1.0 -- --
Pressure loss in engine-external raw water L bar N N -- --
system, max.

LUBE OIL SYSTEM

Heat exchanger Heat exchanger
installed separate
Lube oil operating temperature before en- R °C 85 92 85 92
gine, from
Lube-oil operating temperature before en- R °C 93 100 93 100
gine, to
Lube oil operating pressure before engine, R bar 5.5 5.5 5.5 5.5
from
Lube-oil operating pressure before engine, R bar 6.5 6.5 6.5 6.5
to
Lube oil operating pressure (low idle) R bar
(meas. point: before engine)

FUEL SYSTEM
Heat exchanger Heat exchanger
installed separate
Fuel pressure at engine inlet connection, L bar -0.1 -0.1 -0.1 -0.1
min. (when engine is starting)
Fuel pressure at supply connection to en- L bar -0.3 -0.3 -0.3 -0.3
gine, min. (when engine is running),
Fuel pressure at supply connection to en- L bar 1.5 1.5 1.5 1.5
gine (when engine is starting), max.
Fuel supply flow, max. A Liters/
min

GENERAL OPERATING DATA

Heat exchanger Heat exchanger
installed separate
Firing speed, from R rpm 80 80 80 80
TIM-ID: 0000022940 - 001

Firing speed, to R rpm 120 120 120 120

STARTER (electric)
Heat exchanger Heat exchanger
installed separate
Rated starter voltage (standard design) R V= 24 24 24 24

MS150069/02E 2014-03 | Product Summary | 59

 STARTING (with compressed air/hydraulic starter)
Heat exchanger Heat exchanger
installed separate
Starting-air pressure before starter motor, R bar 8 8 8 8
min.
Starting-air pressure before starter, max. R bar 10 10 10 10

CAPACITIES
Heat exchanger Heat exchanger
installed separate
Engine coolant, engine side (with cooling R Liters 305 305 -- --
system)
Total engine oil capacity at initial filling R Liters N N N N
(standard oil system) (option: max. operat-
ing inclinations)
Oil change quantity, max. (standard oil R Liters 265 265 265 265
system) (option: max. operating inclina-
tions)
Oil pan capacity at dipstick mark “min.” L Liters 195 195 195 195
(standard oil system) (option: max. operat-
ing inclinations)
Oil pan capacity at dipstick mark “max.” L Liters 235 235 235 235
(standard oil system) (option: max. operat-
ing inclinations)

WEIGHTS / MAIN DIMENSIONS

Heat exchanger Heat exchanger
installed separate
Engine dry weight (with attached standard R kg 7640 7640 7240 7240
accessories, without coupling)

ACOUSTICS
Heat exchanger Heat exchanger
installed separate
Exhaust noise, unsilenced - DL (free-field R dB(A) 107 107 107 107
sound pressure level Lp, 1m distance, ISO
6798, +3dB(A) tolerance)
TIM-ID: 0000022940 - 001

60 | Product Summary | MS150069/02E 2014-03

 2.5.3 ENGINE DATA 12V 4000 M33S, IMO Tier II, EPA Tier 2
Explanation:
DL Ref. value: Continuous power
BL Ref. value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power setting)
N Not yet defined value
- Not applicable
X Applicable

Heat exchanger Heat exchanger

installed separate
Application group 3B 3B 3B 3B
Intake air temperature °C 25 45 25 45
Charge-air coolant temperature °C - - - -
Raw water inlet temperature °C 25 32 25 32
Barometric 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)
Heat exchanger Heat exchanger
installed separate
Rated engine speed A rpm 1800 1800 1800 1800
Continuous power ISO 3046 (10% over- A kW 1560 1560 1560 1560
load capability, design power DIN 6280,
ISO 8528)

GENERAL CONDITIONS (for maximum power)

Heat exchanger Heat exchanger
installed separate
Intake depression (new filter) A mbar 15 15 15 15
Intake depression, max. L mbar 30 30 30 30

MODEL-RELATED DATA (basic design)

Heat exchanger Heat exchanger
installed separate
TIM-ID: 0000022939 - 001

Cylinder arrangement: V angle Degrees 90 90 90 90

(°)
Bore mm 170 170 170 170
Stroke mm 210 210 210 210
Cylinder displacement Liters 4.77 4.77 4.77 4.77
Displacement, total Liters 57.2 57.2 57.2 57.2
Inlet valves per cylinder 2 2 2 2
Exhaust valves per cylinder 2 2 2 2

MS150069/02E 2014-03 | Product Summary | 61

 RAW WATER CIRCUIT (open circuit)
Heat exchanger Heat exchanger
installed separate
Raw water pump: Inlet pressure, min. L bar -0.4 -0.4 -- --
Raw water pump: inlet pressure, max. L bar 1.0 1.0 -- --
Pressure loss in engine-external raw water L bar N N -- --
system, max.

LUBE OIL SYSTEM

Heat exchanger Heat exchanger
installed separate
Lube oil operating temperature before en- R °C 83 89 83 89
gine, from
Lube-oil operating temperature before en- R °C 91 97 91 97
gine, to
Lube oil operating pressure before engine, R bar 5.5 5.5 5.5 5.5
from
Lube-oil operating pressure before engine, R bar 6.5 6.5 6.5 6.5
to
Lube oil operating pressure (low idle) R bar
(meas. point: before engine)

FUEL SYSTEM
Heat exchanger Heat exchanger
installed separate
Fuel pressure at engine inlet connection, L bar -0.1 -0.1 -0.1 -0.1
min. (when engine is starting)
Fuel pressure at supply connection to en- L bar -0.3 -0.3 -0.3 -0.3
gine, min. (when engine is running),
Fuel pressure at supply connection to en- L bar 1.5 1.5 1.5 1.5
gine (when engine is starting), max.
Fuel supply flow, max. A Liters/
min

GENERAL OPERATING DATA

Heat exchanger Heat exchanger
installed separate
Firing speed, from R rpm 80 80 80 80
TIM-ID: 0000022939 - 001

Firing speed, to R rpm 120 120 120 120

STARTER (electric)
Heat exchanger Heat exchanger
installed separate
Rated starter voltage (standard design) R V= 24 24 24 24

62 | Product Summary | MS150069/02E 2014-03

 STARTING (with compressed air/hydraulic starter)
Heat exchanger Heat exchanger
installed separate
Starting-air pressure before starter motor, R bar 8 8 8 8
min.
Starting-air pressure before starter, max. R bar 10 10 10 10

CAPACITIES
Heat exchanger Heat exchanger
installed separate
Engine coolant, engine side (with cooling R Liters 305 305 -- --
system)
Total engine oil capacity at initial filling R Liters N N N N
(standard oil system) (option: max. operat-
ing inclinations)
Oil change quantity, max. (standard oil R Liters 265 265 265 265
system) (option: max. operating inclina-
tions)
Oil pan capacity at dipstick mark “min.” L Liters 195 195 195 195
(standard oil system) (option: max. operat-
ing inclinations)
Oil pan capacity at dipstick mark “max.” L Liters 235 235 235 235
(standard oil system) (option: max. operat-
ing inclinations)

WEIGHTS / MAIN DIMENSIONS

Heat exchanger Heat exchanger
installed separate
Engine dry weight (with attached standard R kg 7640 7640 7240 7240
accessories, without coupling)

ACOUSTICS
Heat exchanger Heat exchanger
installed separate
Exhaust noise, unsilenced - DL (free-field R dB(A) 107 107 107 107
sound pressure level Lp, 1m distance, ISO
6798, +3dB(A) tolerance)
TIM-ID: 0000022939 - 001

MS150069/02E 2014-03 | Product Summary | 63

 2.5.4 ENGINE DATA 16V 4000 M33F, RheinSchUO Stage II, IMO Tier II
Explanation:
DL Ref. value: Continuous power
BL Ref. value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power setting)
N Not yet defined value
- Not applicable
X Applicable

Heat exchanger Heat exchanger

installed separate
Application group 3B 3B 3B 3B
Intake air temperature °C 25 45 25 45
Charge-air coolant temperature °C -- -- -- --
Raw water inlet temperature °C 25 32 25 32
Barometric 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)
Heat exchanger Heat exchanger
installed separate
Rated engine speed A rpm 1500 1500 1500 1500
Continuous power ISO 3046 (10% over- A kW 1760 1760 1760 1760
load capability, design power DIN 6280,
ISO 8528)

GENERAL CONDITIONS (for maximum power)

Heat exchanger Heat exchanger
installed separate
Intake depression (new filter) A mbar 15 15 15 15
Intake depression, max. L mbar 30 30 30 30

MODEL-RELATED DATA (basic design)

Heat exchanger Heat exchanger
installed separate
TIM-ID: 0000022941 - 001

Cylinder arrangement: V angle Degrees 90 90 90 90

(°)
Bore mm 170 170 170 170
Stroke mm 210 210 210 210
Cylinder displacement Liters 4.77 4.77 4.77 4.77
Displacement, total Liters 76.3 76.3 76.3 76.3
Inlet valves per cylinder 2 2 2 2
Exhaust valves per cylinder 2 2 2 2

64 | Product Summary | MS150069/02E 2014-03

 RAW WATER CIRCUIT (open circuit)
Heat exchanger Heat exchanger
installed separate
Raw water pump: inlet pressure, min. L bar -0.4 -0.4 -- --
Raw water pump: inlet pressure, max. L bar 1.0 1.0 -- --
Pressure loss in engine-external raw water L bar 1.0 1.0 -- --
system, max.

LUBE OIL SYSTEM

Heat exchanger Heat exchanger
installed separate
Lube oil operating temperature before en- R °C 81 80 81 80
gine, from
Lube-oil operating temperature before en- R °C 89 88 89 88
gine, to
Lube oil operating pressure before engine, R bar 5.0 5.0 5.0 5.0
from
Lube-oil operating pressure before engine, R bar 6.0 6.0 6.0 6.0
to
Lube oil operating pressure (low idle) R bar -- -- -- --
(meas. point: before engine)

FUEL SYSTEM
Heat exchanger Heat exchanger
installed separate
Fuel pressure at engine inlet connection, L bar -0.1 -0.1 -0.1 -0.1
min. (when engine is starting)
Fuel pressure at supply connection to en- L bar -0.3 -0.3 -0.3 -0.3
gine, min. (when engine is running),
Fuel pressure at supply connection to en- L bar 1.5 1.5 1.5 1.5
gine (when engine is starting), max.
Fuel supply flow, max. A Liters/
min

GENERAL OPERATING DATA

Heat exchanger Heat exchanger
installed separate
Firing speed, from R rpm 80 80 80 80
TIM-ID: 0000022941 - 001

Firing speed, to R rpm 120 120 120 120

STARTER (electric)
Heat exchanger Heat exchanger
installed separate
Rated starter voltage (standard design) R V= 24 24 24 24

MS150069/02E 2014-03 | Product Summary | 65

 STARTING (with compressed air/hydraulic starter)
Heat exchanger Heat exchanger
installed separate
Starting-air pressure before starter motor, R bar 8 8 8 8
min.
Starting-air pressure before starter, max. R bar 9 9 9 9

CAPACITIES
Heat exchanger Heat exchanger
installed separate
Engine coolant, engine side (with cooling R Liters 350 350 -- --
system)
Total engine oil capacity at initial filling R Liters N N N N
(standard oil system) (option: max. operat-
ing inclinations)
Oil change quantity, max. (standard oil R Liters 280 280 280 280
system) (option: max. operating inclina-
tions)
Oil pan capacity at dipstick mark “min.” L Liters 210 210 210 210
(standard oil system) (option: max. operat-
ing inclinations)
Oil pan capacity at dipstick mark “max.” L Liters 250 250 250 250
(standard oil system) (option: max. operat-
ing inclinations)

WEIGHTS / MAIN DIMENSIONS

Heat exchanger Heat exchanger
installed separate
Engine dry weight (with attached standard R kg 9020 9020 8590 8590
accessories, without coupling)

ACOUSTICS
Heat exchanger Heat exchanger
installed separate
Exhaust noise, unsilenced - DL (free-field R dB(A) 108 108 108 108
sound pressure level Lp, 1m distance, ISO
6798, +3dB(A) tolerance)
TIM-ID: 0000022941 - 001

66 | Product Summary | MS150069/02E 2014-03

 2.5.5 ENGINE DATA 16V 4000 M33S, RheinSchUO Stage II, IMO Tier II
Explanation:
DL Ref. value: Continuous power
BL Ref. value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power setting)
N Not yet defined value
- Not applicable
X Applicable

Heat exchanger Heat exchanger

installed separate
Application group 3B 3B 3B 3B
Intake air temperature °C 25 45 25 45
Charge-air coolant temperature °C -- -- -- --
Raw water inlet temperature °C 25 32 25 32
Barometric 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)
Heat exchanger Heat exchanger
installed separate
Rated engine speed A rpm 1800 1800 1800 1800
Continuous power ISO 3046 (10% over- A kW 2080 2080 2080 2080
load capability, design power DIN 6280,
ISO 8528)

GENERAL CONDITIONS (for maximum power)

Heat exchanger Heat exchanger
installed separate
Intake depression (new filter) A mbar 15 15 15 15
Intake depression, max. L mbar 30 30 30 30

MODEL-RELATED DATA (basic design)

Heat exchanger Heat exchanger
installed separate
TIM-ID: 0000022943 - 001

Cylinder arrangement: V angle Degrees 90 90 90 90

(°)
Bore mm 170 170 170 170
Stroke mm 210 210 210 210
Cylinder displacement Liters 4.77 4.77 4.77 4.77
Displacement, total Liters 76.3 76.3 76.3 76.3
Inlet valves per cylinder 2 2 2 2
Exhaust valves per cylinder 2 2 2 2

MS150069/02E 2014-03 | Product Summary | 67

 RAW WATER CIRCUIT (open circuit)
Heat exchanger Heat exchanger
installed separate
Raw water pump: inlet pressure, min. L bar -0.4 -0.4 -- --
Raw water pump: inlet pressure, max. L bar 1.0 1.0 -- --
Pressure loss in engine-external raw water L bar 1.0 1.0 -- --
system, max.

LUBE OIL SYSTEM

Heat exchanger Heat exchanger
installed separate
Lube oil operating temperature before en- R °C 84 87 84 87
gine, from
Lube-oil operating temperature before en- R °C 92 95 92 95
gine, to
Lube oil operating pressure before engine, R bar 5.3 5.3 5.3 5.3
from
Lube-oil operating pressure before engine, R bar 6.3 6.3 6.3 6.3
to
Lube oil operating pressure (low idle) R bar -- -- -- --
(meas. point: before engine)

FUEL SYSTEM
Heat exchanger Heat exchanger
installed separate
Fuel pressure at engine inlet connection, L bar -0.1 -0.1 -0.1 -0.1
min. (when engine is starting)
Fuel pressure at supply connection to en- L bar -0.3 -0.3 -0.3 -0.3
gine, min. (when engine is running),
Fuel pressure at supply connection to en- L bar 1.5 1.5 1.5 1.5
gine (when engine is starting), max.
Fuel supply flow, max. A Liters/
min

GENERAL OPERATING DATA

Heat exchanger Heat exchanger
installed separate
Firing speed, from R rpm 80 80 80 80
TIM-ID: 0000022943 - 001

Firing speed, to R rpm 120 120 120 120

STARTER (electric)
Heat exchanger Heat exchanger
installed separate
Rated starter voltage (standard design) R V= 24 24 24 24

68 | Product Summary | MS150069/02E 2014-03

 STARTING (with compressed air/hydraulic starter)
Heat exchanger Heat exchanger
installed separate
Starting-air pressure before starter motor, R bar 8 8 8 8
min.
Starting-air pressure before starter, max. R bar 9 9 9 9

CAPACITIES
Heat exchanger Heat exchanger
installed separate
Engine coolant, engine side (with cooling R Liters 350 350 -- --
system)
Total engine oil capacity at initial filling R Liters N N N N
(standard oil system) (option: max. operat-
ing inclinations)
Oil change quantity, max. (standard oil R Liters 280 280 280 280
system) (option: max. operating inclina-
tions)
Oil pan capacity at dipstick mark “min.” L Liters 210 210 210 210
(standard oil system) (option: max. operat-
ing inclinations)
Oil pan capacity at dipstick mark “max.” L Liters 250 250 250 250
(standard oil system) (option: max. operat-
ing inclinations)

WEIGHTS / MAIN DIMENSIONS

Heat exchanger Heat exchanger
installed separate
Engine dry weight (with attached standard R kg 9020 9020 8590 8590
accessories, without coupling)

ACOUSTICS
Heat exchanger Heat exchanger
installed separate
Exhaust noise, unsilenced - DL (free-field R dB(A) 109 109 109 109
sound pressure level Lp, 1m distance, ISO
6798, +3dB(A) tolerance)
TIM-ID: 0000022943 - 001

MS150069/02E 2014-03 | Product Summary | 69

 2.5.6 ENGINE DATA 16V 4000 M33S, IMO Tier II, EPA Tier 2
Explanation:
DL Ref. value: Continuous power
BL Ref. value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power setting)
N Not yet defined value
- Not applicable
X Applicable

Heat exchanger Heat exchanger

installed separate
Application group 3B 3B 3B 3B
Intake air temperature °C 25 45 25 45
Charge-air coolant temperature °C -- -- -- --
Raw water inlet temperature °C 25 32 25 32
Barometric 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)
Heat exchanger Heat exchanger
installed separate
Rated engine speed A rpm 1800 1800 1800 1800
Continuous power ISO 3046 (10% over- A kW 2080 2080 2080 2080
load capability, design power DIN 6280,
ISO 8528)

GENERAL CONDITIONS (for maximum power)

Heat exchanger Heat exchanger
installed separate
Intake depression (new filter) A mbar 15 15 15 15
Intake depression, max. L mbar 30 30 30 30

MODEL-RELATED DATA (basic design)

Heat exchanger Heat exchanger
installed separate
TIM-ID: 0000022942 - 001

Cylinder arrangement: V angle Degrees 90 90 90 90

(°)
Bore mm 170 170 170 170
Stroke mm 210 210 210 210
Cylinder displacement Liters 4.77 4.77 4.77 4.77
Displacement, total Liters 76.3 76.3 76.3 76.3
Inlet valves per cylinder 2 2 2 2
Exhaust valves per cylinder 2 2 2 2

70 | Product Summary | MS150069/02E 2014-03

 RAW WATER CIRCUIT (open circuit)
Heat exchanger Heat exchanger
installed separate
Raw water pump: inlet pressure, min. L bar -0.4 -0.4 -- --
Raw water pump: inlet pressure, max. L bar 1.0 1.0 -- --
Pressure loss in engine-external raw water L bar 1.0 1.0 -- --
system, max.

LUBE OIL SYSTEM

Heat exchanger Heat exchanger
installed separate
Lube oil operating temperature before en- R °C 84 83 84 83
gine, from
Lube-oil operating temperature before en- R °C 92 91 92 91
gine, to
Lube oil operating pressure before engine, R bar 5.3 5.3 5.3 5.3
from
Lube-oil operating pressure before engine, R bar 6.3 6.3 6.3 6.3
to
Lube oil operating pressure (low idle) R bar -- -- -- --
(meas. point: before engine)

FUEL SYSTEM
Heat exchanger Heat exchanger
installed separate
Fuel pressure at engine inlet connection, L bar -0.1 -0.1 -0.1 -0.1
min. (when engine is starting)
Fuel pressure at supply connection to en- L bar -0.3 -0.3 -0.3 -0.3
gine, min. (when engine is running),
Fuel pressure at supply connection to en- L bar 1.5 1.5 1.5 1.5
gine (when engine is starting), max.
Fuel supply flow, max. A Liters/
min

GENERAL OPERATING DATA

Heat exchanger Heat exchanger
installed separate
Firing speed, from R rpm 80 80 80 80
TIM-ID: 0000022942 - 001

Firing speed, to R rpm 120 120 120 120

STARTER (electric)
Heat exchanger Heat exchanger
installed separate
Rated starter voltage (standard design) R V= 24 24 24 24

MS150069/02E 2014-03 | Product Summary | 71

 STARTING (with compressed air/hydraulic starter)
Heat exchanger Heat exchanger
installed separate
Starting-air pressure before starter motor, R bar 8 8 8 8
min.
Starting-air pressure before starter, max. R bar 9 9 9 9

CAPACITIES
Heat exchanger Heat exchanger
installed separate
Engine coolant, engine side (with cooling R Liters 350 350 -- --
system)
Total engine oil capacity at initial filling R Liters N N N N
(standard oil system) (option: max. operat-
ing inclinations)
Oil change quantity, max. (standard oil R Liters 280 280 280 280
system) (option: max. operating inclina-
tions)
Oil pan capacity at dipstick mark “min.” L Liters 210 210 210 210
(standard oil system) (option: max. operat-
ing inclinations)
Oil pan capacity at dipstick mark “max.” L Liters 250 250 250 250
(standard oil system) (option: max. operat-
ing inclinations)

WEIGHTS / MAIN DIMENSIONS

Heat exchanger Heat exchanger
installed separate
Engine dry weight (with attached standard R kg 9020 9020 8590 8590
accessories, without coupling)

ACOUSTICS
Heat exchanger Heat exchanger
installed separate
Exhaust noise, unsilenced - DL (free-field R dB(A) 109 109 109 109
sound pressure level Lp, 1m distance, ISO
6798, +3dB(A) tolerance)
TIM-ID: 0000022942 - 001

72 | Product Summary | MS150069/02E 2014-03

 2.5.7 Engine data 16V 4000 M43S, IMO Tier II, EPA Tier 2
Explanation:
DL Reference value: Continuous power (CP)
BL Reference value: Fuel stop power (FSP)
A Design value
G Guaranteed value
R Guideline value
L Limit value up to which the engine can be operated without change, e.g. of power setting.
N Not yet defined value
- Not applicable
X Applicable

Heat exchanger Heat exchanger

engine-mounted remote
Application group 3B 3B 3B 3B
Intake air temperature °C 25 45 25 45
Charge-air coolant temperature °C -- -- -- --
Raw water inlet temperature °C 25 32 25 32
Barometric 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)
Heat exchanger Heat exchanger
engine-mounted remote
Rated engine speed A rpm 1800 1800 1800 1800
Continuous power ISO 3046 (10% over- A kW 2240 2240 2240 2240
load capability) (design power DIN 6280,
ISO 8528)

GENERAL CONDITIONS (for maximum power)

Heat exchanger Heat exchanger
engine-mounted remote
Intake depression (new filter) A mbar 15 15 15 15
Intake depression, max. L mbar 30 30 30 30

MODEL-RELATED DATA (basic design)

Heat exchanger Heat exchanger
engine-mounted remote
TIM-ID: 0000028437 - 001

Cylinder arrangement: V angle Degrees 90 90 90 90

(°)
Bore mm 170 170 170 170
Stroke mm 210 210 210 210
Cylinder displacement Liters 4.77 4.77 4.77 4.77
Total displacement Liters 76.3 76.3 76.3 76.3
Inlet valves per cylinder 2 2 2 2
Exhaust valves per cylinder 2 2 2 2

MS150069/02E 2014-03 | Product Summary | 73

 RAW WATER CIRCUIT (open circuit)
Heat exchanger Heat exchanger
engine-mounted remote
Raw water pump: Inlet pressure, min. L bar -0.4 -0.4 -- --
Raw water pump: Inlet pressure, max. L bar 1.0 1.0 -- --
Pressure loss in off-engine raw water sys- L bar 1.0 1.0 -- --
tem, max.

LUBE OIL SYSTEM

Heat exchanger Heat exchanger
engine-mounted remote
Lube oil operating temperature before en- R °C 84 87 84 87
gine, from
Lube oil operating temperature before en- R °C 92 95 92 95
gine, to
Lube oil operating pressure before engine, R bar 5.5 5.5 5.5 5.5
from
Lube oil operating pressure before engine, R bar 6.5 6.5 6.5 6.5
to
Lube oil operating pressure (low idle) R bar -- -- -- --
(meas. point: before engine)

FUEL SYSTEM
Heat exchanger Heat exchanger
engine-mounted remote
Fuel pressure at supply connection to en- L bar -0.3 -0.3 -0.3 -0.3
gine (when engine is running), min.
Fuel pressure at supply connection to en- L bar 1.5 1.5 1.5 1.5
gine (when engine is starting), max.
Fuel supply rate, max. A Liters/
min

GENERAL OPERATING DATA

Heat exchanger Heat exchanger
engine-mounted remote
Firing speed, from R rpm 80 80 80 80
Firing speed, to R rpm 120 120 120 120
TIM-ID: 0000028437 - 001

STARTER (electric)
Heat exchanger Heat exchanger
engine-mounted remote
Rated starter voltage (standard design) R V= 24 24 24 24

74 | Product Summary | MS150069/02E 2014-03

 STARTER (compressed air/hydraulic starter motor)
Heat exchanger Heat exchanger
engine-mounted remote
Starting-air pressure before starter motor, R bar 8 8 8 8
min.
Starting-air pressure before starter, max. R bar 9 9 9 9

CAPACITIES
Heat exchanger Heat exchanger
engine-mounted remote
Engine coolant, engine side (with cooling R Liters 350 350 -- --
system)
Engine oil on initial filling (standard oil sys- R Liters 280 280 280 280
tem) (option: max. operating inclinations)
Oil change quantity, max. (standard oil R Liters
system) (option: max. operating inclina-
tions)
Oil pan capacity at dipstick mark “min.” L Liters 210 210 210 210
(standard oil system) (option: max. operat-
ing inclinations)
Oil pan capacity at dipstick mark “max.” L Liters 250 250 250 250
(standard oil system) (option: max. operat-
ing inclinations)

WEIGHTS / MAIN DIMENSIONS

Heat exchanger Heat exchanger
engine-mounted remote
Dry engine weight (with standard accesso- R kg 9020 9020 8590 8590
ries, without coupling)

NOISE
Heat exchanger Heat exchanger
engine-mounted remote
Exhaust noise, unsilenced - DL (free-field R dB(A) 112 112 112 112
sound-pressure level Lp, 1m distance, ISO
6798, +3dB(A) tolerance)
TIM-ID: 0000028437 - 001

MS150069/02E 2014-03 | Product Summary | 75

 3 Operation
3.1 Controls
Automation system controls
Refer to automation system operating instructions

TIM-ID: 0000016959 - 003

76 | Operation | MS150069/02E 2014-03

 3.2 Putting the engine into operation after extended out-of-service
periods (>3 months)
Preconditions
☑Engine is stopped and starting disabled.
☑MTU Preservation and Represervation Specifications (A001070/..) are available.

Putting the engine into operation after extended out-of-service-periods (>3

months)
Item Task
Engine Depreserve (→ Preservation and Represervation Specifications A001070/..).
Lube oil system Check engine oil level (→ Page 213);
Preheat engine oil if required.
Fuel prefilter Prime with fuel (→ Page 197)
Fuel prefilter, pressure Align adjustable pointer with position of pressure indicator (→ Page 192).
gauge
HP fuel pump Only for engines without oil priming pump:
Fill HP fuel pump with new engine oil (→ Page 179).
Raw-water pump (if located Prime with water (approx. 3 – 4 l).
above waterline (only appli-
cable to engines with en-
gine-mounted heat exchang-
er or with optional remote
heat exchanger))
Coolant circuit If engine is out of service for more than one year, change engine coolant
(→ Page 230).
Coolant circuit Check coolant level (→ Page 229).
Coolant circuit Preheat coolant with preheating unit.
Engine control system Refer to automation system operating instructions.
ECU Check plug connections (→ Page 263).
EMU Check plug connections (→ Page 264)
EIM Check plug connections (→ Page 265).
TIM-ID: 0000010092 - 005

MS150069/02E 2014-03 | Operation | 77

 3.3 Putting the engine into operation after scheduled out-of-
service-period
Preconditions
☑Engine is stopped and starting disabled.

Putting into operation

Item Task
Lube oil system Check engine oil level (→ Page 213);
Preheat engine oil if required.
Coolant system Check coolant level (→ Page 229).
Coolant system Preheat coolant with preheating unit.
Fuel prefilter Drain (→ Page 193);
Check that suction-side pressure indicated at the fuel prefilter pressure
gauge is within the limit (→ Page 192).
Engine control system Refer to automation system operating instructions.
ECU Check plug connections (→ Page 263).
EIM Check plug connections (→ Page 265).
EMU Check plug connections (→ Page 264).

TIM-ID: 0000010655 - 004

78 | Operation | MS150069/02E 2014-03

 3.4 Starting the engine
Start the engine via the automation system
Refer to automation system operating instructions
TIM-ID: 0000017525 - 003

MS150069/02E 2014-03 | Operation | 79

 3.5 Operational checks
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

Operational checks
Item Measure
Engine under load Check engine visually for leaks and general condition; Check air pipework be-
Engine at nominal speed tween air filter and exhaust turbocharger for leaks and damage.
Check for abnormal running noise, vibration, and exhaust color (→ Page 94).
Charge-air cooler Check condensate drain (→ Page 208).
Air filter Check signal ring position of service indicator (→ Page 211).
Replace air filter (→ Page 209), if the signal ring is completely visible in the
service indicator control window.
HP fuel pump Check relief bores for fuel discharge (→ Page 180).
HT coolant pump Check relief bore for oil and coolant discharge and obstructions
(→ Page 236).
Fuel prefilter (optional) Check reading on differential pressure gauge (→ Page 211);
Drain water and contaminants (→ Page 195).
Raw water pump (only on Check relief bore for oil and coolant discharge and obstructions
engines with engine-mount- (→ Page 244).
ed or optional remote heat
exchanger)
Bilge pump (optional) Check relief bore for oil and coolant discharge and obstructions
(→ Page 247).
TIM-ID: 0000018474 - 003

80 | Operation | MS150069/02E 2014-03

 3.6 Tasks after extended out-of-service periods (>3 weeks)

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 83).
2. Shut down fuel treatment system (→ Page 87).
TIM-ID: 0000007730 - 005

MS150069/02E 2014-03 | Operation | 81

 3.7 Checks prior to start-up

Checks prior to start-up

1. Check tank and the entire pipework for cleanness. If microorganisms are detected:
a) Clean affected components.
b) Disinfect affected components with biocides (→ MTU Fluids and Lubricants Specifications
A001061/..).
2. Close drain valves on housing.
3. Open all supply and discharge valves.
4. Switch on fuel treatment system (→ Page 86).
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) Close ball valve at the inlet to the fuel treatment system.
Result: Bypass line is vented via the overflow tank.
d) Open ball valve at the inlet to the fuel treatment system.
7. Check the fuel treatment system for leaks.
Result: The fuel treatment system is ready for operation.

TIM-ID: 0000007736 - 005

82 | Operation | MS150069/02E 2014-03

 3.8 Fuel treatment system – Putting into operation

Overview of fuel treatment system

1 Pressure-free overflow 9 Ball valve, outlet 17 Automatic water drain

2 Bypass 1 10 Check valve 700 mbar 18 Water level electrode
3 Bypass 2 11 Check valve 5 mbar 19 Ball valve, sample extrac-
4 Safety valve, 3 bar 12 Return to overflow con- tion, inlet
5 Ball valve, inlet tainer 20 Switchgear cabinet
6 Pressure gage 13 Engine 21 Pump
7 Ventilation, sample extrac- 14 Overflow container 22 Coarse filter
tion 15 Water separator filter 23 Fuel supply from tank
8 Differential pressure gage 16 Ball valve, drain 24 Tank

Switching on fuel treatment system

1. Switch on fuel treatment system (→ Page 86).
2. Check differential pressure at differential pressure gage (8). Differential pressure in a new system:
0.1 bar to 0.3 bar.
Result: If no differential pressure is measured, the coalescer filter element is probably being bypassed.
TIM-ID: 0000015773 - 006

1. Remove coalescer filter element (→ Page 252).

2. Check sealing surfaces on coalescer filter element and in the pressure tank.

MS150069/02E 2014-03 | Operation | 83

 Initial operation: HAT
1. Replace fuel filter on engine (→ Page 189).
Note: Determine the suction pressure upstream of the engine-mounted fuel delivery pump.
2. Install pressure gage in fuel supply line from Yard fuel system to engine.
3. Switch on fuel treatment system and operate it for some minutes (→ Page 86).
Result: The fuel is drawn from tank (24), cleaned by the water separator filter (15) and then routed via overflow
tank (14) back to tank (24). Water that collects in the tank is separated.
4. Start engine (→ Page 79).
5. Run engine at idling speed.
6. Check suction pressure (see technical data of the engine) at the engine-mounted fuel delivery pump.
Note: If the suction pressure is within the permissible limits and engine operation is satisfactory.
7. Increase engine speed to 1000 rpm and monitor suction pressure.
8. Check suction pressure at the engine-mounted fuel delivery pump.
Result: If the values are within the limits specified by the manufacturer, the system is ready to start filter re-
placement simulation with the engine running as part of the Harbor Acceptance Tests.

Simulation of filter replacement with the engine running: HAT

1. Switch on fuel treatment system (→ Page 86).
2. Start engine (→ Page 79).
3. Run engine at idling 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 bypass (3) and bypass (2).
5. Open ball valve (19) .
Result: Fuel emerges. If no fuel emerges:
• Open ball valve (5) at inlet to fuel treatment system.
• No function of bypasses (2) and (3); carry out functional test of bypasses (2) and (3) .
6. Check suction pressure (see technical data of the engine) at the fuel delivery pump.
Note: If the suction pressure is within the permissible limits and engine operation is satisfactory.
7. Increase engine speed to 1000 rpm and monitor suction pressure.
Result: If all engine operating values are within the specified limits, open ball valve (5) at inlet to fuel treatment
system.

Simulation of power failure (emergency): HAT

1. Switch on fuel treatment system (→ Page 86).
2. Start engine (→ Page 79).
3. Run engine at idling speed.
4. Switch off pump (21) at switchgear cabinet (20).
Result: The engine-mounted fuel delivery 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 permissible limits and engine operation is satisfactory.
6. Increase engine speed to 1000 rpm and monitor suction pressure.
Result: If the suction pressure is within the specified limits, simulation was successful.
TIM-ID: 0000015773 - 006

84 | Operation | MS150069/02E 2014-03

 Simulation of power failure (emergency): SAT
1. Switch on fuel treatment system (→ Page 86).
2. Start engine (→ Page 79).
3. Run engine at idling speed.
4. Switch off pump (21) at switchgear cabinet (20).
Result: The engine-mounted fuel delivery 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 permissible limits and engine operation is satisfactory.
6. Operate engine at full load and monitor suction pressure.
Result: If the suction pressure is within the specified limits, simulation was successful.
TIM-ID: 0000015773 - 006

MS150069/02E 2014-03 | Operation | 85

 3.9 Fuel treatment system – Switching on
Preconditions
☑The on-board power supply is switched on.

NOTICE
Risk of damage to engine/system.
Risk of severe damage to property!
• Before switching on, ensure that the engine/system is ready for operation.
• Before 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 start-up (→ Page 82).
2. Switch on master switch on switchgear cabinet.
Result: Signal lamp “Control voltage present” lights up.
3. Switch on switch for pump.
Result: Signal lamp “Pump running” lights up.

TIM-ID: 0000007731 - 006

86 | Operation | MS150069/02E 2014-03

 3.10 Fuel treatment system – Shutdown

Shutting down fuel treatment system

1. Press the illuminated pushbutton "Water drain" on the switch cabinet 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 system.
5. Open drain valve until pressure has escaped from fuel treatment system.
TIM-ID: 0000007732 - 005

MS150069/02E 2014-03 | Operation | 87

 3.11 Stopping the engine
Stopping the engine via the automation system
Refer to automation system operating instructions

TIM-ID: 0000017528 - 004

88 | Operation | MS150069/02E 2014-03

 3.12 Emergency engine stop
NOTICE
An emergency stop causes extreme stress to the engine plant.
Risk of overheating, damage to components!
• Initiate emergency stop only in emergency situations.

Emergency stop
1. Refer to automation system operating instructions.
2. Follow instructions.
TIM-ID: 0000017530 - 005

MS150069/02E 2014-03 | Operation | 89

 3.13 After stopping the engine
Preconditions
☑MTU Preservation and Re-preservation Specifications (A001070/..) are available.

After stopping the engine

Item Measure
Coolant circuit Drain coolant (→ Page 231) if:
• freezing temperatures are expected and the engine is to remain out of
service for an extended period, but engine coolant has no antifreeze
additive;
• 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-
perature;
• antifreeze concentration is 50% and engine-room temperature is below
-40 °C.
Raw water (only on engines Drain
with engine-mounted heat • if freezing temperatures are expected and the engine is to remain out
exchanger) of service for an extended period.
Engine control system Switch off.
Air intake and exhaust sys- Out-of-service-period > 1 week
tem
• Seal engine on air and exhaust sides.
Out-of-service-period > 1 month
• Preserve engine (→ MTU Preservation and Re-preservation specifica-
tions A001070/..).

TIM-ID: 0000010168 - 004

90 | Operation | MS150069/02E 2014-03

 3.14 Plant – Cleaning
Preconditions
☑Engine is stopped and starting disabled.
☑Operating voltage is not applied.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Steam jet cleaner - 1
Cleaner (Hakupur 312) 30390 1

WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.

WARNING
Steam jet cleaner ejects jet of pressurized water.
Risk of injury to eyes and scalding!
• Never direct water jet at people.
• Wear protective clothing, protective gloves and safety goggles/face mask.

NOTICE
Cleaning agents should not be left to take effect for too long.
Damage to components is possible!
• Observe manufacturer's instructions.

NOTICE
Blowing down product with compressed air.
Entry of dirt and damage to components is possible!
• Do not aim compressed air gun directly 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
protection).
2. Prior to putting the cleaning unit into operation, read the Operating Instructions of the water/steam jet
unit carefully and observe the safety precautions.
3. For external cleaning of the plant with water or steam-jet cleaners:
• The pressure of the high-pressure jet (cleaning jet) must not exceed 50 bar.
• A minimum distance between spray nozzle and plant of 1 m must be observed.
TIM-ID: 0000010171 - 028

• The temperature of the cleaning medium must not exceed 80°C.

4. For external cleaning with high-pressure jet, use a flat-mouth nozzle only.
Note: Never aim compressed air directly at electronic components.
5. Carry out external cleaning as follows:
a) Seal all openings in a suitable way.
b) Remove coarse dirt.
c) Spray on cleaner sparingly and leave it for 1 to 5 minutes.
d) Use the high-pressure jet to remove the loosened dirt.
e) Dry engine with compressed air.

MS150069/02E 2014-03 | Operation | 91

 4 Maintenance
4.1 Maintenance task reference table [QL1]
The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The
Maintenance Schedule is a stand-alone publication.
The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance
Schedule.
Option

Task Maintenance tasks

W0500 Check engine oil level. (→ Page 213)

W0501 Visually inspect engine for leaks and general condition. (→ Page 80)
W0502 Check intercooler drain(s). (→ Page 208)
W0503 Check maintenance indicator of air filter. (→ Page 211)
W0504 Check telltale bores of HP fuel pump . (→ Page 80)
W0505 Check relief bores of water pump(s). (→ Page 236)
W0506 Check engine for abnormal running noises, exhaust color (→ Page 80)
and vibrations.
W0507 Drain water and contaminants from fuel prefilter. (→ Page 80)
W0508 X Check reading on differential pressure gage of fuel prefilter. (→ Page 80)
W1001 Replace fuel filter or fuel filter element. (→ Page 189)
W1005 X Replace air filter. (→ Page 209)
W1006 Replace fuel injectors. (→ Page 181)
W1008 X Replace engine oil filter when changing engine oil, or when (→ Page 218)
the interval (years) is reached, at the latest.
W1009 Check layer thickness of the oil residue, clean out and re- (→ Page 222)
place filter sleeve each time the oil is changed at the latest.
W1011 Perform endoscopic examination. (→ Page 167)
W1016 X Check condition of coupling. (→ Page 246)
W1047 X Check and clean oil indicator filter. (→ Page 220)
W1076 Clean compressor wheel. (→ Page 200)
W1207 Check valve clearance and adjust as necessary. ATTENTION! (→ Page 175)
First adjustment after 1,000 operating hours and after 1,000
operating hours following cylinder head overhaul.
W1244 X Check function of rod electrode. (→ Page 250)
TIM-ID: 0000048360 - 001

W1245 X Check alarm function of differential pressure gage. (→ Page 249)

W1246 X Check pump capacity. (→ Page 251)
W1463 Check general condition of engine mounting (visual inspec- (→ Page 245)
tion).
W1477 X Overhaul preheater. (→ Page 242)
W1481 Replace intermediate fuel filter or intermediate fuel filter ele- (→ Page 188)
ment.
W1581 X Replace impactors. (→ Page 173)

92 | Maintenance | MS150069/02E 2014-03

 Option
Task Maintenance tasks

W1675 X Replace fuel prefilter or fuel prefilter element. (→ Page 197)

W1713 Injector: Reset drift correction parameter (CDC). (→ Page 261)

Table 1: Maintenance task reference table [QL1]

TIM-ID: 0000048360 - 001

MS150069/02E 2014-03 | Maintenance | 93

 5 Troubleshooting
5.1 Troubleshooting
Engine does not turn when starter is actuated
Cause Corrective action
Battery low or faulty u Charge or replace (see separate documentation).
Battery: Cable connections u Check firm seating of cable connections (see separate
faulty documentation).
Engine cabling or starter faulty u Check firm seating of cable connections, contact Service.
Engine cabling defective u Check (→ Page 260).
Loose plug connections on u Check plug connections (→ Page 263).
engine governor
Loose plug connections on u Check plug connections (→ Page 265).
Engine Interface Module (EIM)
Fuse F1 (→ Page 254)in engine u Check fuse (replace if required) and re-start the system by
wiring harness defective (fuse actuating the key switch.
lamp on EIM flashes with
relevant flashing code)
Running gear blocked (engine u Contact Service.
cannot be barred manually)

Engine turns on starting but does not fire

Cause Corrective action
Poor rotation by starter: Battery u Charge or replace battery (see separate documentation).
low or faulty
Engine cabling defective u Check (→ Page 260).
Engine governor defective u Contact Service.

Engine fires unevenly

Cause Corrective action
Injector faulty u Replace (→ Page 181).
Engine cabling defective u Check (→ Page 260).
Engine governor defective u Contact Service.

Engine does not reach nominal speed

TIM-ID: 0000010520 - 004

Cause Corrective action

Easy-change fuel filter clogged u Replace (→ Page 189).
Air supply: Air filter clogged u Check signal ring position of service indicator (→ Page 211).
Fuel injection: Injector faulty u Replace (→ Page 181).
Engine cabling defective u Check (→ Page 260).
Engine: Overload u Contact Service.

94 | Troubleshooting | MS150069/02E 2014-03

 Engine speed not steady
Cause Corrective action
Fuel injection: Injector faulty u Replace (→ Page 181).
Speed transmitter defective u Contact Service.
Engine governor defective u Contact Service.

Charge-air temperature too high

Cause Corrective action
Incorrect coolant concentration u Check (MTU test kit).
Intercooler dirty u Contact Service.
Engine room: Air-intake u Check fans and air supply/ventilation ducts.
temperature too high

Charge-air pressure too low

Cause Corrective action
Air supply: Air filter clogged u Check signal ring position of service indicator (→ Page 211).
Intercooler dirty u Contact Service.
Exhaust turbocharger defective u Contact Service.

Coolant leaks at intercooler

Cause Corrective action
Intercooler leaky, major coolant u Contact Service.
discharge

Black exhaust gas

Cause Corrective action
Air supply: Air filter clogged u Check signal ring position of service indicator (→ Page 211).
Fuel injection: Injector faulty u Replace (→ Page 181).
Engine: Overload u Contact Service.

Blue exhaust gas

Cause Corrective action
Too much oil in engine u Drain engine oil (→ Page 214).
Oil separator or oil-preseparator u Replace.
of crankcase breather clogged
TIM-ID: 0000010520 - 004

Exhaust turbocharger, cylinder u Contact Service.

head, piston rings, cylinder liner
defective

MS150069/02E 2014-03 | Troubleshooting | 95

 White exhaust gas
Cause Corrective action
Engine is not at operating u Run engine to reach operating temperature.
temperature
Intercooler leaky u Contact Service.

TIM-ID: 0000010520 - 004

96 | Troubleshooting | MS150069/02E 2014-03

 5.2 Fuel treatment system – Troubleshooting
Illuminated pushbutton 'water alarm' is lit.
Cause Corrective action
When the maximum water level 1. Press illuminated pushbutton 'Water alarm' for
is reached, the water level acknowledgment.
electrode opens the water drain 2. In addition to the automatic water drain function, water can also
valve and water is discharged. If be drained manually. To do so, press the illuminated pushbutton
the opening period of the valve 'Water drain' to open the drain valve.
exceeds a preset limit
(4 minutes), the pump will
switch off and an alarm is
initiated.

Signal lamp 'Pump fault' is lit.

Cause Corrective action
The drive motor is equipped with u Reset motor protection relay.
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 off.

Signal lamp 'Pre-alarm' is lit.

Cause Corrective action
The differential pressure u Replace coalescer filter element (→ Page 252).
exceeded 1.3 bar.

Illuminated pushbutton 'Replace filter element' is lit.

Cause Corrective action
The max. permissible differential 1. Replace coalescer filter element (→ Page 252).
pressure of 1.5 bar was 2. Press illuminated pushbutton 'Replace filter element' for
exceeded. If the coalescer filter acknowledgment.
element is not replaced,
pressure will increase further
and the safety valve will open.
Fuel will be led via the bypass
directly into the overflow tank.
TIM-ID: 0000007734 - 008

MS150069/02E 2014-03 | Troubleshooting | 97

 5.3 Engine governor ADEC (ECU 7) fault messages for Series 4000
engines, marine application
The fault code numbers are generated by the engine governor and transmitted to the display below (if
fitted).

The fault 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 the table (→ Page 99)
proves unsuccessful.
For explanations of alarm configuration parameters, refer to PR 2.8008.100.
Fault code list (→ Page 99).
TIM-ID: 0000016867 - 006

98 | Troubleshooting | MS150069/02E 2014-03

 5.4 Engine governor ADEC (ECU 7) – Fault codes
3 – HI T-Fuel
ZKP-Number: 2.0122.931
Fuel temperature too high (limit value 1)
Yellow alarm; warning
Cause Corrective action
Fuel tank may be exposed to 1. Reduce power.
heat. 2. Contact Service.

4 – SS T-Fuel
ZKP-Number: 2.0122.932
Fuel temperature too high (limit value 2)
Red alarm; engine shutdown
Cause Corrective action
Fuel tank may be exposed to u Contact Service.
heat.

5 – HI T-Charge Air
ZKP-Number: 2.0121.931
Charge-air temperature too high (limit value 1)
Yellow alarm; warning
Cause Corrective action
Charge-air cooler not 1. Reduce power.
functioning correctly. 2. Check charge-air cooler.
3. Contact Service.

6 – SS T-Charge Air
ZKP-Number: 2.0121.932
Charge-air temperature too high (limit value 2)
Red alarm; engine shutdown
Cause Corrective action
Charge-air cooler not 1. Check charge-air cooler.
TIM-ID: 0000045495 - 001

functioning correctly. 2. Contact Service.

MS150069/02E 2014-03 | Troubleshooting | 99

 9 – HI T-Coolant charge-air cooler
ZKP-Number: 2.0124.931
Coolant temperature in charge-air cooler too high (limit value 1)
Yellow alarm; warning
Cause Corrective action
Coolant circuit for charge air 1. Reduce power.
defective. 2. Check charge-air cooler and coolant cooler.
3. Contact Service.

10 – SS T-Coolant charge-air cooler

ZKP-Number: 2.0124.932
Coolant temperature in charge-air cooler too high (limit value 2)
Red alarm; engine shutdown
Cause Corrective action
Coolant circuit for charge air 1. Check charge-air cooler and coolant cooler.
defective. 2. Contact Service.

15 – LO P-Lube Oil
ZKP-Number: 2.0100.921
Lube-oil pressure too low (limit value 1)
Yellow alarm; warning
Cause Corrective action
Insufficient oil. 1. Check oil level, top up as necessary (→ Page 213).
2. Contact Service.

16 – SS P-Lube Oil
ZKP-Number: 2.0100.922
Lube-oil pressure too low (limit value 2)
Red alarm; engine shutdown
Cause Corrective action
Insufficient oil. 1. Check oil level, top up as necessary (→ Page 213).
2. Acknowledge alarm.
3. Restart engine (→ Page 79).
4. Contact Service.
TIM-ID: 0000045495 - 001

100 | Troubleshooting | MS150069/02E 2014-03

 19 – HI T-Exhaust A
ZKP-Number: 2.0126.931
Exhaust temperature too high, A-side (limit value 1)
Yellow alarm; warning
Cause Corrective action
Wiring damage. 1. Check air filter and wiring (→ Page 260).
2. Contact Service.

20 – SS T-Exhaust A
ZKP-Number: 2.0126.932
Exhaust temperature too high, A-side (limit value 2)
Red alarm; engine shutdown
Cause Corrective action
Wiring damage. 1. Check air filter and wiring (→ Page 260).
2. Contact Service.

21 – HI T-Exhaust B
ZKP-Number: 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 260).
2. Contact Service.

22 – SS T-Exhaust B
ZKP-Number: 2.0127.932
Exhaust temperature too high, B-side (limit value 2)
Red alarm; engine shutdown
Cause Corrective action
Wiring damage. 1. Check air filter and wiring (→ Page 260).
2. Contact Service.

23 – LO Coolant Level
TIM-ID: 0000045495 - 001

ZKP-Number: 2.0152.921
Coolant level too low (limit value 1)
Yellow alarm; warning
Cause Corrective action
Leak in coolant circuit. u Check coolant level in expansion tank (→ Page 229).

MS150069/02E 2014-03 | Troubleshooting | 101

 25 – HI P-Diff. Lube Oil
ZKP-Number: 2.0154.931
Differential oil pressure at oil filter too high (limit value 1)
Yellow alarm; warning
Cause Corrective action
Oil filter not functioning u Replace oil filter (→ Page 218).
correctly.

26 – HI P-Diff. Lube Oil

ZKP-Number: 2.0154.932
Differential oil pressure at oil filter too high (limit value 2)
Red alarm; engine shutdown
Cause Corrective action
Oil filter not functioning 1. Replace oil filter (→ Page 218).
correctly. 2. Contact Service.

27 – HI Level Leakage 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 Too High

ZKP-Number: 1.8004.206
Yellow alarm; warning
Cause Corrective action
Idling speed of one of the u Contact Service.
secondary turbochargers is too
high.

30 – SS Engine Overspeed
TIM-ID: 0000045495 - 001

ZKP-Number: 2.2510.932
Engine overspeed (limit value 2)
Red alarm; engine shutdown
Cause Corrective action
No fuel injection. 1. Restart engine. Fault can possibly be eliminated by a restart
(→ Page 79).
2. Contact Service.

102 | Troubleshooting | MS150069/02E 2014-03

 31 – HI ETC1 Overspeed
ZKP-Number: 2.3011.931
Speed of primary turbocharger too high (limit value 1)
Yellow alarm; warning
Cause Corrective action
Clogged charge-air circuit or 1. Reduce power.
fault in turbocharger. 2. Check air filter.
3. Contact Service.

32 – SS ETC1 Overspeed
ZKP-Number: 2.3012.932
Speed of primary turbocharger too high (limit value 2)
Red alarm; engine shutdown
Cause Corrective action
Clogged charge-air circuit or 1. Check air filter.
fault in turbocharger. 2. Contact Service.

33 – HI P-Diff-Fuel
ZKP-Number: 2.0114.931
Fuel filter differential oil pressure too high (limit value 1)
Yellow alarm; warning
Cause Corrective action
Fuel filter not functioning 1. Replace fuel filter (→ Page 189).
correctly. 2. Contact Service.

34 – SS P-Diff-Fuel
ZKP-Number: 2.0114.932
Fuel filter differential oil pressure too high (limit value 2)
Red alarm; engine shutdown
Cause Corrective action
Fuel filter not functioning 1. Replace fuel filter (→ Page 189).
correctly. 2. Contact Service.

36 – HI ETC2 Overspeed
TIM-ID: 0000045495 - 001

ZKP-Number: 2.3013.931
Speed of 1st secondary turbocharger too high (limit value 1)
Yellow alarm; warning
Cause Corrective action
Clogged charge-air circuit or 1. Reduce power.
fault in turbocharger. 2. Contact Service.

MS150069/02E 2014-03 | Troubleshooting | 103

 37 – SS ETC2 Overspeed
ZKP-Number: 2.3013.912
Speed of 1st secondary turbocharger too high (limit value 2)
Red alarm; engine shutdown
Cause Corrective action
Clogged charge-air circuit or u Contact Service.
fault in turbocharger.

38 – AL ETC Speed Deviation

ZKP-Number: 1.8004.205
Yellow alarm; warning
Cause Corrective action
Synchro fault between primary u Contact Service.
turbocharger and one of the
secondary turbochargers.

39 – AL ETC2 Cut-in Fault

ZKP-Number: 1.8004.204
Yellow alarm; warning
Cause Corrective action
ETC2 failed to cut in. u Contact Service.

44 – LO Coolant Level Charge-Air Cooler

ZKP-Number: 2.0153.921
Coolant level of charge-air cooler too low (limit value 1)
Yellow alarm; warning
Cause Corrective action
Insufficient charge-air coolant, 1. Check coolant level (→ Page 229).
e.g. due to leaks in the charge- 2. Contact Service.
air coolant circuit.

51 – HI T-Lube Oil
ZKP-Number: 2.0125.931
TIM-ID: 0000045495 - 001

Lube oil temperature too high (limit value 1)

Yellow alarm; warning
Cause Corrective action
Insufficient oil. 1. Reduce power.
2. Check engine oil level (→ Page 213).
3. Contact Service.

104 | Troubleshooting | MS150069/02E 2014-03

 52 – SS T-Lube Oil
ZKP-Number: 2.0125.932
Lube oil temperature too high (limit value 2)
Red alarm; engine shutdown
Cause Corrective action
Insufficient oil. 1. Check engine oil level (→ Page 213).
2. Contact Service.

57 – LO P-Coolant
ZKP-Number: 2.0101.921
Coolant pressure too low (limit value 1).
Yellow alarm; warning
Cause Corrective action
Leak in coolant circuit. 1. Check coolant level (→ Page 229).
2. Check coolant circuit.

58 – SS P-Coolant
ZKP-Number: 2.0101.922
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 229).
2. Check coolant circuit.

59 – SS T-Coolant L3
ZKP-Number: 2.0120.933
Coolant temperature too high / low (limit value 3)
Red alarm; forced idle
Cause Corrective action
Coolant circuit not functioning 1. Activate fan emergency operating mode if required.
correctly (e.g. damage, leaks, 2. Allow engine to cool down.
low coolant level). 3. Check coolant cooler, clean if dirty.
4. Acknowledge alarm.
5. Restart engine (→ Page 79).
TIM-ID: 0000045495 - 001

6. Contact Service.

MS150069/02E 2014-03 | Troubleshooting | 105

 60 – SS T-Coolant L4
ZKP-Number: 2.0120.934
Coolant temperature too high / low (limit value 4)
Red alarm; engine shutdown
Cause Corrective action
Coolant circuit not functioning 1. Activate fan emergency operating mode if required.
correctly (e.g. damage, leaks, 2. Allow engine to cool down.
low coolant level). 3. Check coolant cooler, clean if dirty.
4. Acknowledge alarm.
5. Restart engine (→ Page 79).
6. Contact Service.

63 – HI P-Crankcase
ZKP-Number: 2.0106.931
Crankcase pressure too high (limit value 1)
Yellow alarm; warning
Cause Corrective action
Crankcase exhaust system 1. Reduce power.
clogged or leaking. 2. Replace oil mist fine separator element.
3. Contact Service.

64 – SS P-Crankcase
ZKP-Number: 2.0106.932
Crankcase pressure too high (limit value 2)
Red alarm; engine shutdown
Cause Corrective action
Crankcase exhaust system 1. Reduce power.
clogged or leaking. 2. Replace oil mist fine separator element.
3. Contact Service.

65 – LO P-Fuel
ZKP-Number: 2.0102.921
Fuel supply pressure too low (limit value 1)
Yellow alarm; warning
TIM-ID: 0000045495 - 001

Cause Corrective action

Leaking or clogged fuel lines or 1. Check fuel lines for leakage.
fuel filter. 2. Check filter, fuel low-pressure side.
3. Replace fuel filter (→ Page 189).

106 | Troubleshooting | MS150069/02E 2014-03

 66 – SS P-Fuel
ZKP-Number: 2.0102.922
Fuel supply pressure too low (limit value 2)
Red alarm; engine shutdown
Cause Corrective action
Leaking or clogged fuel lines or 1. Check fuel lines for leakage.
fuel filter. 2. Check filter, fuel low-pressure side.
3. Replace fuel filter (→ Page 189).
4. Contact Service.

67 – HI T-Coolant
ZKP-Number: 2.0120.931
Coolant temperature too high (limit value 1)
Yellow alarm; warning
Cause Corrective action
Coolant circuit not functioning 1. Reduce power.
correctly (e.g. damage, leaks, 2. Check coolant circuit.
low coolant level).

68 – SS T-Coolant
ZKP-Number: 2.0120.932
Coolant temperature too high (limit value 2)
Red alarm; engine shutdown
Cause Corrective action
Coolant circuit not functioning u Check coolant circuit.
correctly (e.g. damage, leaks,
low coolant level).

81 – AL Rail Leakage
ZKP-Number: 1.8004.046
Leak
Yellow alarm; warning
Cause Corrective action
During start: Insufficient 1. Check engine for leaks.
TIM-ID: 0000045495 - 001

pressure gradient in rail (HP 2. Contact Service.

system leaking, air in system).
During stop: Pressure gradient 1. Seal engine system.
in rail too high. 2. Contact Service.

MS150069/02E 2014-03 | Troubleshooting | 107

 82 – HI P-Fuel (Common Rail)
ZKP-Number: 2.0104.931
Rail pressure > set value
Red alarm - DBR fuel limitation, start of injection retarded;
Cause Corrective action
Suction restrictor of HP fuel 1. Check wiring (→ Page 260).
block jamming or HP fuel control 2. Contact Service.
block wiring faulty.

83 – LO P-Fuel (Common Rail)

ZKP-Number: 2.0104.921
Rail pressure < set value
Red alarm - DBR fuel limitation
Cause Corrective action
HP fuel control block defective u Contact Service.
or leak in HP system.

085 – HI T-Recirculation
ZKP-Number: 2.0128.931
Recirculation temperature too high (limit value 1)
Cause Corrective action
Charge-air temperature before u Reduce power.
recirculation valve too high.

086 – SS T-Recirculation
ZKP-Number: 2.0128.932
Recirculation temperature too high (limit value 2)
Cause Corrective action
Charge-air temperature before u Reduce power.
recirculation valve too high.

89 – SS Engine Speed too Low

ZKP-Number: 2.2500.030
TIM-ID: 0000045495 - 001

Engine speed too low

Red alarm; engine shutdown
Cause Corrective action
Various causes possible. 1. Acknowledge alarm.
2. Check for additional messages.
3. Contact Service.

108 | Troubleshooting | MS150069/02E 2014-03

 90 – SS Starter Speed Not Reached
ZKP-Number: 2.1090.925
Idling speed not attained
Red alarm; warning
Cause Corrective action
Various causes possible. 1. Check for additional messages.
2. Contact Service.

91 – SS Release Speed Not Reached

ZKP-Number: 2.1090.924
Runup speed was not attained
Red alarm; warning
Cause Corrective action
Various causes possible. 1. Check for additional messages.
2. Contact Service.

92 – SS Starter Speed Not Reached

ZKP-Number: 2.1090.923
Starter speed not reached
Red alarm; warning
Cause Corrective action
Starter rotates too slowly or 1. Check for additional messages.
does not rotate at all. 2. Contact Service.

93 – SS T-Preheat
ZKP-Number: 2.1090.922
Preheating temperature too low (limit value 2)
Red alarm; engine start interlock
Cause Corrective action
Preheating unit not functioning. 1. Check preheater.
2. Contact Service.

94 – LO T-Preheat
TIM-ID: 0000045495 - 001

ZKP-Number: 2.1090.921
Preheating temperature too low (limit value 1)
Yellow alarm; warning
Cause Corrective action
Coolant temperature too low for 1. Check preheating unit.
engine start because preheating 2. Contact Service.
unit is not functioning.

MS150069/02E 2014-03 | Troubleshooting | 109

 95 – AL Prelubrication Fault
ZKP-Number: 2.1090.920
Oil priming fault
Yellow alarm; warning
Cause Corrective action
Priming oil pressure not 1. Check priming system.
reached. 2. Contact Service.

102 – AL Fuel Cons. Counter Defect

ZKP-Number: 1.8004.624
Error in fuel consumption checksum
Yellow alarm; warning
Cause Corrective action
Consumption meter faulty. u Contact Service.

104 – AL Eng Hours Counter Defect

ZKP-Number: 1.8004.623
Operating hours monitoring system 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; warning
Cause Corrective action
Supply voltage at engine 1. Check engine governor supply voltage.
governor too low. 2. Contact Service.

119 – LOLO ECU Power Supply Voltage

ZKP-Number: 2.0140.922
TIM-ID: 0000045495 - 001

Supply voltage too low (limit value 2)

Red alarm; start cancelation
Cause Corrective action
Supply voltage at engine 1. Check Engine Control Unit supply voltage.
governor too low. 2. Contact Service.

110 | Troubleshooting | MS150069/02E 2014-03

 120 – HI ECU Power Supply Voltage
ZKP-Number: 2.0140.931
Supply voltage too high (limit value 1)
Yellow alarm; warning
Cause Corrective action
Supply voltage at engine 1. Check Engine Control Unit supply voltage.
governor too high. 2. Contact Service.

121 – HIHI ECU Power Supply Voltage

ZKP-Number: 2.0140.932
Supply voltage too high (limit value 2)
Red alarm - start cancelation of engine stop
Cause Corrective action
Supply voltage at engine 1. Check Engine Control Unit supply voltage.
governor too high. 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. Improve engine room ventilation.

141 – AL Power too high

ZKP-Number: 1.1088.007
Maximum value exceeded
Yellow alarm; warning
Cause Corrective action
Power mean value has exceeded u Contact Service.
the specified maximum value in
the last 24 hours.

142 – AL MCR exceeded 1 hour

TIM-ID: 0000045495 - 001

ZKP-Number: 1.1088.006
MCR exceeded
Yellow alarm; warning
Cause Corrective action
MCR was exceeded in the last u Contact Service.
12 hours for longer than one
hour.

MS150069/02E 2014-03 | Troubleshooting | 111

 176 – AL LifeData not available
ZKP-Number: 2.4000.004
No (matching) LifeData backup system available
Yellow alarm; warning
Cause Corrective action
After a wait time has elapsed u Contact Service.
after ECU reset: Backup system
has no LifeData function or CAN
bus to backup system
disconnected.

177 – AL LifeData restore incomplete

ZKP-Number: 2.4000.006
Yellow alarm; warning
Cause Corrective action
This error message is generated u Contact Service.
if a CRC is faulty during a data
upload (to the engine governor)
(indicated for each indiv.
module).

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
Connection or communication 1. Check devices connected to CAN.
with a node on CAN bus 1 has 2. Check wiring (→ Page 260).
failed. 3. Contact Service.

181 – AL CAN2 Node Lost

ZKP-Number: 2.0500.681
Connection to a node on CAN bus 2 failed
Yellow alarm; warning
Cause Corrective action
TIM-ID: 0000045495 - 001

Connection or communication 1. Check devices connected to CAN.

with a node on CAN bus 2 has 2. Check wiring (→ Page 260).
failed. 3. Contact Service.

112 | Troubleshooting | MS150069/02E 2014-03

 182 – AL CAN Wrong Parameters
ZKP-Number: 2.0500.682
Incorrect parameters on CAN
Yellow alarm; warning
Cause Corrective action
Wrong parameter value entered u Contact Service.
in data record.

183 – AL CAN No PU-Data

ZKP-Number: 2.0500.683
CAN PU data not present or available
Yellow alarm; warning
Cause Corrective action
The selected CAN mode 1. Check devices connected to CAN.
initializes communication by 2. Contact Service.
means of the application
environment data module. A
faulted occurred during an
attempt to copy a received data
module to the engine governor.

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 u Contact electronic Service.
trying to copy a received PU
data module into the flash
module.

186 – AL CAN1 Bus Off

ZKP-Number: 2.0500.686
CAN controller 1 is in "Bus-Off" status
Yellow alarm; automatic changeover to CAN 2
Cause Corrective action
TIM-ID: 0000045495 - 001

Short circuit, massive 1. Check CAN bus for short circuit, rectify short circuit as
interference or Baud rate necessary.
incompatibility. 2. Check shielding, improve shielding as necessary.
3. Contact Service.

MS150069/02E 2014-03 | Troubleshooting | 113

 187 – AL CAN1 Error Passive
ZKP-Number: 2.0500.687
CAN controller 1 error
Yellow alarm; warning
Cause Corrective action
Missing associated node, minor 1. Check CAN bus for short circuit, rectify short circuit as
disruptions or temporary bus necessary.
overload. 2. Check shielding, improve shielding as necessary.
3. Contact Service.

188 – AL CAN2 Bus Off

ZKP-Number: 2.0500.688
CAN controller 2 is in "Bus-Off" status
Yellow alarm; automatic changeover to CAN 1
Cause Corrective action
Short circuit, massive 1. Check CAN bus for short circuit, rectify short circuit as
interference or Baud rate necessary.
incompatibility. 2. Check shielding, improve shielding as necessary.
3. Contact Service.

189 – AL CAN2 Error Passive

ZKP-Number: 2.0500.689
CAN controller 2 error
Yellow alarm; warning
Cause Corrective action
Missing associated node, minor 1. Check CAN bus for short circuit, rectify short circuit as
disruptions or temporary bus necessary.
overload. 2. Check shielding, improve shielding as necessary.
3. Contact Service.

190 – AL EMU Parameter Not Supported

ZKP-Number: 2.0500.690
Yellow alarm; warning
Cause Corrective action
TIM-ID: 0000045495 - 001

EMU parameters are not u Contact Service.

supported. ==> Incompatibility

114 | Troubleshooting | MS150069/02E 2014-03

 201 – SD T-Coolant
ZKP-Number: 1.8004.570
Signal error, coolant temperature sensor
Yellow alarm; warning
Cause Corrective action
Coolant temperature sensor 1. Check sensor and wiring (B6), replace as necessary
faulty. (→ Page 260).
Short circuit or wire break. 2. Fault is rectified when engine is restarted (→ Page 79).
3. Contact Service.

202 – SD T-Fuel
ZKP-Number: 1.8004.572
Signal error, fuel temperature sensor
Yellow alarm; warning
Cause Corrective action
Fuel temperature sensor faulty. 1. Check sensor and wiring (B33), replace as necessary
Short circuit or wire break. (→ Page 260).
2. Fault is rectified when engine is restarted (→ Page 79).
3. Contact Service.

203 – SD T-Charge Air

ZKP-Number: 1.8004.571
Signal error, charge-air temperature sensor
Yellow alarm; warning
Cause Corrective action
Charge air temperature sensor 1. Check sensor and wiring (B9), replace as necessary
faulty. (→ Page 260).
Short circuit or wire break. 2. Fault is rectified when engine is restarted. (→ Page 79)
3. Contact Service.

204 – SD Level Lube Oil

ZKP-Number: 1.8004.602
Signal error, lube oil level sensor
Yellow alarm; warning
TIM-ID: 0000045495 - 001

Cause Corrective action

Lube oil level sensor faulty. 1. Check sensor and wiring, replace as necessary (→ Page 260).
Short circuit or wire break. 2. Fault is rectified when engine is restarted (→ Page 79).
3. Contact Service.

MS150069/02E 2014-03 | Troubleshooting | 115

 205 – SD T-Coolant Charge-Air Cooler
ZKP-Number: 1.8004.574
Signal error, coolant temperature sensor
Yellow alarm; warning
Cause Corrective action
Coolant pressure sensor of 1. Check sensor and wiring (B26), replace as necessary
charge-air cooler faulty. (→ Page 260).
Short circuit or wire break. 2. Fault is rectified when engine is restarted (→ Page 79).
3. Contact Service.

206 – SD T-Exhaust A
ZKP-Number: 1.8004.576
Signal error, exhaust temperature sensor on A side
Yellow alarm; warning
Cause Corrective action
Exhaust temperature sensor on 1. Check sensor and wiring (B4.21), replace as necessary
A side faulty. (→ Page 260).
Short circuit or wire break. 2. Fault is rectified when engine is restarted (→ Page 79).
3. Contact Service.

207 – SD T-Exhaust B
ZKP-Number: 1.8004.577
Signal error, exhaust temperature sensor on B side
Yellow alarm; warning
Cause Corrective action
Exhaust temperature sensor on 1. Check sensor and wiring (B4.22), replace as necessary
B-side faulty. (→ Page 260).
Short circuit or wire break. 2. Fault is rectified when engine is restarted (→ Page 79).
3. Contact Service.

208 – SD P-Charge Air

ZKP-Number: 1.8004.566
Signal error, charge-air pressure sensor
Yellow alarm; warning
TIM-ID: 0000045495 - 001

Cause Corrective action

Charge air pressure sensor 1. Check sensor and wiring (B10), replace as necessary
faulty. (→ Page 260).
Short circuit or wire break. 2. Fault is rectified when engine is restarted (→ Page 79).
3. Contact Service.

116 | Troubleshooting | MS150069/02E 2014-03

 211 – SD P-Lube Oil
ZKP-Number: 1.8004.563
Signal error, lube oil pressure sensor
Yellow alarm; warning
Cause Corrective action
Lube-oil pressure sensor faulty. 1. Check sensor and wiring (B5), replace as necessary
Short circuit or wire break. (→ Page 260).
2. Fault is rectified when engine is restarted (→ Page 79).
3. Contact Service.

212 – SD P-Coolant
ZKP-Number: 1.8004.564
Signal error, coolant pressure sensor
Yellow alarm; warning
Cause Corrective action
Coolant pressure sensor faulty. 1. Check sensor and wiring (B16), replace as necessary
Short circuit or wire break. (→ Page 260).
2. Fault is rectified when engine is restarted (→ Page 79).
3. Contact Service.

213 – SD P-Coolant Charge-Air Cooler

ZKP-Number: 1.8004.569
Charge-air cooler coolant pressure sensor faulty
Yellow alarm; warning
Cause Corrective action
Charge-air cooler coolant 1. Check sensor and wiring (B43), replace as necessary
pressure sensor faulty. (→ Page 260).
Short circuit or wire break. 2. Fault is rectified when engine is restarted (→ Page 79).
3. Contact Service.

214 – SD P-Crankcase
ZKP-Number: 1.8004.568
Signal error, crankcase pressure sensor
Yellow alarm; warning
TIM-ID: 0000045495 - 001

Cause Corrective action

Crankcase pressure sensor 1. Check sensor and wiring (B50), replace as necessary
faulty. (→ Page 260).
Short circuit or wire break. 2. Fault is rectified when engine is restarted (→ Page 79).
3. Contact Service.

MS150069/02E 2014-03 | Troubleshooting | 117

 215 – SD P-HD
ZKP-Number: 1.8004.567
Signal error, rail pressure sensor
Yellow alarm; high-pressure regulator emergency operation
Cause Corrective action
Rail pressure sensor faulty. ==> 1. Check sensor and wiring (B48), replace as necessary
high-pressure regulator (→ Page 260).
emergency operation. 2. Fault is rectified when engine is restarted (→ Page 79).
Short circuit or wire break. 3. Contact Service.

216 – SD T-Lube Oil

ZKP-Number: 1.8004.575
Signal error, lube oil temperature sensor
Yellow alarm; warning
Cause Corrective action
Lube oil temperature sensor 1. Check sensor and wiring (B7), replace as necessary
faulty. (→ Page 260).
Short circuit or wire break. 2. Fault is rectified when engine is restarted (→ Page 79).
3. Contact Service.

219 – SD T-Intake Air

ZKP-Number: 1.8004.573
Signal error, intake air temperature sensor
Yellow alarm; warning
Cause Corrective action
Intake air temperature sensor 1. Check sensor and cabling (B3), replace as necessary
faulty. (→ Page 260).
Short circuit or wire break. 2. Fault is rectified when engine is restarted (→ Page 79).
3. Contact Service.

220 – SD Level Coolant Water

ZKP-Number: 1.8004.584
Signal error, coolant level sensor
Yellow alarm; warning
TIM-ID: 0000045495 - 001

Cause Corrective action

Coolant level sensor faulty. 1. Check sensor and cabling (F33), replace as necessary
Short circuit or wire break. (→ Page 260).
2. Fault is rectified when engine is restarted (→ Page 79).
3. Contact Service.

118 | Troubleshooting | MS150069/02E 2014-03

 221 – SD P-Diff Lube Oil
ZKP-Number: 1.8004.585
Signal error, lube oil differential pressure sensor faulty
Yellow alarm; warning
Cause Corrective action
Lube oil differential pressure 1. Check sensor and cabling (F25), replace as necessary
sensor faulty. (→ Page 260).
Short circuit or wire break. 2. Fault is rectified when engine is restarted (→ Page 79).
3. Contact Service.

222 – SD Level Leak-off Fuel

ZKP-Number: 1.8004.582
Signal error, leak fuel level sensor
Yellow alarm; warning
Cause Corrective action
Leak fuel level sensor faulty. 1. Check sensor and wiring (F46), replace as necessary
Short circuit or wire break. (→ Page 260).
2. Fault is rectified when engine is restarted (→ Page 79).
3. Contact Service.

223 – SD Level Coolant Charge-Air Cooler

ZKP-Number: 1.8004.583
Charge-air cooler coolant level sensor faulty
Yellow alarm; warning
Cause Corrective action
Charge-air cooler coolant level 1. Check sensor and wiring (F57), replace as necessary
sensor faulty. (→ Page 260).
Short circuit or wire break. 2. Fault is rectified when engine is restarted (→ Page 79).
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
TIM-ID: 0000045495 - 001

Cause Corrective action

Lube oil pressure sensor before 1. Check sensor and wiring (B34.2), replace as necessary
filter faulty. (→ Page 260).
Short circuit or wire break. 2. Fault is rectified when engine is restarted (→ Page 79).
3. Contact Service.

MS150069/02E 2014-03 | Troubleshooting | 119

 228 – SD P-Fuel before Filter
ZKP-Number: 1.8004.595
Signal error, fuel pressure sensor
Yellow alarm; warning
Cause Corrective action
Fuel pressure sensor faulty. 1. Check sensor and wiring (B5.3), replace as necessary
Short circuit or wire break. (→ Page 260).
2. Fault is rectified when engine is restarted (→ Page 79).
3. Contact Service.

229 – AL Stop Camshaft Sensor Defect

ZKP-Number: 1.8004.562
Stop signal error, camshaft sensor
Red alarm; engine shutdown
Cause Corrective action
Camshaft sensor faulty (and a 1. Check sensor and wiring to connector B1, replace as necessary
fault that occurred previously in (→ Page 260).
the crankshaft sensor in the 2. Fault is rectified when engine is restarted (→ Page 79).
same operating cycle). 3. Contact Service.

230 – SD Crankshaft Speed

ZKP-Number: 1.8004.498
Signal error, crankshaft sensor
Yellow alarm; warning
Cause Corrective action
Crankshaft sensor faulty. 1. Check sensor and wiring (B13), replace as necessary
Short circuit or wire break. (→ Page 260).
2. Fault is rectified when engine is restarted (→ Page 79).
3. Contact Service.

231 – SD Camshaft Speed

ZKP-Number: 1.8004.499
Signal error, camshaft sensor
Yellow alarm; warning
TIM-ID: 0000045495 - 001

Cause Corrective action

Camshaft sensor faulty. 1. Check sensor and wiring (B1), replace as necessary
Short circuit or wire break. (→ Page 260).
2. Fault is rectified when engine is restarted (→ Page 79).
3. Contact Service.

120 | Troubleshooting | MS150069/02E 2014-03

 232 – SD Charger 1 Speed
ZKP-Number: 1.3011.128
Signal error, primary turbocharger speed sensor
Yellow alarm; warning
Cause Corrective action
Speed sensor of primary 1. Check sensor and wiring (B44.1), replace as necessary
turbocharger faulty. (→ Page 260).
Short circuit or wire break. 2. Fault is rectified when engine is restarted (→ Page 79).
3. Contact Service.

233 – SD Charger 2 Speed

ZKP-Number: 1.3011.129
Signal error, secondary turbocharger speed sensor
Yellow alarm; warning
Cause Corrective action
Speed sensor of secondary 1. Check sensor and wiring (B44.2), replace as necessary
turbocharger faulty. (→ Page 260).
Short circuit or wire break. 2. Fault is rectified when engine is restarted (→ Page 79).
3. Contact Service.

239 – SD P-Diff Fuel

ZKP-Number: 1.8004.598
Differential pressure sensor for fuel faulty (only occurs with SD alarm 'fuel before filter' or 'fuel after
filter'.
Yellow alarm; warning
Cause Corrective action
Fuel differential pressure sensor u Check for additional messages.
faulty.

240 – SD P-Fuel
ZKP-Number: 1.8004.565
Signal error, fuel pressure sensor
Yellow alarm; warning
Cause Corrective action
TIM-ID: 0000045495 - 001

Fuel pressure sensor faulty. 1. Check sensor and wiring (B34), replace as necessary
Short circuit or wire break. (→ Page 260).
2. Fault is rectified when engine is restarted (→ Page 79).
3. Contact Service.

MS150069/02E 2014-03 | Troubleshooting | 121

 241 – SD T-Recirculation
ZKP-Number: 1.8004.581

Cause Corrective action

Recirculation sensor faulty; u Check sensor and wiring (B49), replace as necessary.
Short circuit or wire break. Fault is rectified following engine restart.

242 – SD T-Coolant (R)

ZKP-Number: 1.8004.622

Cause Corrective action

Redundant coolant pressure u Check sensor and wiring, replace as necessary.
sensor faulty; Short circuit or Fault is rectified following engine restart.
wire break.

244 – SD P-Lube Oil (R)

ZKP-Number: 1.8004.621

Cause Corrective action

Redundant lube oil pressure u Check sensor and wiring, replace as necessary.
sensor faulty; Short circuit or Fault is rectified following engine restart.
wire break.

245 – SD ECU Power Supply Voltage

ZKP-Number: 2.8006.589
Signal error, engine governor supply voltage
Yellow alarm; warning
Cause Corrective action
Internal ECU fault. Electronics 1. Replace Engine Control Unit.
faulty. 2. Contact Service.

266 – SD Speed Demand

ZKP-Number: 2.8006.586
Speed setting signal error
Red alarm; forced idle
Cause Corrective action
TIM-ID: 0000045495 - 001

Analog speed setpoint faulty. 1. Check speed setting transmitter and wiring, replace as
Short circuit or wire break. necessary (→ Page 260).
2. Fault is rectified when engine is restarted (→ Page 79).
3. Contact Service.

122 | Troubleshooting | MS150069/02E 2014-03

 268 – SD Spinning Value
ZKP-Number: 2.8006.591
Skid signal error
Yellow alarm; warning
Cause Corrective action
Analog skid signal faulty. 1. Check sensor and wiring, replace as necessary (→ Page 260).
Short circuit or wire break. 2. Fault is rectified when engine is restarted (→ Page 79).
3. Contact Service.

269 – SD Loadp.Analog filt.

ZKP-Number: 2.8006.588
Load pulse analog signal faulty
Yellow alarm; warning
Cause Corrective action
The filtered analog signal from 1. Check wiring, replace as necessary (→ Page 260).
the load pulse is not present. 2. Fault is rectified when engine is restarted (→ Page 79).
Short circuit or wire break. 3. Contact Service.

270 – SD Frequency Input

ZKP-Number: 2.8006.590
Signal error, frequency input
Red alarm; forced idle
Cause Corrective action
Frequency input faulty. 1. Check wiring (→ Page 260).
Short circuit or wire break. 2. Check speed demand transmitter.
3. Contact Service.

301 – AL Timing Cylinder A1

ZKP-Number: 1.8004.500
Time-of-flight measuring fault of injector
Cause Corrective action
Flight time value extremely low u Replace injector if the fault message appears frequently
or extremely high. (→ Page 181).
TIM-ID: 0000045495 - 001

302 – AL Timing Cylinder A2

ZKP-Number: 1.8004.501
Time-of-flight measuring fault of injector
Cause Corrective action
Flight time value extremely low u Replace injector if the fault message appears frequently
or extremely high. (→ Page 181).

MS150069/02E 2014-03 | Troubleshooting | 123

 303 – AL Timing Cylinder A3
ZKP-Number: 1.8004.502
Time-of-flight measuring fault of injector
Cause Corrective action
Flight time value extremely low u Replace injector if the fault message appears frequently
or extremely high. (→ Page 181).

304 – AL Timing Cylinder A4

ZKP-Number: 1.8004.503
Time-of-flight measuring fault of injector
Cause Corrective action
Flight time value extremely low u Replace injector if the fault message appears frequently
or extremely high. (→ Page 181).

305 – AL Timing Cylinder A5

ZKP-Number: 1.8004.504
Time-of-flight measuring fault of injector
Cause Corrective action
Flight time value extremely low u Replace injector if the fault message appears frequently
or extremely high. (→ Page 181).

306 – AL Timing Cylinder A6

ZKP-Number: 1.8004.505
Time-of-flight measuring fault of injector
Cause Corrective action
Flight time value extremely low u Replace injector if the fault message appears frequently
or extremely high. (→ Page 181).

307 – AL Timing Cylinder A7

ZKP-Number: 1.8004.506
Time-of-flight measuring fault of injector
Cause Corrective action
Flight time value extremely low u Replace injector if the fault message appears frequently
TIM-ID: 0000045495 - 001

or extremely high. (→ Page 181).

308 – AL Timing Cylinder A8

ZKP-Number: 1.8004.507
Time-of-flight measuring fault of injector
Cause Corrective action
Flight time value extremely low u Replace injector if the fault message appears frequently
or extremely high. (→ Page 181).

124 | Troubleshooting | MS150069/02E 2014-03

 309 – AL Timing Cylinder A9
ZKP-Number: 1.8004.508
Time-of-flight measuring fault of injector
Cause Corrective action
Flight time value extremely low u Replace injector if the fault message appears frequently
or extremely high. (→ Page 181).

310 – AL Timing Cylinder A10

ZKP-Number: 1.8004.509
Time-of-flight measuring fault of injector
Cause Corrective action
Flight time value extremely low u Replace injector if the fault message appears frequently
or extremely high. (→ Page 181).

311 – AL Timing Cylinder B1

ZKP-Number: 1.8004.510
Time-of-flight measuring fault of injector
Cause Corrective action
Flight time value extremely low u Replace injector if the fault message appears frequently
or extremely high. (→ Page 181).

312 – AL Timing Cylinder B2

ZKP-Number: 1.8004.511
Time-of-flight measuring fault of injector
Cause Corrective action
Flight time value extremely low u Replace injector if the fault message appears frequently
or extremely high. (→ Page 181).

313 – AL Timing Cylinder B3

ZKP-Number: 1.8004.512
Time-of-flight measuring fault of injector
Cause Corrective action
Flight time value extremely low u Replace injector if the fault message appears frequently
TIM-ID: 0000045495 - 001

or extremely high. (→ Page 181).

314 – AL Timing Cylinder B4

ZKP-Number: 1.8004.513
Time-of-flight measuring fault of injector
Cause Corrective action
Flight time value extremely low u Replace injector if the fault message appears frequently
or extremely high. (→ Page 181).

MS150069/02E 2014-03 | Troubleshooting | 125

 315 – AL Timing Cylinder B5
ZKP-Number: 1.8004.514
Time-of-flight measuring fault of injector
Cause Corrective action
Flight time value extremely low u Replace injector if the fault message appears frequently
or extremely high. (→ Page 181).

316 – AL Timing Cylinder B6

ZKP-Number: 1.8004.515
Time-of-flight measuring fault of injector
Cause Corrective action
Flight time value extremely low u Replace injector if the fault message appears frequently
or extremely high. (→ Page 181).

317 – AL Timing Cylinder B7

ZKP-Number: 1.8004.516
Time-of-flight measuring fault of injector
Cause Corrective action
Flight time value extremely low u Replace injector if the fault message appears frequently
or extremely high. (→ Page 181).

318 – AL Timing Cylinder B8

ZKP-Number: 1.8004.517
Time-of-flight measuring fault of injector
Cause Corrective action
Flight time value extremely low u Replace injector if the fault message appears frequently
or extremely high. (→ Page 181).

319 – AL Timing Cylinder B9

ZKP-Number: 1.8004.518
Time-of-flight measuring fault of injector
Cause Corrective action
Flight time value extremely low u Replace injector if the fault message appears frequently
TIM-ID: 0000045495 - 001

or extremely high. (→ Page 181).

320 – AL Timing Cylinder B10

ZKP-Number: 1.8004.519
Time-of-flight measuring fault of injector
Cause Corrective action
Flight time value extremely low u Replace injector if the fault message appears frequently
or extremely high. (→ Page 181).

126 | Troubleshooting | MS150069/02E 2014-03

 321 – AL Wiring Cylinder A1
ZKP-Number: 1.8004.520
Wiring fault cylinder A1
Yellow alarm; misfire
Cause Corrective action
Short circuit fault in injector 1. Check injector solenoid, replace injector if necessary
wiring cylinder A1. (→ Page 181).
2. Fault is rectified when engine is restarted (→ Page 79).
3. Contact Service.

322 – AL Wiring Cylinder A2

ZKP-Number: 1.8004.521
Wiring fault cylinder A2
Yellow alarm; misfire
Cause Corrective action
Short circuit fault in injector 1. Check injector solenoid, replace injector if necessary
wiring cylinder A2. (→ Page 181).
2. Fault is rectified when engine is restarted (→ Page 79).
3. Contact Service.

323 – AL Wiring Cylinder A3

ZKP-Number: 1.8004.522
Wiring fault cylinder A3
Yellow alarm; misfire
Cause Corrective action
Short circuit fault in injector 1. Check injector solenoid, replace injector if necessary
wiring cylinder A3. (→ Page 181).
2. Fault is rectified when engine is restarted (→ Page 79).
3. Contact Service.

324 – AL Wiring Cylinder A4

ZKP-Number: 1.8004.523
Wiring fault cylinder A4
Yellow alarm; misfire
TIM-ID: 0000045495 - 001

Cause Corrective action

Short circuit fault in injector 1. Check injector solenoid, replace injector if necessary
wiring cylinder A4. (→ Page 181).
2. Fault is rectified when engine is restarted (→ Page 79).
3. Contact Service.

MS150069/02E 2014-03 | Troubleshooting | 127

 325 – AL Wiring Cylinder A5
ZKP-Number: 1.8004.524
Wiring fault cylinder A5
Yellow alarm; misfire
Cause Corrective action
Short circuit fault in injector 1. Check injector solenoid, replace injector if necessary
wiring cylinder A5. (→ Page 181).
2. Fault is rectified when engine is restarted (→ Page 79).
3. Contact Service.

326 – AL Wiring Cylinder A6

ZKP-Number: 1.8004.525
Wiring fault cylinder A6
Yellow alarm; misfire
Cause Corrective action
Short circuit fault in injector 1. Check injector solenoid, replace injector if necessary
wiring cylinder A6. (→ Page 181).
2. Fault is rectified when engine is restarted (→ Page 79).
3. Contact Service.

327 – AL Wiring Cylinder A7

ZKP-Number: 1.8004.526
Wiring fault cylinder A7
Yellow alarm; misfire
Cause Corrective action
Short circuit fault in injector 1. Check injector solenoid, replace injector if necessary
wiring cylinder A7. (→ Page 181).
2. Fault is rectified when engine is restarted (→ Page 79).
3. Contact Service.

328 – AL Wiring Cylinder A8

ZKP-Number: 1.8004.527
Wiring fault cylinder A8
Yellow alarm; misfire
TIM-ID: 0000045495 - 001

Cause Corrective action

Short circuit fault in injector 1. Check injector solenoid, replace injector if necessary
wiring cylinder A8. (→ Page 181).
2. Fault is rectified when engine is restarted (→ Page 79).
3. Contact Service.

128 | Troubleshooting | MS150069/02E 2014-03

 329 – AL Wiring Cylinder A9
ZKP-Number: 1.8004.528
Wiring fault cylinder A9
Yellow alarm; misfire
Cause Corrective action
Short circuit fault in injector 1. Check injector solenoid, replace injector if necessary
wiring cylinder A9. (→ Page 181).
2. Fault is rectified when engine is restarted (→ Page 79).
3. Contact Service.

330 – AL Wiring Cylinder A10

ZKP-Number: 1.8004.529
Wiring fault cylinder A10
Yellow alarm; misfire
Cause Corrective action
Short circuit fault in injector 1. Check injector solenoid, replace injector if necessary
wiring cylinder A10. (→ Page 181).
2. Fault is rectified when engine is restarted (→ Page 79).
3. Contact Service.

331 – AL Wiring Cylinder B1

ZKP-Number: 1.8004.530
Wiring fault cylinder B1
Yellow alarm; misfire
Cause Corrective action
Short circuit fault in injector 1. Check injector solenoid, replace injector if necessary
wiring cylinder B1. (→ Page 181).
2. Fault is rectified when engine is restarted (→ Page 79).
3. Contact Service.

332 – AL Wiring Cylinder B2

ZKP-Number: 1.8004.531
Wiring fault cylinder B2
Yellow alarm; misfire
TIM-ID: 0000045495 - 001

Cause Corrective action

Short circuit fault in injector 1. Check injector solenoid, replace injector if necessary
wiring cylinder B2. (→ Page 181).
2. Fault is rectified when engine is restarted (→ Page 79).
3. Contact Service.

MS150069/02E 2014-03 | Troubleshooting | 129

 333 – AL Wiring Cylinder B3
ZKP-Number: 1.8004.532
Wiring fault cylinder B3
Yellow alarm; misfire
Cause Corrective action
Short circuit fault in injector 1. Check injector solenoid, replace injector if necessary
wiring cylinder B3. (→ Page 181).
2. Fault is rectified when engine is restarted (→ Page 79).
3. Contact Service.

334 – AL Wiring Cylinder B4

ZKP-Number: 1.8004.533
Wiring fault cylinder B4
Yellow alarm; misfire
Cause Corrective action
Short circuit fault in injector 1. Check injector solenoid, replace injector if necessary
wiring cylinder B4. (→ Page 181).
2. Fault is rectified when engine is restarted (→ Page 79).
3. Contact Service.

335 – AL Wiring Cylinder B5

ZKP-Number: 1.8004.534
Wiring fault cylinder B5
Yellow alarm; misfire
Cause Corrective action
Short circuit fault in injector 1. Check injector solenoid, replace injector if necessary
wiring cylinder B5. (→ Page 181).
2. Fault is rectified when engine is restarted (→ Page 79).
3. Contact Service.

336 – AL Wiring Cylinder B6

ZKP-Number: 1.8004.535
Wiring fault cylinder B6
Yellow alarm; misfire
TIM-ID: 0000045495 - 001

Cause Corrective action

Short circuit fault in injector 1. Check injector solenoid, replace injector if necessary
wiring cylinder B6. (→ Page 181).
2. Fault is rectified when engine is restarted (→ Page 79).
3. Contact Service.

130 | Troubleshooting | MS150069/02E 2014-03

 337 – AL Wiring Cylinder B7
ZKP-Number: 1.8004.536
Wiring fault cylinder B7
Yellow alarm; misfire
Cause Corrective action
Short circuit fault in injector 1. Check injector solenoid, replace injector if necessary
wiring cylinder B7. (→ Page 181).
2. Fault is rectified when engine is restarted (→ Page 79).
3. Contact Service.

338 – AL Wiring Cylinder B8

ZKP-Number: 1.8004.537
Wiring fault cylinder B8
Yellow alarm; misfire
Cause Corrective action
Short circuit fault in injector 1. Check injector solenoid, replace injector if necessary
wiring cylinder B8. (→ Page 181).
2. Fault is rectified when engine is restarted (→ Page 79).
3. Contact Service.

339 – AL Wiring Cylinder B9

ZKP-Number: 1.8004.538
Wiring fault cylinder B9
Yellow alarm; misfire
Cause Corrective action
Short circuit fault in injector 1. Check injector solenoid, replace injector if necessary
wiring cylinder B9. (→ Page 181).
2. Fault is rectified when engine is restarted (→ Page 79).
3. Contact Service.

340 – AL Wiring Cylinder B10

ZKP-Number: 1.8004.539
Wiring fault cylinder B10
Yellow alarm; misfire
TIM-ID: 0000045495 - 001

Cause Corrective action

Short circuit fault in injector 1. Check injector solenoid, replace injector if necessary
wiring cylinder B10. (→ Page 181).
2. Fault is rectified when engine is restarted (→ Page 79).
3. Contact Service.

MS150069/02E 2014-03 | Troubleshooting | 131

 341 – AL Open Load Cylinder A1
ZKP-Number: 1.8004.540
Injector wiring fault cylinder A1
Yellow alarm; misfire
Cause Corrective action
Disruption fault in injector wiring 1. Check injector wiring for open circuit.
cylinder A1. 2. Exclude possible injector solenoid fault, replace injector if
necessary (→ Page 181).
3. Fault rectified after each working cycle.
4. Contact Service.

342 – AL Open Load Cylinder A2

ZKP-Number: 1.8004.541
Injector wiring fault cylinder A2
Yellow alarm; misfire
Cause Corrective action
Disruption fault in injector wiring 1. Check injector wiring for open circuit.
cylinder A2. 2. Exclude possible injector solenoid fault, replace injector if
necessary (→ Page 181).
3. Fault rectified after each working cycle.
4. Contact Service.

343 – AL Open Load Cylinder A3

ZKP-Number: 1.8004.542
Injector wiring fault cylinder A3
Yellow alarm; misfire
Cause Corrective action
Disruption fault in injector wiring 1. Check injector wiring for open circuit.
cylinder A3. 2. Exclude possible injector solenoid fault, replace injector if
necessary (→ Page 181).
3. Fault rectified after each working cycle.
4. Contact Service.

344 – AL Open Load Cylinder A4

ZKP-Number: 1.8004.543
Injector wiring fault cylinder A4
TIM-ID: 0000045495 - 001

Yellow alarm; misfire

Cause Corrective action
Disruption fault in injector wiring 1. Check injector wiring for open circuit.
cylinder A4. 2. Exclude possible injector solenoid fault, replace injector if
necessary (→ Page 181).
3. Fault rectified after each working cycle.
4. Contact Service.

132 | Troubleshooting | MS150069/02E 2014-03

 345 – AL Open Load Cylinder A5
ZKP-Number: 1.8004.544
Injector wiring fault cylinder A5
Yellow alarm; misfire
Cause Corrective action
Disruption fault in injector wiring 1. Check injector wiring for open circuit.
cylinder A5. 2. Exclude possible injector solenoid fault, replace injector if
necessary (→ Page 181).
3. Fault rectified after each working cycle.
4. Contact Service.

346 – AL Open Load Cylinder A6

ZKP-Number: 1.8004.545
Injector wiring fault cylinder A6
Yellow alarm; misfire
Cause Corrective action
Disruption fault in injector wiring 1. Check injector wiring for open circuit.
cylinder A6. 2. Exclude possible injector solenoid fault, replace injector if
necessary (→ Page 181).
3. Fault rectified after each working cycle.
4. Contact Service.

347 – AL Open Load Cylinder A7

ZKP-Number: 1.8004.546
Injector wiring fault cylinder A7
Yellow alarm; misfire
Cause Corrective action
Disruption fault in injector wiring 1. Check injector wiring for open circuit.
cylinder A7. 2. Exclude possible injector solenoid fault, replace injector if
necessary (→ Page 181).
3. Fault rectified after each working cycle.
4. Contact Service.

348 – AL Open Load Cylinder A8

ZKP-Number: 1.8004.547
Injector wiring fault cylinder A8
TIM-ID: 0000045495 - 001

Yellow alarm; misfire

Cause Corrective action
Disruption fault in injector wiring 1. Check injector wiring for open circuit.
cylinder A8. 2. Exclude possible injector solenoid fault, replace injector if
necessary (→ Page 181).
3. Fault rectified after each working cycle.
4. Contact Service.

MS150069/02E 2014-03 | Troubleshooting | 133

 349 – AL Open Load Cylinder A9
ZKP-Number: 1.8004.548
Injector wiring fault cylinder A9
Yellow alarm; misfire
Cause Corrective action
Disruption fault in injector wiring 1. Check injector wiring for open circuit.
cylinder A9. 2. Exclude possible injector solenoid fault, replace injector if
necessary (→ Page 181).
3. Fault rectified after each working cycle.
4. Contact Service.

350 – AL Open Load Cylinder A10

ZKP-Number: 1.8004.549
Injector wiring fault cylinder A10
Yellow alarm; misfire
Cause Corrective action
Disruption fault in injector wiring 1. Check injector wiring for open circuit.
cylinder A10. 2. Exclude possible injector solenoid fault, replace injector if
necessary (→ Page 181).
3. Fault rectified after each working cycle.
4. Contact Service.

351 – AL Open Load Cylinder B1

ZKP-Number: 1.8004.550
Injector wiring fault cylinder B1
Yellow alarm; misfire
Cause Corrective action
Disruption fault in injector wiring 1. Check injector wiring for open circuit.
cylinder B1. 2. Exclude possible injector solenoid fault, replace injector if
necessary (→ Page 181).
3. Fault rectified after each working cycle.
4. Contact Service.

352 – AL Open Load Cylinder B2

ZKP-Number: 1.8004.551
Injector wiring fault cylinder B2
TIM-ID: 0000045495 - 001

Yellow alarm; misfire

Cause Corrective action
Disruption fault in injector wiring 1. Check injector wiring for open circuit.
cylinder B2. 2. Exclude possible injector solenoid fault, replace injector if
necessary (→ Page 181).
3. Fault rectified after each working cycle.
4. Contact Service.

134 | Troubleshooting | MS150069/02E 2014-03

 353 – AL Open Load Cylinder B3
ZKP-Number: 1.8004.552
Injector wiring fault cylinder B3
Yellow alarm; misfire
Cause Corrective action
Disruption fault in injector wiring 1. Check injector wiring for open circuit.
cylinder B3. 2. Exclude possible injector solenoid fault, replace injector if
necessary (→ Page 181).
3. Fault rectified after each working cycle.
4. Contact Service.

354 – AL Open Load Cylinder B4

ZKP-Number: 1.8004.553
Injector wiring fault cylinder B4
Yellow alarm; misfire
Cause Corrective action
Disruption fault in injector wiring 1. Check injector wiring for open circuit.
cylinder B4. 2. Exclude possible injector solenoid fault, replace injector if
necessary (→ Page 181).
3. Fault rectified after each working cycle.
4. Contact Service.

355 – AL Open Load Cylinder B5

ZKP-Number: 1.8004.554
Injector wiring fault cylinder B5
Yellow alarm; misfire
Cause Corrective action
Disruption fault in injector wiring 1. Check injector wiring for open circuit.
cylinder B5. 2. Exclude possible injector solenoid fault, replace injector if
necessary (→ Page 181).
3. Fault rectified after each working cycle.
4. Contact Service.

356 – AL Open Load Cylinder B6

ZKP-Number: 1.8004.555
Injector wiring fault cylinder B6
TIM-ID: 0000045495 - 001

Yellow alarm; misfire

Cause Corrective action
Disruption fault in injector wiring 1. Check injector wiring for open circuit.
cylinder B6. 2. Exclude possible injector solenoid fault, replace injector if
necessary (→ Page 181).
3. Fault rectified after each working cycle.
4. Contact Service.

MS150069/02E 2014-03 | Troubleshooting | 135

 357 – AL Open Load Cylinder B7
ZKP-Number: 1.8004.556
Injector wiring fault cylinder B7
Yellow alarm; misfire
Cause Corrective action
Disruption fault in injector wiring 1. Check injector wiring for open circuit.
cylinder B7. 2. Exclude possible injector solenoid fault, replace injector if
necessary (→ Page 181).
3. Fault rectified after each working cycle.
4. Contact Service.

358 – AL Open Load Cylinder B8

ZKP-Number: 1.8004.557
Injector wiring fault cylinder B8
Yellow alarm; misfire
Cause Corrective action
Disruption fault in injector wiring 1. Check injector wiring for open circuit.
cylinder B8. 2. Exclude possible injector solenoid fault, replace injector if
necessary (→ Page 181).
3. Fault rectified after each working cycle.
4. Contact Service.

359 – AL Open Load Cylinder B9

ZKP-Number: 1.8004.558
Injector wiring fault cylinder B9
Yellow alarm; misfire
Cause Corrective action
Disruption fault in injector wiring 1. Check injector wiring for open circuit.
cylinder B9. 2. Exclude possible injector solenoid fault, replace injector if
necessary (→ Page 181).
3. Fault rectified after each working cycle.
4. Contact Service.

360 – AL Open Load Cylinder B10

ZKP-Number: 1.8004.559
Injector wiring fault cylinder B10
TIM-ID: 0000045495 - 001

Yellow alarm; misfire

Cause Corrective action
Disruption fault in injector wiring 1. Check injector wiring for open circuit.
cylinder B10. 2. Exclude possible injector solenoid fault, replace injector if
necessary (→ Page 181).
3. Fault rectified after each working cycle.
4. Contact Service.

136 | Troubleshooting | MS150069/02E 2014-03

 361 – AL Power Stage Low
ZKP-Number: 1.8004.496
Internal electronic fault
Red alarm; engine shutdown possible
Cause Corrective action
Electronics faulty. 1. Start ITS.
2. Replace engine governor if required.
3. Check additional messages if ITS indicates diagnosis
"Electronics OK" (e.g. wiring faulty).
4. Check solenoid valve wiring.
5. Contact Service.

362 – AL Power Stage high

ZKP-Number: 1.8004.497
Internal electronic fault.
Red alarm; engine shutdown possible
Cause Corrective action
Electronics faulty. 1. Start ITS.
2. Replace engine governor if required.
3. Check additional messages if ITS indicates diagnosis
"Electronics OK" (e.g. wiring faulty).
4. Check solenoid valve wiring.
5. Contact Service.

363 – AL Stop Power Stage

ZKP-Number: 1.8004.560
Internal electronic fault.
Red alarm; engine shutdown
Cause Corrective action
Electronics faulty. 1. Start ITS.
2. Replace engine governor.
3. Check additional messages if ITS indicates diagnosis
"Electronics OK" (e.g. wiring faulty).
4. Check solenoid valve wiring.
5. Contact Service.
TIM-ID: 0000045495 - 001

MS150069/02E 2014-03 | Troubleshooting | 137

 365 – AL Stop MV-Wiring Ground
ZKP-Number: 1.8004.561
Injector wiring error
Red alarm - engine shutdown via Protection Module possible
Cause Corrective action
Short circuit of injector positive 1. Check wiring (→ Page 260).
connection to ground of one or 2. Engine restart (→ Page 79).
more injectors. 3. Replace wiring harness if necessary (→ Contact Service).
Short circuit of the negative
injector connection or of one or
more injectors to ground.

371 – AL Wiring TO 1
ZKP-Number: 1.8004.634
Line disruption
Cause Corrective action
Short circuit or wire break on 1. Check charger valve/wiring, repair as necessary.
transistor output 1 (TO 1). 2. Replace engine governor.

372 – AL Wiring TO 2
ZKP-Number: 1.8004.635
Line disruption
Cause Corrective action
Short circuit or wire break on 1. Check recirculation valve/wiring, repair as necessary.
transistor output 2 (TO 2). 2. Replace engine governor.

373 – AL Wiring TO 3
ZKP-Number: 1.8004.636
Line disruption
Cause Corrective action
Short circuit or wire break on u-
transistor output 3 (TO 3).

374 – AL Wiring TO 4
TIM-ID: 0000045495 - 001

ZKP-Number: 1.8004.637
Line disruption
Cause Corrective action
Short circuit or wire break on u-
transistor output 4 (TO 4).

138 | Troubleshooting | MS150069/02E 2014-03

 381 – AL Wiring TOP 1
ZKP-Number: 2.8006.638
Line disruption on digital input 1
Yellow alarm; warning
Cause Corrective action
Short circuit or wire break on u Check wiring to plant.
transistor output, plant-side 1
(TOP 1).

382 – AL Wiring TOP 2

ZKP-Number: 2.8006.639
Line disruption on digital input 2
Yellow alarm; warning
Cause Corrective action
Short circuit or wire break on u Check wiring to plant.
transistor output, plant-side 2
(TOP 2).

383 – AL Wiring TOP 3

ZKP-Number: 2.8006.640
Line disruption on digital input 3
Yellow alarm; warning
Cause Corrective action
Short circuit or wire break on u Check wiring to plant.
transistor output, plant-side 3
(TOP 3).

384 – AL Wiring TOP 4

ZKP-Number: 2.8006.641
Line disruption on digital input 4
Yellow alarm; warning
Cause Corrective action
Short circuit or wire break on u Check wiring to plant.
transistor output, plant-side 4
TIM-ID: 0000045495 - 001

(TOP 4).

MS150069/02E 2014-03 | Troubleshooting | 139

 390 – AL MCR exceeded
ZKP-Number: 1.1085.009
Speed limiter/MCR function: the maximum continuous rate was exceeded
Yellow alarm; engine power limited to permissible continuous power
Cause Corrective action
Engine was overloaded u With a continuous alarm, contact Service.
continuously.

392 – HI T-Coolant Red

ZKP-Number: 2.0129.931
Limit value 1
Cause Corrective action
Redundant coolant temperature 1. Check wiring.
reading too high. 2. Contact Service.

393 – SS T-Coolant Red

ZKP-Number: 2.0129.932
Limit value 2
Cause Corrective action
Redundant coolant temperature 1. Check wiring and sensor.
reading too high; engine stop. 2. Contact Service.

394 – LO P-Lube Oil Red

ZKP-Number: 2.0112.921
Limit value 1
Cause Corrective action
Redundant lube oil pressure 1. Check wiring and sensor.
reading too low. 2. Contact Service.

395 – SS P-Lube Oil Red

ZKP-Number: 2.0112.922
Limit value 2
Cause Corrective action
TIM-ID: 0000045495 - 001

Redundant lube oil pressure 1. Check wiring and sensor.

reading too low. 2. Contact Service.

396 – TD T-Coolant Sensor Deviation

ZKP-Number: 1.0480.193

Cause Corrective action

Maximum coolant temperature 1. Check wiring and sensor.
deviation. 2. Contact Service.

140 | Troubleshooting | MS150069/02E 2014-03

 397 – TD P-Oil Sensor Deviation
ZKP-Number: 1.0480.293

Cause Corrective action

Maximum lube oil pressure 1. Check wiring and sensor.
deviation. 2. Contact Service.

400 – AL Open Load Digital Input 1

ZKP-Number: 2.8006.625
Line disruption on digital input 1
Yellow alarm; warning
Cause Corrective action
Wiring faulty. 1. Check wiring (→ Page 260).
No resistance over switch. 2. Check target device input.
3. Contact Service.

401 – AL Open Load Digital Input 2

ZKP-Number: 2.8006.626
Line disruption on digital input 2
Yellow alarm; warning
Cause Corrective action
Wiring faulty. 1. Check wiring (→ Page 260).
No resistance over switch. 2. Check target device input.
3. Contact Service.

402 – AL Open Load Digital Input 3

ZKP-Number: 2.8006.627
Line disruption on digital input 3
Yellow alarm; warning
Cause Corrective action
Wiring faulty. 1. Check wiring (→ Page 260).
No resistance over switch. 2. Check target device input.
3. Contact Service.

403 – AL Open Load Digital Input 4

TIM-ID: 0000045495 - 001

ZKP-Number: 2.8006.628
Line disruption on digital input 4
Yellow alarm; warning
Cause Corrective action
Wiring faulty. 1. Check wiring (→ Page 260).
No resistance over switch. 2. Check target device input.
3. Contact Service.

MS150069/02E 2014-03 | Troubleshooting | 141

 404 – AL Open Load Digital Input 5
ZKP-Number: 2.8006.629
Line disruption on digital input 5
Yellow alarm; warning
Cause Corrective action
Wiring faulty. 1. Check wiring (→ Page 260).
No resistance over switch. 2. Check target device input.
3. Contact Service.

405 – AL Open Load Digital Input 6

ZKP-Number: 2.8006.630
Line disruption on digital input 6
Yellow alarm; warning
Cause Corrective action
Wiring faulty. 1. Check wiring (→ Page 260).
No resistance over switch. 2. Check target device input.
3. Contact Service.

406 – AL Open Load Digital Input 7

ZKP-Number: 2.8006.631
Line disruption on digital input 7
Yellow alarm; warning
Cause Corrective action
Wiring faulty. 1. Check wiring (→ Page 260).
No resistance over switch. 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
Wiring faulty. 1. Check wiring (→ Page 260).
No resistance over switch. 2. Check target device input.
TIM-ID: 0000045495 - 001

3. Contact Service.

142 | Troubleshooting | MS150069/02E 2014-03

 408 – AL Open Load Emerg. Stop Input ESI
ZKP-Number: 2.8006.633
Line disruption at input for emergency stop
Yellow alarm; warning
Cause Corrective action
Wiring faulty or no resistance 1. Check wiring (→ Page 260).
over switch. 2. Check target device input.
3. Contact Service.

410 – LO U-PDU
ZKP-Number: 2.0141.921
Injector voltage too low (limit value 1)
Yellow alarm; warning
Cause Corrective action
Wiring damage or faulty current 1. Check wiring (→ Page 260).
supply. 2. Check supply.
3. Contact Service.

411 – LOLO U-PDU

ZKP-Number: 2.0141.922
Injector voltage too low (limit value 2)
Red alarm; engine shutdown
Cause Corrective action
Wiring damage or faulty current 1. Check wiring (→ Page 260).
supply. 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 damage or faulty current 1. Check wiring (→ Page 260).
TIM-ID: 0000045495 - 001

supply. 2. Check supply.

3. Contact Service.

MS150069/02E 2014-03 | Troubleshooting | 143

 413 – HIHI U-PDU
ZKP-Number: 2.0141.932
Injector voltage too high (limit value 2)
Red alarm; engine shutdown
Cause Corrective action
Wiring damage or faulty current 1. Check wiring (→ Page 260).
supply. 2. Check supply.
3. Acknowledge alarm.
4. Contact Service.

414 – HI Level Water Fuel Prefilter

ZKP-Number: 2.0156.931
Water level in fuel prefilter too high (limit value 1)
Yellow alarm; warning
Cause Corrective action
Water content in fuel too high. u Empty fuel prefilter.
Water ingress in fuel tank.

415 – LO P-Coolant Charge-Air Cooler

ZKP-Number: 2.0107.921
Coolant pressure in charge-air cooler too low (limit 1)
Yellow alarm; warning
Cause Corrective action
Leak in coolant circuit. u Top up coolant.

416 – SS P-Coolant Charge-Air Cooler

ZKP-Number: 2.0107.922
Coolant pressure in charge-air cooler 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

TIM-ID: 0000045495 - 001

ZKP-Number: 1.8004.594
Signal error, fuel prefilter water level sensor
Yellow alarm; warning
Cause Corrective action
Fuel prefilter water level sensor 1. Check sensor and wiring, replace as necessary (→ Page 260).
faulty. 2. Contact Service.
Short circuit or wire break.

144 | Troubleshooting | MS150069/02E 2014-03

 419 – SD T-Coolant b.Engine
ZKP-Number: 18.004.604

Cause Corrective action

Coolant inlet temperature u Check sensor and wiring (B3), replace as necessary.
sensor faulty. Short circuit or
wire break

420 – AL L1 Aux 1
ZKP-Number: 2.0160.921
Limit value 1
Cause Corrective action
Input signal of Aux 1 has u Determine cause of limit value violation and rectify fault.
exceeded/not attained limit
value 1, depending on
configuration.

421 – AL L2 Aux 1
ZKP-Number: 2.0160.922
Limit value 2
Cause Corrective action
Input signal of Aux 1 has u Determine cause of limit value violation and rectify fault.
exceeded/not attained limit
value 2, depending on
configuration.

428 – AL L1 T-Aux 1
ZKP-Number: 2.0130.921
Limit value 1
Cause Corrective action
Temperature signal of Aux 1 has u Determine cause of limit value violation and rectify fault.
exceeded / not attained limit
value 1, depending on
configuration.

434 – AL L2 P-Aux 1
TIM-ID: 0000045495 - 001

ZKP-Number: 2.0173.931
Limit value 1
Cause Corrective action
Coolant temperature too high. u Check coolant circuit.

MS150069/02E 2014-03 | Troubleshooting | 145

 440 – AL L1 P-Aux 1
ZKP-Number: 2.0110.921
Limit value 1
Cause Corrective action
Pressure signal of Aux 1 has u Determine cause of limit value violation and rectify fault.
exceeded / not attained limit
value 1, depending on
configuration.

442 – AL L2 P-Aux 1
ZKP-Number: 2.0110.931
Limit value 2
Cause Corrective action
Pressure signal of Aux 1 has u Determine cause of limit value violation and rectify fault.
exceeded / not attained limit
value 2, depending on
configuration.

444 – SD U-PDU
ZKP-Number: 1.8004.578
Injector power stage supply voltage fault
Yellow alarm; warning
Cause Corrective action
Sensor defect of injector power u Replace Engine Control Unit.
stage, or internal fault of engine
governor.

445 – SD P-Ambient Air

ZKP-Number: 1.8004.580
Signal error, ambient air pressure sensor
Yellow alarm; warning
Cause Corrective action
Ambient air pressure sensor u Replace Engine Control Unit.
faulty.
TIM-ID: 0000045495 - 001

146 | Troubleshooting | MS150069/02E 2014-03

 446 – SD P-HD2
ZKP-Number: 1.8004.599
Signal error, rail pressure sensor
Yellow alarm; high-pressure regulator emergency operation
Cause Corrective action
Rail pressure sensor faulty. 1. Check sensor and wiring (B48), replace as necessary
Short circuit or wire break. (→ Page 260).
2. Contact Service.

448 – HI P-Charge Air

ZKP-Number: 2.0103.931
Charge-air pressure too high (limit value 1)
Yellow alarm; warning
Cause Corrective action
Fault at turbine bypass flap. u Contact Service.

449 – SS P-Charge Air

ZKP-Number: 2.0103.932
Charge-air pressure too high (limit value 2)
Red alarm; engine shutdown
Cause Corrective action
Fault at turbine bypass flap. u Contact Service.

450 – SD Idle/End-Torque Input [%]

ZKP-Number: 2.8006.592
Signal error, start/end torque
Yellow alarm; warning
Cause Corrective action
Input signal for start/end torque 1. Check signal transmitter and wiring, replace as necessary.
faulty. (→ Page 260)
Short circuit or wire break. 2. Fault is rectified when engine is restarted (→ Page 79).
3. Contact Service.
TIM-ID: 0000045495 - 001

MS150069/02E 2014-03 | Troubleshooting | 147

 454 – SS Power Reduction Active
ZKP-Number: 2.7000.011
Power reduction activated
Red alarm - power reduction activated
Cause Corrective action
Engine operation outside u Check for additional messages.
standard limit values.
This message has the following
possible causes: Intake
depression, exhaust back
pressure, charge-air coolant
temperature or intake air
temperature outside the limit
values

455 – AL L1 Aux1 Plant

ZKP-Number: 2.8006.650
Limit value 1
Cause Corrective action
Input signal of Aux 1 (plant side) u Determine cause of limit value violation and rectify fault.
has exceeded/not attained limit
value 1, depending on
configuration.

456 – AL L2 Aux1 Plant

ZKP-Number: 2.8006.651
Limit value 2
Cause Corrective action
Input signal of Aux 1 (plant side) u Determine cause of limit value violation and rectify fault.
has exceeded/not attained limit
value 2, depending on
configuration.

460 – HI T-Exhaust EMU

ZKP-Number: 2.8006.652
Limit value 1
TIM-ID: 0000045495 - 001

Cause Corrective action

EMU exhaust gas temperature 1. Check wiring.
value too high. 2. Contact Service.

148 | Troubleshooting | MS150069/02E 2014-03

 461 – LO T-Exhaust EMU
ZKP-Number: 2.8006.653
Limit value 1
Cause Corrective action
EMU exhaust gas temperature 1. Check wiring.
value too low. 2. Contact Service.

462 – HI T-Coolant EMU

ZKP-Number: 2.8006.654
Limit value 1
Cause Corrective action
EMU coolant temperature value u Check configuration with DiaSys.
too high / low.

464 – SD P-AUX 1
ZKP-Number: 1.8004.589

Cause Corrective action

Analog input signal for Aux 1 u Check pressure transmitter and wiring, replace as necessary.
pressure faulty; short circuit or Fault is rectified following engine restart.
wire break.

467 – AL L2 T-Aux 1
ZKP-Number: 2.0130.922
Limit value 2
Cause Corrective action
Temperature signal of Aux 1 has u Determine cause of limit value violation and rectify fault.
exceeded / not attained limit
value 2, depending on
configuration.

468 – SD T-AUX 1
ZKP-Number: 1.8004.579
Signal error, temperature Aux 1
Yellow alarm; warning
TIM-ID: 0000045495 - 001

Cause Corrective action

Analog input for Aux 2 u-
temperature faulty.

MS150069/02E 2014-03 | Troubleshooting | 149

 469 – SD AUX 1
ZKP-Number: 1.8004.590

Cause Corrective action

Analog input signal for Aux 1 u Check signal sensor and wiring, replace as necessary.
faulty; short circuit or wire Fault is rectified following engine restart.
break.

470 – SD T-ECU
ZKP-Number: 1.8004.587
Signal error, engine governor temperature
Yellow alarm; warning
Cause Corrective action
Temperature sensor for engine 1. Check sensor and wiring, replace as necessary (→ Page 260).
governor faulty. 2. Engine restart (→ Page 79).
Short circuit or wire break. 3. Contact Service.

471 – SD Coil Current

ZKP-Number: 1.8004.592
Signal error, HP fuel control block
Yellow alarm; warning
Cause Corrective action
Actuation of HP fuel control 1. Check sensor and wiring, replace as necessary (→ Page 260).
block faulty. 2. Contact Service.
Short circuit or wire break.

472 – AL Stop SD
ZKP-Number: 2.8006.593
Engine stops
Red alarm; engine shutdown
Cause Corrective action
Engine stops because 'Sensor 1. Check wiring (→ Page 260).
faulty" present at channels. 2. Contact Service.

473 – AL Wiring PWM_CM2

TIM-ID: 0000045495 - 001

ZKP-Number: 1.8004.593

Cause Corrective action

Wire break or short circuit on 1. Check wiring.
channel PWM_CM2. 2. Contact Service.

150 | Troubleshooting | MS150069/02E 2014-03

 474 – AL Wiring FO
ZKP-Number: 2.8006.655
Wiring fault on FO
Yellow alarm; warning
Cause Corrective action
Wire break or short circuit on 1. Check wiring (→ Page 260).
channel FO. 2. Contact Service.

475 – AL CR Engine Shutdown Trigger

ZKP-Number: 1.8010.009
Crash recorder was triggered by an engine shutdown.
Yellow alarm; warning
Cause Corrective action
Crash recorder was triggered by u Contact Service.
an engine shutdown.

476 – AL Crash Rec. Init. Error

ZKP-Number: 1.8010.007
Initialization error of crash recorder.
Cause Corrective action
Initialization error of crash u Contact Service.
recorder.

478 – AL Comb. Alarm Yel (Plant)

ZKP-Number: 2.8006.001
Yellow combined alarm from system
Yellow alarm; warning
Cause Corrective action
Various causes possible. u Check for additional messages.

479 – AL Comb. Alarm Red (Plant)

ZKP-Number: 2.8006.002
Red combined alarm from system
TIM-ID: 0000045495 - 001

Red alarm
Cause Corrective action
Various causes possible. u Check for additional messages.

MS150069/02E 2014-03 | Troubleshooting | 151

 480 – AL Ext. Engine Protection
ZKP-Number: 2.0291.921
External engine protection function active
Yellow alarm; warning
Cause Corrective action
The external engine protection 1. Check plant signal.
function is active. 2. Contact Service.
Monitoring of plant signal by
ECU active (plant side).

482 – SD T-Exhaust C
ZKP-Number: 18.004.596

Cause Corrective action

Exhaust temperature sensor on u Check sensor and wiring (B4.23), replace as necessary.
A side faulty. Short circuit or
wire break

483 – SD T-Exhaust D
ZKP-Number: 18.004.597

Cause Corrective action

Exhaust temperature sensor on u Check sensor and wiring (B4.24), replace as necessary.
A side faulty. Short circuit or
wire break

484 – HI T-Exhaust C
ZKP-Number: 20.133.931
Limit value 1
Cause Corrective action
Exhaust gas temperature (C- 1. Reduce power.
side) too high. 2. Contact Service.

485 – SS T-Exhaust C
ZKP-Number: 20.133.932
Limit value 2
TIM-ID: 0000045495 - 001

Cause Corrective action

Exhaust gas temperature (C- 1. Reduce power.
side) too high. 2. Contact Service.

152 | Troubleshooting | MS150069/02E 2014-03

 486 – HI T-Exhaust D
ZKP-Number: 20.134.931
Limit value 1
Cause Corrective action
Exhaust gas temperature (D- 1. Reduce power.
side) too high. 2. Contact Service.

487 – SS T-Exhaust D
ZKP-Number: 20.134.932
Limit value 2
Cause Corrective action
Exhaust gas temperature (D- 1. Reduce power.
side) too high. 2. Contact Service.

488 – HI ETC3 Overspeed

ZKP-Number: 2.3014.931
Speed of 2nd secondary turbocharger too high (limit value 1)
Yellow alarm; warning
Cause Corrective action
Clogged charge-air circuit or u Reduce power.
fault in turbocharger.

489 – SS ETC3 Overspeed

ZKP-Number: 2.3014.932
Speed of 2nd secondary turbocharger too high (limit value 2)
Red alarm; engine shutdown
Cause Corrective action
Clogged charge-air circuit or u Reduce power.
fault in turbocharger.

490 – HI ETC4 Overspeed

ZKP-Number: 2.3015.931
Speed of the 3rd secondary turbocharger too high (limit value 1)
TIM-ID: 0000045495 - 001

Yellow alarm; warning

Cause Corrective action
Clogged charge-air circuit or u Reduce power.
fault in turbocharger.

MS150069/02E 2014-03 | Troubleshooting | 153

 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 circuit or u Reduce power.
fault in turbocharger.

492 – AL ETC4 Cutin Failure

ZKP-Number: 18.004.202
Yellow alarm; warning
Cause Corrective action
ETC4 failed to cut in. u Check control valve at turbocharger 4.

493 – AL ETC3 Cutin Failure

ZKP-Number: 18.004.203
Yellow alarm; warning
Cause Corrective action
ETC3 failed to cut in. u Check control valve at turbocharger 3.

500 – AL Wiring POM Starter 1

ZKP-Number: 1.4500.900
Wiring fault, connection of starter 1 at POM
Yellow alarm; warning
Cause Corrective action
Missing consumer. u Check connection between POM and starter.
Short circuit or wire break

501 – AL Wiring POM Starter 2

ZKP-Number: 1.4500.901
Wiring fault, connection of starter 2 at POM
Yellow alarm; warning
TIM-ID: 0000045495 - 001

Cause Corrective action

Missing consumer. u Check connection between POM and starter.
Short circuit or wire break

154 | Troubleshooting | MS150069/02E 2014-03

 502 – AL Open Load POM Battery-charging Generator
ZKP-Number: 1.4500.902
Power disruption, battery-charging generator connection of POM
Yellow alarm; warning
Cause Corrective action
Wiring faulty or no resistance u Check connection between POM and battery-charging
over switch. generator.

503 – AL Battery Not Charging

ZKP-Number: 1.4500.903
No battery charge
Yellow alarm; warning
Cause Corrective action
Battery is not charged by u Check battery-charging generator and wiring (→ Page 260).
battery-charging generator.

504 – AL CAN POM Node Failure

ZKP-Number: 1.4500.904
POM missing on CAN bus
Yellow alarm; warning
Cause Corrective action
If alarm 508 occurs in addition, u Check connection and POM.
the resistor in the POM wiring is
missing.

506 – AL Low Starter Voltage

ZKP-Number: 1.4500.906
The battery voltage is too low for the starting process
Yellow alarm; warning
Cause Corrective action
Wiring faulty or battery is flat. u Check starter battery and wiring (→ Page 260).

507 – AL POM Fault

TIM-ID: 0000045495 - 001

ZKP-Number: 1.4500.907
A general POM fault occurred.
Yellow alarm; warning
Cause Corrective action
Fault in POM. u Replace POM.

MS150069/02E 2014-03 | Troubleshooting | 155

 508 – AL Incorrect POM ID
ZKP-Number: 1.4500.908
POM sends a different ID number than expected
Yellow alarm; warning
Cause Corrective action
If alarm 504 occurs in addition, u Check POM wiring harness.
the resistor in the POM wiring is
missing.

510 – AL Override applied

ZKP-Number: 2.7002.010
Override was activated
Yellow alarm; warning
Cause Corrective action
Override suppresses other u Deactivate Override pushbutton again.
alarms.

515 – AL Starter Not Engaged

ZKP-Number: 2.1090.926
Yellow alarm - possible start cancelation
Cause Corrective action
Starter on POM could not be 1. Repeat start.
engaged. 2. Check POM, starter and wiring (→ Page 260).
3. Contact Service.

519 – Oil Level Calibration Error

ZKP-Number: 1.0158.921
Error writing calibration value into flash or SD of level sensor.
Yellow alarm; warning
Cause Corrective action
Oil level sensor or wiring faulty. 1. Check sensor and wiring, replace as necessary (→ Page 260).
2. Contact Service.

531 – AL Wiring PWM_CM1

TIM-ID: 0000045495 - 001

ZKP-Number: 1.1044.900
Red alarm
Cause Corrective action
Wire break or short circuit on u Check wiring to TecJet throttle, replace TecJet throttle if
channel PWM_CM1. necessary.

156 | Troubleshooting | MS150069/02E 2014-03

 532 – AL Wiring PWM1
ZKP-Number: 1.1046.900
Red alarm
Cause Corrective action
Wire break or short circuit on u Check wiring to mixture throttle on A side, replace mixture
channel PWM1. throttle on A side if necessary.

533 – AL Wiring PWM2

ZKP-Number: 1.1047.900
Red alarm
Cause Corrective action
Wire break or short circuit on u Check wiring to mixture throttle on B side, replace mixture
channel PWM2. throttle on B side if necessary.

543 – AL Multiple FDH Slaves

ZKP-Number: 2.0555.005
Yellow alarm
Cause Corrective action
There is more than one device u Contact Service (configuration fault).
activated as backup medium for
FDH.

544 – AL Configuration Changed

ZKP-Number: 2.0555.003
Yellow alarm
Cause Corrective action
This alarm is activated when the u Contact Service (configuration fault).
system configuration was
changed, e.g. because the ECU
or SAM was exchanged.

549 – AL Power Disruption

ZKP-Number: 2.7001.952
Alarm from the emergency stop counter function
TIM-ID: 0000045495 - 001

Yellow alarm; warning

Cause Corrective action
Engine governor power has been u Instruct operators to switch off the power supply only after the
disconnected with the engine engine has come to a standstill.
still running. This may lead to
overpressure in the HP system
which can damage the engine.

MS150069/02E 2014-03 | Troubleshooting | 157

 551 – SS Engine Overspeed Camshaft
ZKP-Number: 22.510.933
Limit value 2
Cause Corrective action
Camshaft overspeed. 1. Acknowledge alarm.
2. Attempt engine restart.

555 – AL Call MTU Field Service

ZKP-Number: 20.555.001

Cause Corrective action

This fault becomes active if a u Request activation code via Internet.
maintenance case has been
processed by the ECU Field Data
Handling (FDH) feature that
results in a change of engine
parameters.
This fault remains active even
after switching off and back on
until a valid enabling code is
entered via the SAM display and
key controls. This enabling code
can be requested via the
Internet using a special
procedure.

576 – AL ESCM Override

ZKP-Number: 1.1075.083
Engine overload
Yellow alarm; warning
Cause Corrective action
Violation of corrected MCR or u Reduce power.
DBR/MCR curve.

577 – SD T-Lube Oil Pan

ZKP-Number: 1.0137.900
Signal error, oil pan temperature sensor
Yellow alarm; warning
TIM-ID: 0000045495 - 001

Cause Corrective action

Oil pan temperature sensor u Check sensor and cabling, replace as necessary (→ Page 260).
faulty.
Short circuit or wire break.

158 | Troubleshooting | MS150069/02E 2014-03

 582 – AL Emergency Stop Failure
ZKP-Number: 1.1005.006
Emergency stop command was not executed
Flashing pre-alarm and alarm
Cause Corrective action
Engine speed does not come to u Contact Service.
a standstill within a configurable
period.

584 – AL CAN Start clearance failed

Yellow alarm; warning
Cause Corrective action
Yellow alarm; warning; CAN u Contact Service.
object Start clearance was not
received within the expected
time period.

586 – LO P-Oil Refill Pump

ZKP-Number: 2.0159.911
Oil pressure in refill pump is too low - limit value 1
Yellow alarm; warning
Cause Corrective action
Oil level in oil refill tank too low. 1. Check oil level, top up as necessary (→ Page 213).
2. Contact Service.

588 – SD P-Oil Refill Pump

ZKP-Number: 1.0159.910
Signal error, refill pump oil pressure sensor
Yellow alarm; warning
Cause Corrective action
Pressure sensor defective. 1. Check sensor and wiring, replace as necessary (→ Page 260).
Short circuit or wire break. 2. Contact Service.

593 – AL T-Lube Oil in Oil Pan too Low

TIM-ID: 0000045495 - 001

ZKP-Number: 2.1090.929
Lube oil temperature in oil pan is too low.
Cause Corrective action
Preheating time is insufficient. 1. Extend preheating period.
2. Contact Service.

MS150069/02E 2014-03 | Troubleshooting | 159

 596 – AL Test Parameters
ZKP-Number: 1.8004.645
Yellow alarm; warning
Cause Corrective action
The parameter set is used for u Contact Service.
trials. The alarm remains set
until a series parameter set is
loaded.

600 – SD T-Exhaust A+B

ZKP-Number: 1.8004.646
Signal error, exhaust temperature sensor A- and B-side
Yellow alarm; warning
Cause Corrective action
Exhaust temperature sensor on 1. Check sensor and wiring, replace as necessary (→ Page 260).
A- and B-side faulty. 2. Contact Service.
Short circuit or wire break.

601 – SD ETC1+ETC2
ZKP-Number: 1.3011.227
Signal error, ETC speed sensor 1 and 2
Yellow alarm; warning
Cause Corrective action
ETC speed sensors 1 and 2 1. Check sensor and wiring, replace as necessary (→ Page 260).
faulty. 2. Contact Service.
Short circuit or wire break.

602 – AL CAN Engine Start Lock

ZKP-Number: 2.1090.930
Start interlock from plant pending
Yellow alarm; warning
Cause Corrective action
Start interlock initiated by plant. u The alarm is reset by canceling the engine start instruction or
the CAN request.
TIM-ID: 0000045495 - 001

160 | Troubleshooting | MS150069/02E 2014-03

 606 – AL Double Nodes Lost CAN 1+2
ZKP-Number: 2.0500.691
ECU does not detect a monitored CAN bus.
Red alarm; forced idle
Cause Corrective action
A node on both CANs has failed. 1. Check wiring and power supply of plant (→ Page 260).
Short circuit or wire break. 2. Acknowledge alarm.
3. Restart engine (→ Page 79).
4. Contact Service.

614 – AL L1 P-Fuel Supp. Filt. Diff.

ZKP-Number: 2.0119.001
Fuel prefilter differential pressure too high
Yellow alarm; warning
Cause Corrective action
Fuel prefilter not functioning 1. Replace fuel prefilter.
correctly. 2. Contact Service.

625 – SD P-Fuel b. Supp. Filter

ZKP-Number: 1.8004.600
Signal error, fuel pressure sensor before supplementary filter
Yellow alarm; warning
Cause Corrective action
Analog input signal for fuel 1. Check pressure transmitter and wiring, replace as necessary
pressure before supplementary (→ Page 260).
filter faulty. 2. Fault is rectified when engine is restarted (→ Page 79).
Short circuit or wire break. 3. Contact Service.

641 – AL System Restart by Watchdog

ZKP-Number: 1.8012.902
System is restarted by watchdog
Cause Corrective action
System restart by watchdog u-
detected.
TIM-ID: 0000045495 - 001

687 – SD Oil Level Switch

ZKP-Number: 1.0150.920
Level switch faulty
Cause Corrective action
Lube oil level switch is faulty. 1. Check sensor and wiring (B24), replace as necessary. Alarm is
==> Short circuit or wire break. reset when fault is eliminated (→ Page 260).
2. Contact Service.

MS150069/02E 2014-03 | Troubleshooting | 161

 690 – AL Oil Level too Low
ZKP-Number: 1.0150.921

Cause Corrective action

Alarm, lube oil level is too low. u-

759 – AL L1 T-Fuel b. Engine

ZKP-Number: 2.0080.921
Fuel before engine (limit 1)
Cause Corrective action
Fuel temperature before engine u-
too high.

760 – AL L2 T-Fuel b. Engine

ZKP-Number: 2.0080.922
Fuel before engine (limit 2)
Cause Corrective action
Fuel temperature before engine u-
too high.

761 – SD T-Fuel b. Engine

ZKP-Number: 1.0080.900

Cause Corrective action

Oil pan temperature sensor 1. Check sensor and wiring (B24), replace as necessary.
faulty. (→ Page 260).
==> Short circuit or wire break. 2. Contact Service.

782 – SD P-Lube oil ETC A

ZKP-Number: 1.0222.920

Cause Corrective action

SD turbocharger lube oil u-
pressure.

788 – Cyl. cutout detects turbocharger speed error

TIM-ID: 0000045495 - 001

ZKP-Number: 1.3000.069

Cause Corrective action

The cyl. cutout system has u-
detected an invalid turbocharger
speed at turbochargers 1 or 2.

162 | Troubleshooting | MS150069/02E 2014-03

 850 – SD Alive FIP
ZKP-Number: 2.0900.002
Frequency input faulty.
Cause Corrective action
Short circuit or wire break. u-
Fault in Backup ECU, Alive signal
not transmitted

856 – SD P-Lube oil ETC B

ZKP-Number: 1.0223.920

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 oil pressure too low. u Check ETC oil lubrication.

867 – AL L1 P-Lube Oil ETC A

ZKP-Number: 1.0222.923
Limit value 1
Cause Corrective action
Lube oil pressure too low. u Check ETC oil lubrication.

868 – AL L2 P-Lube Oil ETC A

ZKP-Number: 1.0222.924
Limit value 2
Cause Corrective action
Lube oil pressure too low. u Check ETC oil lubrication.

869 – AL L2 P-Lube Oil ETC B

TIM-ID: 0000045495 - 001

ZKP-Number: 1.0223.922
Limit value 2
Cause Corrective action
Lube oil pressure too low. u Check ETC oil lubrication.

MS150069/02E 2014-03 | Troubleshooting | 163

 6 Task Description
6.1 Engine
6.1.1 Engine – Barring manually
Preconditions
☑Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Barring device F6555766 1
Ratchet with extension F30006212 1

DANGER
Rotating and moving engine 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 engine, make sure that all safety devices are put back in place and all
tools are removed from the engine.

Barring engine manually

1. Release screws (1) and remove end cov-
er (2) from flywheel housing.

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164 | Task Description | MS150069/02E 2014-03

 2. Engage barring device (2) in ring gear of fly-
wheel and mount on flywheel housing.
3. Fit ratchet (1) onto barring device (2).
Note: No resistance other than compression re-
sistance must be encountered.
4. Rotate crankshaft in engine direction of ro-
tation.
Result: If the resistance exceeds the normal com-
pression resistance, contact Service.
5. Barring device is removed by same proce-
dure in reverse.
TIM-ID: 0000000917 - 010

MS150069/02E 2014-03 | Task Description | 165

 6.1.2 Engine – Barring with starting system
Barring using the automation system
Refer to automation system operating instructions

TIM-ID: 0000017532 - 003

166 | Task Description | MS150069/02E 2014-03

 6.2 Cylinder Liner
6.2.1 Cylinder liner – Endoscopic examination
Preconditions
☑Engine is stopped and starting disabled

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Rigid endoscope Y20097353 1

Preparatory steps
1. Remove cylinder head cover (→ Page 178).
2. Remove injector (→ Page 182).

Positioning crankshaft at BDC

1. Using barring gear, turn crankshaft until crankshaft journal of the cylinder to be inspected has reached
BDC.
2. Insert endoscope into cylinder liner through injector seat.

Cylinder liner – Endoscopic examination

Findings Task
• Thin carbon coating around circumference of carbon scraper ring No action required.
• Slight localized additive deposits at top edge
• Localized smooth areas at bottom edge
• Carbon deposits around circumference between top piston ring and
bottom edge of carbon scraper ring
• First signs of marks left by top piston ring
• Bright mark around circumference
• Faultless, even honing pattern
• First signs of marks left by lower cooling bores
• Running pattern seems darker
• Darker areas of even or varying color intensity Further endoscopic examina-
• Beginning and end of the discoloration are not sharply defined and tion required as part of mainte-
do not cover the entire stroke area nance work.
• Dark areas in the upper section of the cooling bore, remaining cir-
cumference cannot be faulted
• Piston rings faultless
• On the entire circumference not only bright discoloration (not criti- Cylinder liner must be replaced,
cal for operation) clearly visible darker stripes that begin at the top contact Service.
piston ring
TIM-ID: 0000000015 - 016

• Heat discoloration in the direction of stroke and honing pattern

damage
• Heat discoloration of piston rings

1. Compile endoscopy report using the table.

2. Use technical terms for description of the liner surface (→ Page 169).
3. Depending on findings:
• Do not take any action or
• Carry out further endoscopic examination as part of maintenance work or
• Contact Service; cylinder liner must be replaced.

MS150069/02E 2014-03 | Task Description | 167

 Final steps
1. Install injector (→ Page 182).
2. Install cylinder head cover (→ Page 178).

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168 | Task Description | MS150069/02E 2014-03

 6.2.2 Instructions and comments on endoscopic and visual examination of cylinder
liners
Terms used for endoscopic examination
Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic ex-
amination report.
Findings Explanations/Action
Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing products,
particles, broken-off burrs). Removed cylinders clearly show such scoring on the
running surface under endoscope magnification. Cannot be felt with the fingernail.
Findings not critical.
Single scores Clearly visible scores caused by hard particles. They usually start in the TDC area
and cross through the hone pattern in the direction of stroke.
Findings not critical.
Scored area These areas consist of scores of different length and depth next to one another. In
most cases, they are found at the 6-o'clock and 12-o'clock positions (inlet/
exhaust) along the transverse engine axis.
Findings not critical.
Smoothened area Smoothened areas are on the running surface but almost the whole honing pattern
is still visible. Smoothened areas appear brighter and more brilliant than the sur-
rounding running surface.
Findings not critical.
Bright area Bright areas are on the running surface and show local removal of the honing pat-
tern. Grooves from honing process are not visible any more.
Discoloration This is caused by oxidation (surface discoloration through oil or fuel) and tempera-
ture differences around 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 may be interrupted.
Findings not critical.
Corrosion fields / Corrosion fields / spots result from water (condensed water) with the valves in the
spots overlap (open) position. They are clearly visible due to the dark color of the honing
groove bottom.
This corrosion is not critical unless there is corrosion pitting.
Black lines Black lines are a step towards heat discoloration. They are visible as a clear discol-
oration from TDC to BDC in the running surface and the start of localized damage
to the honing pattern.
Cylinder liners with a large number of black lines around the running surface have
limited service life and should be replaced.
Burn mark This is caused by a malfunction in the liner / ring tribosystem. Usually they run
over the whole ring-travel area (TDC/BDC), starting at the first TDC-ring and be-
coming more visible from the second TDC-ring 2 onwards and less pronounced
from TDC-ring 1. The honing pattern is usually no longer visible and displays a
TIM-ID: 0000000014 - 015

clearly defined (straight) edge to the undisturbed surface. The damaged surface is
usually discolored. The circumferential length varies.
Liners with burn marks, or heat discoloration, starting in TDC-ring 1 have to be re-
placed.
Seizure marks, scuff- Irregular circumference lengths and depths. Can be caused either by the piston
ing skirt or the piston crown. Material deposits on the liner (smear), heavy discolora-
tion. Severe, visible scoring.
Replace liner.

MS150069/02E 2014-03 | Task Description | 169

 Evaluation of findings and further measures
The findings in the start phase of oxidation discoloration and heat discoloration 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 be carried out after
further operation of the engine.

TIM-ID: 0000000014 - 015

170 | Task Description | MS150069/02E 2014-03

 6.3 Crankcase Breather
6.3.1 Crankcase breather – Overview
For 12V engines

1 Vent pipe 5 Bracket 9 Spigot pipe

2 Plug 6 Oil line 10 Drain pipe
3 Oil separator 7 Service block 11 Bracket
4 Impactor carrier 8 Vent housing 12 Connection
TIM-ID: 0000038424 - 001

MS150069/02E 2014-03 | Task Description | 171

 For 16V engines

1 Vent pipe 5 Service block 9 Bracket

2 Impactor carrier 6 Vent housing 10 Plug
3 Bracket 7 Spigot pipe 11 Oil separator
4 Oil line 8 Drain pipe

TIM-ID: 0000038424 - 001

172 | Task Description | MS150069/02E 2014-03

 6.3.2 Crankcase breather – Oil mist fine separator replacement
Preconditions
☑Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Engine oil
Oil mist fine separator (→ Spare Parts Catalog)
O-ring (→ Spare Parts Catalog)

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 inhale oil vapor.

Replacing oil mist fine separator

1. Remove screws (1) and take off together
with holder (2).
2. Replace oil mist fine separator (3).
3. Replace O-ring (4) if necessary.
4. Replace further oil mist fine separators in
the same way.
TIM-ID: 0000018590 - 008

MS150069/02E 2014-03 | Task Description | 173

 6.4 Valve Drive
6.4.1 Valve gear – Lubrication
Preconditions
☑Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Engine oil

Valve gear – Lubrication

1. Remove cylinder head covers
(→ Page 178).
2. Fill oil chambers of valve bridges with oil.
3. Fill oil chambers of rocker arms and adjust-
ing screws with oil.
4. Install cylinder head covers (→ Page 178).

TIM-ID: 0000000921 - 010

174 | Task Description | MS150069/02E 2014-03

 6.4.2 Valve clearance – Check and adjustment
Preconditions
☑Engine is stopped and starting disabled.
☑Engine coolant temperature is max. 40 °C.
☑Valves are closed.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Feeler gage Y20010128 1
Torque wrench, 60-320 Nm F30452768 1
Socket wrench, 24 mm F30039526 1
Engine oil

Preparatory steps
1. Remove cylinder head cover (→ Page 178).
2. Install barring gear (→ Page 164).
3. The OT mark (1) on the flywheel (if applica-
ble) must not be used for reference.
TIM-ID: 0000012224 - 007

MS150069/02E 2014-03 | Task Description | 175

 4. Rotate crankshaft with barring tool in en-
gine direction of rotation until marking “OT-
A1” and pointer are aligned.

Diagram for 12V engines (two

crankshaft positions)
1 Cylinder A1 is in firing TDC
2 Cylinder A1 is in overlap TDC
I Inlet valve
X Exhaust valve

Diagram for 16V engines (two

crankshaft positions)
1 Cylinder A1 is in firing TDC
2 Cylinder A1 is in overlap TDC
I Inlet valve
X Exhaust valve
TIM-ID: 0000012224 - 007

176 | Task Description | MS150069/02E 2014-03

 Checking valve clearance in two crankshaft positions
1. Check TDC position of piston in cylinder A1:
• If the rocker arms are unloaded on cylinder A1, the piston is in firing TDC.
• If the rocker arms are loaded on cylinder A1, the piston is in overlap TDC.
2. Check valve clearance adjustment with engine cold:
• Inlet valves (long rocker arm) = 0.2 mm
• Exhaust valves (short rocker arm) = 0.5 mm
3. Check all valve clearances at two crankshaft positions (firing and overlap TDC for cylinder A1) as per
diagram.
4. Use feeler gage to determine the distance between valve bridge and rocker arm.
5. If the deviation from the reference value exceeds 0.1 mm, adjust valve clearance.

Adjusting valve clearance

1. Release locknut (1).
2. Insert feeler gage (3) between valve bridge
and rocker arm.
3. Using Allen key, set adjusting screw (2) so
that the specified valve clearance is provid-
ed.
Note: Feeler gage must just pass through the
gap.
4. Pull feeler gage (3) between valve bridge
and rocker arm.

5. Tighten locknut (1) to the specified tightening torque, holding adjusting screw (2) firmly.
Name Size Type Lubricant Value/Standard
Locknut M16 x 1.5 Tightening torque (Engine oil) 90 Nm + 9 Nm
6. Replace or rectify adjusting screws and/or locknuts which do not move freely.
7. Check valve clearance.

Final steps
1. Remove barring gear (→ Page 164).
2. Install cylinder head cover (→ Page 178).
3. Enable engine start.
TIM-ID: 0000012224 - 007

MS150069/02E 2014-03 | Task Description | 177

 6.4.3 Cylinder head cover – Removal and installation
Preconditions
☑Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Assembly compound (Kluthe Hakuform 30-11C/Emulgier) X00059351 1
O-ring (→ Spare Parts Catalog)

Removing cylinder head cover

1. Clean very dirty cylinder head covers (1)
prior to removal.
2. Remove screws (3, 4) with washers (2, 5).
3. Take off cylinder head cover (1) with O-
ring (6) from cylinder head (7).

Installing cylinder head cover

1. Clean mounting surface.
2. Check O-ring (6) for damage, replace as necessary.
3. Coat O-ring (6) with assembly compound.
4. Position O-ring (6) in groove of cylinder head cover (1).
5. Fit cylinder head cover (1) on cylinder head (7).
6. Install cylinder head cover (1) with screws (3, 4) and washers (2, 5).
TIM-ID: 0000012309 - 012

178 | Task Description | MS150069/02E 2014-03

 6.5 Injection Pump / HP Pump
6.5.1 HP pump – Filling with engine oil
Preconditions
☑Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Engine oil

WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.

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 fuel pump not filled with engine oil.
Damage to components, major material damage!
• Ensure that th HP fuel pump is filled with engine oil before it is installed or put into operation.

Filling HP pump
1. Remove plug screw (1).
2. Use pump oiler to fill HP pump with engine
oil until engine oil emerges.
3. Install plug screw (1).
TIM-ID: 0000001640 - 012

MS150069/02E 2014-03 | Task Description | 179

 6.5.2 HP pump – Relief bore check
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine'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-
charge.
2. For jacketed HP lines, leakage is indicated
by the yellow combined alarm.
3. If fuel discharge is found or indicated, con-
tact Service.

TIM-ID: 0000012375 - 007

180 | Task Description | MS150069/02E 2014-03

 6.6 Injector
6.6.1 Injector – Replacement
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Injector (→ Spare Parts Catalog)

Injector – Replacement
u Remove injector and install new one (→ Page 182).
TIM-ID: 0000042329 - 002

MS150069/02E 2014-03 | Task Description | 181

 6.6.2 Injector – Removal and installation
Preconditions
☑Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Installation/removal jig F6789889 1
Milling cutter F30452739 1
Torque wrench, 0.5-5 Nm 0015384230 1
Torque wrench, 10-60 Nm F30452769 1
Ratchet adapter F30027340 1
Torque wrench, 60-320 Nm F30452768 1
Ratchet adapter F30027341 1
Assembly paste(Optimoly Paste White T) 40477 1
Assembly compound (Kluthe Hakuform 30-11C/Emulgier) X00059351 1
Engine oil
O-ring (→ Spare Parts Catalog)

WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.

Preparatory steps
1. Shut off fuel supply to engine.
2. Remove cylinder head cover (→ Page 178).

Removing injector
1. Disconnect connectors on injector.
TIM-ID: 0000000925 - 012

182 | Task Description | MS150069/02E 2014-03

 2. Remove HP fuel line 4).
Note: While the adapter is removed, the injector
is drained.
3. Remove adapter (3).
4. Remove screw (2) and take off hold-down
clamp (1).

5. Install installation/removal jig on cylinder

head.
6. Remove injector with installation/removal
jig.
7. Remove installation/removal jig.

8. Remove sealing ring (4) from injector or

use a self-made hook to take it out of the
cylinder head.
9. Remove O-rings (3), O-ring (2) and damper
ring (1) from injector.
10. Clean all mating and sealing surfaces.
11. Cover all connections and bores, or seal
with suitable plugs.
TIM-ID: 0000000925 - 012

MS150069/02E 2014-03 | Task Description | 183

 Installing injector
1. Remove plug before installing the injec-
tor. (Do not remove the plug from the HP
line before installing the adapter).
2. Coat injector with assembly paste at the
seat of the nozzle retaining nut.
3. Fit new sealing ring (included in the scope
of delivery of the injector) with assembly
compound on injector, observe installation
position of sealing ring.

4. Fit new O-rings (3) (included in the scope

of delivery of the injector), O-ring (2) and
damping ring (1) onto the injector and coat
with assembly compound (Kluthe Hakuform
30-11C/Emulgier).
5. Remove oil carbon from sealing face on cyl-
inder head and protective sleeve with mill-
ing cutter.
6. Insert injector into cylinder head, ensuring
that the HP line adapter is correctly
aligned.

7. Press in injector with installation/removal

jig.
8. Remove installation/removal jig.
TIM-ID: 0000000925 - 012

184 | Task Description | MS150069/02E 2014-03

 9. Coat screw head mating face (2) and
thread with engine oil.

10. Fit hold-down clamp (1) in the correct position and use torque wrench to tighten screw (2) to the speci-
fied initial tightening torque.
Name Size Type Lubricant Value/Standard
Screw M12 Preload torque (Engine oil) 5 Nm to 10 Nm
Note: Ensure special cleanness.
11. Coat thread and sealing cone of adapter (3) with engine oil.
12. Install adapter (3) and use torque wrench to tighten to the specified initial tightening torque.
Name Size Type Lubricant Value/Standard
Adapter Preload torque (Engine oil) 5 Nm to 10 Nm
13. Tighten screw (2) with torque wrench to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw M12 Tightening torque 100 Nm + 10 Nm
14. Tighten adapter (3) with torque wrench to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Adapter Tightening torque 100 Nm + 10 Nm
Note: Ensure special cleanness.
15. Coat thread and sealing cone of HP line (5) with engine oil.
16. Mount jacketed HP line (5) and use torque wrench to tighten to the specified torque. Tightening se-
quence:
1 Adapter (4)
TIM-ID: 0000000925 - 012

2 Rail (6)
Name Size Type Lubricant Value/Standard
Union nut / thrust Tightening torque 40 Nm + 5 Nm
screw

MS150069/02E 2014-03 | Task Description | 185

 17. Fit connectors on injector.
Note: Failure to reset drift compensation (CDC)
will void the emissions certification.
18. Reset drift compensation (CDC) with Dia-
Sys® (→ E531920/...). If DiaSys® is not
available, contact Service.

Final steps
1. Install cylinder head cover (→ Page 178).
2. Open fuel supply to engine.

TIM-ID: 0000000925 - 012

186 | Task Description | MS150069/02E 2014-03

 6.7 Fuel Filter
6.7.1 Supplementary fuel filter – Overview

1 Storage tank 3 Passive standard prefilter 5 Supplementary fuel filter

2 Day tank with water separator 6 Main engine filter
4 LP pump
TIM-ID: 0000012629 - 004

MS150069/02E 2014-03 | Task Description | 187

 6.7.2 Additional fuel filter – Replacement
Preconditions
☑Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Filter wrench F30379104 1
Diesel fuel
Easy-change filter (→ Spare Parts Catalog)
Synthetic ring (→ Spare Parts Catalog)

DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

NOTICE
Damage to component!
Severe material damage!
• For filter replacement with the engine running, operate the engine at low engine load.
• The filter which is to be replaced must be cut out for a brief period only.

Additional fuel filter – Replacement

1. Replace additional fuel filter with the engine stopped (→ Page 189).
2. Replace additional fuel filter with the engine running (→ Page 189).
TIM-ID: 0000012645 - 003

188 | Task Description | MS150069/02E 2014-03

 6.7.3 Fuel filter – Replacement
Preconditions
☑Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Filter wrench F30379104 1
Diesel fuel
Easy-change filter (→ Spare Parts Catalog)
Synthetic ring (→ Spare Parts Catalog)

DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

NOTICE
Damage to component!
Severe material damage!
• For filter replacement with the engine running, operate the engine at low engine load.
• The filter which is to be replaced must be cut out for a brief period only.

Replacing fuel filter with the en-

gine stopped
1. Cut out the filter to be replaced (1):
B Left filter cut out
C Right filter cut out
2. Remove the cut-out oil filter (1) using an oil
filter wrench.
TIM-ID: 0000045359 - 001

3. Clean sealing surface on filter head.

4. Check sealing ring of new filter (1) and coat
with fuel.
5. Screw on filter (1) and tighten manually.
6. Turn three-way cock into position (A) where
both filters are operational.
7. Replace other fuel filters in the same way.
8. Venting fuel system (→ Page 191)

MS150069/02E 2014-03 | Task Description | 189

 Replacing fuel filter with the en-
gine running
1. Cut out the filter to be replaced (1):
B Left filter cut out
C Right filter cut out
2. Remove the cut-out oil filter (1) using an oil
filter wrench.
3. Clean sealing surface on filter head.
4. Check sealing ring of new filter (1) and coat
with fuel.
5. Screw on filter (1) and tighten manually.
6. Turn three-way cock into position (A) where
both filters are operational.
7. Replace other fuel filters in the same way.

TIM-ID: 0000045359 - 001

190 | Task Description | MS150069/02E 2014-03

 6.7.4 Fuel system – Venting
Preconditions
☑Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Diesel fuel

WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.

Venting LP fuel system

1. Turn three-way cock (3) into position (C)
where both filters are operational.
2. Open threaded vent plugs (1).
3. Unlock fuel priming pump (2), screw out
handle by turning it counterclockwise.
4. Operate fuel 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 must be tightened.
8. Put filters back into operation:
A Right filter in operation
B Left filter in operation
Result: During operation, one filter is cut in.
TIM-ID: 0000012552 - 004

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 6.7.5 Fuel prefilter – Differential pressure check and adjustment of gauge
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

Setting adjustable pointer of dif-

ferential pressure gauge
1. After installation of a new filter element,
align adjustable pointer (2) with pressure-
indicating pointer (3) of pressure gauge (1).
2. Verify that differential pressure is within
the limit.

Fuel prefilter – Checking differential pressure

1. With the engine running at full load or rated power, read off pressure at gauge (1).
2. If differential pressure as indicated between position of adjustable pointer (2) and pressure-indicating
pointer (3) of pressure gauge is ≥ 0.3 bar, flush filter element of the cut-in filter (→ Page 195).
TIM-ID: 0000004925 - 008

192 | Task Description | MS150069/02E 2014-03

 6.7.6 Fuel prefilter – Draining
Preconditions
☑Engine is stopped and starting disabled.

WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.

Draining fuel prefilter

1. Cut out the filter to be replaced (A or B).
1 Filter A cut out
2 Filter B cut out

2. Open vent plug (1) of filter to be drained.

3. Open drain valve (2).
4. Drain water and contaminants from filter
until pure fuel emerges.
5. Close drain cock (2).
TIM-ID: 0000018510 - 004

MS150069/02E 2014-03 | Task Description | 193

 6. Connect filling pump to filling connection
(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. Open rotary slide valve (4) a little (by ap-
prox. 30°) and open vent valve(s) (2), until
fuel emerges from the vent pipe (3).
10. Close vent valve(s) (2).
11. Turn rotary slide valve (4) back to locked
position.

TIM-ID: 0000018510 - 004

194 | Task Description | MS150069/02E 2014-03

 6.7.7 Fuel prefilter – Flushing
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Diesel fuel

DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

Flushing fuel prefilter

1. Cut out dirty filter.
1 Filter A cut out
2 Filter B cut out
TIM-ID: 0000012728 - 006

MS150069/02E 2014-03 | Task Description | 195

 2. Open vent plug (1) of filter to be flushed.
3. Open drain valve (2) and drain fuel.
Result: Fuel flows from filtered side back to the un-
filtered side, flushing the filter deposits
downwards out of the filter.
4. Close vent plug (1) and drain valve (2).

Fuel prefilter – Filling with fuel

1. Stop engine (→ Page 88) and disable engine start.
2. Connect filling pump to 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. Open rotary slide valve (4) a little (by ap-
prox. 30°) and open vent valve(s) (2), until
fuel emerges from the vent pipe (3).
6. Close vent valve(s) (2).
7. Turn rotary slide valve (4) back to locked
position.
8. Check differential pressure (→ Page 192).
Result: Replace filter element in fuel prefilter
(→ Page 197) if flushing did not improve dif-
ferential pressure.
TIM-ID: 0000012728 - 006

196 | Task Description | MS150069/02E 2014-03

 6.7.8 Fuel prefilter with water separator – Filter element replacement
Preconditions
☑Engine is stopped and starting disabled.
☑System is at atmospheric pressure.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Torque wrench, 10-60 Nm F30452769 1
Ratchet adapter F30027340 1
Filter element (→ Spare Parts Catalog)
O-ring (→ Spare Parts Catalog)

WARNING
Tank is pressurized.
Risk of eye injuries resulting from fluid escaping under high pressure!
• Open tank slowly.
• Wear goggles or safety mask.

WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.

WARNING
Component is hot.
Risk of burning!
• Wear protective gloves.

Fuel prefilter with water separa-

tor – Filter element replacement
1. Cut out the filter to be replaced (A or B):
1 Filter A cut out
2 Filter B cut out
TIM-ID: 0000012750 - 006

MS150069/02E 2014-03 | Task Description | 197

 2. Open vent valve (1) of the filter to be re-
placed.
3. Open drain valve (5) and drain fuel.
4. Loosen screws (3) and screw out filter
housing (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 el-
ement (4).

9. Tighten screws (6 or 3) with torque wrench to the specified tightening torque (maximum half a turn per
screw).
Name Size Type Lubricant Value/Standard
Screw Tightening torque 40 Nm
10. Connect filling pump to filling connection
(1) on the suction side of the filter.
11. Open vent valve (2) and fill with fuel until
fuel emerges from the vent pipe (3).
12. Close vent valve (2).
13. Open rotary slide valve (4) a little (by ap-
prox. 30°) and open vent valve(s) (2), until
fuel emerges from the vent pipe (3).
14. Close vent valve(s) (2).
15. Turn rotary slide valve (4) back to locked
position.

TIM-ID: 0000012750 - 006

198 | Task Description | MS150069/02E 2014-03

 6.7.9 Fuel prefilter with water separator – O-ring replacement in rotary slide valve
Preconditions
☑Engine is stopped and starting disabled.
☑System is at atmospheric pressure.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
O-ring (→ Spare Parts Catalog)

WARNING
Tank is pressurized.
Risk of eye injuries resulting from fluid escaping under high pressure!
• Open tank slowly.
• Wear goggles or safety mask.

WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.

Fuel prefilter with water separa-

tor – O-ring replacement in rota-
ry slide valve
1. Open vent valves (1) carefully to make sure
that the system is not pressurized.
2. Open drain valves (6) and drain fuel.
3. Remove rotary slide valve retainer (4) with
handle (5).
4. Remove rotary slide valve (3) with O-rings
(2).
5. Replace O-rings (2).
6. For assembly, follow the reverse sequence
of working steps as described for disas-
sembly.
TIM-ID: 0000012751 - 004

MS150069/02E 2014-03 | Task Description | 199

 6.8 Exhaust Turbocharger
6.8.1 Compressor wheel – Cleaning
Preconditions
☑Engine is stopped and starting disabled

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Torque wrench, 10-60 Nm F30452769 1
Ratchet adapter F30027340 1
Cleaner 40377 1
Engine oil
Engine coolant
Sealing rings (→ Spare Parts Catalog) 3
Sealing rings (→ Spare Parts Catalog) 4

WARNING
Chemical substances.
Risk of irritation and chemical burns!
• Observe the instructions of the cleaning agent manufacturer.

NOTICE
Inappropriate cleaning tool.
Risk of damage to component!
• Observe manufacturer's instructions.
• Use appropriate cleaning tool.

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 installation position of components.

Preparatory steps – Horizontal air intake

1. Drain engine coolant (→ Page 231).
2. Remove air filter (→ Page 210).
3. Seal all openings with suitable covers.
TIM-ID: 0000018629 - 006

200 | Task Description | MS150069/02E 2014-03

 4. Remove charge-air pipework (1) from ex-
haust turbocharger to intercooler.
5. Remove oil lines (2).

6. Loosen clamp (1).

7. Remove intake housing (3) with actuating
cylinder (2).

8. Remove coolant lines (1) from compressor

housing (3).
9. Remove coolant ventilation line (2) from
compressor housing (3).
TIM-ID: 0000018629 - 006

MS150069/02E 2014-03 | Task Description | 201

 10. Undo screws (1).
11. Remove compressor housing (2).

Cleaning compressor wheel

Note: Do not use wire brushes, scrapers or simi-
lar tools for cleaning!
1. Clean compressor housing with a smooth
paint brush or brush.
2. Clean compressor wheel (2) and bearing
housing (1).
3. Thoroughly remove cleaner from all compo-
nents.
4. Fit new sealing rings between bearing
housing/compressor housing and plug-in
sleeves if necessary.

Final steps – Horizontal air in-

take
1. Install compressor housing (2).
TIM-ID: 0000018629 - 006

202 | Task Description | MS150069/02E 2014-03

 2. Tighten screws (1) to specified torque using a torque wrench.
Name Size Type Lubricant Value/Standard
Screw Tightening torque (Engine oil) 20 Nm + 2.5 Nm
3. Install coolant ventilation line and coolant lines on compressor housing.
4. Install intake housing (3) with actuating cyl-
inder (2).

5. Align clamp (1) and tighten to specified torque using a torque wrench.
Name Size Type Lubricant Value/Standard
Clamp Tightening torque 15 Nm + 2 Nm
TIM-ID: 0000018629 - 006

6. Install oil lines (2). Tighten threaded adapter at actuating cylinder to specified torque using a torque
wrench.
Name Size Type Lubricant Value/Standard
Threaded adapter 10 G 1/4 Tightening torque (Engine oil) 40 Nm +4 Nm
A
7. Install charge-air pipework (1) between exhaust turbocharger and intercooler.
8. Install air filter (→ Page 210).
9. Fill with engine coolant (→ Page 234).

MS150069/02E 2014-03 | Task Description | 203

 Preparatory steps – Vertical air intake
1. Drain engine coolant (→ Page 231).
2. Remove air filter (→ Page 210).
3. Seal all openings with suitable covers.
4. Remove charge-air pipework (1) from ex-
haust turbocharger to intercooler.
5. Remove oil lines (2).

6. Loosen clamp (1).

7. Remove intake housing (3) with actuating
cylinder (2).

TIM-ID: 0000018629 - 006

204 | Task Description | MS150069/02E 2014-03

 8. Remove coolant lines (1) from compressor
housing (3).
9. Remove coolant ventilation line (2) from
compressor housing (3).

10. Undo screws (1).

11. Remove compressor housing (2).

Cleaning compressor wheel

Note: Do not use wire brushes, scrapers or simi-
lar tools for cleaning!
1. Clean compressor housing with a smooth
paint brush or brush.
2. Clean compressor wheel (2) and bearing
housing (1).
3. Thoroughly remove cleaner from all compo-
nents.
TIM-ID: 0000018629 - 006

4. Fit new sealing rings between bearing

housing/compressor housing and plug-in
sleeves if necessary.

MS150069/02E 2014-03 | Task Description | 205

 Final steps – Vertical air intake
1. Install compressor casing (2).

2. Tighten screws (1) to specified torque using a torque wrench.

Name Size Type Lubricant Value/Standard
Screw Tightening torque (Engine oil) 20 Nm + 2.5 Nm
3. Install coolant ventilation line and coolant lines on compressor housing.
4. Install intake housing (3) with actuating cyl-
inder (2).

5. Align clamp (1) and tighten to specified torque using a torque wrench.
Name Size Type Lubricant Value/Standard
Clamp Tightening torque 15 Nm + 2 Nm
TIM-ID: 0000018629 - 006

206 | Task Description | MS150069/02E 2014-03

 6. Install oil lines (2). Tighten threaded adapter at actuating cylinder to specified torque using a torque
wrench.
Name Size Type Lubricant Value/Standard
Threaded adapter 10 G 1/4 Tightening torque (Engine oil) 40 Nm +4 Nm
A
7. Install charge-air pipework (1) between exhaust turbocharger and intercooler.
8. Install air filter (→ Page 210).
9. Fill with engine coolant (→ Page 234).
TIM-ID: 0000018629 - 006

MS150069/02E 2014-03 | Task Description | 207

 6.9 Charge-Air Cooling
6.9.1 Intercooler – Checking condensate drain for water discharge and obstruction
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.

Intercooler – Checking conden-

sate drain for water discharge
and obstruction
1. With the engine running, check if air
emerges from drain bore(s) on the left and
right sides on engine driving end.
Result: If no air emerges:
• Clean condensate drain bore(s).
• Blow out with compressed air.
2. If a large amount of coolant is continuously
discharged, the intercooler is leaking. Con-
tact Service.

Emergency measures prior to engine start with a leaking intercooler

1. Remove injectors (→ Page 182).
2. Bar engine manually (→ Page 164).
3. Bar engine with starting system to blow out combustion chambers (→ Page 164).
TIM-ID: 0000013214 - 006

4. Install injectors (→ Page 182).

208 | Task Description | MS150069/02E 2014-03

 6.10 Air Filter
6.10.1 Air filter – Replacement
Special tools, Material, Spare 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 210).
2. Reset signal ring of contamination indicator (→ Page 211).
TIM-ID: 0000005447 - 009

MS150069/02E 2014-03 | Task Description | 209

 6.10.2 Air filter – Removal and installation
Preconditions
☑Engine is stopped and starting disabled.

Air filter
1. Loosen clamp (2).
2. Remove air filter (1) and clamp (2) from
connecting flange of housing (3).
3. Verify that there are no objects in the
flange of the intake housing (3) and clean
it.
4. Attach air filter (1) with clamp (2) onto in-
take housing (3).
5. Tighten clamp (2).

Air filter with intake silencer

1. Loosen clamp (2).
2. Remove air filter (1) and clamp (2) from in-
take silencer (3).
3. Clean intake silencer (3) and check for ob-
structions.
4. Attach air filter (1) with clamp (2) onto in-
take silencer (1).
5. Tighten clamp (2).

TIM-ID: 0000013401 - 007

210 | Task Description | MS150069/02E 2014-03

 6.11 Air Intake
6.11.1 Service indicator – Signal ring position check (optional)
Preconditions
☑Engine is stopped and starting disabled.

Checking signal ring position

1. If the signal ring is completely visible in the
control window (2), replace air filter
(→ Page 209).
2. After installation of new filter, press reset
button (1).
Result: Engaged piston with signal ring moves
back to initial position.
TIM-ID: 0000005484 - 008

MS150069/02E 2014-03 | Task Description | 211

 6.12 Starting Equipment
6.12.1 Starter – Condition check
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 260).

TIM-ID: 0000000905 - 017

212 | Task Description | MS150069/02E 2014-03

 6.13 Lube Oil System, Lube Oil Circuit
6.13.1 Engine oil – Level check
Preconditions
☑Engine is stopped and starting disabled.

Oil level check prior to engine

start
1. Withdraw dipstick from guide tube and
wipe it.
2. Insert dipstick into guide tube to stop,
withdraw after approx. 10 seconds and
check oil level.
Note: After extended standstill, 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
exchanger flowing back into the oil pan.
3. The oil level must reach mark (1) or exceed
mark (1) by up to 2 cm.
4. Top up with oil to mark (1) as necessary
(→ Page 214).
5. Insert dipstick into guide tube up to the
stop.

Oil level check after the engine is stopped

1. 5 minutes after stopping the engine, remove oil dipstick from the guide tube and wipe it.
2. Insert dipstick into guide tube to stop, withdraw after approx. 10 seconds and check oil level.
3. Oil level must be between marks (1) and (2).
4. Top up with oil to mark (1) as necessary (→ Page 214).
5. Insert dipstick into guide tube up to the stop.
TIM-ID: 0000000931 - 012

MS150069/02E 2014-03 | Task Description | 213

 6.13.2 Engine oil – Change
Preconditions
☑Engine is stopped and starting disabled.
☑Engine is at operating temperature.
☑MTU Fluids and Lubricants Specifications (A001061/..) are available.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Torque wrench, 40-200 Nm F30027337 1
Ratchet adapter F30027341 1
Engine oil
Sealing ring (→ Spare Parts Catalog)

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 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 drain plug(s) and drain oil.
3. Install drain plug(s) with new sealing ring.

Oil change with semirotary hand pump: Oil extraction

1. Provide a suitable container to collect the oil.
2. Draw all oil from oil pan using the semirotary hand pump.

Draining residual oil at gearcase

1. Provide a suitable container to collect the
oil.
2. Remove drain plugs (1) and (2) and drain
oil:
• Approx. 12 liters at (1)
• Approx. 5 liters at (2)
3. Install drain plug(s) with new sealing ring.
TIM-ID: 0000014099 - 003

214 | Task Description | MS150069/02E 2014-03

 4. Tighten drain plugs (1) and (2) to specified torque using a torque wrench:
Name Size Type Lubricant Value/Standard
Screw M26x1.5 Tightening torque (Engine oil) 100 Nm+10 Nm

Filling with new oil

1. Open cap on filler neck.
2. Pour oil in at filler neck up to 'max.' mark
at oil dipstick.
3. Close cap on filler neck.
4. Check engine oil level (→ Page 213).
5. Turn engine with starting system after oil
change (→ Page 166).
TIM-ID: 0000014099 - 003

MS150069/02E 2014-03 | Task Description | 215

 6.13.3 Engine oil – Sample extraction and analysis
Preconditions
☑MTU Fluids and Lubricants Specifications (A001061/..) are available.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
MTU test kit 5605892099/00 1

DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.

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 inhale oil vapor.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

Engine oil – Sample extraction

and analysis
1. With the engine running at operating tem-
perature, open screw on centrifugal oil fil-
ter carrier by 1 to 2 rotations.
2. Drain approx. 2 liters engine oil to flush out
the oil sludge.
3. Drain approx. 1 liter engine oil into a clean
container.
4. Close screw.
5. Using the equipment and chemicals in the
MTU test kit, analyze the engine oil for:
• Dispersion capability (spot test);
• Water content;
• Dilution by fuel.
TIM-ID: 0000014113 - 005

216 | Task Description | MS150069/02E 2014-03

 Engine oil – Sample extraction
and analysis (engines with
switchable oil filter)
1. With the engine running at operating tem-
perature, open screw on flange of centrifu-
gal oil filter by 1 to 2 rotations.
2. Drain approx. 2 liters engine oil to flush out
the oil sludge.
3. Drain approx. 1 liter engine oil into a clean
container.
4. Close screw.
5. Using the equipment and chemicals in the
MTU test kit, analyze the engine oil for:
• Dispersion capability (spot test);
• Water content;
• Dilution by fuel.
TIM-ID: 0000014113 - 005

MS150069/02E 2014-03 | Task Description | 217

 6.14 Oil Filtration / Cooling
6.14.1 Engine oil filter ‒ Replacement
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Filter wrench F30379104
Engine oil
Oil filter (→ Spare Parts Catalog)

DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

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 inhale oil vapor.

NOTICE
Damage to component!
Severe material damage!
• For filter replacement with the engine running, operate the engine at low engine load.
• The filter which is to be replaced must be cut out for a brief period only.

Engine oil filter ‒ Replacement

1. Stop engine (→ Page 88) and disable en-
gine start.
2. Unscrew oil filter using filter wrench.
3. Clean sealing surface on connecting piece.
4. Check condition of new oil filter sealing
ring and moisten it with oil.
5. Screw on and tighten new oil filter by hand.
TIM-ID: 0000014238 - 006

6. Replace other oil filters in the same way.

7. Turn engine with starting system after ev-
ery oil change and filter replacement
(→ Page 166).
8. Check oil level (→ Page 213).

218 | Task Description | MS150069/02E 2014-03

 Oil filter with diverter (option):
Oil filter replacement with the
engine stopped
1. Stop engine (→ Page 88) and disable en-
gine start.
2. Unscrew oil filter using oil filter wrench.
3. Clean sealing surface on connecting piece.
4. Check condition of new oil filter sealing
ring and moisten it with oil.
5. Fit SOLAS shield (→ Page 15).
6. Screw on and tighten new oil filter by hand.
7. Replace other oil filters in the same way.
8. Turn engine with starting system after ev-
ery oil change and filter replacement
(→ Page 166).
9. Check oil level (→ Page 213).

Oil filter with diverter (option):

Oil filter replacement with the
engine running
1. To cut out the filter to be replaced, set the
three-way cock to the corresponding posi-
tion.
• Position A: Lower filters cut out
• Position B: Both filters cut in (normal op-
erating position)
• Position C: Upper filters cut out.

2. Unscrew oil filter using oil filter wrench.

3. Clean sealing surface on connecting piece.
4. Check condition of new oil filter sealing
ring and moisten it with oil.
5. Fit SOLAS shield (→ Page 15).
6. Screw on and tighten new oil filter by hand.
7. Replace other oil filters in the same way.
8. Check oil level (→ Page 213).
TIM-ID: 0000014238 - 006

MS150069/02E 2014-03 | Task Description | 219

 6.14.2 Oil indicator filter – Cleaning and check
Preconditions
☑Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Cleaning agent (Snow-White 11-0) 40460 1
Cleaning agent (Hakupur 312) 30390 1
Engine oil
Strainer (→ Spare Parts Catalog)
Square-section ring (→ Spare Parts Catalog)
O-ring (→ Spare Parts Catalog)

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 inhale oil vapor.

WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.

NOTICE
Inappropriate cleaning tool.
Risk of damage to component!
• Observe manufacturer's instructions.
• Use appropriate cleaning tool.

Removing strainer
1. Clean oil indicator filter before disassem-
bling it.
2. Remove screws (1).
3. Take off cover (2) with O-ring (3).
4. Take strainer (5) from filter housing.
TIM-ID: 0000006402 - 006

220 | Task Description | MS150069/02E 2014-03

 Checking strainer
Item Findings Action
Strainer Metallic residues • Clean
• Monitor engine operation
• Check strainer daily
• Contact Service
Strainer Damaged Fit 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 compressed air from inside.

Installing strainer
1. Coat square-section ring (4) on strainer (5) with engine oil and install strainer (5).
2. Coat O-ring (3) with engine oil and fit in filter housing.
3. Fit cover (2) and secure with screws (1) and washers.
TIM-ID: 0000006402 - 006

MS150069/02E 2014-03 | Task Description | 221

 6.14.3 Centrifugal oil filter – Cleaning and filter sleeve replacement
Preconditions
☑Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Torque wrench, 6-50 Nm F30027336 1
Filter wrench F30379104 1
Cleaner Hakutex 60
Grease (Kluthe Hakuform 30-10/emulsifier) X00029933 1
Filter sleeve (→ 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 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 inhale oil vapor.

WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.

TIM-ID: 0000014256 - 004

222 | Task Description | MS150069/02E 2014-03

 Centrifugal oil filter – Cleaning
and filter sleeve replacement
1. Remove clamp (14).
2. Release Tommy nut (2) and take off cov-
er (1).
3. Carefully lift rotor (11), allow oil to drain
and remove from housing.
4. Holding the rotor (11) firmly, release rotor
cover nut (3).
5. Take off rotor cover (4).
6. Remove filter sleeve (6).
7. Measure layer thickness of oil residues on
filter sleeve (6).
Result: If the oil residues exceed the maximum lay-
er thickness of 45 mm, shorten the mainte-
nance interval.
8. Disassemble rotor tube (7), conical disk (8)
and rotor base (10).
9. Wash rotor cover (4), rotor tube (7), conical
disk (8) and rotor base (10) with cold
cleaner.
10. Blow out with compressed air.
11. Check sealing ring (9), fit new one if neces-
sary.
12. Assemble rotor tube (7), conical disk (8)
and rotor base (10) with sealing ring (9).
13. Insert new filter sleeve (6) in rotor tube (7)
with the smooth paper surface facing the
outer wall.
14. Check sealing ring (5), fit new one if neces-
sary.
15. Mount rotor cover (4) with sealing ring (5).
16. Tighten rotor cover nut (3) with torque wrench to the specified torque.
Name Size Type Lubricant Value/Standard
Nut Tightening torque 35 Nm to 45 Nm
17. Place rotor (11) in housing (12) and check for ease of movement.
18. Check sealing ring (13), fit new one if necessary.
19. Fit sealing ring (13) on housing (12).
20. Fit hood (1).
21. Tighten Tommy nut (2) by hand.
22. Install clamp (14) and tighten with torque wrench to the specified torque.
Name Size Type Lubricant Value/Standard
TIM-ID: 0000014256 - 004

Clamp Tightening torque 8 Nm to 10 Nm

23. Tighten cover nut (2) with torque wrench to the specified torque.
Name Size Type Lubricant Value/Standard
Screw Tightening torque 5 Nm to 7 Nm

MS150069/02E 2014-03 | Task Description | 223

 Cleaning centrifugal oil filter
and replacing filter sleeve (en-
gines with switchable oil filter)
1. Undo and remove screw (1).
2. Remove clamp (3) and take off hood (2).
3. Carefully remove rotor (5) from housing.
4. Hold rotor assembly (5) firmly in position
with filter wrench and undo knurled nut (7).
5. Take off rotor cap (8).
6. Remove filter sleeve (9), stiffener plate (10)
and sealing ring (11).
7. Measure thickness of oil residues on filter
sleeve.
8. If maximum layer thickness of oil residues
exceeds 30 mm, shorten maintenance in-
terval.
9. Remove standpipe (12) from lower rotor
section (13).
10. Wash hood (2), rotor cap (8), stiffener
plate (10), standpipe (12), lower rotor sec-
tion (13) and nozzles (14) with cleaner and
blow out with compressed air. Do not use
sharp objects for cleaning.
11. Check nozzles (14) for obstructions.
12. Push 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. Check sealing ring (11), replace if necessa-
ry. Coat sealing ring with grease and insert
in groove of rotor cap (8).
15. Place rotor cap (8) onto standpipe (12).
16. Hold rotor assembly (5) firmly in position
with filter wrench and tighten knurled
nut (7).
17. Lubricate bearings of rotor (5), insert in
housing (6) and check for ease of move-
ment.
18. Check sealing ring (4), replace if necessary.
Fit sealing ring on housing (6).
19. Fit hood (2).
20. Tighten screw (1) by hand.
21. Install clamp (3) and tighten to specified torque using a torque wrench:
TIM-ID: 0000014256 - 004

Name Size Type Lubricant Value/Standard

Clamp Tightening torque 6 Nm + 1 Nm
22. Tighten screw (1) to specified torque using a torque wrench:
Name Size Type Lubricant Value/Standard
Screw Tightening torque 6 Nm + 1 Nm

224 | Task Description | MS150069/02E 2014-03

 6.15 Coolant Circuit, General, High-Temperature Circuit
6.15.1 Drain and vent points
Coolant lines on ETC
1 Vent point

Coolant line to intercooler

1 Vent point
TIM-ID: 0000014545 - 004

MS150069/02E 2014-03 | Task Description | 225

 1 Vent point

Coolant line to raw water cooler

1 Vent point

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226 | Task Description | MS150069/02E 2014-03

 Vent line – Distribution cross
1 Vent point

Coolant drain point, engine driving end

1 Drain point
TIM-ID: 0000014545 - 004

MS150069/02E 2014-03 | Task Description | 227

 Coolant drain point, engine free end
1 Drain point

TIM-ID: 0000014545 - 004

228 | Task Description | MS150069/02E 2014-03

 6.15.2 Engine coolant level – Check
Preconditions
☑Engine is stopped and starting disabled.
☑MTU Fluids and Lubricants Specifications (A001061/..) are available.

WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.

Checking engine coolant level at filler neck:

1. Turn breather valve on coolant expansion tank (for engines with remote heat exchanger: the expansion
tank is part of the remote cooling 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 bottom edge of the cast-in eye in the filler neck).

Checking engine coolant level at

external cooler:
1. Check coolant level (coolant must be visi-
ble at marker plate).
2. Top up with treated coolant as necessary
(→ Page 234).
3. Check and clean breather valve.
4. Set breather valve onto filler neck and
close it.

Checking engine coolant level by means of level sensor:

1. Switch on engine control system and check readings on the display.
2. Top up with treated coolant as necessary (→ Page 234).
TIM-ID: 0000014605 - 003

MS150069/02E 2014-03 | Task Description | 229

 6.15.3 Engine coolant – Change
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Coolant

Engine coolant change

1. Drain engine coolant (→ Page 231).
2. Fill with engine coolant (→ Page 234).

TIM-ID: 0000000036 - 031

230 | Task Description | MS150069/02E 2014-03

 6.15.4 Engine coolant – Draining
Preconditions
☑Engine is stopped and starting disabled.

WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.

Preparatory steps
1. Provide an appropriate container to drain the coolant into.
2. Switch off preheating unit.

Engine coolant – Draining

1. Turn breather valve on expansion tank (for engines with remote heat exchanger: the expansion tank is
part of the remote cooling system) counterclockwise up to the first stop and allow pressure to escape.
2. Continue to turn breather valve counterclockwise and remove.
3. Draw off precipitated corrosion inhibitor oil from the expansion tank through filler neck.
4. Open vent valves on carrier housing (1).
TIM-ID: 0000014593 - 005

MS150069/02E 2014-03 | Task Description | 231

 5. Open vent valve on exhaust pipework (driv-
ing end) (1).

6. Open vent valve on seawater cooler (1) (or

remote heat exchanger).

7. Open drain plug (1) and drain coolant at

crankcase. TIM-ID: 0000014593 - 005

232 | Task Description | MS150069/02E 2014-03

 8. Open drain screw (1) and drain coolant on
coolant pump elbow.

Final steps
1. Seal all open vent and drain points.
2. Set breather valve onto filler neck and close it.
TIM-ID: 0000014593 - 005

MS150069/02E 2014-03 | Task Description | 233

 6.15.5 Engine coolant – Filling
Preconditions
☑Engine is stopped and starting disabled.
☑MTU Fluids and Lubricants Specifications (A001061/..) are available.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Engine coolant

WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective 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 steps
1. Turn breather valve on expansion tank (for
engines with remote heat exchanger: the
expansion tank is part of the remote cool-
ing system) counterclockwise up to the
first stop and allow pressure to escape.
2. Continue to turn breather valve counter-
clockwise and remove.

TIM-ID: 0000014569 - 005

234 | Task Description | MS150069/02E 2014-03

 Filling coolant through filler
neck
1. Open vent points on charge-air cooler, ex-
haust turbochargers and on plate-core heat
exchanger (arrows).
2. Fill coolant through the filler neck of the
expansion tank (for engines with remote
heat exchanger: the expansion tank is part
of the remote cooling system) until the
coolant level at the top edge of the filler
neck remains constant.
3. When coolant emerges from the vent
points, close vent points one by one, pro-
ceeding from the lowest point upwards.
4. Check proper condition of breather valve
and clean sealing faces if required.
5. Set breather valve onto filler neck and turn
until the first stop.
6. Start engine (→ Page 79).
7. After 10 seconds of running the engine
without load, shut down the engine
(→ Page 88).
8. Turn breather valve counterclockwise and
remove.
9. Check coolant level (→ Page 229) and top
up engine coolant as required:
a) Repeat the steps from starting the en-
gine (→ Step 6) until no coolant needs
to be topped up any more.
b) Check proper condition of breather
valve and clean sealing faces if re-
quired.
c) Set breather valve onto filler neck and
close it.

Final steps
1. Start the engine and run it without load for some minutes.
2. Check coolant level (→ Page 229) and top up engine coolant as required.
TIM-ID: 0000014569 - 005

MS150069/02E 2014-03 | Task Description | 235

 6.15.6 HT coolant pump – Relief bore check
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING
High level of engine noise when the engine is running.
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 elec-
tronic system) and disable engine start.
3. Clean the relief bore with a wire if it is
dirty.
• Permissible engine coolant discharge:
up to 10 drops per hour;
• Permissible oil discharge: up to 5 drops
per hour.
4. If discharge exceeds the specified limits,
contact Service.

TIM-ID: 0000006803 - 004

236 | Task Description | MS150069/02E 2014-03

 6.15.7 Engine coolant – Sample extraction and analysis
Preconditions
☑MTU Fluids and Lubricants Specifications (A001061/..) are available.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
MTU test kit 5605892099/00 1

DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

Engine coolant – Sample extrac-

tion and analysis
1. Open drain valve (arrow) with the engine
running.
2. Flush sampling point by draining approx. 1
liter coolant.
3. Drain approx. 1 liter of engine coolant into
a clean container.
4. Close drain valve (arrow).
5. Use the equipment and chemicals of the
MTU test kit to check the coolant for:
• Antifreeze concentration
• Corrosion inhibitor concentration
• pH value
6. Engine coolant change intervals (→ MTU
Fluids and Lubricants Specifications).
TIM-ID: 0000014608 - 007

MS150069/02E 2014-03 | Task Description | 237

 6.15.8 Engine coolant filter – Replacement
Preconditions
☑Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Filter wrench F30379104 1
Engine oil
Engine coolant filter (→ Spare Parts Catalog)

WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.

Engine coolant filter – Replace-

ment
1. Remove locking device (1).
2. Close shut-off cock (3).
3. Remove engine coolant filter (2) with filter
wrench.
4. Clean sealing surface on connecting piece.
5. Coat seal on new engine coolant filter (2)
with engine oil.
6. Screw on engine coolant filter (2) and tight-
en hand-tight.
7. Open shut-off cock (3).
8. Install locking device (1).

TIM-ID: 0000014677 - 008

238 | Task Description | MS150069/02E 2014-03

 6.15.9 Preheating unit
Hotstart preheating unit

1 Plastic cap (drain) 4 Shutoff valve 7 Thermostat

2 On/Off switch 5 Continuous flow heater 8 Circulation pump
3 Plastic cap (supply line) 6 Vent valve
Cylinders Nominal voltage / frequency Heating power kW
12 V 230 V / 50 Hz 9
400 V / 50 Hz 9
230 V / 60 Hz 9
440 V / 60 Hz 9
16 V 230 V / 50 Hz 12
400 V / 50 Hz 12
230 V / 60 Hz 12
440 V / 60 Hz 12

Function
TIM-ID: 0000014749 - 005

The preheating unit is intended to warm up the engine coolant. The circulating pump (8) ensures the
circulation of the preheated engine coolant through the engine.
The continuous flow heater (5) comprises a heating element. The thermostat (7) switches off the pre-
heating unit via contactors when the engine coolant temperature has reached the setting of the thermo-
stat (7).
In the event of excessive coolant temperature, the temperature limiter of the thermostat (7) opens the
control loop. The preheating unit is switched off.
The unit must be reset manually after the fault has been rectified.

MS150069/02E 2014-03 | Task Description | 239

 Hilzinger preheating unit

1 On/Off switch
Cylinders Nominal voltage / frequency Heating power kW
12 V and 16 V 230 V / 50 Hz 9
400 V / 50 Hz 9
230 V / 60 Hz 9
440 V / 60 Hz 9

TIM-ID: 0000014749 - 005

240 | Task Description | MS150069/02E 2014-03

 Hilzinger preheating unit, side view

1 Flange (supply and return) 3 Non-return flap 5 Thermostat

2 Junction box 4 Continuous flow heater 6 Circulation pump

Function
The preheating unit is intended to warm up the engine coolant. The circulation pump (6) ensures the
circulation of the preheated coolant through the engine.
The continuous flow heater (4) comprises a heating element. A non-return flap (3) prevents coolant
from flowing through the preheating unit when the engine is running.
When the coolant temperature has reached the value of the thermostat setting (5), the thermostat (5)
switches off the preheating unit via contactors.
In the event of excessive coolant temperature, the temperature limiter of the thermostat (5) opens the
control loop. The preheater is switched off.
The unit must be reset manually after the fault has been rectified.
TIM-ID: 0000014749 - 005

MS150069/02E 2014-03 | Task Description | 241

 6.15.10 Preheater – Overhaul
Preconditions
☑Engine is stopped and starting disabled.

DANGER
Electric voltage supply for operation.
Danger of burns and fatal electric shock!
• Make certain that the power supply to the product is switched off before starting work. Secure
against unintentional switching on!

WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.

Overhauling preheater
1. Disconnect power supply to heating element.
2. Close shut-off valve in coolant line before and after preheater.
3. Drain coolant at drain valve into a clean container.
4. Clean and flush coolant circuit.
5. Check hoses for cracks and other damage. Replace as necessary.
6. Check wiring for damage and overheating.
7. Remove heating element.
8. Clean heating element and tank.
9. Remove pump from volute (if applicable) and check for residues in impeller and lines.
10. Install heating element.
11. Connect heating element to power supply.
12. Connect hoses and open shut-off valves.
13. Check preheater for leakage and correct operation (→ Page 243).
14. Check coolant level (→ Page 229).

TIM-ID: 0000048876 - 001

242 | Task Description | MS150069/02E 2014-03

 6.15.11 Preheater – Function and leak-tightness check
Preconditions
☑Preheater is switched on.

WARNING
Coolant is hot and highly pressurized.
Risk of injury! Risk of scalding!
• Allow engine to cool down.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.

Checking operation
Note: The coolant temperature must correlate to the control range of the thermostat when the preheater is
ready for operation.
1. Check coolant preheating temperature.
2. Set the thermostat accordingly if the temperatures are not in the control range.

Checking for leaks

1. Check leak-tightness at coolant inlet and outlet.
2. Tighten any leaking unions.
TIM-ID: 0000048882 - 001

MS150069/02E 2014-03 | Task Description | 243

 6.16 Raw Water Pump with Connections
6.16.1 Raw water pump – Relief bore check
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING
High level of engine noise 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 en-
gine start.
3. Clean the relief bore with a wire if it is
dirty.
• Permissible engine coolant discharge:
up to 10 drops per hour;
• Permissible oil discharge: up to 5 drops
per hour.
4. If discharge exceeds the specified limits,
contact Service.

TIM-ID: 0000015173 - 005

244 | Task Description | MS150069/02E 2014-03

 6.17 Engine Mounting / Support
6.17.1 Engine mounting – Check

Engine mounting – Check

Item Findings Action
Visually inspect mounts. • Damage Replace (contact Service).
• Brittleness
• Deformation
• Crack formation
• Swelling
visible
TIM-ID: 0000015370 - 004

MS150069/02E 2014-03 | Task Description | 245

 6.18 Battery-Charging Generator
6.18.1 Battery-charging generator drive – Coupling condition check
Preconditions
☑Engine is stopped and starting disabled.

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 deformation or crack for-
mation, contact Service.
5. Install protective cover (2) with screws (1).

TIM-ID: 0000007390 - 008

246 | Task Description | MS150069/02E 2014-03

 6.19 Auxiliary PTO
6.19.1 Bilge pump – Relief bore check
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

Bilge pump – Relief bore check

1. Check relief bores for oil and water dis-
charge.
2. Stop engine (→ Page 88) and disable en-
gine start.
3. Clean relief bores with a wire if dirty.
• Permissible water discharge: up to 10
drops per hour;
• Permissible oil discharge: up to 5 drops
per hour
4. If discharge exceeds the specified limits:
Contact Service.
TIM-ID: 0000015791 - 006

MS150069/02E 2014-03 | Task Description | 247

 6.20 Fuel Supply System
6.20.1 Water drain valve – Check

Water drain valve – Check

1. Open water drain valve.
2. Check water outlet for obstructions.
3. Close water drain valve.

TIM-ID: 0000007733 - 007

248 | Task Description | MS150069/02E 2014-03

 6.20.2 Differential pressure gauge – Check
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.

Checking differential pressure gauge

1. Switch on fuel treatment system (→ Page 86).
2. Set the alarm points at the differential pressure gauge to zero.
Result: Alarm is initiated with preset delay.
3. Reset the alarm points at the differential pressure gauge to the specified values.
TIM-ID: 0000007737 - 005

MS150069/02E 2014-03 | Task Description | 249

 6.20.3 Water level probe (3-in-1 rod electrode) – Check
Preconditions
☑System is put out of operation and emptied.

WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.

Checking water level probe (3-in-1 rod electrode)

1. Disconnect connector from water level 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 system on.
Result: Water drain valve opens.
6. Leave water level probe in tank.
Result: Alarm must be triggered with the preset delay.
7. Switch off the system.
8. Disconnect connector from water level probe.
9. Remove water level probe from tank.
10. Screw in water level probe.
11. Connect connector for water level probe.
12. Fill and vent the system then put it into operation.

TIM-ID: 0000007739 - 007

250 | Task Description | MS150069/02E 2014-03

 6.20.4 Pump capacity – Check
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.

Pump capacity – Check

1. Install suitable pressure gauge at the neck of the intake side of the pump.
2. Check pump pressure.
a) Switch on fuel treatment system (→ Page 86).
Note: The pressure limiting valve at the pump might respond and open. Audible noise is caused by overflow-
ing fuel and can be disregarded.
b) Close ball valve at 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. Check pump pressure with reduced suction.
a) Reduce suction pressure of pump to -0.8 bar with the shutoff valve at the pump intake side.
b) Check pressure at the pressure gauge in the inlet to the fuel treatment system and note down.
c) Open ball valve at inlet and outlet of fuel treatment system.
4. Calculate wear limit.
Example:
Measured value (normal condition). 3 bar
Measured value (reduced suction condition). 2.6 bar
If the measured value (reduced suction condition) is 10% lower than the measured value (normal condition),
the wear limit is reached. Repair pump (contact Service).
TIM-ID: 0000007740 - 008

MS150069/02E 2014-03 | Task Description | 251

 6.20.5 Coalescer filter element – Replacement
Preconditions
☑System is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Torque wrench, 6-50 Nm F30027336 1
Ratchet F30027339 1
Diesel fuel
Engine oil
Coalescer filter element (→ Spare Parts Catalog)
Gasket (→ Spare Parts Catalog)

WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.

NOTICE
Contamination of components.
Damage to component!
• Observe manufacturer's instructions.
• Check components for 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 installation position of components.

Coalescer filter element – Re-

placement
1. Close ball valve at the inlet and outlet of
the fuel treatment system.
2. Open drain valve.
3. Drain fuel.
4. Close drain valve.
5. Remove nuts (9) and washers (2).
6. Remove screws (1).
7. Remove cover with gasket (10).
TIM-ID: 0000007735 - 009

8. Remove nut (3), washer (8) and end

plate (4).
9. Remove coalescer filter element (5).
10. Catch fuel as it runs out.
11. Clean housing with a non-linting cloth,
rinse with fuel if required.
12. Check housing for corrosion.
13. Clean housing sealing surfaces.
14. Install coalescer filter element (5).
15. Install end plate (4), washer (8) and nut (3).

252 | Task Description | MS150069/02E 2014-03

 16. Tighten nut (3) to specified tightening torque using a torque wrench.
Name Size Type Lubricant Value/Standard
Nut M16 Tightening torque (Engine oil) 30 Nm +3 Nm
17. Fit gasket (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: The fuel treatment system is ready for operation.
TIM-ID: 0000007735 - 009

MS150069/02E 2014-03 | Task Description | 253

 6.21 Wiring (General) for Engine/Gearbox/Unit
6.21.1 Engine wiring harness – Overview
Engine wiring harnesses – Terminal assignment
Description Terminal assignment
Sensors B1 Camshaft speed
B3 Intake air temperature
B4.21 Exhaust temperature, A side
B4.22 Exhaust temperature, B-side
B5.1 Oil pressure downstream of filter
B5.3 Oil pressure upstream of filter
B6 Coolant temperature
B7 Oil temperature
B9 Charge-air temperature
B10 Charge-air pressure
B13 Crankshaft speed
B16 Coolant pressure
B33 Fuel temperature
B34.1 Fuel pressure downstream of filter
B34.2 Fuel pressure upstream of filter
B34.3 Fuel pressure upstream of external filter
B44.1 Rotation speed, exhaust turbocharger A
B44.2 Rotation speed, exhaust turbocharger B
B48 HP fuel pressure
B49 Charge air before recirculation
B50 Crankcase pressure
B54 Replenishment pump pressure
Level monitor F33 Coolant level
XF33 Coolant level adaptation
XXF33 Coolant level, hull-mounted cooling system
F46 Fuel overflow level
Pump M8 Fuel pump
Limit switch S37.1 Start interlock A
TIM-ID: 0000038739 - 002

S37.2 Start interlock B

Adaptation X2 ECU-7 governor
X4 ECU-7 governor
X37 Cranking start interlock
XG03 Battery-charging generator
Valves Y26 Charge-air recirculation
Y27 Exhaust turbocharger

254 | Task Description | MS150069/02E 2014-03

 Description Terminal assignment
Injectors Y39A1 to Y39AX Engine A side
Y39B1 to Y39BX Engine B side

Engine wiring harness for sensors, 12V engine

1 M8 13 B4.22 25 B4.21
2 B1 14 B9 26 B10
3 B6 15 S37.1 27 B13
4 X2 16 B34.3 28 S37.2
5 X37 17 B34.2 29 B7
6 XXF33 18 B34.1 30 B5.1
7 F33 19 B50 31 B48
8 B16 20 B49 32 B33
9 XF33 21 B44.1 33 F46
10 B54 22 Y26 34 XG03
11 B44.2 23 B5.3
12 Y27 24 B3
TIM-ID: 0000038739 - 002

MS150069/02E 2014-03 | Task Description | 255

 Engine wiring harness for sensors, 16V engine

1 M8 13 B4.22 25 B4.21
2 B1 14 B9 26 B10
3 B6 15 S37.1 27 B13
4 X2 16 B34.3 28 S37.2
5 Y27 17 B34.2 29 B7
6 B44.2 18 B34.1 30 B5.1
7 X37 19 B50 31 B48
8 XF33 20 B49 32 B33
9 B54 21 B44.1 33 F46
10 B16 22 Y26 34 XG03
11 XXF33 23 B5.3
12 F33 24 B3
TIM-ID: 0000038739 - 002

256 | Task Description | MS150069/02E 2014-03

 Engine wiring harness for injectors, 12V engine

1 Y39A1 6 Y39A6 11 Y39B3

2 Y39A2 7 X4 12 Y39B2
3 Y39A3 8 Y39B6 13 Y39B1
4 Y39A4 9 Y39B5
5 Y39A5 10 Y39B4
TIM-ID: 0000038739 - 002

MS150069/02E 2014-03 | Task Description | 257

 Engine wiring harness for injectors, 16V engine

1 Y39A1 7 Y39A7 13 Y39B5

2 Y39A2 8 Y39A8 14 Y39B4
3 Y39A3 9 X4 15 Y39B3
4 Y39A4 10 Y39B8 16 Y39B2
5 Y39A5 11 Y39B7 17 Y39B1
6 Y39A6 12 Y39B6

TIM-ID: 0000038739 - 002

258 | Task Description | MS150069/02E 2014-03

 Engine wiring harness for electric starter

1 Connection terminals, EIM 2 Fuse F1 3 Connection terminals,

starter
TIM-ID: 0000038739 - 002

MS150069/02E 2014-03 | Task Description | 259

 6.21.2 Engine wiring – Check
Preconditions
☑Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Isopropyl alcohol X00058037 1

Engine wiring – Check

1. Check securing screws of cable clamps on engine and tighten loose threaded connections.
2. Ensure that cables are fixed in their clamps and cannot swing freely.
3. Verify that all cable clips are closed and in proper condition.
4. Replace cable clips if defective.
5. Check that cable clamps are firm, tighten loose cable clamps.
6. Replace faulty cable clamps.
7. Visually inspect the following electrical line components for damage:
• Connector housing
• Contacts
• Sockets
• Cables and terminals
• Plug-in contacts
Result: Contact Service if cable conductors are damaged.
Note: Close male connectors that are not plugged in with the protective cap supplied.
8. Clean dirty connector housings, sockets and contacts using isopropyl alcohol.
9. Ensure that all sensor connectors are securely engaged.

TIM-ID: 0000000029 - 020

260 | Task Description | MS150069/02E 2014-03

 6.22 Accessories for (Electronic) Engine Governor / Control System
6.22.1 CDC parameters – Reset
Preconditions
☑Engine is stopped and starting disabled.

Note: Failure to reset drift compensation (CDC parameters) will void the emissions certification.

Resetting CDC parameters with DiaSys®

u (→ Dialog system DiaSys® E531920/..).

Resetting CDC parameters without DiaSys®

u If no DiaSys® is available, contact Service.
TIM-ID: 0000044684 - 001

MS150069/02E 2014-03 | Task Description | 261

 6.22.2 Limit switch for start interlock ‒ Check
Preconditions
☑Engine is stopped and starting disabled.

Note: In the OFF position, the limit switch initiates a start interlock, i.e. the engine cannot be started.
Checking limit switch for start
interlock
1. Check whether switches (3) and guard
plate (1) with engine support (4) are instal-
led on both sides of flywheel housing (2).
2. Check whether both switches (3) are actu-
ated.
3. If switches (3) and/or guard plate (1) with
engine support (4) is/are not installed:
• Screw on guard plate (1) with engine
support (4).
• Then screw on switch (3), ensuring that
the switch (3) is actuated by the guard
plate (1).
4. If switch (3) and guard plate (1) are instal-
led, but switch (3) is in the OFF position:
• Make certain that the guard plate (1) at
the side of the switch (3) is not distort-
ed.
• Release guard plate (1) and screw on
such that the switch (3) is actuated.

TIM-ID: 0000016782 - 006

262 | Task Description | MS150069/02E 2014-03

 6.22.3 Engine Control Unit ECU 7 – Checking plug connections
Preconditions
☑Engine is stopped and starting disabled.

Check plug connections on ECU

7
1. Check all connectors on ECU for firm seat-
ing. Ensure that the clips (1) are engaged.
2. Check screws (2) of cable clamps on ECU
for firm seating. Ensure that cable clamps
are not faulty.
TIM-ID: 0000016847 - 006

MS150069/02E 2014-03 | Task Description | 263

 6.22.4 Engine Monitoring Unit EMU 7 – Plug connection check
Preconditions
☑Engine is stopped and starting disabled.

Checking EMU plug connections

1. Check both connectors on EMU (2) for firm
seating. Make sure that frames (3) are en-
gaged.
2. Check screws (1) of cable clamps on EMU
(2) for firm seating. Make sure that cable
clamps are not defective.

TIM-ID: 0000016798 - 005

264 | Task Description | MS150069/02E 2014-03

 6.22.5 Interface module EIM plug connections – Check
Preconditions
☑Engine is stopped and starting disabled.

Checking EIM plug connections

1. Check both Tyco plugs (62-pole) (2) on EIM
for firm seating. Ensure that clips (3) are
engaged.
2. Check screws (1) of cable clamps on EIM
for firm seating. Ensure that cable clamps
are not faulty.
TIM-ID: 0000017034 - 004

MS150069/02E 2014-03 | Task Description | 265

 6.22.6 Engine Control Unit ECU 7 – 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.

Removing Engine Control Unit

from engine
1. Note or mark assignment of cables and
connectors.
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 Unit.

Installing Engine Control Unit on engine

1. Install in reverse order. Ensure correct assignment of connectors and sockets.
2. Check resilient mount before installing.
Result: If resilient mount is porous or defective then replace it.

TIM-ID: 0000000049 - 008

266 | Task Description | MS150069/02E 2014-03

 6.22.7 EMU 7 – 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.

Removing ECU with EMU from

engine
1. Note or mark assignment of cables and
connectors.
2. Remove all screws (2).
3. Undo latches (3) of the 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 connectors and sockets in so doing.
2. Check resilient mount before installing.
Result: Replace resilient mount if porous or defective.
TIM-ID: 0000016799 - 007

MS150069/02E 2014-03 | Task Description | 267

 6.22.8 Engine Interface Module EIM – Removal and installation
Preconditions
☑Engine is stopped and starting disabled.

Removing EIM from the engine

1. Note or mark assignment of cables and
connectors.
2. Unscrew all screws (1).
3. Undo clips (2) on connectors.
4. Disconnect all connectors.
5. Unscrew power and starter cable.
6. Remove screws (3).
7. Take off EIM.

Installing EIM on the engine

1. Install in reverse order. 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 appropriate FSW and parameter/descriptor module (the diagnostic
lamp (DILA) indicates flashing code 4 when the power supply is connected, (→ Page 269)).
2. The FSW and the parameter/descriptor module must first be downloaded from the central database
(CDB) based on the relevant engine number using the DiaSys software tool, and then loaded in the EIM.

TIM-ID: 0000017035 - 005

268 | Task Description | MS150069/02E 2014-03

 6.22.9 Diagnostic features of EIM
Diagnostic lamp (DILA)
A diagnostic lamp (LED, blue) is integrated in the housing of the Engine Interface Module (EIM).
It indicates the operating status of the EIM.
Functions of diagnostic lamp DILA
DILA lights Engine Interface Module (EIM) is OK.
DILA dark EIM supply voltage missing or diagnostic lamp activation is faulty.
DILA flashes Hardware or software fault in the Engine Interface Module.

The diagnostic lamp (DILA) signals the following states:

1 Time in seconds 4 Application loader active 7 No firmware

2 Timing: 1/8 s 5 External RAM faulty 8 Application crashed
3 Ready for operation 6 External FLASH faulty

Fuse lamp (SILA)

A second indicator is the fuse lamp.
TIM-ID: 0000038009 - 003

This is also integrated in the housing of the Engine Interface Module. It indicates the status of the fuses.
An orange LED is provided to allow diagnosis of a “tripped fuse” fault directly at the unit as it is often
difficult to pinpoint a fault in the field without cabling diagrams.
This LED is activated by the controller.
Functions of fuse lamp SILA
SILA dark Norma operating state.
SILA flashes orange One or more fuses have tripped.

The fuse lamp (SILA) signals the following states:

MS150069/02E 2014-03 | Task Description | 269

 1 Preamble 6 VSP current path failed 11 ES pushbutton current
2 ECU current path failed (S5) path failed – 24V external
(S1) 7 SLD current path failed (S10)
3 MCS current path failed (S6) 12 Key switch current path
(S2) 8 DDV current path failed failed (S11)
4 EMU current path failed (S7) 13 SDAF 1+2 current path
(S3) 9 Gear monitoring current failed (S12)
5 Starter voltage: Terminal path failed (S8) 14 PIM current path failed
30, 31 not connected and 10 Emergency stop current (S13)
PR 10.0600.001 has value path failed – 24V internal 15 Spare current path failed
1 or 2 (S4) (S9) (S14)
The failed current paths are signaled consecutively following the preamble (LED on for 4 seconds (1)).
There is a pause lasting 4 seconds in between. TIM-ID: 0000038009 - 003

270 | Task Description | MS150069/02E 2014-03

 Sample flashing sequences

A Fuse S5 failure (1/2 sec- B Fuse S1 and fuse S4 fail-

ond steps) ure (1/2 second steps)
Note:
These bit sequences are transmitted constantly.

Information about the status of the current paths of the EIM is also provided in the CAN message “Sta-
tus internal power supply”.
TIM-ID: 0000038009 - 003

MS150069/02E 2014-03 | Task Description | 271

 7 Appendix A
7.1 Abbreviations
Abbrevia- Meaning Explanation
tion
ADEC Advanced Diesel Engine Control Engine governor
AL Alarm Alarm (general)
ANSI American National Standards Institute Governing body for US American standards
ETC Exhaust turbocharger
BR Baureihe (Series)
BV Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU Publication
No. A01061/..
CAN Controller Area Network Data bus system, bus standard
CDC Calibration Drift Compensation Setting for drift correction with DiaSys in engine gov-
ernor
CPP Controllable Pitch Propeller
DILA Diagnostic lamp on EIM
DIN Deutsches Institut für Normung e. V. German Standardization Organization, at the same
time identifier of German standards ("Deutsche In-
dustrie-Norm")
DIS Display unit Display 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 Engine Interface Module Interface to engine monitoring system
EMU Engine Monitoring Unit
SPC Spare Parts Catalog
FPP Fixed Pitch Propeller
GCU Gear Control Unit
GMU Gear Monitoring Unit
HAT Harbor Acceptance Test
HI High Alarm: Measured value exceeds 1st maximum limit
HIHI High High Alarm: Measured value exceeds 2nd maximum limit
HT High Temperature
TIM-ID: 0000002050 - 005

ICFN ISO - Continuous rating - Fuel stop Power specification in accordance with DIN-ISO
power - Net 3046-7
IDM Interface Data Module Memory module for interface data
IIG Initial Injector Equalization Entering of injector code with DiaSys in engine gover-
nor
IMO International Maritime Organization
ISO International Organization for Stand- International umbrella organization for all national
ardization standardization institutes
KGS Kraftgegenseite Engine free end in accordance with DIN ISO 1204

272 | Appendix A | MS150069/02E 2014-03

 Abbrevia- Meaning Explanation
tion
KS Kraftseite Engine driving end in accordance with DIN ISO 1204
LCD Liquid Crystal Display, Liquid Crystal
Device
LCU Local Control Unit LOP subassembly
LED Light Emitting Diode
LMU Local Monitoring Unit LOP subassembly
LO Low Alarm: Measured value lower than 1st minimum limit
LOLO Low Low Alarm: Measured value lower than 2nd minimum limit
LOP Local Operating Panel Control console, control panel
LOS Local Operating Station
MCS Monitoring and Control System
MG Message
MPU Microprocessor Unit, Microprocessing Microprocessor (unit)
Unit
TDC Top Dead Center
P-xyz Pressure-xyz Pressure measuring point xyz
PAN Panel Operating panel
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 organization
SAT Sea Acceptance Test
SD Sensor Defect Alarm: Sensor failure
SDAF Shut Down Air Flaps Emergency-air shutoff flap(s)
SILA Fuse lamp on EIM
SOLAS International Convention for the Safety
of Life at Sea
SS Safety System Indicated alarm is initiated by the safety system
SSK Emergency-air shutoff flap(s)
T-xyz Temperature-xyz Temperature measuring point xyz
TD Transmitter Deviation Alarm: Sensor comparison fault
BDC Bottom Dead Center
VS Voith Schneider Voith-Schneider drive
WJ Water Jet Water jet drive
TIM-ID: 0000002050 - 005

TC Tool Catalog
ZKP Zugehörigkeit-Kategorie-Parameter Numbering plan for ADEC ECU signals

MS150069/02E 2014-03 | Appendix A | 273

 7.2 MTU contact persons/service partners
Our worldwide sales network with its subsidiaries, sales offices, representatives and customer service
centers ensures fast and direct support on site and the high availability of our products.

Local support
Experienced and qualified specialists place their knowledge and expertise at your disposal.
For locally available support, go to the MTU Internet site: http://www.mtu-online.com

24h hotline
With our 24h hotline and the outstanding flexibility of our service staff, we are always ready to assist
you – either during operation, for preventive maintenance, corrective work in case of malfunction or
changed operating conditions, or for spare parts supply.
Your contact person in our Customer Assistance Center:
E-mail: [email protected]
Tel.: +49 7541 9077777
Fax: +49 7541 9077778
Asia/Pacific: +65 6100 2688
North and Latin America: +1 248 560 8000

Spare parts service

Fast, simple and correct identification of spare parts for your drive system or vehicle fleet. The right
spare part at the right time at the right place.
With this aim in mind, we can call on a globally networked spares logistics system, a central warehouse
at headquarters and on-site stores at our subsidiary companies, agencies and service workshops.
Your contact at Headquarters:
E-mail: [email protected]
Tel.: +49 7541 908555
Fax: +49 7541 908121
TIM-ID: 0000000873 - 015

274 | Appendix A | MS150069/02E 2014-03

 8 Appendix B
8.1 Special Tools
Barring device
Part No.: F6555766
Qty.: 1
Used in: 6.1.1 Engine – Barring manually (→ Page 164)

Feeler gage
Part No.: Y20010128
Qty.: 1
Used in: 6.4.2 Valve clearance – Check and adjustment
(→ Page 175)

Filter wrench
Part No.: F30379104
Qty.: 1
Used in: 6.7.2 Additional fuel filter – Replacement (→ Page 188)
Qty.: 1
Used in: 6.7.3 Fuel filter – Replacement (→ Page 189)
Qty.:
Used in: 6.14.1 Engine oil filter ‒ Replacement (→ Page 218)
Qty.: 1
Used in: 6.14.3 Centrifugal oil filter – Cleaning and filter sleeve
replacement (→ Page 222)
Qty.: 1
DCL-ID: 0000030904 - 001

Used in: 6.15.8 Engine coolant filter – Replacement

(→ Page 238)

MS150069/02E 2014-03 | Appendix B | 275

 Installation/removal jig
Part No.: F6789889
Qty.: 1
Used in: 6.6.2 Injector – Removal and installation (→ Page 182)

Milling cutter
Part No.: F30452739
Qty.: 1
Used in: 6.6.2 Injector – Removal and installation (→ Page 182)

MTU test kit

Part No.: 5605892099/00
Qty.: 1
Used in: 6.13.3 Engine oil – Sample extraction and analysis
(→ Page 216)
Qty.: 1
Used in: 6.15.7 Engine coolant – Sample extraction and analysis
(→ Page 237)

Ratchet
Part No.: F30027339
Qty.: 1
Used in: 6.20.5 Coalescer filter element – Replacement
(→ Page 252)
DCL-ID: 0000030904 - 001

276 | Appendix B | MS150069/02E 2014-03

 Ratchet adapter
Part No.: F30027340
Qty.: 1
Used in: 6.6.2 Injector – Removal and installation (→ Page 182)
Qty.: 1
Used in: 6.7.8 Fuel prefilter with water separator – Filter ele-
ment replacement (→ Page 197)
Qty.: 1
Used in: 6.8.1 Compressor wheel – Cleaning (→ Page 200)

Ratchet adapter
Part No.: F30027341
Qty.: 1
Used in: 6.6.2 Injector – Removal and installation (→ Page 182)
Qty.: 1
Used in: 6.13.2 Engine oil – Change (→ Page 214)

Ratchet with extension

Part No.: F30006212
Qty.: 1
Used in: 6.1.1 Engine – Barring manually (→ Page 164)

Rigid endoscope
Part No.: Y20097353
Qty.: 1
Used in: 6.2.1 Cylinder liner – Endoscopic examination
(→ Page 167)
DCL-ID: 0000030904 - 001

MS150069/02E 2014-03 | Appendix B | 277

 Socket wrench, 24 mm
Part No.: F30039526
Qty.: 1
Used in: 6.4.2 Valve clearance – Check and adjustment
(→ Page 175)

Steam jet cleaner

Part No.: -
Qty.: 1
Used in: 3.14 Plant – Cleaning (→ Page 91)

Torque wrench, 0.5-5 Nm

Part No.: 0015384230
Qty.: 1
Used in: 6.6.2 Injector – Removal and installation (→ Page 182)

Torque wrench, 10-60 Nm

Part No.: F30452769
Qty.: 1
Used in: 6.6.2 Injector – Removal and installation (→ Page 182)
Qty.: 1
Used in: 6.7.8 Fuel prefilter with water separator – Filter ele-
ment replacement (→ Page 197)
Qty.: 1
Used in: 6.8.1 Compressor wheel – Cleaning (→ Page 200)
DCL-ID: 0000030904 - 001

278 | Appendix B | MS150069/02E 2014-03

 Torque wrench, 40-200 Nm
Part No.: F30027337
Qty.: 1
Used in: 6.13.2 Engine oil – Change (→ Page 214)

Torque wrench, 6-50 Nm

Part No.: F30027336
Qty.: 1
Used in: 6.14.3 Centrifugal oil filter – Cleaning and filter sleeve
replacement (→ Page 222)

Torque wrench, 6-50 Nm

Part No.: F30027336
Qty.: 1
Used in: 6.20.5 Coalescer filter element – Replacement
(→ Page 252)

Torque wrench, 60-320 Nm

Part No.: F30452768
Qty.: 1
Used in: 6.4.2 Valve clearance – Check and adjustment
(→ Page 175)
Qty.: 1
DCL-ID: 0000030904 - 001

Used in: 6.6.2 Injector – Removal and installation (→ Page 182)

MS150069/02E 2014-03 | Appendix B | 279

 8.2 Index
Preheating unit 239 D
Differential pressure gauge
A – Check 249
Abbreviations 272 Drain and vent points 225
Actuators Drift compensation
– Overview 31 – Reset 261
Additional fuel filter
– Replacement 188 E
ADEC (ECU 7) ECU 7
– Fault codes 99 – Installation 266
– Fault messages 98 – Removal 266
After stopping the engine 90 EMU 7
Air filter – Installation 267
– Removal and installation 210 – Removal 267
– Replacement 209 Engine
– Barring manually 164
B – Barring with starting system 166
Battery-charging generator drive – Emergency stop 89
– Coupling condition check 246 – Main dimensions 52
Bilge pump – Start 79
– Relief bore check 247 – Stopping 88
– Wiring check 260
C Engine Control Unit ECU 7
CDC parameters – Checking plug connections 263
– Reset 261 – Installation 266
Centrifugal oil filter – Removal 266
– Cleaning 222 Engine coolant
Checks – Change 230
– Prior to start-up 82 – Draining 231
Coalescer filter element – Filter replacement 238
– Replacement 252 – Sample analysis 237
Compressor wheel – Sample extraction 237
– Cleaning 200 Engine coolant level
Contact persons 274 – Check 229
Controls 76 Engine coolant – Filling 234
Coolant Engine data
– Change 230 – 16V 4000 M43S 73
Cooler ENGINE DATA 12V 4000 M33F, RheinSchUO Stage II,
– Charge-air IMO Tier II 55
– Checking condensate drain for water discharge and ENGINE DATA 12V 4000 M33S, IMO Tier II, EPA Tier 2
obstruction 208 61
Crankcase breather ENGINE DATA 12V 4000 M33S, RheinSchUO Stage II,
– Oil mist fine separator IMO Tier II 58
– Replacement 173 ENGINE DATA 16V 4000 M33F, RheinSchUO Stage II,
Crankcase breather system
DCL-ID: 0000030904 - 001

IMO Tier II 64
– Overview 171 ENGINE DATA 16V 4000 M33S, IMO Tier II, EPA Tier 2
Cylinder 70
– Designation 51 ENGINE DATA 16V 4000 M33S, RheinSchUO Stage II,
Cylinder head cover IMO Tier II 67
– Installation 178 Engine governor ADEC (ECU 7)
– Removal 178 – Fault codes 99
Cylinder liner – Fault messages 98
– Endoscopic examination 167 Engine Interface Module EIM
– Instructions and comments on endoscopic and visual – Removal and installation 268
examination 169 Engine layout 27

280 | Appendix B | MS150069/02E 2014-03

 Engine Monitoring Unit EMU 7 H
– Plug connection check 264 Hotline 274
Engine mounting HP pump
– Check 245 – Filling with engine oil 179
Engine oil – Relief bore check 180
– Sample extraction and analysis 216 HT coolant pump
Engine oil – Relief bore check 236
– Change 214
Engine oil filter I
– Replacement 218 Injector
Engine oil level – Installation 182
– Check 213 – Removal 182
Engine sides – Replacement 181
– Designation 51 Intercooler
Engine wiring – Checking condensate drain for water discharge and
– Check 260 obstruction 208
Engine wiring harness Interface module EIM
– Overview 254 – Check 265

F L
Fault codes Limit switch for start interlock
– Engine governor ADEC (ECU 7) 99 – Check 262
Fault messages
– Engine governor ADEC (ECU 7) 98 M
Filter Maintenance schedule
– Coalescer element – Maintenance task reference table [QL1] 92
– Replacement 252 MTU contact persons 274
– Engine coolant
– Replacement 238 O
Filter sleeve Oil indicator filter
– Replacement 222 – Check 220
Firing order 54 – Cleaning 220
Fuel Operational checks 80
– Treatment system
– Switching on 86 P
– Troubleshooting 97 Plant
– treatment system – Cleaning 91
– Shutdown 87 Plug connections
Fuel filter – Check 265
– Replacement 189 Preheater
Fuel prefilter – Overhaul 242
– Flushing 195 – Function and leak-tightness
Fuel prefilter – check 243
– Draining 193 Product description 15
Fuel prefilter with water separator Pump capacity
– Filter element replacement 197 – Check 251
Fuel prefilter with water separator – Rotary slide valve O- Putting the engine into operation after extended out-of-
DCL-ID: 0000030904 - 001

rings service periods (>3 months) 77

– Replacement 199 Putting the engine into operation after scheduled out-of-
Fuel prefilter – Differential pressure gauge service-period 78
– Adjustment 192
– Check 192 R
Fuel system Raw water pump
– Venting 191 – Relief bore check 244
Fuel treatment system
– Putting into operation 83 S
– Shutdown 87 Safety notices, standards 14
– Switching on 86

MS150069/02E 2014-03 | Appendix B | 281

 Safety regulations
– Auxiliary materials 12
– Environmental protection 12
– Fire prevention 12
– Fluids and lubricants 12
– Important provisions 5
– Maintenance work 9
– Operation 8
– Organizational requirements 6
– Personnel requirements 6
– Repair work 9
– Safety notices, standards 14
– Startup 8
Sensors
– Overview 31
Service indicator
– Signal ring position check 211
Service partners 274
Spare parts service 274
Starter
– Condition check 212
Supplementary fuel filter
– Overview 187

T
Tasks
– After extended out-of-service periods 81
Tasks after extended out-of-service periods (>3 weeks) 81
transport 7
Troubleshooting 94
– Fuel treatment system 97

V
Valve clearance
– Adjustment 175
– Check 175
Valve gear
– Lubrication 174

W
Water drain valve
– Check 248
Water level probe (3-in-1 rod electrode)
– Check 250
DCL-ID: 0000030904 - 001

282 | Appendix B | MS150069/02E 2014-03

Functional Description
Diesel engine
12 V 4000 Mx3 x
16 V 4000 Mx3 x

MS13015/03E
Engine model kW/Cyl. Application group
12V 4000 M23S 115 kW/Cyl. 3A, continuous operation, unrestricted
12V 4000 M23F 95 kW/Cyl. 3A, continuous operation, unrestricted
12V 4000 M33S 130 kW/Cyl. 3B, continuous operation, variable
12V 4000 M33F 110 kW/Cyl. 3B, continuous operation, variable
12V 4000 M53R 95 kW/Cyl. 1A, continuous operation, unrestricted
12V 4000 M53 115 kW/Cyl. 1A, continuous operation, unrestricted
12V 4000 M63 125 kW/Cyl. 1A, continuous operation, unrestricted
16V 4000 M23S 115 kW/Cyl. 3A, continuous operation, unrestricted
16V 4000 M23F 95 kW/Cyl. 3A, continuous operation, unrestricted
16V 4000 M33S 130 kW/Cyl. 3B, continuous operation, variable
16V 4000 M33F 110 kW/Cyl. 3B, continuous operation, variable
16V 4000 M43S 140 kW/Cyl. 3B, continuous operation, variable
16V 4000 M53R 95 kW/Cyl. 1A, continuous operation, unrestricted
16V 4000 M53 115 kW/Cyl. 1A, continuous operation, unrestricted
16V 4000 M63 125 kW/Cyl. 1A, continuous operation, unrestricted
16V 4000 M63R 120 kW/Cyl. 1A, continuous operation, unrestricted
16V 4000 M63L 140 kW/Cyl. 1A, continuous operation, unrestricted

Table 1: Overview of applicability

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© 2013 Copyright MTU Friedrichshafen GmbH
This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior
written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, mi-
crofilming and storage or processing on electronic systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage
during operation.
Subject to alterations and amendments.
 Table of Contents
1 Engines of the Series 1.10 Cooling system 30
1.11 Fuel treatment system 33
1.1 Product summary 4 1.12 Engine management and monitoring 36
1.2 Crankcase with oil pan 13
1.3 Gear train 15
2 Appendix A
1.4 Crank drive 17
1.5 Cylinder head with injector 19 2.1 MTU contact persons/service partners 41
1.6 Valve gear 21
1.7 Fuel system with common-rail injection 23 3 Appendix B
1.8 Charge-air and exhaust system 26
1.9 Lube oil system 28 3.1 Index 42
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MS13015/03E 2013-05 | Table of Contents | 3

 1 Engines of the Series
1.1 Product summary
The following overview drawings apply analogously to engine models 12 V 4000 Mx3 x.

Engines with remote heat exchanger and horizontal air intake

1 Exhaust outlet 10 Oil distribution housing 19 Cylinder head

2 Carrier housing 11 Coolant inlet from remote 20 Air line to charge-air cool-
3 Exhaust turbocharger cooling system er
4 Dry-type air filter 12 Thermostat housing 21 Flywheel housing
5 Air flap 13 Coolant filter 22 Flywheel
6 Coolant pipe to charge-air 14 Coolant pump 23 Charge-air cooler
cooler 15 Engine mounting 24 Exhaust flap
7 Coolant pipe from charge- 16 Oil pan 25 Exhaust manifold
air cooler 17 Crankcase KS Driving end
8 Oil cooler 18 Charge-air line
9 Engine management and
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monitoring

4 | Engines of the Series | MS13015/03E 2013-05

 1 Engine management and 10 Recirculation line 19Battery-charging generator
monitoring 11 Exhaust manifold 20HP fuel pump
2 Oil cooler 12 Engine mounting 21Oil filter
3 Centrifugal oil filter 13 Charge-air line 22Bilge pump (option)
4 Crankcase breather 14 Oil pan 23Coolant outlet to remote
5 Dry-type air filter 15 Oil filler neck cooling system
6 Exhaust turbocharger 16 Crankcase 24 Coolant inlet from remote
7 Exhaust outlet 17 Cylinder head cooling system
8 Air line to charge-air cool- 18 Fuel filter KGS Free end
er
9 Charge-air cooler
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MS13015/03E 2013-05 | Engines of the Series | 5

 Engines with engine-mounted heat exchanger and horizontal air intake

1 Exhaust outlet 10 Oil cooler 19 Cylinder head

2 Carrier housing 11 Engine management and 20 Crankcase
3 Exhaust turbocharger monitoring 21 Charge-air line
4 Dry-type air filter 12 Oil distribution housing 22 Air line to charge-air cool-
5 Air flap 13 Thermostat housing er
6 Coolant expansion tank 14 Raw water inlet 23 Flywheel housing
7 Coolant line to charge-air 15 Coolant filter 24 Flywheel
cooler 16 Coolant pump 25 Charge-air cooler
8 Coolant line from charge- 17 Engine mounting 26 Exhaust flap
air cooler 18 Oil pan KS Driving end
9 Plate-core heat exchanger TIM-ID: 0000011194 - 005

6 | Engines of the Series | MS13015/03E 2013-05

 1 Raw water outlet 10 Exhaust outlet 19 Cylinder head
2 Engine management and 11 Air line to charge-air cool- 20 Crankcase
monitoring er 21 Fuel filter
3 Plate-core heat exchanger 12 Recirculation line 22 Battery-charging generator
4 Oil cooler 13 Exhaust manifold 23 HP fuel pump
5 Coolant expansion tank 14 Charge-air cooler 24 Oil filter
6 Centrifugal oil filter 15 Charge-air line 25 Bilge pump (option)
7 Crankcase breather 16 Engine mounting 26 Raw water inlet
8 Dry-type air filter 17 Oil pan KGS Free end
9 Exhaust turbocharger 18 Oil filler neck

The following overview drawings apply analogously to engine models 16 V 4000 Mx3 x.
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MS13015/03E 2013-05 | Engines of the Series | 7

 Engines with remote heat exchanger and vertical air intake

1 Exhaust outlet 10 Oil cooler 19 Engine mounting

2 Carrier housing 11 Engine management and 20 Oil pan
3 Exhaust turbocharger monitoring 21 Crankcase
4 Dry-type air filter 12 Oil distribution housing 22 Charge-air cooler
5 Air flap 13 Thermostat housing 23 Exhaust manifold
6 Exhaust flap 14 Coolant inlet from remote 24 Flywheel housing
7 Air line to charge-air cool- cooling system 25 Flywheel
er 15 Coolant filter KS Driving end
8 Coolant line to charge-air 16 Coolant pump
cooler 17 Cylinder head
9 Coolant line from charge- 18 Charge-air line
air cooler
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8 | Engines of the Series | MS13015/03E 2013-05

 1 Coolant outlet to remote 10 Exhaust turbocharger 19 Cylinder head
cooling system 11 Exhaust outlet 20 Fuel filter
2 Coolant inlet from remote 12 Air line to charge-air cool- 21 Oil filter
cooling system er 22 HP fuel pump
3 Engine management and 13 Charge-air cooler 23 Battery-charging generator
monitoring 14 Engine mounting 24 Bilge pump (option)
4 Oil cooler 15 Charge-air line KGS Free end
5 Centrifugal oil filter 16 Oil pan
6 Crankcase breather 17 Oil filler neck
7 Dry-type air filter 18 Crankcase
8 Exhaust manifold
9 Recirculation line
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MS13015/03E 2013-05 | Engines of the Series | 9

 Engines with engine-mounted heat exchanger and vertical air intake

1 Exhaust outlet 11 Plate-core heat exchanger 21 Oil pan

2 Carrier housing 12 Oil cooler 22 Crankcase
3 Exhaust turbocharger 13 Engine management and 23 Charge-air cooler
4 Exhaust flap monitoring 24 Flywheel housing
5 Air line to charge-air cool- 14 Oil distribution housing 25 Flywheel
er 15 Coolant filter 26 Exhaust manifold
6 Dry-type air filter 16 Raw water inlet 27 Thermostat housing
7 Coolant line to charge-air 17 Coolant pump KS Driving end
cooler 18 Engine mounting
8 Air flap 19 Charge-air line
9 Coolant line from charge- 20 Cylinder head
air cooler
10 Coolant expansion tank
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10 | Engines of the Series | MS13015/03E 2013-05

 1 Raw water outlet 10 Recirculation line 19 Crankcase
2 Engine management and 11 Exhaust turbocharger 20 Cylinder head
monitoring 12 Exhaust outlet 21 Fuel filter
3 Oil cooler 13 Air line to charge-air cool- 22 Oil filter
4 Plate-core heat exchanger er 23 HP fuel pump
5 Coolant expansion tank 14 Charge-air cooler 24 Battery-charging generator
6 Centrifugal oil filter 15 Charge-air line 25 Bilge pump (option)
7 Crankcase breather 16 Engine mounting 26 Raw water inlet
8 Dry-type air filter 17 Oil pan KGS Free end
9 Exhaust manifold 18 Oil filler neck

Engines of series 12/16 V 4000 M23 x - M63 x

These engines are compact, powerful, reliable, maintenance-friendly and extremely economical.
The common rail injection system combines optimum fuel efficiency with the observation of all relevant
environmental standards.
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MS13015/03E 2013-05 | Engines of the Series | 11

 Technical data
• Four-stroke, four-valve direct injection
• 12 and 16 cylinders
• 90° Vee angle
• Power rating
– 1140 - 2240 kW
• Bore
– 170 mm
• Stroke
– 210 mm
• Displacement
– 4.77 l per cylinder
• Counterclockwise rotation
• Electronically-controlled common rail injection
• Sequential turbocharging with charge-air cooling
• Split-circuit cooling system
• Piston cooling
• Triple-walled exhaust lines
• Electric or pneumatic starter
• Resilient, height-adjustable engine mounting (M53x-M63x)
• Rigid, height-adjustable engine mounting (M23x-M43x)
• Service block with pumps, filters, coolers and coolant expansion tank (engines with engine-mounted
heat exchanger)

Benefits
Low life cycle costs
• Long service intervals
• High running capacity
• Low fuel consumption over the entire performance map
• Low oil consumption

Environmental compatibility
• RheinSchUO Stufe II / IMO NOx certified; IMO-20% / EPA Tier 2 certified; EU Nonroad IIIA certified
• Complies with the above-mentioned exhaust emission regulations

Safety
• Complies with SOLAS requirements

Service
• 24/7 service
• Worldwide
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12 | Engines of the Series | MS13015/03E 2013-05

 1.2 Crankcase with oil pan

1 Crankcase 8 Oil dipstick 15 Crankshaft bearing

2 Coolant chamber 9 Oil return from cylinder 16 Oil pipe for piston cooling
3 Main oil gallery head 17 Oil spray nozzle for piston
4 Upper end cover 10 Oil filler neck cooling
5 Cylinder liner 11 Sealing rings 18 Camshaft bearing
6 Oil transfer to cylinder 12 Inspection port cover KS Driving end
head and valve gear 13 Oil pan
7 Coolant transfer to cylin- 14 Crankshaft bearing cap
der head

Crankcase
The oil pan is attached to the bottom of the crankcase; gearcase, coolant distribution housing and fly-
wheel housing are mounted on free end and the flywheel housing is mounted on driving end.
The cylinder heads with exhaust pipe, turbochargers and charge-air cooler are mounted on the two top
decks.

Technical data
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• Crankcase cast as one piece

• Integrated coolant pipework
• Integrated main oil gallery in upper end cover
• Oil supply for piston cooling
• Replaceable, wet cylinder liners
• Split sleeve bearings for crankshaft
• Sleeve bearings for camshaft
• Crankshaft bearing caps secured vertically and horizontally
• Crankcase ventilation (closed / open circuit)
• Large inspection port covers

MS13015/03E 2013-05 | Engines of the Series | 13

 Benefits
• High rigidity
• Low noise and vibration levels

TIM-ID: 0000011301 - 004

14 | Engines of the Series | MS13015/03E 2013-05

 1.3 Gear train

1 Drive gear for raw water 5 Idler gear 9 Idler gear

pump 6 Drive gear for high-pres- 10 Drive gear for supplemen-
2 Drive gear for coolant sure fuel pump and fuel tary drive system (option-
pump delivery pump al)
3 Crankshaft gear 7 Drive gear for battery- KGS Free end
4 Camshaft gear charging generator
8 Drive gear for oil pump

Gear train
The gear train consists of the drive and idler gears installed in the gearcase.

Technical data
Straight toothed gears

Benefits
• Low-wear power transmission
• Low maintenance
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• No axial forces

MS13015/03E 2013-05 | Engines of the Series | 15

 Operation
The crankshaft gear (free end) drives the camshaft gear and the following auxiliary units via idler gears:
• HP fuel pump
• Fuel delivery pump
• Oil pump
• Coolant pump
• Raw water pump
• Battery-charging generator
• Supplementary drive system (optional)

TIM-ID: 0000011602 - 004

16 | Engines of the Series | MS13015/03E 2013-05

 1.4 Crank drive
This overview also applies to 8 V and 12 V.

1 PTO flange 5 Piston 9 Crankshaft

2 Coupling 6 Vibration damper KS Driving end
3 Ring gear 7 Crankshaft gear
4 Conrod 8 Counterweight

Crank drive
Well-matched components ensure maximum performance and minimum wear.

Technical data
Piston

• Light-metal skirt
• Bolt-on piston crown
• Two compression rings, one oil-scraper ring
• Piston cooling via oil spray nozzles
TIM-ID: 0000011695 - 004

Conrod
• Forged
• Machined as one piece, providing high rigidity and weight optimization
• Split bearing shells
• Upper conrod bearings lubricated by piston cooling oil as it returns
• Lubrication of lower conrod bearings via crankshaft

MS13015/03E 2013-05 | Engines of the Series | 17

 Crankshaft
• Forged
• Bolt-on counterweights
• Press-fitted crankshaft gear
• Low-wear plain bearings, oil supply from lube oil system
• Axial fixing by thrust bearing
• Radial sealing rings for sealing against external influences (driving end and free end)

Vibration damper (free end)

• Torsional-vibration damper with hydraulic damping
• Oil supply via lube oil system
• Auxiliary PTO on engine free end (option)

Flywheel (driving end)

• Drive flange
• Coupling
• Ring gear

Benefits
• High performance
• Minimum weight
• Long service intervals
• Long service life
• Low oil consumption

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18 | Engines of the Series | MS13015/03E 2013-05

 1.5 Cylinder head with injector

1 Exhaust valve 6 Inlet valve 11 HP fuel line

2 Valve guide 7 Injector a Charge air
3 Piston 8 Hold-down clamp b Exhaust gas
4 Sealing ring 9 Cylinder head c Coolant
5 Crankcase 10 Fuel return line d Engine oil

Cylinder head with injector

The cylinder heads containing the valve gear and fuel injection equipment are mounted on the crank-
case.
Coolant (c) for cylinder head cooling as well as engine oil (d) for valve gear lubrication are supplied from
the crankcase.
Cylinder head covers seal the cylinder heads, injectors, and valve gear on top.
The following components are connected to the cylinder head:
• Charge-air manifolds
• Exhaust manifolds (triple-walled)
• HP fuel lines
• Fuel return lines
TIM-ID: 0000011981 - 004

Technical data
• Individual cylinder heads
• Two inlet and two exhaust valves per cylinder
• Centrally located fuel injector
• Additional cooling bores to cool cylinder head and valve seats
• Metallically sealed to crankcase
• Engine oil and coolant transfers between crankcase and cylinder head sealed by gasket

MS13015/03E 2013-05 | Engines of the Series | 19

 Benefits
• Design allows high cylinder pressure
• Low fuel consumption
• Low smoke index and exhaust-gas emissions
• Long service life

Operation
Charge air (a) flows into the combustion chamber of the cylinder when the inlet valves (6) are open.
When the injector (7) injects fuel into the combustion chamber, an air/fuel mixture is generated which
ignites spontaneously under compression.
When the exhaust valves (1) open, exhaust gases (b) created by the combustion process flow via the
outlet duct to the exhaust manifold leading to the exhaust turbochargers. The valve gear opens and
closes the inlet and exhaust valves (6, 1).

TIM-ID: 0000011981 - 004

20 | Engines of the Series | MS13015/03E 2013-05

 1.6 Valve gear

1 Adjusting screw 6 Rocker arm (inlet) 11 Pushrod, exhaust

2 Locknut 7 Rocker arm (exhaust) 12 Pushrod, inlet
3 Bearing pedestal 8 Camshaft 13 Camshaft drive gear
4 Swing follower shaft 9 Valve bridge
5 Swing follower 10 Cylinder head

Valve gear
The camshaft with drive gear and the swing followers are installed in the crankcase. Pushrods connect
the swing followers and rocker arms. The bearing pedestals with the rocker arms are secured on the
cylinder heads.
Rocker arm movements are transferred to the valves by valve bridges.

Technical data
• Central camshaft, plain bearings lubricated from the crankcase
• The drive gear of the camshaft is directly driven by the crankshaft gear
• Valves controlled by swing followers, pushrods, rocker arms and valve bridges
• Bearing pedestal and rocker arms supplied with engine oil from the lube oil system
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• Floating valve bridges for inlet and exhaust valves

• Valve clearance adjustment on adjusting screws of rocker arms

Benefits
• Lightweight design
• Low rotating masses

MS13015/03E 2013-05 | Engines of the Series | 21

 Operation
The camshaft (8) controls the opening and closing of the inlet and exhaust valves. The motion applied
from the cams of the camshaft to actuate the valves is transferred by swing followers (5), pushrods (11,
12) and rocker arms (6, 7) onto the valve bridges (9) of the inlet and exhaust valves. The valves are
opened against the spring action and closed by the spring action of the valve springs.

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22 | Engines of the Series | MS13015/03E 2013-05

 1.7 Fuel system with common-rail injection
The following overview drawings also apply similarly to 8 V and 16 V.

Engines with remote heat exchanger

1 Distributor 5 Solenoid valve 9 HP pump

2 Common rail (pressure ac- 6 HP line KGS Free end
cumulator) 7 Filters
3 Return line 8 Delivery pump with bypass
4 Injector valve
TIM-ID: 0000012326 - 003

MS13015/03E 2013-05 | Engines of the Series | 23

 Engines with engine-mounted heat exchanger

1 Distributor 5 Solenoid valve 9 Delivery pump with bypass

2 Plate-core heat exchanger 6 HP line valve
with fuel cooler 7 Injector 10 HP pump
3 Common rail (pressure ac- 8 Filters KGS Free end
cumulator)
4 Return line

Fuel system with common-rail injection

The fuel system consists of a low-pressure system and a high-pressure system (common rail system).
Controlled by the electronic engine management system the common rail injection system determines
injection pressure, timing and quantity independently of engine speed.
Injection pressures up to 1800 bar ensure optimum fuel injection and combustion conditions.

Technical data
Low-pressure system
The low-pressure system comprises:
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• Delivery pump with bypass valve

• Fuel filter

24 | Engines of the Series | MS13015/03E 2013-05

 High-pressure system
The common rail injection system comprises:
• HP pump
• HP distributor block with pressure relief valve
• Distributor rails (common rail)
• HP lines
• Individual injectors with integrated, individual accumulator and limiting valve
• Electronic control

Return
• From the individual injectors and HP fuel distributor via the fuel cooler back to the tank or to the LP
fuel supply line.

Open-loop control
• Electronic with electronic engine management system

Benefits
• Optimum control of injection timing, fuel quantity and injection pressure
• Considerable reduction of particulate and pollutant emissions
• Low fuel consumption over the entire performance map
• Good acceleration
• Service-friendly
• High degree of reliability
• No mechanical adjustment required

Operation
Driven by a follower on the HP fuel pump, the fuel delivery pump (8/9) draws fuel from the tank through
the prefilter and delivers it via a check valve to filter (7/8) and to the HP pump (9/10).
The HP pump increases fuel pressure to 1,800 bar and delivers it via the distributor (1) to the common
rail (2/3). Fuel is distributed to the individual injectors (4/7) via the HP fuel lines (6). The solenoid
valves (5) of the injectors, which are controlled by the electronic engine management system, deter-
mine timing and quantity of fuel injection. Fuel injected by the injectors is distributed evenly in the com-
bustion chamber.
Surplus fuel is routed through return lines (3/4) to the fuel cooler (2) (located in the periphery for en-
gines with a remote heat exchanger), where it cools down and flows through an overflow valve back to
the tank or to the supply line of the low-pressure fuel system.

Safety devices
In the event of failure (e.g. of HP pump (9/10)), the pressure limiting valve installed in HP distributor (1)
reduces the maximum system pressure, thereby protecting the remaining components of the HP sys-
tem from overpressure.
The fuel drawn off is returned via the return line to the line leading to the tank. At decreased system
TIM-ID: 0000012326 - 003

pressure, the engine can be operated safely at partial load until the next service is possible.
In order to prevent continuous fuel injection and a possible fuel lock, e.g. in case of a jamming nozzle
needle, a limiting valve is integrated in the injector.
The valve interrupts the fuel supply from the accumulator to the injector if the flow rate is excessive.

MS13015/03E 2013-05 | Engines of the Series | 25

 1.8 Charge-air and exhaust system
Applies analogously to 12 V.

1 Exhaust gas discharge 7 Intake housing, left side 13 Charge-air line

2 Carrier housing 8 Recirculation line 14 Exhaust flap
3 Exhaust turbocharger 9 Recirculation valve 15 Actuating cylinder for ex-
4 Actuating cylinder for ex- 10 Intake housing, right side haust flap
haust flap 11 Exhaust manifold 16 Air line to charge-air cool-
5 Air flap 12 Cylinder head er
6 Dry-type air filter 17 Charge-air cooler
KGS Free end

Charge-air and exhaust system

The components of the charge-air and exhaust system are installed on the driving end (KS) in the en-
gine Vee. High power and acceleration requirements require wide-range performance maps for these
engines. Continuous improvement of charge-air and exhaust system design has realized engine torque
characteristics which fulfill these requirements.

Technical data
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• Sequential turbocharging
• Two coolant-cooled exhaust turbochargers
• Right turbocharger can be cut in/out
• Recirculation system
• Coolant-cooled, triple-walled exhaust manifold
• Charge-air cooling

26 | Engines of the Series | MS13015/03E 2013-05

 Benefits
• Low exhaust emissions
• Low fuel consumption
• Low surface temperatures
• Low thermal stress
• High torque at low speeds
• Excellent acceleration characteristics
• Smooth transition from single to dual turbocharger operation
• Optimum charging efficiency adaptation to the air requirements of the engine
• Complete gas-tightness

Operation
Exhaust system
Exhaust gases flow out of the cylinder combustion chambers through the exhaust ducts (12) in the cyl-
inder heads and the cooled exhaust manifolds (11) to the exhaust turbochargers (3). Exhaust gas flow-
ing into the turbine housing (2) drives the turbine wheel of the rotor assembly before being routed out
to atmosphere via the exhaust discharge pipe (1).

Charge-air system
Turbine wheel and compressor wheel are located on one shaft. The compressor wheel draws in air
through the dry-type air filter (6) and compresses it. The compressed air flows through the charge-air
pipe (16) to charge-air cooler (17) and further through charge-air pipe (13) to the inlet ducts of the cyl-
inder heads (12).
Charge-air cooler functions
• Cooling – in load operation
• Preheating – warms up charge air to achieve optimum performance at low-load operation

Sequential turbocharging
The left exhaust turbocharger (3) is always in operation. The right exhaust turbocharger (3) can be cut
in/out.
A hydraulically actuated exhaust flap (14) is provided in the exhaust supply for this purpose.
The actuating cylinder of the exhaust flap (4) is controlled by the electronic engine management sys-
tem. When the exhaust turbocharger is not running, the hydraulically actuated air flap (5) closes the air
supply to the turbocharger. In low-speed operation, only the left turbocharger is running. The drawn-in
air is compressed and supplied through the charge-air cooler (17) to the cylinders. When the engine
runs up to nominal speed, the electronic engine management system cuts in the right turbocharger (3)
by opening the exhaust supply to it.
At the same time, the engine management system opens the air flap (5) and the recirculation valve (9).
Part of the compressed air is now routed to the exhaust side of the turbocharger.
The increased flow rate allows the right turbocharger (3) to reach the optimum operating range more
quickly and to increase charge-air pressure. Now both turbochargers supply the engine with combus-
TIM-ID: 0000013022 - 003

tion air via the charge-air cooler. With increasing engine speed, the engine management system closes
the recirculation valve (9).

MS13015/03E 2013-05 | Engines of the Series | 27

 1.9 Lube oil system
Applies analogously to 16 V.

1 Exhaust turbocharger 6 Vibration damper 11 Oil cooler

bearings 7 Pressure control valve 12 Camshaft bearing
2 Crankcase breather 8 Idler gear bearings in gear- 13 Main oil gallery
3 Centrifugal oil filter case 14 Conrod bearings
4 Oil filter 9 Oil pan KGS Free end
5 HP fuel pump 10 Piston cooling oil spray
nozzles

Lube oil system

The lube oil system comprises the oil circuit and the piston cooling oil system.

Technical data
• Wet-sump forced-feed lubrication system
• High engine-oil cleaning efficiency provided by centrifugal oil filters
TIM-ID: 0000014078 - 003

Benefits
• Long oil-change intervals

Operation
The engine oil pump draws oil from the oil pan (9) through a suction basket and delivers it via a pres-
sure control valve (7) to the oil cooler (11). Upstream of the oil cooler, part of the oil flow is routed to
the centrifugal oil filters (3). These clean (centrifuge) the oil. The cleaned oil returns to the oil pan by
gravity.

28 | Engines of the Series | MS13015/03E 2013-05

 The main oil flow is cooled in cooler (11), purified in oil filter (4) and delivered to the points of direct
lubrication in the engine and to the main oil gallery (13).
The following components / assemblies are supplied directly:
• Crankshaft support bearing, free end
• Vibration damper (6)
• Idler gear bearings in gearcase (8)
• Piston cooling oil spray nozzles (10)
• HP fuel pump (5)
The following components / assemblies are supplied from the main oil gallery (13):
• Swing followers and rocker shaft supports
• Camshaft thrust bearings (12)
• Crankshaft main bearings
• Exhaust turbocharger bearings (1)
• Control equipment for sequential turbocharging
• Crankshaft support bearing, driving end
• Conrod bearings (14) (via main bearings)
The oil pump is a gear pump. It is driven by the crankshaft via an idler gear. A pressure relief valve
protects it from excessive oil pressure.
The pressure control valve (7) provides oil-pressure control independent of engine speed.
The two pressure maintaining valves control the oil supply to the piston cooling oil spray nozzles. They
do not open before the minimum oil pressure is reached. They thus ensure lubrication of the crank drive
at lower speeds.

Piston cooling
With the pressure maintaining valves open, the oil flows from the oil duct into the gearcase through
both pipes in the crankcase to the spray nozzles (10) of the individual cylinders. They spray cooled and
filtered oil into the oil chambers under the piston crowns. The piston crowns are thereby cooled and the
upper conrod bearings are lubricated by the oil as it flows away.
TIM-ID: 0000014078 - 003

MS13015/03E 2013-05 | Engines of the Series | 29

 1.10 Cooling system
The following overview drawings also apply to 16 V.

Engines with remote heat exchanger

1 Flywheel housing 7 Exhaust manifold (triple- 13 Oil distribution housing

2 Charge-air cooler walled) 14 Coolant pump
3 Air line to charge-air cool- 8 Oil cooler 15 Crankcase
er 9 Coolant outlet to remote 16 Cylinder head
4 Exhaust turbocharger car- cooling system KGS Free end
rier housing 10 Coolant distribution hous- a Coolant
5 Exhaust turbocharger ing
compressor casing 11 Coolant filter
6 Exhaust turbocharger 12 Thermostat
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30 | Engines of the Series | MS13015/03E 2013-05

 Engines with engine-mounted heat exchanger

1 Flywheel housing 9 Plate-core heat exchanger 17 Oil cooler

2 Charge-air cooler 10 Raw water outlet to sea 18 Oil distribution housing
3 Air line to charge-air cool- 11 Raw water inlet from sea 19 Coolant pump
er 12 Coolant distribution hous- 20 Crankcase
4 Exhaust manifold (triple- ing 21 Cylinder head
walled) 13 Raw water pump KGS Free end
5 Exhaust turbocharger car- 14 Coolant filter a Coolant
rier housing 15 Coolant expansion line b Raw water
6 Exhaust turbocharger 16 Thermostat
compressor casing
7 Exhaust turbocharger
8 Coolant expansion tank

Cooling system
The cooling system comprises the coolant circuit (high-temperature and low-temperature) and the raw-
water circuit.

Technical data
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• Two separate cooling circuits:

– Coolant circuit
– Raw water circuit (seawater)
• Coolant cooling by raw water-cooled plate-core heat exchanger (titanium plates) (only on engines
with engine-mounted heat exchanger)
• Thermostat-controlled split-circuit cooling system
• Coolant-cooled / preheated charge-air
• Triple-walled exhaust manifolds

MS13015/03E 2013-05 | Engines of the Series | 31

 Benefits
• Optimum operating temperatures for coolant, engine oil and charge air
• Charge-air preheating in idle and low-load operation prevents white-smoke formation
• Charge-air cooling during load-operation
• No raw water (seawater) in the engine
• Low surface temperatures

Operation
Coolant circuit (high temperature)
The engine-mounted coolant pump (14/19) delivers coolant (a) via the coolant distribution hous-
ing (10/12) into the coolant chambers of the crankcase (15/20), where it cools the cylinder liners and
flows into the cylinder heads (16/21). In the cylinder heads, the coolant flows through the coolant
chambers and ducts. After entering the triple-walled exhaust manifolds (7/4), the coolant flows through
the carrier housings (4/5) of the exhaust turbochargers and from the exhaust manifolds (7/4) through
the coolant distribution housing (10/12) to the thermostat (12/16).
Upstream of the thermostat, a small part of the coolant flow (limited by a flow restrictor) is routed di-
rectly to the coolant pump (14/19). A small part of the coolant flow is filtered in filter (11/14) and also
routed to the coolant pump.
When the engine is at operating temperature, the thermostat (12/16) controls the coolant flow (a) to
the plate-core heat exchanger (9) depending on coolant temperature (applicable to engines with engine-
mounted heat exchangers) or to the remote cooling system (9) (applicable to engines with remote cool-
er). The cooled coolant is mixed with the uncooled coolant from the thermostat and flows through the
exhaust turbochargers (6/7) and the charge-air cooler (2) (components of the low-temperature circuits)
back to the coolant pump (14/19). When the engine is cold, the coolant flow bypasses the plate-core
heat exchanger (9) or the coolant outlet to the remote cooling system (9), which allows the engine and
coolant to reach the operating temperature very quickly.

Coolant circuit (low temperature)

After the coolant (a) from the thermostat (12/16) and the plate-core heat exchanger (9) or from the
remote cooling system (9) were combined, the coolant flows through the distribution housing (10/12)
to the charge-air cooler (2), the compressor casings (5/6) of the exhaust turbochargers (6/7) and to
the air lines (3). After passing the charge-air cooler (2), the coolant flow (a) together with the coolant
from the two charge-air manifolds (3) is routed either through the oil cooler (8/17) or, in part, directly
to the coolant pump (14/19). The flow rate to be routed directly to the coolant pump is determined by
a flow restrictor.
On engines with engine-mounted heat exchanger, the coolant expansion tank (8) together with the ex-
pansion line (15) ensures constant coolant flow and pressure under varying temperature conditions.
To preheat the engine (if required) before startup, a preheating unit can be connected to the “preheat-
ing line outlet” connection on the coolant distribution housing (10/12) and on the two “preheating line
inlet” connections on the flywheel housing (1) (option).

Raw water circuit (only on engines with engine-mounted heat exchanger)

TIM-ID: 0000014535 - 004

The raw water pump (13), which is driven by the gear train, draws raw water from sea (11) via a raw-
water filter and delivers it through the plate-core heat exchanger (9) back to sea (10) or to the (optional)
gear-oil heat exchanger.

32 | Engines of the Series | MS13015/03E 2013-05

 1.11 Fuel treatment system

1 Open position 5 Three-phase current motor 9 Closed position

2 Switch cabinet 6 Dirt trap 10 Open position
3 Overflow valve, bypass 7 Gear pump 11 Pressure vessel
3 bar 8 Frame 12 Closed position
4 Coupling
The KFWA fuel treatment system was designed to separate solid substances and water from fuel. It is
to be installed in the main fuel flow between fuel tank and propulsion engine.
The fuel treatment system provides three operating modes:
• Normal operation
• Operation with clogged filter-coalescer element
• Emergency operation in the event of a power failure
TIM-ID: 0000007729 - 005

MS13015/03E 2013-05 | Engines of the Series | 33

 1 Overflow, atmospheric 9 Ball valve on fuel treat- 17 Automatic water drain
pressure ment system outlet 18 Water level probe (3-in-1
2 Bypass 1 10 Disco check valve rod electrode)
3 Bypass 2 700 mbar 19 Sampling connection, inlet
4 Safety valve, 3 bar 11 Disco check valve 5 mbar 20 Switch cabinet
5 Ball valve on fuel treat- 12 Return 21 Pump
ment system inlet 13 Diesel engine 22 Coarse filter
6 Pressure gauge 14 Overflow tank 23 Supply
7 Venting point/sampling 15 Water separator filter 24 Tank
connection, outlet 16 Ball valve for draining
8 Differential-pressure
gauge

Normal operation
The fuel treatment system comprises a filter coalescer unit. A gear pump supplies fuel to the coalescer
filter, where it flows from the inside to outside of the filter element. First, the fuel flows through the
filter layer, then the coalescer layer, where water is separated from fuel.
The coalescer element contains various hydrophilic materials which are able to retain very small water
droplets, thus providing water separation.
After a certain time, these small droplets merge to drops of approx. 3 mm size, emerge from the ele-
TIM-ID: 0000007729 - 005

ment and sink to the bottom of the container. Water accumulation is monitored by a water level
probe (3-in-1 rod electrode). When the maximum water level is reached, water is discharged via the au-
tomatic drain valve.
The drain valve opens and closes automatically when the fuel treatment system is in operation. There is
no need to interrupt propulsion engine operation, because subsequent venting of the fuel treatment
system is not required.
The contamination of the filter coalescer element is monitored via the differential pressure. If a differen-
tial pressure of 1.5 bar is reached, an alarm is displayed and the filter coalescer element should be re-
placed as soon as possible. The differential pressure is to be determined for visual inspection using the
pressure gauge mounted on the inlet and outlet sides.

34 | Engines of the Series | MS13015/03E 2013-05

 The engine-mounted fuel delivery pump is sensitive to pressure fluctuations at the inlet. In order to sep-
arate the fuel delivery pump from the fuel treatment system with regard to pressure and flow rate varia-
tions, the fuel flows through an unpressurized overflow tank, which is installed downstream of the hous-
ing. The fuel delivery pump draws fuel from this tank.

Operation with clogged filter-coalescer element

If it is not possible to replace the element in spite of an alarm message, the pressure continues to in-
crease until the overflow valve at the bypass 2 (3) opens.
In this case, the fuel flows into bypass 1 (2), bypassing the fuel treatment plant, into the overflow tank,
and fuel purification is provided by the engine-mounted fuel filters only. Water separation is no longer
provided.

Emergency operation in the event of a power failure

In order to ensure continuous fuel supply, even if the pump unit should be stopped due to a power fail-
ure or for filter element replacement, the fuel treatment system is equipped with a bypass.
In normal operation with the system being pressurized, this bypass is closed.
It opens automatically when the engine-mounted fuel delivery pump draws fuel from the tank through
this bypass line. The opening pressure is 5 mbar. In this case, fuel purification is provided by the en-
gine-mounted fuel filters.
TIM-ID: 0000007729 - 005

MS13015/03E 2013-05 | Engines of the Series | 35

 1.12 Engine management and monitoring
Figure also applies similarly to 8 V and 12 V engines.

Item Designation Explanation

1 Voltage supply Input of on-board power supply
2 Interface Plant/control system
3 ECU 7 Engine governor
4 EIM Interface to engine monitoring system
5 EMU 8 Engine monitoring
6 Interfaces Between engine control and monitoring units and en-
gine sensors/actuators/starter/battery-charging
generator (wiring harnesses)
7 Engine
8 Interface Power supply for starter

Engine management and monitoring

TIM-ID: 0000016282 - 003

One of the key innovations on Series 4000-03 engines is the new generation of the MTU-specific elec-
tronic engine management system.
The new engine governor "ADEC" (ECU7) is very robust, which makes it even more suitable for the
harsh engine room environment.
The engine monitoring system ensures operational availability and prolongs the service life of the en-
gine. Injection timing, injection duration and the resulting injection quantity are recalculated for each
firing and for each cylinder. This guarantees low consumption, minimum exhaust gas emissions and
maximum power.

36 | Engines of the Series | MS13015/03E 2013-05

 ADEC (Advanced Diesel Engine Controller)
The main tasks of the ADEC governor (ECU7) are engine management/engine governing, controlling
common rail injection and monitoring vital engine operating values.

Technical data
• Flat housing with 4 self-locking edge connectors
• Integrated engine monitoring
• Integrated safety functions
• 24 VDC power supply
• LED for self-diagnostics
• All sensors and actuators directly connected to the ECU
• Integrated test system ITS
• All sensors and actuators are monitored for short circuits and defective wiring
• Expansion capability via engine-side bus system (EMU)

Functions
Closed-loop control
• Engine speed or torque
• Fuel high pressure

Open-loop control
• Injection (fuel pressure, injection timing, injection duration, operating status)
• Engine protection with dual-level safety systems. The following responses by the governor can be
programmed:
– Controlled torque reduction
– Torque limitation by deduction of an absolute value
– Torque limitation by deduction of a relative value
– Shutdown

Engine monitoring
• Engine speed
• Coolant level
• Coolant temperature
• Charge-air temperature
• Fuel temperature (rail)
• Intake air temperature
• Charge-air coolant temperature
• Oil temperature
• Coolant pressure
• Crankcase pressure
• Fuel pressure after filter
• Fuel pressure (rail)
• Oil pressure
TIM-ID: 0000016282 - 003

• Charge-air pressure
• Charge-air coolant pressure
• Turbocharger speed

Benefits
• Maintenance-free
• Screen pages for operating status, measured values and fault display (on optional color display)
• Screen pages for monitoring CAN communication (on optional color display)

MS13015/03E 2013-05 | Engines of the Series | 37

 Purpose of the units
Engine governor ECU 7

Central control unit for the engine

• Implements MCS-5 and RCS-5 settings at the engine
• Control of the injection system
• Registration and analysis of engine operating states
• Limit value monitoring
• In the event of inadmissible states and limit value violations: Initiation of power reduction, engine
shutdown or emergency engine stop (configurable)
• Self-monitoring
• Diagnosis via CAN interface for dialog unit
TIM-ID: 0000016282 - 003

38 | Engines of the Series | MS13015/03E 2013-05

 Engine Monitoring Unit EMU 8

Additional monitoring unit for the engine

• Conversion of inputs from the monitoring system into signals to the engine
• Acquisition and evaluation of engine operating states
• Limit value monitoring
• Redundant monitoring of central engine-specific sensors
• In the event of inadmissible states and limit value violations: Initiation of power reduction, engine
shutdown or emergency engine stop (configurable)
• Transfer of fault messages to the monitoring and control system
• Download of engine and plant-related settings
• Self-monitoring
• Diagnosis with dialog unit (laptop)
TIM-ID: 0000016282 - 003

MS13015/03E 2013-05 | Engines of the Series | 39

 Engine Interface Module (EIM)

MTU provides a defined interface with all the necessary connection assemblies (connectors or optional
cables) for such applications to allow customer plants to be adapted to the engine components.
The Engine Interface Module (EIM) is the central connection box on the engine. There are no control
elements and maintenance parts on this interface module.
All engine signals integrated in the engine wiring harness.
The Engine Interface Module provides the following features:
• Starter control
• Battery-charging generator monitoring
• Open bus interface (CAN) SAE J1939 to the plant
• Emergency stop functions
• Redundant power supply
• Optional control of emergency-air shutoff flaps
• Key switch logic
• Interface to ECU and EMU
• Interface for MCS-5 dialog
• Oil priming pump control via separate MTU PPC box
TIM-ID: 0000016282 - 003

40 | Engines of the Series | MS13015/03E 2013-05

 2 Appendix A
2.1 MTU contact persons/service partners
Our worldwide sales network with its subsidiaries, sales offices, representatives and customer service
centers ensures fast and direct support on site and the high availability of our products.

Local support
Experienced and qualified specialists place their knowledge and expertise at your disposal.
For locally available support, go to the MTU Internet site: http://www.mtu-online.com

24h hotline
With our 24h hotline and the outstanding flexibility of our service staff, we are always ready to assist
you – either during operation, for preventive maintenance, corrective work in case of malfunction or
changed operating conditions, or for spare parts supply.
Your contact at Headquarters: [email protected]

Spare parts service

Fast, simple and correct identification of spare parts for your drive system or vehicle fleet. The right
spare part at the right time at the right place.
With this aim in mind, we can call on a globally networked spares logistics system, a central warehouse
at headquarters and on-site stores at our subsidiary companies, agencies and service workshops.
Your contact at Headquarters:
E-mail: [email protected]
Phone: +49 7541 908555
Fax: +49 7541 908121
TIM-ID: 0000000873 - 014

MS13015/03E 2013-05 | Appendix A | 41

 3 Appendix B
3.1 Index
C
Charge-air and exhaust system 26
Contact persons 41
Cooling system 30
Crank drive 17
Crankcase with oil pan 13
Cylinder head with injector 19

E
Engine management and monitoring 36

F
Fuel system with common-rail injection 23
Fuel treatment system 33

G
Gear train 15

H
Hotline 41

L
Lube oil system 28

M
MTU contact persons 41

P
Product summary 4

S
Service partners 41
Spare parts service 41

V
Valve gear 21
DCL-ID: 0000006641 - 003

42 | Appendix B | MS13015/03E 2013-05

Functional Description
Engine Interface Module
EIM for Series 4000
Application: Marine

E532284/02E
Printed in Germany
© 2012 Copyright MTU Friedrichshafen GmbH
This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior
written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, micro‐
filming and storage or processing on electronic systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage
during operation.
Subject to alterations and amendments.
 Table of Contents
1 General Information 4 Dialog System
1.1 Introduction 4 4.1 Parameter setting 41
1.2 Engine Interface Module EIM – Design 7

5 Appendix
2 Functions
5.1 Index 42
2.1 Power supply concept 8
2.2 Diagnosis 11

3 Connections, Cabling
3.1 Plant connector X51 13
3.2 High current connections – EIM and starter 33
3.3 External sensors 39
DCL-ID: 0000010149 - 002

E532284/02E - 2011.03 - | Table of Contents | 3

 1 General Information
1.1 Introduction

Engine room interfaces, MTU – Third-party systems

This manual describes the connection between all available interfaces on the engine and systems sup‐
plied by third-party manufacturers.
The following connections must be established:
• Plant connector X51 on the Engine Interface Module
• Power supply for EIM
• Power supply(ies) for the starter(s) (for electric starting only)
• If applicable: External starting air pressure sensor (for air starting only)
• If applicable: External coolant level sensor (for external expansion tank only)

Installation locations of the various interfaces

The figure below shows the various interfaces and all other MTU devices installed on the engine.

TIM-ID: 0000017032 - 002

4 | General Information | E532284/02E - 2011.03 -

 1 Connector XD1 – Dialog 4 Connector XF33 for con‐ 7 Fuese F2 (integrated in
unit nection of F33 for exter‐ wiring harness)
2 ECU – Engine Control nal expansion tank 8 Starter
Unit: Engine governor 5 Connector XB19 for ex‐
3 EMU – Engine Monitor‐ ternal starting air pres‐
ing Unit: Auxiliary en‐ sure sensor (for air start‐
gine monitoring device; ing only)
for classifiable systems 6 EIM – Engine Interface
only Module: Interface mod‐
ule with plant connector
X51

Block circuit diagram

The work boat engine room monitoring system can be designed as a classifiable marine automation sys‐
tem. The maximum scope features numerous elements:
• Higher-level automation system, including but not restricted to:
• Remote Control System RCS
• Monitoring and Control System MCS
• Local Operating Station LOS
• Engine Interface Module EIM
TIM-ID: 0000017032 - 002

However, the minimum scope for one engine comprises only the Engine Control Unit ECU, the starter(s),
the battery-charging generator (option), the Engine interface Module EIM and the barring gear.
An extended monitoring component (the EMU) and a Local Operating Station (LOS) are required for the
classifiable applications mentioned above. These individual components are acquired and controlled
centrally by the Engine Module Interface EIM on the engine.
All wiring is realized in the engine wiring harness. A Local Operating Station is also required for classified
automation solutions.

E532284/02E - 2011.03 - | General Information | 5

 1 Tyco plant connector 8 Engine wiring harness ECU Engine control
X51 9 Plant cable Cool Coolant level, optional
2 Tyco engine connector LOS Local Operating Station EMU Engine Monitoring Unit
X52 SSK Emergency air-shutoff PPC Priming Pump Control‐
3 Default supply flaps (option) ler (option, only in con‐
4 Redundant supply Air P-Start-Air junction with MTU Moni‐
5 Electric starter terminals BG Barring gear toring and Control Sys‐
6 Default system battery Lima. Battery-charging genera‐ tem)
7 DiaSys dialog connector tor, optional D Diagnostic lamp
F Fuse lamp
MTU provides a defined interface with all required connection assemblies (male connectors or several
cables as option) for applications with customized engine connections to the customer's system.
The Engine Interface Module EIM is the central connection box on the engine. Covers the entire mini‐
mum scope of a marine engine. Has no controls or parts requiring maintenance.
All engine signals integrated in the engine wiring harness.
The following functions are realized by the interface:
• Starter control (start repetition, tooth alignment, starter protection)
• Battery-charging generator monitoring
• Open bus interface to the plant (SAE J1939)
TIM-ID: 0000017032 - 002

• Emergency stop function with line break monitoring

• Redundant power supply
• Optional control of emergency air-shutoff flaps
• Key switch logic
• Interface to ECU and EMU
• MCS5 dialog interface
• Control of an MTU lube-oil priming pump (power components in separate MTU PPC Box)
• Connection facility for an MTU Local Operating Station (LOS)

6 | General Information | E532284/02E - 2011.03 -

 1.2 Engine Interface Module EIM – Design

Housing

The EIM comprises a metal housing suitable for mounting directly on the engine.
Connection to the engine is established via connector X52. No other connecting work is necessary (with
the exception of the starter) at the engine.Furthermore, the connectors for the two sensors F33 and B19
must be plugged in (if applicable). The connectors are already pre-assembled.
Connection to the plant is established via connector X51.
A suitable plant connector is delivered together with the EIM.
A cable with plug and open end or a prefabricated cable are available on an optional basis.

Plant interface
Tyco connector, 62-pole:
• Basic supply for higher-level MTU automation system
• combined plant signals from the ECU (connector X52) and additional signals
• For RCS: Disengagement for RCS
• For MCS: Engine Start signal and FB Local Active
• CAN interface (3-fold)
• Redundant gearbox monitoring
• Priming pump control
• Emergency stop interface
• Key switch
• On-board current supply PIM
TIM-ID: 0000017033 - 001

• Spare supply
• Serial RS422 interface for diagnosis
• Jumper to detect BDM server functionality for MTU automation systems

High current contacts (M threaded pin)

• Default positive supply
• Default negative supply
• Redundant positive supply
• Redundant negative supply

E532284/02E - 2011.03 - | General Information | 7

 2 Functions
2.1 Power supply concept

Batteries
1 Default system battery (main battery)
2 Redundant system battery (backup
battery)

The EIM can be supplied by two separated voltage sources. This redundant supply enables the system
to remain ready for operation should one of the supply voltages fail. The two power supply inputs are
each monitored separately for failure.
The redundant supply voltage must always be connected for this reason.
The two negative battery terminals must be connected to ground to protect the internal EIM connections
from circulating currents.
The EIM and all devices connected to it are switched on by a key switch which can be connected to the
EIM.
TIM-ID: 0000017036 - 001

8 | Functions | E532284/02E - 2011.03 -

 Internal power distribution

1 Default system battery 5 Engine wiring harness X11 Plug-in connection

2 Redundant system bat‐ X51 Plant interface EIM Engine Interface Mod‐
tery X52 Engine interface ule EIM
3 Key switch X3 Plug-in connection
4 Basic supply (plant, dis‐
play, (max. 6A))
The various supply voltages for the individual devices and EIM-internal functions are provided from the
main supply supplied by the batteries by means of an internal matrix. Protection is afforded by electronic
fuses (monitored PROFET fuses). The PROFET is switched off to limit the current in case of an inadmis‐
sible current increase. The figure depicts the principle distribution of voltages.

Supplied devices and protection

The following devices are supplied from the Engine Interface Module:
• ECU supply with max. 30A
• EMU supply with max. 6A
• Control supply with max. 6A
The starter circuit is supplied directly by the starter battery. The Engine Interface Module does not supply
the starter circuit with current, it merely activates the output for the engagement signal.
TIM-ID: 0000017036 - 001

• Starter with max. 60A

The EIM also provides the following supplies as required:
• Air starter with max. 1A
• 2 x emergency air-shutoff flap with max. 6A respectively

E532284/02E - 2011.03 - | Functions | 9

 Furthermore, the following outputs are separately supplied, protected and monitored by the Engine Inter‐
face Module:
• Barring gear supply with max. 1A
• Starting air pressure sensor supply with max. 1A
• Emergency stop input supply (plant) with max. 1A
• Key switch supply with max. 1A
• SDAF1+2 feedback supply with max. 1A
• PIM supply with max. 1A
• Spare supply with max. 1A
The outputs are protected to safeguard the cabling against thermal overloading and short-circuit. All
fuses are electronic. The fuse does not restore itself once tripped. Fuses must be reset. Tripping of de‐
vice fuses is monitored and an alarm is signaled.
An LED indicates that the current was switched off due to an inadmissible increase and a CAN message
signals an alarm.

TIM-ID: 0000017036 - 001

10 | Functions | E532284/02E - 2011.03 -

 2.2 Diagnosis

Diagnostic lamp
A diagnostic lamp (LED DILA, green) is integrated in the housing of the Engine Interface Module.
It indicates the operating status of the EIM.
The DILA has the following functions:
• Diagnostic lamp lit:
Engine Interface Module is OK
• Diagnostic lamp dark:
Engine Interface Module supply voltage missing or diagnostic lamp activation is faulty
• Diagnostic lamp flashes:
Hardware or software fault in the Engine Interface Module
The diagnostic lamp (DILA) signals the following states:

1 Time in seconds 4 Application loader active 7 No firmware

2 Timing: 1/8 s 5 External RAM faulty 8 Application crashed
3 Ready for operation 6 External FLASH faulty
TIM-ID: 0000017037 - 001

Fuse lamp
A second indicator is the fuse lamp SILA
This is also integrated in the housing of the Engine Interface Module. It indicates the status of the fuses.
An orange LED is provided to allow diagnosis of a “tripped fuse” fault directly at the unit as it is often
difficult to pinpoint a fault in the field without cabling diagrams.
This LED is activated by the controller.

E532284/02E - 2011.03 - | Functions | 11

 Brief description of SILA:
• SILA dark
Norma operating state
• SILA flashes orange
One or more fuses have tripped
The fuse lamp (SILA) signals the following states:

1 Preamble 6 VSP current path failed 11 ES pushbutton current

2 ECU current path failed (S5) path failed –24V exter‐
(S1) 7 SLD current path failed nal (S10)
3 MCS current path failed (S6) 12 Key switch current path
(S2) 8 DDV current path failed failed (S11)
4 EMU current path failed (S7) 13 SDAF 1+2 current path
(S3) 9 Gear monitoring current failed (S12)
5 Starter current path path failed (S8) 14 PIM current path failed
failed (S4) 10 Emergency stop current (S13)
path failed –24V internal 15 Spare current path
(S9) failed (S14)
The failed current paths are signaled consecutively following the preamble (LED on for 4 seconds (1)).
There is a pause lasting 4 seconds in between.
TIM-ID: 0000017037 - 001

12 | Functions | E532284/02E - 2011.03 -

 3 Connections, Cabling
3.1 Plant connector X51

Connection variants
MTU offers 4 different connection options for various configuration levels and variants:
• Standard: Just one cable connector for connector X51 on EIM
The Yard must connect a cable in the connector. Resistors provided in the connector must not be re‐
moved.
Connection of the MTU Local Operating Station LOS and the MTU Priming Pump Controller PPC is
not possible in the standard configuration but only in Option 3 (see below).
• Option 1: Connector with open cable end W51
The cable can be cut to the appropriate length and fully connected to a terminal strip provided by the
Yard. Cable connections can then be established from here.
• Option 2: Cable with 3 connected DEUTSCH connectors X51.3, X51.4 and X51.5
The following third-party systems can be directly connected to appropriate DEUTSCH mating connec‐
tors here:
• Remote control system to X51.5
• Monitoring system to X51.4
• J1939 bus to X51.3
• Option 3: Cable with 5 connected DEUTSCH connectors X51.1...5
The following MTU and third-party systems can be directly connected to appropriate DEUTSCH mat‐
ing connectors here:
• MTU Local Operating Station LOS to X51.2
• MTU Priming Pump Controller PPC to X51.1
• Remote control system to X51.5
• Monitoring system to X51.4
• J1939 bus to X51.3
• Oil priming pump VSP is detected automatically, reset via DiaSys® is possible
TIM-ID: 0000017040 - 002

E532284/02E - 2011.03 - | Connections, Cabling | 13

 Cable for option 1

Cable for option 2

TIM-ID: 0000017040 - 002

14 | Connections, Cabling | E532284/02E - 2011.03 -

 Cable for option 3

Signal overview
The table below list signal distribution at plant connector X51 and distribution to:
• the wires in cable W51
• the DEUTSCH connectors of options 2 and 3
The columns provide the following information:
• FR: Function range
• X51: Pin no. of connector X51
• CS: Required cross-section when cable is supplied by the Yard
• I/O: Input signal or output signal (from the MTU perspective)
• Signal function: What is controlled?
• W51: Wire number of MTU cable W51 (option 1)
• X: Connector number of DEUTSCH connector for options 2 and 3
• No.: Pin no. of DEUTSCH connectors for options 2 and 3
• Note: Additional information
TIM-ID: 0000017040 - 002

E532284/02E - 2011.03 - | Connections, Cabling | 15

 Cable with connectors fitted at both ends: X51 at one end and X51.1 to
3 (for third-party systems) or X51.1 to 5 (for MTU systems)
Connector with pigtail cable (open end)
Connector only Note
W N
Signal 5 o
FB X51 Q I/O Signal function name 1 X .

0.
57 I 1 1
5 +Ub_MCS
Power supply for MCS
0. functions and devices
60 O 2 2 Includes current monitoring al‐
5 +Ub_MCS
lowing cabling damage to be
0. detected. Max. current 6 A
59 - 3 3
5 Ground for supply GND_MCS
voltage at wires 1 and
0. 2
62 - 4 4
5 GND_MCS

0.
49 I Engine start signal 5 5 Signal stored
5 DI_START

0. Supply voltage for key

16 O 6 6 Max. current: 1A
5 switch +Ub_SS
MCS
2 15 0. Input for key switch
I 7 7 Supply static signal
5 “ON” SS_ON
X
0. Input for key switch 51
14 I 8 . 4 8 Supply static signal
5 “OFF” SS_OFF

0. ECU_DI1_
42 I Engine stop signal 9 9 Stored
5 STOP

Deactivated cylinder ECU_DI2_

0. 1 1
38 I cutout (also called “full CYLCUT‐
5 0 0
engine”) OUT OFF

Corresponding ground Electrical isolation between

0. 1 1
43 - for both signals at GND_ECU_ the grounds at wires 11 and
5 1 1
wires 9 and 10 DI1_2 30
0. Set when LOS is in T_OUT_ 1 1 Max. current 1 A, line disrup‐
53 O
5 “LOCAL” mode LOCAL 2 2 tion not detected
TIM-ID: 0000017040 - 002

16 | Connections, Cabling | E532284/02E - 2011.03 -

 Cable with connectors fitted at both ends: X51 at one end and X51.1 to
3 (for third-party systems) or X51.1 to 5 (for MTU systems)
Connector with pigtail cable (open end)
Connector only Note
W N
Signal 5 o
FB X51 Q I/O Signal function name 1 X .

0. CAN-Low of J1939 in‐ CAN_ 1

55 I/O 1
5 terface J1939_L 3

0. CAN-High of J1939 in‐ CAN_ 1

56 I/O 2
5 terface J1939_H 4

CAN_
0. Ground of CAN bus 1
54 - J1939_GN 3
5 J1939 5
D

CAN_
0. Ground of CAN bus 1
54 - J1939_GN 4
5 J1939 6
D

0. CAN-Low of J1939 in‐ CAN_ 1 Connection is intended for 120

45 I/O 5
MCS 5 terface J1939_L 7 ohm terminator
1 X
0. CAN-High of J1939 in‐ CAN_ 1 Connection is intended for 120
41 I/O 51 6 ohm terminator
5 terface J1939_H 8
.3
Power supply for +Ub_
0. 1
12 O emergency stop push‐ EMERG_ 7 Max. current: 1A
5 9
button STOP

0. DI_EMERG 2 Input is monitored for wire

11 I Emergency stop input 8
5 STOP 0 break

A High signal on this DI_START Input is monitored for wire

0. 5
23 I input activates start in‐ INTER‐ 9 break
5 1
terlock LOCK

0. Power supply + 24 V 5 1 Max. current: 1A

24 O
5 DC +Ub 2 0
TIM-ID: 0000017040 - 002

E532284/02E - 2011.03 - | Connections, Cabling | 17

 Cable with connectors fitted at both ends: X51 at one end and X51.1 to
3 (for third-party systems) or X51.1 to 5 (for MTU systems)
Connector with pigtail cable (open end)
Connector only Note
W N
Signal 5 o
FB X51 Q I/O Signal function name 1 X .

Reference voltage for

0. 2
36 A the analog input at ECU_UREF 1 Output with 5V: Do not use
5 1
wire 22 _ AI

ECU_AI1_
0. Speed demand signal 2
40 I SPEED_DE 2 Current supply
5 4 ... 20 mA 2
M

0. Ground for speed de‐ ECU_GND_ 2

32 - 3 Ground is electrically isolated
5 mand signal AI1 3

Ground for the analog

0. 2
28 - outputs at wires 25 ECU_GND_ 4 Ground is electrically isolated
5 4
and 26 AO

0. Engine load signal ECU_AO2_ 2 Engine load signal at 0.5V:

31 A 5
5 0...10V ENGLOAD 5 Load is on DBR

ECU_AO1_
0. Engine speed signal 2
27 A ENG‐ 6
5 0...10V 6
SPEED

0. ECU_DI5_ 2
34 I Speed increase input 7
5 SPEEDUP 7
RCS
ECU_DI6_
0. 2
30 I Speed decrease input SPEEDDW X 8
5 8
N 51
.5
Select between speed de‐
mand via pushbutton (speed
0. Speed demand selec‐ 2
26 I ECU_DI8_ 9 change by signals at wires 27
5 tion 9
SW_SPD_ and 28) or analog speed de‐
DEM mand (current at wire 22)

Combined ground for speed

Corresponding ground
0. 3 1 demand via pushbutton sig‐
35 - for signals at wires 27,
5 ECU_GND_ 0 0 nals (routed out separately for
28 and 29
DI5_6_8 reasons of safety)
TIM-ID: 0000017040 - 002

Max. load: 1A, monitored for

open-load, minimum load is
0. Disengagement re‐ 3 1 therefore necessary (resist‐
29 A
5 quest 1 1 ance must be less than 2
T_OUT_ kohm). Rin(mating point) <
DISENG U(switching threshold) / 1mA

Mating point input must be

0. Corresponding ground 3 1
33 - GND_T_OU electrically isolated to preclude
5 for wire 31 2 2
T circulating currents.

18 | Connections, Cabling | E532284/02E - 2011.03 -

 Cable with connectors fitted at both ends: X51 at one end and X51.1 to
3 (for third-party systems) or X51.1 to 5 (for MTU systems)
Connector with pigtail cable (open end)
Connector only Note
W N
Signal 5 o
FB X51 Q I/O Signal function name 1 X .

0. 3
20 1
5 3

0. 3
19 2
5 4

0. 3
13 Only when an MTU 3
5 5
PPC Priming Pump Con‐ X No function when a third-party
0. - troller is used 3 51 4 priming pump controller is
18
5 6 .1 used
0. 3
17 5
5 7

3
6
8
TIM-ID: 0000017040 - 002

E532284/02E - 2011.03 - | Connections, Cabling | 19

 Cable with connectors fitted at both ends: X51 at one end and X51.1 to
3 (for third-party systems) or X51.1 to 5 (for MTU systems)
Connector with pigtail cable (open end)
Connector only Note
W N
Signal 5 o
FB X51 Q I/O Signal function name 1 X .

0. 3
52 1
5 9

0. 4
51 2
5 0

0. 4
48 3
5 1

0. 4
47 4
5 2

0. 4
50 5
5 3

0. 4
46 Only when an MTU 6
5 4 No function when a third-party
LOS Local Operating Sta‐
local control system is used
0. tion LOS is used 4
21 X 7
5 5
- 51
0. 4 .2
25 8
5 6

0. 4
12 9
5 7

0. 4 1
11
5 8 0

0. 4 1
5 9 1

0. 5 1
5 0 2

0.
7 Not assigned
5

0.
TIM-ID: 0000017040 - 002

9 Not assigned
5

0.
10 Not assigned
5

0.
58 Not assigned
5

0. Only when an MTU

4
5 MCS/RCS is used

20 | Connections, Cabling | E532284/02E - 2011.03 -

 Cable with connectors fitted at both ends: X51 at one end and X51.1 to
3 (for third-party systems) or X51.1 to 5 (for MTU systems)
Connector with pigtail cable (open end)
Connector only Note
W N
Signal 5 o
FB X51 Q I/O Signal function name 1 X .

0. Only when an MTU

8
5 MCS/RCS is used

0. Only when an MTU

22
5 MCS/RCS is used

0. Only when an MTU

37
5 MCS/RCS is used

0. Only when an MTU

44
5 MCS/RCS is used

0. Only when an MTU

1
5 MCS/RCS is used

0. Only when an MTU

2
5 MCS/RCS is used

0. Only when an MTU

3
5 MCS/RCS is used

0. Only when an MTU

5
5 MCS/RCS is used

0. Only when an MTU

6
5 MCS/RCS is used

0. Only when an MTU

39
5 MCS/RCS is used

S
hi
61 Shielding
el
d

MCS 2 function range

The figure below illustrates connection performed by the Yard. Note that connections must be establish‐
ed either directly at connector X51, at cable W51 or at the DEUTSCH connectors depending on which of
the variants (standard or one of the options 1 to 3) is being realized. In this example the internal operat‐
TIM-ID: 0000017040 - 002

ing voltage is used to activate the inputs.

E532284/02E - 2011.03 - | Connections, Cabling | 21

 In contrast to the figure above, the following figure illustrates supply of the inputs by an external (Yard)
power source. Note that the ground of this external power source must be connected to the ground
GND_ECU_DI1_2.

TIM-ID: 0000017040 - 002

22 | Connections, Cabling | E532284/02E - 2011.03 -

 Output for higher-level automation system, supply voltage +Ub_MCS, GND_MCS

Purpose
For smaller, straightforward plants the Engine Interface Module incorporates a basic supply for higher
level plant components. 4 supply voltage pins (2x +24V, 2x GND) are routed out at the plant connector.
The current is limited to 6A. Higher-level plant components must be supplied separately if they require
more current.

Output specification
• Output voltage: 0 ... +UBATT minus max. 0.35V @ 1A
• Short-circuit current: Overcurrent cutout (temperature-dependent)
• Max. rated current: Min. 6A
• Settling time: —
• Electrical isolation: None
• Wire break monitoring: No
• Switched by key switch

Engine start signal input – DI_START

Operation
A signal applied to this input trips an automatic engine start. The status “Local/Remote mode” is disre‐
garded in this case.

Input specification D_IN

• Switches: +UBATT
• Input voltage range: 0..32V
• LOW detection: UIN < 4 V
• HIGH detection: UIN > 8 V
• Input impedance: 3.5 ... 4.6 kΩ
• Electrical isolation: None
• Input filter: f < 144 Hz
• Reverse-polarity protection: –UBATT

Stop signal input – ECU_DI1_STOP

Operation
A normal engine stop is tripped when a signal is applied to this input. The status “Local/Remote mode” is
disregarded in this case.

Input specification (signal looped through to ECU 7 – DI1)

• Switches: External voltage or +UBATT
• Input voltage 0 ... 32 VDC
• LOW detection: UIN < 4 V
• HIGH detection: UIN > 8 V
TIM-ID: 0000017040 - 002

• Input impedance: 12.1 kΩ

• Input filter: f < 19 Hz
• Electrical isolation: Up to 50 VDC

Key switch signal input – +Ub_SS, SS_ON, SS_OFF

Operation
The EIM and all devices supplied by it can be switched on and off by means of a key switch. Evaluation
of the key switch is realized by hardware as the microcontroller is also switched off when the supply is
discontinued.

E532284/02E - 2011.03 - | Connections, Cabling | 23

 Only the key switch logic is still supplied when the device is switched off. A transistor circuit realizes the
evaluation.
• A broken wire does not lead to switching off.
• The ON signal has priority over the OFF signal.
• The ON signal can be used to switch on and off if the OFF signal is constantly high (however, a bro‐
ken SS_ON wire then leads to switch off).
• The engine is stopped in accordance with the normal stop routine if the key switch is switched to the
off position when the engine is running. Only then is the supply disconnected.
The diode in the input circuit ensures that the supply voltage output for the key switch is protected from
reverse voltage. The key switch switches this voltage between the ON pin (SS_ON) and the OFF pin
(SS_OFF) alternately.

Note:
The following causes may prevent the plant being switched on via the key switch:
• Wire break SS_ON
• Wire break +Ub_SS
• Fuse failure (e.g. due to short circuit to ground); monitored via SILA
The following causes may prevent the plant being switched off via the key switch:
• Short circuit of key switch fuse:
• Stop engine
• Switch off plant (by disconnecting the battery)
• Rectify fault; the fuse is automatically reset the next time the plant is switched on
• IMPORTANT: The plant cannot be switched back on after disconnecting the battery if the fault is
not rectified.

Schematic circuit diagram

1 Key switch
2 Output signal “ON”

TIM-ID: 0000017040 - 002

Deactivate cylinder cutout signal input – ECU_DI2_CYLCUTOUTOFF

Operation
The Engine Control Unit prevents cylinder cutout when a signal is applied to this input (also referred to as
“full engine”).

24 | Connections, Cabling | E532284/02E - 2011.03 -

 Input specification (signal looped through to ECU 7 – DI2)
• Switches: External voltage or +UBATT
• Input voltage 0 ... 32 VDC
• LOW detection: UIN < 4 V
• HIGH detection: UIN > 8 V
• Input impedance: 12.1 kΩ
• Input filter: f < 19 Hz
• Electrical isolation: Up to 50 VDC

Signal output Local — T_OUT_LOCAL

Operation
This output is activated by the following events:
• LOS in local control mode
When the plant is operated in local control mode, the plant is controlled exclusively via the LOS. Control
signals from RCS, regardless of whether they are hardwired or CAN signal, are disregarded.

Output specification T_OUT

• Output voltage: 0 ... +UBATT minus max. 0.35V @ 1A
• Short-circuit current: Overcurrent cutout, temperature-dependent
• Max. rated current: minimum 1 A
• Settling time: —
• Electrical isolation: None
• Wire break monitoring: No

MCS 1 function range

The figure below illustrates connection performed by the Yard. Note that connections must be establish‐
ed either directly at connector X51, at cable W51 or at the DEUTSCH connectors depending on which of
the variants (standard or one of the options 1 to 3) is being realized.
TIM-ID: 0000017040 - 002

E532284/02E - 2011.03 - | Connections, Cabling | 25

 CAN 3 bus – SAE J1939

Operation
The Engine Interface Module has an interface for an open CAN protocol (SAE J1939 or CANopen).
SAEJ1939 is generally envisaged as the open protocol. CANopen is also to be implemented in future for
other cases.
• Standard: ISO 11898 (High Speed CAN)
• Specification: Version 2.0A/B (simple format with 11 bit identifier and extended format with 29 bit iden‐
tifier)
• Data rate: Up to 1Mbit/s
• Short-circuit rating in voltage range between –3 and +32V
• Transmitter output current > 25mA
• Max. bus length (as per CAN in automation CIA DS-102):
• 500m at 125kbit/s
• 250m at 250kbit/s
• El. isolation: 50V DC electrical isolation
• Bus line: Sym. signal transmission via 2-wire line with common return line, alternatively twisted or
shielded
• Line impedance: Typ. 120Ohm
• Bus termination: Termination resistor 120 Ohm at the end of the bus line (see figure*: ONLY ONE
RESISTOR MAY BE CONNECTED, it must be at the end of the bus).

Emergency stop signal input – DI_EMERG_STOP

Operation
The emergency stop feature is a class-relevant safety facility. Special directives apply to such facilities.
The following functions are implemented to this end:
• Safety facilities are designed as simply as possible and take unavoidable effect
• Designed with conventional technology (hard-wired)
• Monitored load current principle
• Power supply is monitored, failure leads to alarm signaling
• Possible faults (e.g. voltage failure or wire break) will not lead to a hazardous condition; Their occur‐
rence leads to alarm signaling
• Tripping the safety feature leads to alarm signaling
The principle element of the emergency stop circuit is the emergency stop root which couples all inputs
and outputs together. The emergency stop root is activated and maintains itself (self-holding) when an
emergency stop signal is applied to one of the emergency stop inputs, .
The source of an emergency stop may be either one of the devices (ECU and EMU), or one of the emer‐
gency stop pushbuttons.
The emergency stop pushbuttons are monitored for wire break by parallel-connected resistors. As a cur‐
rent always flows in the emergency stop pushbutton circuit, wire break is detected by the change in cur‐
rent flow or the change in voltage at the measuring resistor. The objective of an emergency stop is to
shut down the engine. The ECU (engine governor) must receive an active ECU_ESI (Emergency Stop
Input) signal for this, or, if a cable is disrupted, the supply voltage of the ECU must be switched off.
TIM-ID: 0000017040 - 002

As ECU4 has neither an ESI input nor an FB_OL output, the supply voltage is always switched off in this
case.
The emergency stop root is monitored and a “Disengage for RCS” signal is output in the event of an
emergency stop in order to disengage the gear to prevent the engine being turned by a dragging propel‐
ler.

26 | Connections, Cabling | E532284/02E - 2011.03 -

 If the engine is equipped with emergency air-shutoff flaps (SDAFs) these are tripped by a PROFET con‐
nected to the emergency stop root. The SDAFs have a limited activation period and must therefore be
shut down after a timeout. When the SDAFs close as intended a limit switch outputs a feedback signal
ensuring that activation is switched off. The feedback signal is evaluated and an engine stop message is
transmitted to the ECU via the CAN. This is necessary in case one or both SDAF(s) was (were) tripped
by a mechanical fault. The SDAFs remain closed until they are returned to their original position manual‐
ly.

Input specification NS_IN

• Input voltage range: 0..32V
• LOW detection: UIN < 10 V
• HIGH detection: UIN > 12 V
• Max. number of emergency stop pushbuttons: 8 pcs.
• Input impedance: 1.1 kΩ
• Electrical isolation: None
• Input filter: f < 123 Hz
• Reverse-polarity protection: –UBATT
• Wire break monitoring:
• One resistor respectively connected in parallel to the switching contact: 33.2 kΩ ± 1%
• Pushbutton detection switching thresholds:
• 0 pushbutton: > 68.9 kΩ
• 1 pushbutton: 68.9 ... 22.66 kΩ
• 2 pushbuttons: 22.66 ... 13.57 kΩ
• 3 pushbuttons: 13.57 ... 9.68 kΩ
• 4 pushbuttons: 9.68 ... 7.53 kΩ
• 5 pushbuttons: 7.53 ... 6.16 kΩ
• 6 pushbuttons: 6.16 ... 5.21 kΩ
• 7 pushbuttons: 5.21 ... 4.52 kΩ
• 8 pushbuttons: 4.52 ... 3.99 kΩ
TIM-ID: 0000017040 - 002

E532284/02E - 2011.03 - | Connections, Cabling | 27

 Schematic circuit diagram

1 Emergency stop push‐

button – up to 8 pcs.,
33.2 kΩ respectively
parallel to contact
The emergency stop interface incorporates the following signals both to the plant and the engine (paral‐
lel):
• +24V_emergency stop (output, fuse-protected)
• Emergency stop input (D_IN), wire-break monitoring
• Parallel connection of max. 8 emergency stop pushbuttons possible
• Furthermore, the following engine signals are incorporated in the emergency stop circuit:
• EMU_Emergency Stop (EIM input)
• ECU_Emergency Stop (EIM input)
• ECU_ESI (EIM output)
• ECU_FB_OpenLoad (EIM input)
• Option: Control of emergency air-shutoff flap 1 (EIM output)
• Option: Control of emergency air-shutoff flap 2 (EIM output)
• Option: FB SDAF1 shut (EIM input)
• Option: FB SDAF1 shut (EIM input)
TIM-ID: 0000017040 - 002

Signal input of external start interlock DI_EXT.STARTINTERLOC

Operation
A signal applied to this input will inhibit an engine start (provided that parameter ZKP 10.2000.005 is de‐
activated).

28 | Connections, Cabling | E532284/02E - 2011.03 -

 Input specification D_IN
• Switches +UBATT
• Input voltage range: 0..32 V
• LOW detection: UIN < 4 V
• HIGH detection: UIN > 8 V
• Input impedance: 3.5 ... 4.6 kΩ
• Electrical isolation: None
• Input filter: f < 144 Hz
• Reverse-polarity protection: –UBATT

RCS function range

The figure below illustrates connection performed by the Yard. Note that connections must be establish‐
ed either directly at connector X51, at cable W51 or at the DEUTSCH connectors depending on which of
the variants (standard or one of the options 1 to 3) is being realized.

Speed demand signal input – ECU_AI1_SPPED_DEM

Operation
An analog signal (current) applied at this input is evaluated as a speed demand. Scaling (i.e. the correla‐
TIM-ID: 0000017040 - 002

tion between electrical value and speed value) must be set with the dialog system DiaSys.

Input specification (signal looped through to ECU 7 – AI1)

• Current sources
• Sensor supply: 5 VDC ± 3%, max. 25mA (ECU_UREF_AI)
• Current: 0 ... 20 mA nom., 0 ... 25 mA max.; compliance voltage 4.5 V at 20 mA
• Electrical isolation: 50 VDC
• Fault detection current input: I < 4 mA, I > 20 mA
• Power supply protection: Short circuit to GND, overvoltage 36 VDC

E532284/02E - 2011.03 - | Connections, Cabling | 29

 Engine load signal output – ECU_AO2_ENGLOAD

Operation
The engine load signal is an analog output signal (between 0 VDC and 10 VDC) which is defined as
follows:
• 0 V DC: No engine load
• U = 10 VDC: Engine load at 120%

Output specification (signal looped through from ECU 7 – AO2)

• Control of:
• Display instruments
• Analog inputs
• Channel specification
• Output voltage: 0 ... 10 V
• Output voltage without load: Approx. 0V
• Short-circuit current: 17 mA
• Imax: 0 ... 8 mA at 10 V
• Settling time: 45 ms
• Electrical isolation: None
• Wire break monitoring: No
• Overvoltage protection: 36 VDC

Engine speed signal output – ECU_AO1_ENGSPEED

Operation
A DC voltage signal the value of which is proportional to the engine speed is applied to this output. The
following applies:
• 0V: 0 rpm
• 10V: Max. speed

Output specification (signal looped through from ECU 7 – AO1)

• Control of:
• Display instruments
• Analog inputs
• Channel specification
• Output voltage: 0 ... 10 V
• Output voltage without load: Approx. 0V
• Short-circuit current: 17 mA
• Imax: 0 ... 8 mA at 10 V
• Settling time: 45 ms
• Electrical isolation: None
• Wire break monitoring: No
• Overvoltage protection: 36 VDC

Speed UP and Speed DOWN signal inputs – ECU_DI5_SPPEDUP, ECU_DI6_SPEEDDWN

TIM-ID: 0000017040 - 002

Operation
The “Speed demand switching” signal must be active at DI8 to allow these two inputs to be evaluated.
A signal briefly applied to these inputs increases (DI5) or decreases (DI6) the present engine speed by a
certain value. The speed increases or decreases along a defined ramp if the signal is applied for a longer
period.

30 | Connections, Cabling | E532284/02E - 2011.03 -

 Input specification (signals looped through to ECU 7 – DI5 -“Speed UP” and DI6-“Speed DOWN”)
• Switches: External voltage or +UBATT
• Input voltage 0 ... 32 VDC
• LOW detection: UIN < 4 V
• HIGH detection: UIN > 8 V
• Input impedance: 12.1 kΩ
• Input filter: f < 19 Hz
• Electrical isolation: Up to 50 VDC
• Wire break monitoring: Current monitoring with ROL = 33 kΩ ± 10%, see figure

Speed demand switching signal input – ECU_DI8_SW_SPD_DEM

Operation
A signal at this input makes the two inputs DI5 and DI6 “live”.

Input specification (signal looped through to ECU 7 – DI8)

• Switches: External voltage or +UBATT
• Input voltage 0 ... 32 VDC
• LOW detection: UIN < 4 V
• HIGH detection: UIN > 8 V
• Input impedance: 12.1 kΩ
• Input filter: f < 19 Hz
• Electrical isolation: Up to 50 VDC
• Wire break monitoring: Current monitoring with ROL = 33 kΩ ± 10%, see figure
The switching function must be checked manually at regular intervals.

Disengage signal output – T_OUT_DISENG

Operation
This output is activated by the following events:
• Engine start is activated
• Emergency stop is activated
• Engine stop is activated
• Emergency shutdown due to low speed is activated
Any connected remote control system MUST evaluate this signal and disengage when the T_OUT_DIS‐
ENG signal is active.

Output specification T_OUT

• Output voltage: 0 ... +UBATT minus max. 0.35V @ 1A
• Short-circuit current: Overcurrent cutout (temperature-dependent)
• Max. rated current: Min. 1A
• Settling time: —
• Electrical isolation: None
• Wire break monitoring: Configurable (monitoring current flows when configured)
TIM-ID: 0000017040 - 002

This signal must be electrically isolated on the plant side to prevent circulating currents via signal ground
if an RCS is connected here which is not supplied by the same battery and thus does not have the same
reference ground.
The function must be monitored by the customer if wire break monitoring is not configured.

MTU devices LOS and PPC

Suitable cables are delivered for connection of the two MTU devices LOS and PPC. The cables cannot
be interchanged and are connected to the two DEUTSCH connectors X51.1 and X51.2 and the two devi‐
ces.

E532284/02E - 2011.03 - | Connections, Cabling | 31

 Manual wiring is not necessary.
A connected oil priming pump is detected automatically and detection is stored internally. Automatic pri‐
ming takes place in accordance with the configuration when a lube-oil priming pump has been detected.
To deactivate a lube-oil priming pump which has been detected the lube-oil priming pump must be reset
with the aid of DiaSys®.

Plant control with LOS

Plant control with the Local Operating Station LOS is described in a separate Quick Reference.

Oil priming features

Starting prelubrication
If starting prelubrication is part of the project design, the VSP is activated prior to each engine start. In
local control mode, the start signal is not stored, which means that the start signal must be applied until
the engine has reached the starter disengagement speed (n > 300 rpm).
Starting prelubrication is activated for a configurable period of time before the starter is activated. Detec‐
tion of a prelubrication fault leads to termination of the starting prelubrication process. Faults might be a
missing feedback signal to VSP or a VSP fault. When message „Ext. Stop Priming“ is received via
J1939, the prepublication process is terminated. A re-start within a time frame tmax, which can be config‐
ured with parameter “Restart Time“, will be conducted without prelubrication.

Intermittent oil priming

Intermittent oil priming involves cyclical lubrication of the engine when at standstill by repeatedly activat‐
ing the electrical lube-oil priming pump (prelube pump) for a certain period.
The lube-oil priming pump is activated with the engine at a standstill on expiry of the configurable interval
(tinterval). The lube-oil priming pump is switched off when the oil pressure reaches the priming target val‐
ueppriming or the maximum priming time tmax expires. When the oil pressure limit value ppriming for oil pri‐
ming is reached, the priming process is terminated. Parameter tpriming can be used to set the period of
time the priming pump continues running after reaching the desired oil pressure. This prevents excessive
lubrication of the engine. If tpriming is zero, oil priming is stopped immediately. Oil priming is stopped when
the maximum oil priming time tmax expired irrespective whether the desired oil pressure ppriming has been
reached or not. For alarm signaling, see below.When the oil priming time tpriming or the maximum oil
priming time tmax (also possible in continuous mode) expire, the oil priming pump is switched off and the
interval time (t interval starts again. The priming sequence recommences when the interval is over. If the
engine is re-started within a configurable period of time tpause following a successful oil priming se‐
quence, the start is conducted without repeated oil priming. If the time interval is set to zero in the data
record, oil priming is carried out at each engine start.

Pressure monitoring and alarm signaling

The lube-oil priming pump is monitored to ensure that the required oil pressure is reached within a cer‐
tain time regardless of the priming sequence itself.
Alarm "AL P-Priming Pump Low" is output if the measured oil pressure value fails to reach the configura‐
ble limit value pAlarm within a configurable period tAlarm (reason: pump fault, low oil level, oil leak, excessive
TIM-ID: 0000017040 - 002

temperature…). If the oil pressure value is between pAlarm and ppriming (pAlarm < plube oil < ppriming), no alarm
signal is output. Alarm "AL P-Priming Pump Low" is not set if lube oil temperature Tlube oil > TAlarm. Param‐
eter TAlarm is set to a value ensuring that an alarm is always output – regardless of the lube oil tempera‐
ture.
The pump continues running until the maximum oil priming time is reached.

Control with Priming Pump Control PPC

Oil priming pump control with the Priming Pump Control PPC is described in a separate Quick Refer‐
ence.

32 | Connections, Cabling | E532284/02E - 2011.03 -

 3.2 High current connections – EIM and starter

Starter battery to starter

The starter battery must be connected to the starter by the Yard.
Minimum cable cross-sections apply depending on the distance between starter battery and starter.
The figure below illustrates connection for engines with one starter.

1 Terminal 30 – Starter + 3 Starter battery

2 Terminal 31 – Starter – F1 Fuse
Establish the connection as follows:
1. Undo nuts at terminals 31 (ground) and 30 (supply) and remove together with the washers.
2. Route cable between battery and starter.
3. Fit M12 cable rings for the ground cable and M12 for the supply cables on the EIM side.
4. Connect cables to the appropriate stud bolts and fit one washer and nut respectively:
• (1): Starter battery + terminal
• (2): Starter battery – terminal
5. Tighten nuts to 29.8 Nm countering the stud bolt (starter side) in so doing.
TIM-ID: 0000017038 - 002

Both starters are connected in series on engines with 2 starters. Both starters must be connected directly
to the starter battery. The figure below is a schematic representation illustrating connection. Note that no
metal jumper may be installed between starter and starter relay at the starter connected to the + terminal
of the battery (starter 1 in the figure).

E532284/02E - 2011.03 - | Connections, Cabling | 33

 1 to 4 Starter WITHOUT jump‐ 3 Starter 1 – Terminal 31: 7 Starter 2 – Terminal 31:
er between terminals 45 Apply to battery negative Apply to battery nega‐
and 30b (connection not shown) tive
5 to 7 Starter WITH jumper 4 Starter 1– Starter relay 8 Starter battery
between terminals 45 output F1 Fuse
and 30b 5 Starter 2 – Terminal 30 +
1 Starter 1 – Terminal 30 6 Starter 2 – Motor supply
+ +/starter relay output
2 Starter 1 – Motor supply
+

Battery to EIM

General information about battery cabling

Various battery cabling applications are possible.
One system battery and one starter battery are always provided for each engine. The starter battery is
generally used as a redundant supply. The other starter battery is generally used as a redundant system
battery in order to prevent significant voltage dips during starting:
• Starter battery Motor 1 is the redundant system battery for Motor 2
• Starter battery Motor 2 is the redundant system battery for Motor 1
TIM-ID: 0000017038 - 002

A second redundant system battery may also be provided in some cases.

The negative terminals of the two batteries must be connected to the protect internal circuitry against
circulating currents and grounding.
Notes regarding the EIM connection to the system battery (default and redundant): The nominal current
of the EIM is typically 40A (depending on the consumers connected, without starter). Standard design
fuses are used (see F3 and F4). The total nominal current is the sum off all currents mentioned in section
"Supplied devices and protection" (→ Functional Description).

34 | Connections, Cabling | E532284/02E - 2011.03 -

 The cable from the starter battery to the starter (Tl. 30, Tl. 31) is solid (short-circuit resistant) and is not
necessarily fuse-protected. Fuse protection, should, however be provided by the yard. This fuse protec‐
tion must be dimensioned by the Yard, considering the following factors:
• Starter (power/current)
• Battery (internal resistance)
• Cable length (cross-section and line resistance)
A fuse is provided directly at the starter owing to the tapering cross-section as an engine cable with a
smaller cross-section runs from the starter to the Engine Interface Module (integrated in the wiring har‐
ness).
When isolating one of the batteries disconnect either the positive line at one terminal or both terminals. In
this arrangement, disconnecting at just one negative terminal would have no direct effect as there is an
alternative current path via the internal connection of default and redundant, the two grounds of the neg‐
ative terminals and via the jumpers. The alternative current path is not designed to withstand loading by
the starter.

Version with default system battery with redundant system battery and starter battery

Schematic circuit diagram

1 Redundant system bat‐ 5 Starter battery (system 9 Engine wiring harness

tery battery) EMU EMU supply
TIM-ID: 0000017038 - 002

2 Redundant supply 6 Connector for EMU, ECU ECU supply

3 Terminals to starter ECU, PS PS Pneumatic starter
4 Starter 7 Default supply
8 Default system battery

E532284/02E - 2011.03 - | Connections, Cabling | 35

 Connection to EIM

Four M6 stud bolts are provided for connection at the EIM. The batteries are connected here in accord‐
ance with the diagrams above. Proceed as follows:
1. Undo nuts and remove together with the washers.
2. Remove covers.
3. Route cable between batteries and EIM.
4. Fit M6 cable rings to the cables on the EIM side.
5. Connect cables to the appropriate stud bolts and fit one washer and nut respectively:
• (1): Main battery + terminal
• (2): Main battery: – terminal
• (3): Backup battery: + terminal
• (4): Backup battery: – terminal
6. Tighten nuts to 4 Nm.
TIM-ID: 0000017038 - 002

36 | Connections, Cabling | E532284/02E - 2011.03 -

 Version with default system battery with starter battery as redundant system battery

Schematic circuit diagram

1 Redundant supply 5 Starter battery (system 9 Engine wiring harness

2 Terminals to starter battery) EMU EMU supply
3 Jumpers 6 Connector for EMU, ECU ECU supply
4 Starter ECU, PS PS Pneumatic starter
7 Default supply
8 Default system battery
TIM-ID: 0000017038 - 002

E532284/02E - 2011.03 - | Connections, Cabling | 37

 Connection at EIM when starter battery is used as a redundant system battery.

Four M6 stud bolts are provided for connection at the EIM. The batteries are connected here in accord‐
ance with the diagrams above. Proceed as follows:
1. Undo nuts and remove together with the washers.
2. Remove covers.
3. Route cable between battery and EIM.
4. Fit M6 cable rings to the cables on the EIM side.
5. Connect cables to the appropriate stud bolts and fit one washer and nut respectively:
• (1): Main battery: + terminal to (1)
• (2): Main battery: – terminal to (2)
• (3): Jumper terminal 30 to (1)
• (4) Jumper terminal 31 to (2)
6. Tighten nuts to 4 Nm.

Exception when using one starter battery as a redundant battery

The jumpers on the EIM must have a minimum cross-section of 6 mm2.
TIM-ID: 0000017038 - 002

38 | Connections, Cabling | E532284/02E - 2011.03 -

 3.3 External sensors

Starting air pressure sensor B19

The connector XB19 for the starting air pressure sensor is located on engine wiring harness W2 directly
next to Engine Control Unit ECU 7.
Plug in the cable with the appropriate mating connector and open end here. The sensor is connected to
the open end as follows:

The sensor must meet the following electrical specifications:

• Signal 4 ... 20 mA
• Range 0 .... 50 bar (standard, may be changed on an optional basis)
Establish the connection as follows:
1. Route the cable along the engine to starting air pressure sensor B19 and secure at suitable points
using cable ties.
2. Wire number 1: Signal +U_STAIR at sensor B10 pin +
3. Wire number 2: Signal P_IN_STAIR at sensor B10 pin -
The channel is switched off for safety reasons (protection) if a sensor current exceeding 24 mA is meas‐
ured. The sensor value is then displayed as “SD”.
TIM-ID: 0000017039 - 001

A functional sensor is not detected automatically after repair or replacement. The system must be RE‐
SET for this reason (switched off and back on).

Coolant level sensor F33

The coolant level sensor F33 must only be connected by the Yard when an external expansion tank is
installed. The sensor is already wired up by MTU in all other cases.
Cable connector XF33 for the coolant level sensor is located on engine wiring harness W2 in the immedi‐
ate vicinity of the ECU.

E532284/02E - 2011.03 - | Connections, Cabling | 39

 The cable with the appropriate mating connector and suitable connector for the coolant level sensor is
connected here when an external expansion tank is installed:
1. Plug in connector XF33 on engine wiring harness XF33 and secure it.
2. Route cable to sensor F33.
3. Plug in connector F33 at the sensor and secure it.
If a current exceeding 24 mA is measured at this input the load resistor in the EIM is switched off and
“voltage measuring” mode is activated. This results in detection of a sensor failure. The system must be
reset (switch off and back on) following repair of the sensor so that the functioning sensor is detected as
such.

TIM-ID: 0000017039 - 001

40 | Connections, Cabling | E532284/02E - 2011.03 -

 4 Dialog System
4.1 Parameter setting
Check and/or set the following parameters when an EIM is intended to be used:
• 10.2100.001 Number of emergency stop buttons
• 10.2100.004 J1939 Alarms not stored
• 10.2100.006 Speed Demand Config
• 10.2600.001 Limit L1L P-Start Air
• 10.2600.001 Limit L1L P-Start Air
• 10.2600.003 Delay LO P-Start Air
• 10.2600.004 Hysteresis LO-P-Start Air
• 10.2600.005 Measuring range P-Start Air
• 10.2600.006 T_max_Start_Air

The DiaSys dialog system is required to set these parameters. If this equipment hsould not be available,
contact the MTU Product Support.
TIM-ID: 0000026664 - 001

E532284/02E - 2011.03 - | Dialog System | 41

 5 Appendix
5.1 Index
D
Diagnosis 11

E
Engine Interface Module EIM – Design 7
External sensors 39

H
High current connections – EIM and starter 33

I
Introduction 4

P
Plant connector X51 13
Power supply concept 8

DCL-ID: 0000010149 - 002

42 | Appendix | E532284/02E - 2011.03 -

System Documentation
Electronic Equipment
GenoLine System
with LOP 10, ADEC and EIM
for Onboard Power Generators
Engine Series:
4000 M
Application: Marine

E532300/01E
© 2014 Copyright MTU Friedrichshafen GmbH
This publication is protected by copyright and may not be used in any way, whether in whole or in part, without the prior
written consent of MTU Friedrichshafen GmbH. This particularly applies to its reproduction, distribution, editing, transla-
tion, microfilming and storage or processing in electronic systems including databases and online services.
All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen
GmbH reserves the right to change, delete or supplement the information provided as and when required.
 Table of Contents
1 Safety 3.1.1 Local Operating Panel LOP 10 – Controls and
displays 30
1.1 Important requirements for all products 4 3.1.2 Display on LOP 10 – Screen pages, navigation
1.2 Personnel and organizational requirements 5 and function keys 32
1.3 Safety requirements for startup and 3.1.3 PPC – Controls and indicators 44
operation 6 3.1.4 Priming the engine after extended out-of-
1.4 Safety requirements for maintenance and service periods (> 1 month) 45
3.1.5 Local control – Activation/deactivation at LOP 46
repair work 7
3.1.6 Ready for operation – Activation/deactivation
1.5 Standards for safety notices in the text 10
at LOP 47
3.1.7 Engine start 48
2 Functional Description 3.1.8 Engine speed – Change 50
3.1.9 Engine stop 51
2.1 Design and Function 11 3.1.10 Emergency engine stop 52
2.1.1 System overview and features 11
3.1.11 Overspeed test 54
2.1.2 Local Operating Panel LOP 10 – Purpose and
3.1.12 Safety system override – Override activation 58
functions 15
3.1.13 Safety system override cancellation –
2.1.3 Engine Interface Module EIM – Purpose and
Deactivating override 59
functions 18
2.1.4 Engine Control Unit ECU 7 – Purpose and 3.2 Repair Work 60
functions 19 3.2.1 Fuse on motherboard CIB 4 – Replacement 60
2.1.5 EMU – Purpose and functions 20 3.2.2 SAM fuse – Replacement 62
2.1.6 Priming Pump Controller PPC – Purpose 21
2.1.7 LOP 10 – Technical data 22
2.1.8 EIM – Technical data 23 4 Appendix A
2.1.9 ECU 7 – Technical data 24
4.1 Conversion tables 63
2.1.10 EMU 8 – Technical data 26
2.1.11 PPC – Technical data 27 4.2 List of abbreviations 68
2.1.12 Local Operating Panel LOP – Interfaces and 4.3 MTU contact persons/service partners 71
connections 28
2.1.13 LOP – RS 422 serial interface 29 5 Appendix B
5.1 Index 72
3 Operating Instructions
3.1 Operation 30
DCL-ID: 0000006665 - 002

E532300/01E 2014-11 | Table of Contents | 3

 1 Safety
1.1 Important requirements for all products
Nameplate
The product is identified by a nameplate, model designation or serial number which must match the
information on the title page of this manual.
Nameplate, model designation or serial number can be found on the product.

General information
This product may pose a risk of injury or damage in the following cases:
• Improper use
• Operation, maintenance and repair by unqualified personnel
• Changes or modifications
• Noncompliance with the safety instructions and warning notices

Intended use
The product is intended for use in accordance with its contractually-defined purpose as described in the
relevant technical documents only.
Intended use entails operation:
• Within the permissible operating parameters in accordance with the (→ Technical data)
• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubri-
cants Specifications of the manufacturer)
• With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU
contact/Service partner)
• In the original as-delivered configuration or in a configuration approved by the manufacturer in writ-
ing (including engine management/parameters)
• In compliance with all safety regulations and in accordance with all warning notices in this manual
• With maintenance work performed in accordance with the (→ Maintenance Schedule) throughout the
useful life of the product
• In compliance with the maintenance and repair instructions 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
repair
• By contracting only workshops authorized by the manufacturer to carry out repair and overhaul
Any other use shall be considered non-intended. Such improper use increases the risk of injury and
damage when working with the product. The manufacturer shall not be held liable for any damage re-
sulting from improper, non-intended use.

Changes or modifications
Unauthorized changes to the product represent a contravention of its intended use and compromise
TIM-ID: 0000040530 - 005

safety.
Changes or modifications shall only be considered to comply with the intended use when expressly au-
thorized by the manufacturer. The manufacturer shall not be held liable for any damage resulting from
unauthorized changes or modifications.

4 | Safety | E532300/01E 2014-11

 1.2 Personnel and organizational requirements
Organizational measures of the operator
This manual must be issued to all personnel involved in operation, maintenance, repair or transporta-
tion.
Keep this manual handy in the vicinity of the product such that it is accessible to operating, mainte-
nance, repair and transport personnel at all times.
Use this manual as a basis for instructing personnel on product operation and repair, whereby the safe-
ty-relevant instructions, in particular, must be read and understood.
This is particularly important in the case of personnel who only occasionally perform work on or around
the product. This personnel must be 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
• Qualified personnel specialized in mechanical and plant engineering
The operator must define the responsibilities of the personnel involved in operation, maintenance, re-
pair and transport.

Working clothes and personal protective equipment

Wear proper protective clothing for all work.
When working, always wear the necessary personal protective equipment (e.g. ear protectors, protec-
tive gloves, goggles, breathing protection). Observe the information on personal protective equipment
in the respective activity description.
TIM-ID: 0000040531 - 003

E532300/01E 2014-11 | Safety | 5

 1.3 Safety requirements for startup and operation
Safety requirements for startup
The product must be installed and accepted in accordance with manufacturers' specifications prior to
initial startup.
All the requisite regulatory approvals must have been granted and all startup requirements fulfilled prior
to initial startup.
Whenever the product is started, always ensure that:
• All maintenance and repair work has been completed.
• All loose parts have been removed from rotating machine components.
• Wearers of cardiac pacemakers or other active medical implants are well clear.
• The operating room is adequately ventilated.
• Exhaust pipework is leak-tight and routed to atmosphere.
• Battery terminals, generator terminals and cables are guarded to preclude accidental contact.
• All personnel is clear of the danger zone represented by moving parts.
Immediately after putting the product into operation, make sure that all control and display instruments
as well as the monitoring, signaling and alarm systems are working properly.

Safety requirements for operation

The operator must be familiar with the controls and displays.
The operator must be aware of the consequences of any operations he/she performs.
During operation, the display instruments and monitoring units must be constantly observed in regard
of present operating status, limit value violation and warning or alarm messages.

Malfunctions and emergency stop

Emergency procedures, in particular emergency stop, must be practiced on a regular basis.
Take the following steps if a system malfunction is detected or signaled by the system:
• Inform the duty supervisor(s).
• Evaluate the message.
• Respond to the emergency appropriately, e.g. execute an emergency stop.

Operation
Do not stay in the operating room when the product is running unless absolutely necessary and then as
briefly as possible.
Keep a safe distance away from the product whenever possible. Do not touch the product unless ex-
pressly instructed to do so.
Do not inhale exhaust gases emitted by the product.
Ensure that the following requirements have been fulfilled before starting the product:
• Ear protectors are worn.
• Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binding
TIM-ID: 0000040533 - 006

agent.

Operation of electrical equipment

Some components are live (high voltage) when electrical equipment is in operation.
Observe the safety instructions for these appliances.

6 | Safety | E532300/01E 2014-11

 1.4 Safety requirements for maintenance and repair work
Safety requirements before commencing maintenance and repair work
Have maintenance or repair work carried out by qualified and authorized personnel only.
Allow the product to cool down to less than 50°C (risk of explosion for oil vapors, fluids and lubricants,
risk of burning).
Relieve pressure in fluid and lubricant systems and compressed-air lines which are to be opened. Use
suitable collection vessels with a sufficient filling volume.
Ensure that the operating room is adequately ventilated when changing the oil or working on the fuel
system.
Do not perform maintenance or repair work when the product is running unless:
• expressly instructed to do so.
• the product is running in the low load range and only for as long as necessary to complete the task.
Lock-out the product to preclude undesired starting, e.g. start interlock.
Tag-out the product with a “Do Not Start” sign in the operation room or on the control facility.
Disconnect the battery. Lock the contactor.
Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic
starters are fitted.
Disconnect the control facility from the product.
For starters with pinions made of copper-beryllium alloy:
• Wear a respirator mask (filter class P3). Do not blow out the interior of the flywheel housing or the
starter with compressed air. Clean the interior of the flywheel housing with a class H dust extractor.
• Observe the safety data sheet.

Safety requirements during maintenance and repair work

Take special care when removing vent plugs or plug screws from the product. Hold a cloth over the
screw or plug to prevent discharge of highly pressurized liquids.
Take care when draining hot fluids and lubricants (risk of burning).
Use suitable and calibrated tools only. Observe the specified tightening torques during assembly or dis-
assembly.
Carry out work only on assembles and/or installations which are properly secured.
Never climb up on the lines.
Keep fuel injection lines and connections clean.
Always seal connections with caps or covers if a line is removed or opened.
Fit new seals when re-installing lines.
Avoid damaging lines, particularly the fuel lines.
TIM-ID: 0000040535 - 006

Ensure that all retainers and dampers are installed correctly.

Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent
contact with other components. Never route fuel or oil lines in the vicinity of hot components.
Do not touch elastomeric seals (e.g. Viton sealing rings) with your bare hands if they have a carbonized
or resinous appearance.
Observe the cooling time for components which have been heated for installation or removal (risk of
burning!).
Always use suitable ladders and work platforms when working above head-height. Ensure that compo-
nents or assemblies are placed on stable surfaces.

E532300/01E 2014-11 | Safety | 7

 Pay particular attention to cleanliness at all times.

Safety requirements after completing maintenance and repair work

Ensure that all personnel is clear of danger zones before cranking.
Check that all access ports/apertures which have been opened to facilitate working are closed again.
Check that all safety equipment has been installed and that all tools and loose parts have been re-
moved (especially the barring gear).
Ensure that no unattached parts have been left in/on the product (e.g. including rags and cable straps).

Welding work
Do not perform welding on the product or its attachments. Cover the product when performing welding
work in the vicinity.
Before commencing welding work:
• Switch off the master power supply switch.
• Disconnect the battery.
• Disconnect electronic and genset grounds.
Do not perform maintenance or repair work on the product when welding is in progress in its vicinity.
Risk of explosion or fire due to oil vapors and highly flammable process materials.
Do not use the product as a grounding terminal.
Do not route the welding cable over or near the wiring harnesses of the product. The welding current
may otherwise induce an interference voltage in the wiring harnesses which could conceivably damage
the electrical system.
Remove components (e.g. exhaust pipe) from the product before performing necessary welding work .

Hydraulic installation and removal

Check function and satisfactory condition of the jigs and fixtures to be used. Use only the specified jigs
and fixtures for hydraulic removal/installation.
Observe the max. permissible force-on pressure specified for the installation/removal jig.
Do not attempt to bend or exert force on HP lines.
Before starting work, pay attention to the following:
• Vent the installation/removal jig, the pumps and 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 hydraulic installation/removal jigs with central expansion pressure supply, screw the spindle into
the shaft end until correct sealing has been established.
During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of
the component to be installed/removed.

Working with batteries

TIM-ID: 0000040535 - 006

Observe the safety requirements of the battery manufacturer when working with batteries.
Gases released from the battery are explosive. Avoid sparks and naked flames.
Do not allow electrolyte (battery acid) to come into contact with skin or clothing.
Wear goggles and protective gloves.
Do not place tools on the battery.
Check polarity before connecting the cable to the battery. Battery polarity reversal may lead to injury by
the sudden discharge of acid or bursting of the battery unit.

8 | Safety | E532300/01E 2014-11

 Working on electrical/electronic assemblies
Always obtain the permission of the duty supervisor before commencing maintenance or repair work or
switching off any part of the electronic system required to do so.
De-energize the appropriate areas prior to working on assemblies.
Avoid damaging cabling during removal. When reconnecting, ensure that cabling cannot be damaged
during operation by:
• Contact with sharp edges
• Chafing on components
• Contact with hot surfaces.
Do not secure cabling to lines bearing fluids.
Do not use cable ties to secure cabling.
Always use connector pliers to tighten union nuts on connectors.
Subject the device and also the product to appropriate function testing whenever repair work has been
completed. In particular, check the function of the emergency stop feature.
Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Pack-
age faulty electronic components or assemblies properly before dispatching for repair:
• Moisture-proof
• Shock-proof
• Wrapped in antistatic foil if necessary.

Working with laser equipment

Always wear special laser-protection goggles when working with laser equipment (danger due to in-
tensely focused radiation).
Laser equipment must be fitted with the protective devices necessary for safe operation according to
type and application.
For conducting light-beam procedures and measurement work, only the following laser devices must be
used:
• Laser devices of classes 1, 2 or 3A.
• Laser devices of class 3B, which have maximum output in the visible wavelength range (400 nm to
700 nm), a maximum output of 5 mW, and in which the beam axis and surface are designed to pre-
vent any risk to the eyes.

Measuring component deviations

Workpieces, components and measuring instruments are within specified tolerances at a reference
temperature of 20°C.
TIM-ID: 0000040535 - 006

E532300/01E 2014-11 | Safety | 9

 1.5 Standards for safety notices in the text
DANGER
In the event of immediate danger.
Consequences: Death, serious or permanent injury!
• Remedial action.

WARNING
In the event of a situation involving potential danger.
Consequences: Death, serious or permanent injury!
• Remedial action.

CAUTION
In the event of a situation involving potential danger.
Consequences: Minor or moderate injuries!
• Remedial action.

NOTICE
In the event of a situation involving potentially adverse effects on the product.
Consequences: Material damage!
• Remedial action.
• Additional product information.

Safety notices
1. This manual with all safety instructions and safety notices must be issued to all personnel involved in
operation, maintenance, repair or transportation.
2. The higher level warning notice is used if several hazards apply at the same time. Warnings related to
personal injury shall be considered to include a warning of potential damage.

TIM-ID: 0000040578 - 004

10 | Safety | E532300/01E 2014-11

 2 Functional Description
2.1 Design and Function
2.1.1 System overview and features
Overview

1 Power supply for PPC 6 Engine Interface Module 11 Diesel engine

2 24 VDC power supply EIM 12 Lube-oil priming pump (op-
3 Hard-wired control and 7 Engine Monitoring Unit tion)
display units EMU 8 13 Priming Pump Controller
4 Yard supply 8 Engine management sys- PPC (option)
5 Local Operating Panel LOP tem ECS 14 ECU 7 engine governor
10 with SAM 9 Starter and battery-charg-
ing generator
10 Generator
The GenoLine system is used to operate, control and monitor an onboard power generator.
TIM-ID: 0000020165 - 002

Electronic engine management and monitoring optimize consumption and performance.

Devices
Local Operating Panel (LOP)
LOP = Local Operating Panel

E532300/01E 2014-11 | Functional Description | 11

 • Installed in engine room
• Main component: Service and Automation Module (SAM)
(SAM = Service and Automation Module)
• Central data processing functions of the system
• Central control and display unit of the system

Engine Interface module (EIM)

EIM = Engine Interface Module
• Installed on the engine
• Engine start:
Start air pressure monitoring, starting sequence, starter control, start interlocks, start repeat.
• Engine stop:
Stopping sequence, automatic safety shutdown.
• Emergency engine stop control
• Coolant level monitoring
• Engine start and engine stop possible in Local mode.

Engine Control Unit (ECU)

ECU = Engine Control Unit
• Installed on the engine
• Engine management and closed-loop control, open-loop control and monitoring of engine values
• All sensors and actuators are directly connected to the Engine Control Unit. Sensor failure, sensor
function and cabling damage are monitored.
• Closed-loop control
– Speed (as per setpoint signals)
– Injection (fuel pressure, injection timing, injection duration, operating status)
• Control
– Sequential turbocharging (right turbocharger cut-in/out)
– Emergency stop be engine safety system
• Monitoring

Engine Monitoring Unit (EMU)

EMU = Engine monitoring unit
• Installed on the engine
• The main values for engine speed, lube-oil pressure and coolant temperature are redundantly moni-
tored parallel to the Engine Control Unit.
• The Engine Monitoring Unit monitors additional engine parameters.
• The sensors are directly connected to the Engine Monitoring Unit, sensor failure and cabling damage
are monitored.

Option: Priming Pump Controller (PPC)

PPC = Priming Pump Controller
Type PPC 5 to PPC 8, depending on AC input voltage peak value, frequency and number of phases
TIM-ID: 0000020165 - 002

Switches the voltage for an oil priming pump via a contactor.

• Automatic or manual, depending on switch position
• Output voltage limitation, e.g. in case of pump failure

12 | Functional Description | E532300/01E 2014-11

 Monitored variables
By ECU:
• Combined exhaust gas temperature A side
• Combined exhaust gas temperature B side
• Exhaust turbocharger speed
• Intake air temperature
• Fuel pressure (high pressure)
• Fuel pressure after filter
• Fuel temperature
• Leak-off fuel
• Coolant pressure
• Coolant level
• Crankcase pressure
• Charge-air pressure
• Charge-air temperature
• Lube oil differential pressure at filter
• Lube oil temperature
• Camshaft speed
• Air temperature before air recirculation valve
By ECU and EMU:
• Coolant temperature
• Lube oil pressure
• Engine speed (crankshaft)
By EMU:
• Individual exhaust gas temperatures (option)
• Raw water pressure
By EIM:
• Coolant level monitoring
• Monitoring of installed barring device
By SAM in LOP:
• Monitoring of generator measured values and signals

Features
Design and function
• Compact, highly-integrated devices
• Digital data transmission
• Consideration of individual engine characteristics

Safety
• Integral alarm system
• Integral self-test features
• Redundant data bus with automatic switching
TIM-ID: 0000020165 - 002

• Additional parallel connection of safety-relevant signals

Installation
• Straightforward installation and startup
• Centralized cabling of all system components in the engine room
• Configurable on-site without any auxiliary equipment (Compact Flash memory card, minidialog in
CCU)

Operation
• Straightforward operation at the LOP

E532300/01E 2014-11 | Functional Description | 13

 Service
• Fault message display (display on LOP, minidisplay on SAM)
• Full diagnosis and configuration via connectible dialog unit (notebook) with appropriate software

Available upgrades and variants

• Connection of customized pushbuttons and indicator lamps
• Device connection via RS 422 interface
• Option: Device connection via CANopen or J1939 interface

TIM-ID: 0000020165 - 002

14 | Functional Description | E532300/01E 2014-11

 2.1.2 Local Operating Panel LOP 10 – Purpose and functions
Local Operating Panel LOP 10

Central data processing, monitoring and control unit for diesel engine and generator
• Communication with Engine Control Unit, Engine Monitoring Unit and MTU dialog unit via redundant
CAN field bus with redundant switching
• Conversion of operator and generator controller settings into control signals for the Engine Control
Unit and Engine Monitoring Unit
• Acquisition and evaluation of generator operating states and other plant signals
• Conversion of acquired values, feedback signals, fault messages etc. into displays/alarms
• Limit value monitoring
• In the event of inadmissible states and limit value violations: Initiation of power reduction, engine
stop
• Communication with non-MTU devices via serial RS422 interface and optional CANopen/J1939 inter-
face
Configuration via minidialog:
• Adaptation to the plant
• Adaptation to the engine
• Setting of limit values for alarm signaling and engine stop
• Optional devices and sensors can be switched off.
Integral test system for:
• Analog inputs
• RAM
• EEPROM
• Watchdog
TIM-ID: 0000020192 - 002

• Temperature
• Supply voltage (analog acquisition)
• CAN bus failure
The LOP requires a 24 VDC power supply and distributes this to the Engine Control Unit, Engine Moni-
toring Unit, MTU dialog unit and other optionally connected devices.

User interfaces
• TFT color monitor
• Combined pushbuttons/signal lamps
• Minidisplay inside (fault codes, configuration)

E532300/01E 2014-11 | Functional Description | 15

 Electrical interfaces
• Binary inputs (24 VDC)
• Analog inputs (4 to 20 mA)
• Analog inputs (PT 100)
• Binary transistor outputs (24 VDC, max. 0.5 A)
• Binary transistor output (24 VDC) for starter
• Binary relay outputs (24 VDC, max. 0.5 A)
• (24 VDC, max. 1 A)
• Analog outputs (4 to 20 mA)
• Analog output (0 to 10 V)

Electrical connections
• Separable connectors for the cables to the Engine Interface Module, to the MTU dialog unit and to
the optional Priming Pump Control
• Terminal block inside housing and cable bushings at the bottom of the device for all other connec-
tions

Engine-related features
• In local mode:
– Engine start signal to Engine Interface Module EIM
– Engine stop signal to Engine Interface Module EIM
• Engine emergency stop signal to Engine Interface Module EIM
• Fuel prefilter monitoring

Engine start
Can be initiated by:
• Start pushbutton on LOP
• External start pushbuttons
• Starting signal via RS422 interface
• Starting signal via CANopen/J1939 interface (option)

Engine stop
• Can be initiated by:
– Stop pushbutton on LOP
– External stop pushbuttons
– Stop signal via RS422 interface
– Stop signal via CANopen/J1939 interface (option)
– Activation of Test mode at minidisplay of CCU in LOP

Emergency stop features

• Emergency stop via emergency stop pushbutton on LOP
• Acquisition of emergency stop request by
– Engine governor ECU
TIM-ID: 0000020192 - 002

– Engine monitoring Unit EMU (on classified plants)

– External (yard signals, plant sensors)
• Emergency stop signal is stored.
• Emergency stop signal acknowledgment/reset.

Display and signaling features

• Acquisition of illuminated pushbuttons.
• Control of signal lamps and illuminated pushbuttons.
• Control of horn and/or beacon.
• Summary alarm generation and acknowledgment.
• Alarm output on integral minidisplay.

16 | Functional Description | E532300/01E 2014-11

 Additional features
• Acquisition of the key switch to switch the GenoLine automation system on/off.
• Power supply for optionally connected devices.
• Override (cancellation of safety shutdowns and interlocks).
• Binary signal outputs for:
– Engine start activated;
– Engine stop activated;
– Engine ready for start;
– Nominal engine speed reached.
• Binary switching outputs for:
– Summary alarm message;
– Engine stop pending;
– Engine stop activated.
• Extension for RS422 interface (MCS-5 protocol).

Generator monitoring features

• Winding temperature monitoring; (PT100)
• Bearing temperature monitoring; (PT100)
• Coolant temperature monitoring; (PT100)
• Coolant leakage monitoring; floating contact
• Differential protection monitoring; floating contact
The LOP provides a binary input for connection of an external differential protection device. The fault
message is transmitted together with the data acquired by the LOP to the superordinate Monitoring
and Control System (RS422, option CANopen/J1939).
• Effective power output; (4 to 20 mA)
The LOP provides an analog input for the acquisition of the effective generator power output realized
by an external instrument transformer. The value is transmitted together with the data acquired by
the LOP to the superordinate Monitoring and Control System (RS422, option CANopen/J1939).

Control features
Nominal speed setting either analog (4 – 20 mA) or binary by pushbutton (increase/decrease) depend-
ing on selector switch input Speed demand switch).
TIM-ID: 0000020192 - 002

E532300/01E 2014-11 | Functional Description | 17

 2.1.3 Engine Interface Module EIM – Purpose and functions
Engine Interface Module EIM

The EIM is the main interface on the engine. It covers the entire minimum scope of a marine engine. It
has no controls or parts requiring maintenance.
All engine signals are integrated in the engine wiring harness:
• Starter control (start repetition, tooth alignment, starter protection)
• Generator monitoring
• Open bus interface to plant (SAE J1939)
• Emergency stop function with wire break monitoring
• Redundant power supply
• Key switch logic
• Interface to ECU and EMU
• Interface for MCS-5 dialog
• Control of an MTU lube-oil priming pump (power components in separate MTU PPC Box)
• Monitoring of barring device
• Connection point for an MTU local control unit
Cable W51 is suitable for connecting LOP 10 to the EIM and is included in the scope of delivery. The
ends of the cable cannot be mixed up as only one connector (X51) is connected to the EIM whereas two
connectors (X22/X51.1) are provided for connection at LOP 10.
TIM-ID: 0000016861 - 003

18 | Functional Description | E532300/01E 2014-11

 2.1.4 Engine Control Unit ECU 7 – Purpose and functions
(Engine Control Unit) ECU 7

Central open- and closed-loop controller for the engine

• Conversion of input signals from the monitoring and control system into signals to the engine
• Control of the injection system
• Control of other actuators on the engine
• Acquisition and evaluation of engine operating states
• Limit value monitoring
• In the event of inadmissible states and limit value violations: Initiation of power reduction, engine
stop or emergency engine stop (configurable)
• Transfer of fault messages to the monitoring and control system
System communication via CAN bus
Download of engine and plant-related settings.
Self-monitoring
Diagnosis via CAN interface for dialog unit
TIM-ID: 0000020504 - 003

E532300/01E 2014-11 | Functional Description | 19

 2.1.5 EMU – Purpose and functions
Engine Monitoring Unit EMU

Redundant monitoring unit for the engine

• Acquisition of important sensors and evaluation of engine operating states
as done by the ECU, but with autonomous measuring points
• Acquisition of additional measured values
• Limit value monitoring
• In the event of inadmissible states and limit value violations: Initiation of power reduction, engine
stop or emergency engine stop (configurable)
• Transfer of fault messages to the monitoring and control system
System communication via CAN bus
Download of engine and plant-related settings.
Self-monitoring
Diagnosis via CAN interface for dialog unit

TIM-ID: 0000020503 - 003

20 | Functional Description | E532300/01E 2014-11

 2.1.6 Priming Pump Controller PPC – Purpose
Priming Pump Controller PPC

1 Indicator lamp “Oil priming 2 Rotary switch for oil pri-

pump ON” ming pump
PPC = Priming Pump Controller
Type PPC 5 to PPC 8, depending on AC input voltage peak value, frequency and number of phases
Switches the voltage for an oil priming pump via a contactor:
• Automatic or manual depending on switch setting
• Output voltage limitation, e.g. in case of pump failure
TIM-ID: 0000040030 - 001

E532300/01E 2014-11 | Functional Description | 21

 2.1.7 LOP 10 – Technical data
Term Unit Value
Dimensions
(10 mm free space is required
around all 3 axes when installed
on shock absorbers)
WxHxD mm 500 x 500 x 243
(without shock absorbers)
WxHxD mm 500 x 500 x 294
(with shock absorbers, door
closed)
WxHxD mm 500 x 500 x approx. 794
(with shock absorbers, door
open)
Weight kg 32
Current consumption A Typ. 15,
max. 30,
temporary 80
Operating voltage VDC 24, +30%, –25%
EMC protection IEC 60533 standard
Insulation resistance IEC 92-504 (550 VAC / 1 min)
Operational ambient temperature °C +5 to +55
Storage temperature °C -10 to 70
Relative air humidity % 5 to 95, non-condensing
Shock resistance 15 g / 11 ms (half-sine shock pulse) IEC 68-2-27
5 g / 30 ms (half-sine shock pulse) DIN EN 61373
Vibrostability
2 to 13 Hz xpp = ± 1.0 mm
13 to 150 Hz a= ±0.7 g
Degree of protection IP 54 as per DIN 40050
Installation position Wall-mounting, vertical
(NL90 as per DIN 16257) TIM-ID: 0000017715 - 003

22 | Functional Description | E532300/01E 2014-11

 2.1.8 EIM – Technical data
Term Unit Value
Dimensions
LxWxH mm 254 x 193 x 103
Draw-out clearance upwards mm 157
Draw-out clearance in longitudi- mm Max. 100
nal direction
Weight kg 4.4
Power consumption A 0.12 to 40
(without starter)
Heat dissipation W Max. 25
Operating voltage VDC 16 to 32 (operation) (STANAG 1008, Ed. 9 : 2004) (Marine,
on-board genset)
16 to 32 (operation) (DIN EN 50155 : 2004) (Rail)
12 to 16.8 (dialog)
Supply impedance Ω 0.15
Ri(power source) + Rcable
Grounding Required, via grounding strip
EMC protection IEC 60533: 1999 (Marine)
DIN EN 50121-3-2 : 2007 (Rail)
DIN EN 50155 : 2004 (Rail)
DIN EN 61000-6-2 : 2006 (CE classification industrial/
immunity)
DIN EN 61000-6-4 : 2007 (CE classification industrial/
emissions)
Insulation resistance IEC 60092-504 : 2001
Ri > 10 MΩ (IEC 60092-504
Utest = 50 VDC
Operational ambient temperature °C -30 to +85
Storage temperature °C -40 to +85
Relative air humidity % 0 to 95, condensing
Shock resistance 15g / 11 ms (half-sine shock pulse)
Vibrostability
5 to 25 Hz xpp = ± 1.6 mm
25 to 100 Hz a = ±4 g
Degree of protection
Mated IP 69K as per IEC 60529 / DIN 40050
Not mated IP 20 as per IEC 60529 / DIN 40050
TIM-ID: 0000020235 - 003

With connector protection cap IP 54 as per IEC 60529 / DIN 40050

Installation position As desired
MTBF h 20000 (at an ambient temperature of 75 °C)

Table 1: EIM – Technical data

E532300/01E 2014-11 | Functional Description | 23

 2.1.9 ECU 7 – Technical data
Term Unit Value
Housing material AlSi10Mg
Dimensions (length x width x mm 361 x 315 x 63
height)
Draw-out clearance (height) mm 135
Weight kg 5.5
(without cable connection)
Installation position As desired
Operating voltage VDC 20 to 32 (operation, injection without power reduction)
16.8 to 20 (operation, injection with power reduction)
11 to 16.8 (interactive mode, without injection)
(EN 50155; STANAG 1008)
Supply impedance Ω 0.25 (max.)
(Ri, voltage source + Rline + Rcontact)
Power consumption A 0.2 to 17 (typical)
24 (maximum, at 24 V DC)
5AppAC / 200 to 400 Hz
approx. 7 mA at ignition OFF
approx. 250 mA at ignition ON (without injection)
Heat dissipation W 35 (max.)
Grounding Required, via grounding strip
EMC protection IEC 60533: 1999 (Marine)
EN 50121-3-2: 2001 (Rail)
EN 50155: 2004 (Rail)
EN 61000-6-2: 2002 (CE classification industrial)
EN 61000-6-4: 2004 (CE classification industrial)
EN 55025: 2003 (C&I international)
EN 13309: 2000 (C&I international)
DIN ISO 7637-2: 2002 (C&I international)
DIN ISO 7637-3: 1995 (C&I international)
Dielectric strength 10 MΩ (IEC 60092-504)
Utest ≥ 50 VDC (device removed for test)
500 V DC (EN 50155)
ESD protection EN 61000-4-2: 2002, IEC 61000-4-2 (CE, railway and na-
val)
ISO 10605: 2001 (C&I international)
Operational ambient temperature °C –40 to +75
Storage temperature range °C -40 to +85
Housing temperature °C 105 (maximum; for at most 30 min.)
TIM-ID: 0000016864 - 003

Relative air humidity % 0 to 95, condensing

Degree of protection Plugged in: IP69K (IEC 60529, DIN 40050)
Not plugged in: IP 20
With connector protective cap: IP 54
Shock resistance 15 g (11 ms period) (IEC 68-2-27)

24 | Functional Description | E532300/01E 2014-11

 Term Unit Value
Vibrostability 3.7 g*ms; 31.5 to 150 Hz 11 g peak (IEC 60068-2-6)
0.00057 g2/Hz at 5 Hz
0.06 g2/Hz at 31.5 Hz
0.06 g2/Hz at 150 Hz
0.00057 g2/Hz at 1000 Hz
0.00057 g2/Hz at 1500 Hz
MTBF h 20000 (at an ambient temperature of 75 °C)

Table 2: ECU 7 – Technical data

TIM-ID: 0000016864 - 003

E532300/01E 2014-11 | Functional Description | 25

 2.1.10 EMU 8 – Technical data
Term Unit Value
Housing material AlSi10Mg
Dimensions (length x width x mm 318 x 263 x approx. 70
height)
Draw-out clearance (height) mm 116
Weight (without cable connec- kg 3.3
tion)
Installation position As desired
Operating voltage VDC 16.8 to 32 (operation) (STANAG 1008, Ed. 8: 1994)
11 to 16.8 (dialog)
Supply impedance Ω 0.25 (max.)
Power consumption A 0.1 to 3.5 (typical)
5.5 (max., at 24 VDC)
Heat dissipation W 6 (max.)
Load impedance, switching out- Ω 32 to 20000
puts
Grounding Required, via grounding strip
EMC protection IEC 60533: 1999 (Marine)
MIL-STD-461E: 1999 (surface ships)
EN 50121-3-2: 2001 (Rail)
EN 50155: 2004 (Rail)
EN 61000-6-2: 2002 (CE classification industrial)
EN 61000-6-4: 2004 (CE classification industrial)
Dielectric strength > 2 MΩ (IEC 60092-504)
Utest ≥ 50 VDC (device removed for test)
ESD protection EN 61000-4-2: 2002, IEC 61000-4-2
Operational ambient temperature °C –40 to 75
Storage temperature °C -40 to +85
Housing temperature °C 80 (max.)
Relative air humidity % 0 to 95, condensing
Protection (mated) IP69K (IEC 60529, DIN 40050)
Shock resistance 15 g (11 ms period) (IEC 68-2-27)
Vibrostability 3.7 grms; 31.5 to 150 Hz: 11 g peak (IEC 60068-2-6)
0.00057 g2/Hz at 5 Hz
0.06 g2/Hz at 31.5 Hz
0.06 g2/Hz at 150 Hz
0.00057 g2/Hz at 1000 Hz
0.00057 g2/Hz at 1500 Hz
TIM-ID: 0000016808 - 004

MTBF h 20000 (at 75° ambient temperature)

Table 3: Technical data – EMU 8

26 | Functional Description | E532300/01E 2014-11

 2.1.11 PPC – Technical data
Term Unit Value
Dimensions (length x width x mm Approx. 280 x 200 x 136
height)
Draw-out clearance (longitudinal mm Approx. 125
direction)
Weight kg Approx. 3.5
(without cable connection)
Installation position As desired
Operational ambient temperature °C –25 to +55
Storage temperature °C -35 to +70
Relative air humidity % 0 to 95, condensing
Degree of protection IP 65 (DIN 40050)
Shock resistance 10 g (semi-sinusoidal shock, duration 11 ms)
Vibrostability 2 to 12.8 Hz: xpp = 3 mm
12.8 to 100 Hz: a = ± 1 g
EMC protection IEC 801
Operating voltage (PPC) VDC 24; +30% / –25%
PPC 5
Oil priming pump operating volt- 3-phase, 400 V, 50 Hz
age
Oil priming pump power W 750
Oil priming pump rated current A 2.0
PPC 6
Oil priming pump operating volt- 1-phase, 230 V, 50 Hz
age
Oil priming pump power W 1100
Oil priming pump rated current A 7.5
PPC 7
Oil priming pump operating volt- 3-phase, 230 V, 60 Hz
age
Oil priming pump power W 900
Oil priming pump rated current A 4.0
PPC 8
Oil priming pump operating volt- 3-phase, 440 V, 60 Hz
age
Oil priming pump power W 900
TIM-ID: 0000016795 - 006

Oil priming pump rated current A 2.0

Table 4: PPC – Technical data

E532300/01E 2014-11 | Functional Description | 27

 2.1.12 Local Operating Panel LOP – Interfaces and connections

Item Name Explanation

1 Connection for display instruments Analog instruments;
2 Connection for illuminated pushbuttons, in- Customer supply – not included in MTU scope of de-
dicator lamps for operating states and horn livery
3 Priming Pump Controller PPC -
4 Local Operating Panel LOP In the engine room;
Access only necessary during startup, troubleshoot-
ing and servicing.
5 Interface To optional LOP signal inputs and outputs (Yard sig-
nals)
6 Power supply To LOP for overall GenoLine system
7 Interface To MTU diagnostic unit
8 Engine Interface Module EIM Engine-mounted device
9 Diesel engine –
10 Generator –
TIM-ID: 0000020226 - 002

28 | Functional Description | E532300/01E 2014-11

 2.1.13 LOP – RS 422 serial interface
The LOP communicates with those parts of the plant which are not described here via the RS422 inter-
face.
The data are transmitted in the form of one of the following types of block:
• Analog measured value block
• Binary measured value block
• Request block
• Alarm block
The form, structure and contents (interface parameters) of the blocks are precisely specified for Geno-
Line (→ Installation and initial operation instructions).
TIM-ID: 0000017546 - 001

E532300/01E 2014-11 | Functional Description | 29

 3 Operating Instructions
3.1 Operation
3.1.1 Local Operating Panel LOP 10 – Controls and displays

Pushbuttons to control the plant

Item Color Inscription Meaning/function
1 White ENGINE SPEED • Holding the pushbutton down increases engine speed.
INCREASE • Lit as long as the pushbutton is held down.
2 White ENGINE SPEED • Holding the pushbutton down decreases engine speed.
DECREASE • Lit as long as the pushbutton is held down.
3 White – (Not assigned)
4 Green – (Not assigned)
5 Green – (Not assigned)
TIM-ID: 0000017713 - 003

6 Green – (Not assigned)

7 White START • Pressing the pushbutton initiates engine start.
• Lit during the starting sequence.
8 White STOP • Pressing the pushbutton initiates engine shutdown.
• Lit during the stopping sequence and as long as the stop signal is
applied.
9 White – (Not assigned)

30 | Operating Instructions | E532300/01E 2014-11

 Item Color Inscription Meaning/function
10 Green READY FOR OP- • Pressing the pushbutton makes the Engine Control System
ERATION ECS-5 of the power train concerned ready for operation.
The operator thus cancels the manual start interlock.
• Lit when power train is ready for operation.
11 Green LOCAL CON- • Pressing the pushbutton activates Local mode.
TROL • Lit when Local mode is activated.
12 White OVERSPEED • Pressing the pushbutton initiates an overspeed test.
TEST • Lit during the test.
13 Red EMERGENCY • Pressing the pushbutton initiates an immediate emergency en-
STOP gine stop.
• Lit when an emergency engine stop has been tripped.
• Lit until the “Emergency engine stop” alarm is acknowledged.
14 White – (Not assigned)
15 White – (Not assigned)

Function keys to operate the LCD display

Item Color Inscription Meaning/function
16 White F5 Function:
17 F4 • to adjust brightness of the LCD display and pushbutton illumina-
tion on the LOP
18 F3 • to control and operate the graphic screen pages on the LCD dis-
19 F2 play
20 F1 • The context-sensitive functions of the pushbuttons vary and are
indicated graphically on the LCD display.
• Each pushbutton is lit as long as it is held down.

Additional displays and indicators

Item Color Designation Meaning/function
21 Green Function LED Indicates display operating state:
• LED dark: Operating voltage missing.
• LED lit: Normal operation, configuration data loaded, no error de-
tected.
• LED flashes slowly: Communication via field bus disrupted or
CAN buses failed. Display panel has no configuration data.
• LED flashes rapidly: Watchdog tripped. System in hardware reset
state.
22 – LCD display • Displays detailed information about the propulsion plant.
• The display can be controlled with the function keys below the
window.
TIM-ID: 0000017713 - 003

E532300/01E 2014-11 | Operating Instructions | 31

 3.1.2 Display on LOP 10 – Screen pages, navigation and function keys
General screen page layout

Item Name Meaning/function

1 Page Name of displayed screen page
2 Combined alarm display field “Common Alarm” is displayed in this field when at
least one alarm is pending; the field is otherwise
blank.
The background of the field
• is red when at least one red alarm is applied (ac-
knowledged or unacknowledged)
• is yellow when at least one yellow alarm is applied
but no red alarm
• is light blue when messages are applied but no
yellow or red alarm
The text
• flashes as long as at least one unacknowledged
alarm is applied
• does not flash when all applied alarms have been
acknowledged and no new alarm has occurred
since
3 Alarm display field Number of alarms applied
4 Override display field The appropriate text appears in this field when safe-
ty system override is active; the field is otherwise
blank.
TIM-ID: 0000017722 - 005

32 | Operating Instructions | E532300/01E 2014-11

 Item Name Meaning/function
5 System status display field The following messages can be displayed:
• Initiali
System initialization
• Bus error
CAN bus inactive (timeout or error)
• Bootup Sys
Testing of current system software
• Download Sys
Downloading system software.
• Bootup Prj
Testing of current project configuration data
• Download Prj
Project configuration data download
• BDM OK
System operating with BDM
• BDM receiving
Data reception
• BDM PPSError
BDM error, PPS in network too much
6 Status bar –
7 Central display area Displays individual graphic or text pages
8 Function key assignment Indicates assignment of function keys F1 to F5 on
the currently selected screen page.

Screen page hierarchy

TIM-ID: 0000017722 - 005

E532300/01E 2014-11 | Operating Instructions | 33

 Item Name Meaning/function
Pages
S (Start page) “Generator Overview” page (see below);
always appears as first page following bootup.
O Overview Page List of available screen pages
1 ECU Engine Control Unit
1.1 ECU Overview Graphic representation of important measured val-
ues, supplied by Engine Control Unit ECU
1.2 ECU Status Graphic representation of engine measured values
and states, supplied by Engine Control Unit ECU
1.3 ECU Temperature Graphic representation of measured temperature
values from Engine Control Unit ECU
1.4 ECU Temperature Graphic representation of measured temperature
values from Engine Control Unit ECU
(classified plants only)
1.5 ECU Pressure Graphic representation of measured pressure values
from Engine Control Unit ECU
2 EMU Engine Monitoring Unit (Classified plants only)
2.1 EMU Overview Graphic representation of important measured val-
ues supplied by extended Engine Monitoring Unit
EMU
(classified plants only)
2.2 EMU Exhaust A Graphic representation of exhaust gas temperature
measured values from optional extended Engine
Monitoring Unit EMU (A side)
(classified plants only)
2.3 EMU Exhaust B Graphic representation of exhaust gas temperature
measured values from optional extended Engine
Monitoring Unit EMU (B side)
(classified plants only)
3 Extension Page Graphic representation of additional operating val-
ues
(only if exhaust gas pressure and/or starting-air
pressure are acquired)
3.1 Extension Page Graphic representation of exhaust gas pressure
and/or starting-air pressure
(only if acquired)
4 Generator Overview
4.1 Generator Overview Graphic representation of important generator meas-
ured values
4.2 Generator Overview Graphic representation of important generator meas-
TIM-ID: 0000017722 - 005

ured values
5 Error Annular Memory List of faults which have occurred
6 Measuring Point List Display of measured values in text form
7 Brightness Page Brightness adjustment for LOP controls and displays
8 System Page Displays information about the automation system
and graphic display in text form
9 Service Page Displays and modifies system settings (automation
system and graphic display)

34 | Operating Instructions | E532300/01E 2014-11

 Item Name Meaning/function
10 BDM Page Displays project configuration data stored and used
by the automation system
A Alarm Page Displays alarms including color and state
H1 Help Page 1/2 Explains abbreviations used in alarm messages
H2 Help Page 2/2 Explains abbreviations used in alarm messages
Navigation
E Enter (function key F5) Opens page selected in list
F2 Function key F2 Opens Alarm Page or Help Pages
F3 Function key F3 Selects page for display from list or scrolls through
pages belonging together
F4 Function key F4 Selects page for display from list or scrolls through
pages belonging together
F5 Function key F5 Returns to higher-level page or Overview Page

Symbols on pages with graphic representations

Barcharts
Analog values e.g.
• Speeds
• Injection quantity
• Temperatures
• Pressures
are represented by barcharts.
TIM-ID: 0000017722 - 005

E532300/01E 2014-11 | Operating Instructions | 35

 1 Designation of displayed 4 Scale 7 Alphanumeric measured
measurand 5 1st lower limit value (yel- value display
2 Measured value barchart low) 8 1st upper limit value (yel-
3 Unit 6 2nd lower limit value (red) low)
9 2nd upper limit value (red)
One of the following abbreviations is displayed in place of the numerical value if it violates the valid
measuring range:
SD Sensor Defect
MD Missing Data
## Value out of range
The barchart is blank in such cases.

Power train
Binary states of the power train components are represented schematically together with additional in-
formation.
TIM-ID: 0000017722 - 005

36 | Operating Instructions | E532300/01E 2014-11

 Item Designation Meaning/function
1 Priming text field Text displayed on a green background when the op-
tional lube-oil priming pump is running.
2 Remote mode text field Text displayed on a green background when the gen-
set engine is being controlled at the control stand.
3 Graphic symbol for engine (CC mode) • Green when engine is running (idling speed or
higher) and cylinder cutout is inactive.
• Gray when engine is running (idling speed or high-
er) and cylinder cutout is active (CC mode).
• Gray when engine is shut down.
4 Graphic symbols for primary and secondary Green when corresponding exhaust turbocharger is
exhaust turbocharger cut in.
5 Graphic symbol for tertiary exhaust turbo- Green when corresponding exhaust turbocharger is
charger (option) cut in.
6 Graphic symbol for engine • Green when engine is running (idling speed or
higher) regardless of cylinder cutout.
• Gray when engine is shut down.
7 Graphic symbol for PTO flange Connection to generator shaft
• Green when crankshaft is turning;
• gray when crankshaft is stationary.
8 Operating hours text field • Displays number of engine operating hours.

Screen pages in detail

Overview Page
TIM-ID: 0000017722 - 005

The pages on the highest level of the hierarchy can be selected for display with a bar on this page.
The entries available for selection are umbrella terms which may lead to pages on lower levels of the
hierarchy. Example: The following pages can be accessed consecutively via the entry
• ECU Engine Control Unit
the pages
• ECU Overview
• ECU Status,
• ECU Temperature and
• ECU Pressure
can be reached.

E532300/01E 2014-11 | Operating Instructions | 37

 Error Annular Memory
All alarm events (occurrence and acknowledgment) which have occurred since the last reset, and a
number of events relevant for system maintenance, are recorded in the display area of this page in the
order of their occurrence. Up to 1000 messages can be stored here.
The list can be cleared via the Service page.
The display area is divided into five columns:
1. Capacity of the ring memory in the form of a barchart
2. Message text
• Abbreviation
• Alarm designation
3. Date of occurrence and acknowledgment
4. Time of occurrence and acknowledgment
5. Alarm status
• 1 = Unacknowledged
• 0 = Acknowledged

Measuring Point List

A number of configured variables are displayed alphanumerically in the display area of this page.
• Status of binary values (yes, no)
• Analog values with units of measure
Invalid measured values are indicated as follows:
SD Sensor Defect
MD Missing Data
## Value out of range

Brightness Page
The brightness set for LOP pushbutton and LCD background illumination is represented as a barchart in
the display area of this page.
The brightness can be adjusted using the function keys when this page is displayed (→ Page 41).

System Page
The System Page opens automatically in case of system error.
Software information and system status are indicated in the display area of this page:
• Proj Design: Internal counter
• Security status no: Internal counter
• Display Temperature: Temperature inside the display
• Graphic Version: Version number of the order-related application software
• Qvis Version: Version number of the Qvis software with which the application software was devel-
oped
• Term Version: Version number of the functional software of the LOP
• Status CAN 1: Operating state of the default CAN bus
• Status CAN 2: Operating state of the redundant CAN bus
TIM-ID: 0000017722 - 005

• System Status: Operating state of the system

• Internal State: Internal message from the display
• Printer State: Operating state of the printer
• MEM State: Status of the memory for the backup function (not used for GenoLine)
• BDM State: Status of the backup function
• Life Data State: Status signals from the redundant CAN bus (always “Off” for GenoLine)
• Modem State: Status signal for data transmission via modem (always “Deactivated” for GenoLine)
The language of all display pages can be changed by pressing the F3 key when this page is displayed.

38 | Operating Instructions | E532300/01E 2014-11

 Available standard languages are:
• English
• German
• Chinese
• Russian
The following languages may be implemented for special orders:
• Italian
• French
• Spanish
• Portuguese

Service Page
On this page
• system settings are displayed (display mode),
• system settings can be modified (Edit mode).

Displayed settings
These are:
• CAN Baud Rate
– 125 Kbit/s
– 250 Kbit/s
• CAN Node Number
– 1 to 31
• Node Guarding
– Off = Node monitoring inactive
– Active = Node monitoring active
• Printer Driver
– Activate/deactivate printer function
• Com1 Baud Rate
– Transmission rate of the serial printer interface
• Modem Selection
• BDM Function
• Unit Switching
– System of units used for the variables displayed on other pages
• Clear Error Annular Memory
– Resets the alarm memory on the Error Annular Memory page
• Acknowledge Single Alarm
– Not all raised alarms are acknowledged together by pressing the key or activating the binary input
“Acknowledge”, each alarm must be acknowledged separately.
• Horn
– On = Internal horn (of display in LOP) is not activated.
– Off = Internal horn (of display in LOP) is activated.
• Horn Test
– On = Start horn test
– Off = Stop horn test

Service Page in Display mode

TIM-ID: 0000017722 - 005

• The Service Page opens automatically in Display mode approx. 20 seconds after booting has been
completed.
• A lamp test can be performed in Display mode by pressing the F3 key.

Service Page in Edit mode

• To open in Edit mode: Actively open the Service Page from the Overview Page within 20 seconds
after booting has been completed.
• The settings for CAN baud rate, CAN node number and node monitoring must not be changed as this
would lead to failure of the LOP.

E532300/01E 2014-11 | Operating Instructions | 39

 Alarm Page
The total number of alarms is indicated on the display in the status bar (on every page).
The alarms are listed in the order of their occurrence in the display area of the Alarm Page.
The display area is divided into three columns:
1. Message text
• Abbreviation (→ Table 5)
• Alarm designation
2. Alarm status (→ Table 6)
3. Alarm type (light blue, yellow, red; (→ Table 7)
Alarm display sequence:
• Any new alarm is initially listed as an unacknowledged alarm with status UNACK at the bottom of the
alarm list. The text flashes in this state.
• If the alarm is canceled before the operator acknowledges it the status changes to UARTN. The text
continues flashing.
• When the operator acknowledges the alarm its status changes to ACK, flashing stops and the text
lights up steadily.
• The alarm remains in the list as long as it applies.
Entry Meaning
AL... Alarm
Warning or alarm raised by a binary signal.
DL... Default Lost
Warning due to node failure on the default field bus.
HI... High
Warning or alarm due to upper limit violation (analog signal).
LO... Low
Warning or alarm due to lower limit violation (analog signal).
MG... Message
Message from external system or device
PB... Pushbutton
Status indication due to activation of certain control keys.
RL... Redundancy Lost
Warning due to node failure on the redundant field bus.
SD... Sensor Defective
Warning or alarm raised by a sensor defect.
SE... System Error
Warning due to node failure on the default field bus.
SF... Switch Fault
Warning or alarm due to inadmissible combination of states of two complementary
switches.
SS... Security Shutdown
Alarm leading to emergency engine shutdown.
TIM-ID: 0000017722 - 005

TD... Transmitter Deviation

Warning or alarm due to excessive deviation between the analog values of two
complementary switches.

Table 5: Standardized abbreviations for alarm designations (1st column)

40 | Operating Instructions | E532300/01E 2014-11

 Entry Meaning
UNACK Unacknowledged alarm
Fault message is active and was not acknowledged since last occurrence.
UARTN Unacknowledged Returned Alarm
Fault message was active and disappeared again before it was acknowledged.
ACK Acknowledged Alarm
Fault message was acknowledged by operator and has not occurred again since.

Table 6: Standardized abbreviations in the alarm lines (2nd column)

Color Entry Meaning

Light blue – Message without warning or alarm meaning
Yellow Yel Warning (yellow alarm)
Red Red Alarm (red alarm)

Table 7: Standardized colors in the alarm lines and abbreviations in the 3rd column

Function keys F1 to F5
The display is operated with the five function keys F1 to F5 below the screen. The key functions vary
depending on the screen page displayed. The current function is indicated by symbols on the bottom
edge of the screen page.
The figure below illustrates function key assignment on the various screen pages in an overview.
TIM-ID: 0000017722 - 005

1 Overview Page 4 Brightness Page 7 System Page

2 All pages not listed here 5 Service Page in display 8 Error Annular Memory
3 Alarm Page mode
6 Service Page in edit mode;
BDM Page

E532300/01E 2014-11 | Operating Instructions | 41

 Icon Key Meaning/function
F1 Alarm acknowledgment:
• Press once: Horn in LOP is silenced.
• Press again: All unacknowledged alarms, warnings and
messages are acknowledged.
– Alarm acknowledgment not possible.

F2 Open Alarm Page.

F3 Up.
Depending on page displayed:
• Select previous menu option or entry on the page
• Scroll up page-by-page
• Scroll up section-by-section
- Uppermost entry has been reached. Scrolling up no longer
possible.
F4 Down.
Depending on page displayed:
• Select next menu option or entry on the page
• Scroll down page-by-page
• Scroll down section-by-section
- Lowermost entry has been reached. Scrolling down no lon-
ger possible.
F5 On Overview Page: Opens selected page.

F2 On Service Page in Edit mode: Selects input fields.

• Selected input field is represented inversely.
• The input value concerned is activated for editing.
F5 Open Overview Page.

F2 Open (first) Help Page.

F5 Return from Alarm Page to previously selected page.

F1 Switch between day and night modes

F2 Increase brightness level in stages:

• LCD background illumination
• Illuminated pushbutton
• LED for operating status display
F3 Increase brightness level in stages:
TIM-ID: 0000017722 - 005

• LCD background illumination

• Illuminated pushbutton
• LED for operating status display
F1 1. Modification of activated variables is not saved in the
memory.
2. Exit input field.
F3 Modify:
• Increase input value.
• Switch to next available value.

42 | Operating Instructions | E532300/01E 2014-11

 Icon Key Meaning/function
F4 Modify:
• Decrease input value.
• Switch to previous available value.
F3 Lamp test:
• All illuminated pushbuttons and indicator lamps on LOP
light up brightly.
F3 Select language for screen display:
• Each key stroke switches to the next available lan-
guage.
F2 Scroll down 50 entries in the fault ring memory:
• Hold down key , simultaneously press key
or to scroll.

Table 8: Meanings of symbols

TIM-ID: 0000017722 - 005

E532300/01E 2014-11 | Operating Instructions | 43

 3.1.3 PPC – Controls and indicators
Controls and indicators

1 Indicator lamp “Oil priming 2 Rotary switch for oil pri-

pump ON” ming pump
Switch settings/operating modes:
0 Off
AU- Automatic mode
TO • The engine is primed at preset intervals providing it is “ready for operation”.
• A fault message is output if the preset pressure is not reached.
MAN Manual mode
• Not necessary for normal engine operation.
• Used for initial priming when the engine has been out of use for a longer period.
TIM-ID: 0000008424 - 006

44 | Operating Instructions | E532300/01E 2014-11

 3.1.4 Priming the engine after extended out-of-service periods (> 1 month)
Preconditions
☑Operating voltage of Priming Pump Control (PPC) is present.

NOTICE
Operating the oil priming pump in manual mode may lead to over-lubrication and cause damage to
the engine.
Engine damage due to over-lubrication!
• Do not operate the oil priming pump in manual mode for more than 3 minutes.

Engine priming
Note: Priming Pump Controller PPC signals a fault message at the Local Operating Panel if the priming se-
quence is not successfully completed. The engine starts nevertheless.
1. Set rotary switch of Priming Pump Control to MAN (manual mode).
Result: Oil priming of the engine takes place.
2. After one minute, at the latest: Set rotary switch to AUTO.
TIM-ID: 0000019444 - 003

E532300/01E 2014-11 | Operating Instructions | 45

 3.1.5 Local control – Activation/deactivation at LOP
Preconditions
☑GenoLine system switched on.
☑Illuminated pushbutton LOCAL MODE dark.

Activating Local mode

1. Press dark pushbutton LOCAL MODE.
Result: • Pushbutton LOCAL MODE lights up.
• Local mode is activated.
– GenoLine automation system can be operated at the LOP.
– GenoLine automation system can only be operated with limitation at the control stand and by the
plant.
– Emergency engine stop remains possible at LOP, at all control stands and by the plant.
2. Operation continues at Local Operating Panel LOP.

Deactivating Local mode

1. Press lit pushbutton LOCAL MODE.
Result: • Pushbutton LOCAL MODE goes out.
• Local mode is deactivated.
– GenoLine automation system can only be operated at the control stand and by the plant.
– GenoLine automation system cannot be operated at the LOP.
– Emergency engine stop remains possible at LOP, at all control stands and by the plant.
2. Operation continues at control stand or by the plant.

TIM-ID: 0000017717 - 002

46 | Operating Instructions | E532300/01E 2014-11

 3.1.6 Ready for operation – Activation/deactivation at LOP
Preconditions
☑Entire GenoLine system switched on.
☑System ready for operation.

Activate ready for operation

1. Press dark READY FOR OPERATION pushbutton on LOP or activate binary input READY FOR OPERA-
TION.
Result: 1. Starting requirements are checked:
• Engine is shut down.
• Barring gear is closed.
• Stop not activated.
• Emergency stop not activated.
• External start interlock not activated.
2. READY FOR OPERATION pushbutton on LOP lit and binary output READY FOR START is active.
3. Engine start is released, if the start conditions are satisfied.
4. Alarms, if start conditions are not satisfied.
2. If required, start engine.

Deactivate ready for operation

1. Press lit READY FOR OPERATION pushbutton on LOP or deactivate binary input READY FOR OPERA-
TION.
Result: 1. READY FOR OPERATION pushbutton on LOP dark and binary output READY FOR START is inactive.
2. Engine starting is interlocked.
2. Return plant to ready state.
TIM-ID: 0000017716 - 002

E532300/01E 2014-11 | Operating Instructions | 47

 3.1.7 Engine start
Preconditions
☑Engine ready for startup (→ Engine Operating Instructions).
☑Entire GenoLine system switched on.
☑Genset is switched ready for operation: Pushbutton READY FOR OPERATION lit on LOP.
☑Pushbutton START not lit and not flashing.

DANGER
Rotating and moving engine 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 engine, make sure that all safety devices are put back in place and all
tools are removed from the engine.

Engine start in engine room

1. If pushbutton LOCAL MODE is not lit on LOP: Switch on Local mode (→ Page 46).
2. Briefly press pushbutton START on LOP.
Result: 1. Desired result: Engine start successful
• Pushbutton START lights up.
• LOP binary output “Start activated” is active.
• Automatic starting sequence is executed.
• Engine speed increases.
• Current measured values are indicated on the screen pages of the LOP display.
• Binary output “Start activated” is deactivated when the engine speed increases above the thresh-
old value of 300 rpm.
• Engine runs at nominal speed on completion of automatic starting sequence.
• Illuminated pushbutton START goes out.
2. Possible: Engine start unsuccessful
• Starter is only activated for a certain period (“starter on time”). This depends on the duration of
the previous starting process and the subsequent interval (“cool down time”). The starting time is
max. 30 s to protect the electric starter. This process does not apply to pneumatic starters.
• Engine start is automatically terminated when the maximum starting time has expired:
– Illuminated pushbutton START flashes.
– A summary alarm is output (LOP display, minidisplay on SAM in LOP, binary output, RS422,
CANopen (option)).
• Following the automatically calculated interval:
– Illuminated pushbutton START goes out.
– Restarting is admissible: Briefly press pushbutton START on LOP.
3. Repeat procedure for each additional engine (if applicable).
Result: • The starting sequence is repeated in the same way as for the first engine.

Engine start at control stand or by the plant

TIM-ID: 0000017723 - 003

1. If pushbutton LOCAL MODE is lit on LOP: Switch off Local mode (→ Page 46).
2. Activate LOP binary input “Start”(pulse).
Result: • As for engine start in engine room (see above).
• Current measured values are represented on any display instruments installed.
3. Repeat procedure for each additional engine (if applicable).
Result: • The starting sequence is repeated in the same way as for the first engine.

48 | Operating Instructions | E532300/01E 2014-11

 LOP binary output “ready for start”
LOP binary output “ready for Engine is shut down.
start” can activate an external No “Stop” signal active.
signal lamp and is set when
the following conditions are No “Emergency stop” signal active.
fulfilled. No external start interlock active.
Emergency air-shutoff flaps (if applicable) open.
LOP binary output “Local operation” active.
The engine also starts when a fault message signaled by the Priming Pump Controller PPC.
TIM-ID: 0000017723 - 003

E532300/01E 2014-11 | Operating Instructions | 49

 3.1.8 Engine speed – Change
Preconditions
☑Engine running.
☑Pushbutton READY FOR OPERATION lit on LOP.

Changing engine speed in the engine room

1. If pushbutton LOCAL MODE is not lit on LOP: Switch on Local mode (→ Page 46).
2. Press and hold down one of the following illuminated pushbuttons on the LOP as required:
• Illuminated pushbutton ENGINE SPEED INCREASE
• Illuminated pushbutton ENGINE SPEED DECREASE
Result: • The selected pushbutton lights up when pressed.
• The engine speed increases or decreases.
• The currently changing engine speed is indicated on the LOP display.
• The currently changing engine speed is indicated on any display instruments installed.
3. Release the illuminated pushbutton as soon as the desired engine speed has been reached.
Result: The engine speed remains constant.

Changing engine speed at the control stand or by the plant

1. If pushbutton LOCAL MODE is lit on LOP: Switch off Local mode (→ Page 46).
Note: Engine speed setting at the LOP can be set to binary or analog.
2. Depending on requirements and setting:
• Either activate LOP binary input “Engine speed increase” (voltage level).
• or activate LOP binary input “Engine speed decrease” (voltage level).
• or activate analog input “Engine speed setting” (current).
Result: • As for changing speed in engine room (see above);
• Exception: LOP pushbuttons INCREASE ENGINE SPEED and DECREASE ENGINE SPEED do not light
up.
3. As soon as the desired engine speed has been reached depending on type of setting:
• Deactivate active LOP binary input (“Engine speed increase” or “Engine speed decrease”).
• Or leave present signal value at analog input “Engine speed setting”.
Result: The engine speed remains constant.

TIM-ID: 0000017724 - 001

50 | Operating Instructions | E532300/01E 2014-11

 3.1.9 Engine stop
Preconditions
☑Engine running.
☑Pushbutton READY FOR OPERATION lit on LOP.

Engine stop in engine room

1. If pushbutton LOCAL MODE is not lit on LOP: Switch on Local mode (→ Page 46).
2. Briefly press pushbutton STOP on LOP.
Result: • Pushbutton STOP lights up.
• LOP binary output “Stop activated” is active.
• Automatic stop sequence is executed.
• Engine speed drops.
• Current measured values are indicated on the screen pages of the LOP display.
• Binary output “Stop activated” is deactivated when the engine speed drops below the threshold value
of 300 rpm.
• The engine is stopped when the automatic stop sequence has been completed.
• Illuminated pushbutton STOP goes out.
3. Repeat procedure for each additional engine (if applicable).
Result: • The stop sequence is repeated in the same way as for the first engine.

Engine stop at control stand or by the plant

1. If pushbutton LOCAL MODE is lit on LOP: Switch off Local mode (→ Page 46).
2. Activate LOP binary input “Stop” (pulse).
Result: As for engine stop in engine room (see above).
3. Repeat procedure for each additional engine (if applicable).
Result: • The stop sequence is repeated in the same way as for the first engine.
TIM-ID: 0000017718 - 001

E532300/01E 2014-11 | Operating Instructions | 51

 3.1.10 Emergency engine stop
Preconditions
☑Engine running.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

NOTICE
An emergency stop causes extreme stress to the engine plant.
Risk of overheating, damage to components!
• Initiate emergency stop only in emergency situations.

Emergency engine stop in the engine room

1. If pushbutton LOCAL MODE is not lit on LOP: Switch on Local mode (→ Page 46).
2. Raise protective flap covering pushbutton EMERGENCY STOP on the LOP.
3. Press illuminated pushbutton EMERGENCY STOP.
Result: • Engine Control Unit is switched off (ECU 4 only).
• On engines with emergency air-shutoff flaps: Flaps close.
• Engine is stopped by interrupting fuel injection.
• Pushbutton EMERGENCY STOP lights up.
• Pushbutton STOP lights up.
• Binary output to control horn/beacon is activated.
• LOP binary output “Emergency stop activated” is active.
• Various alarms are displayed.
• The emergency stop memory is set.
4. Close protective flap covering pushbutton EMERGENCY STOP on the LOP.
5. Acknowledge alarms (see below).

Emergency engine stop at control stand or by the plant

1. If pushbutton LOCAL MODE is lit on LOP: Switch off Local mode (→ Page 46).
2. Activate LOP binary input “Emergency stop” (pulse).
Result: As for emergency engine stop in engine room (see above).
3. Acknowledge alarms (see below).

Alarm acknowledgment in engine room

1. If pushbutton LOCAL MODE is not lit on LOP: Switch on Local mode (→ Page 46).
2. Open Alarm Page on LOP display.
3. Consecutively for all alarms caused by the emergency stop:
a)
TIM-ID: 0000017725 - 002

Use scroll keys F3 and F4 to select the alarm line.

b)
Use key F1 to acknowledge the alarm.
Result: • Acknowledged alarm disappears from display.
After individual acknowledgment of all alarms caused by the emergency stop:
• Pushbutton EMERGENCY STOP goes out.
• Pushbutton STOP goes out.
• Binary output to control horn/beacon is deactivated.
• LOP binary output “Emergency stop activated” is inactive.
• The emergency stop memory is reset.
• Engine Control Unit is switched back on (ECU 4 only).

52 | Operating Instructions | E532300/01E 2014-11

 Alarm acknowledgment at control stand or by the plant
1. If pushbutton LOCAL MODE is lit on LOP: Switch off Local mode (→ Page 46).
2. Activate binary input “Acknowledge”. Ensure that no alarms are acknowledged unless their cause is
known.
Result: As for acknowledgment in engine room (see above).

Actions following emergency engine stop

1. When emergency stop tripped by the system: Determine and rectify the cause.
2. When emergency stop tripped manually: Rectify the cause.
3. Make plant ready for operation again.
4. Open flaps manually on engines with emergency air-shutoff flaps.
Result: Engine is ready for starting.
TIM-ID: 0000017725 - 002

E532300/01E 2014-11 | Operating Instructions | 53

 3.1.11 Overspeed test
Preconditions
☑Engine shut down or being started or running at nominal speed.
☑Pushbutton READY FOR OPERATION lit on LOP.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

NOTICE
An emergency stop causes extreme stress to the engine plant.
Risk of overheating, damage to components!
• Initiate emergency stop only in emergency situations.

Overspeed test in engine room with engine shut down

Note: The safety instructions listed here are not relevant when the engine is shut down.
1. If pushbutton LOCAL MODE is not lit on LOP: Switch on Local mode (→ Page 46).
2. Press and hold down pushbutton OVERSPEED TEST.
Result: • Engine Control Unit is switched off (ECU 4 only).
• Pushbutton EMERGENCY STOP lights up.
• Pushbutton STOP lights up.
• Binary output for activation of a horn/flashing lamp is activated.
• LOP binary output “Emergency stop activated” is active.
• Various alarms are displayed.
• The emergency stop memory is set.
3. Release pushbutton OVERSPEED TEST.
Result: Pushbutton OVERSPEED TEST goes out.
4. Acknowledge alarms (see below)

Overspeed test at control stand or by plant with engine shut down

1. If pushbutton LOCAL MODE is lit on LOP: Switch off Local mode (→ Page 46).
2. Activate LOP binary input “Test Overspeed” (pulse).
Result: As for overspeed test in engine room with engine shut down (see above):
3. Acknowledge alarms (see below).
TIM-ID: 0000018127 - 002

54 | Operating Instructions | E532300/01E 2014-11

 Overspeed test in engine room during starting sequence
1. If pushbutton LOCAL MODE is not lit on LOP: Switch on Local mode (→ Page 46).
2. During starting sequence and as long as engine speed is below 1000 rpm: Press and hold down push-
button OVERSPEED TEST.
Result: • Overspeed limit value is lowered (to 1320 rpm for 50 Hz generator),
– visible on LOP display (red limit value indicator of engine speed barchart),
– to conserve engine and generator.
• Engine speed continues to increase.
• On reaching test window (1320 rpm to 1500 rpm for 50 Hz generator):
– Pushbutton OVERSPEED TEST lights up.
• An emergency engine stop is tripped on reaching the overspeed limit value.
– Engine Control Unit is switched off (ECU 4 only).
– On engines with emergency air-shutoff flaps: Flaps close.
– Engine is stopped by interrupting fuel injection.
– Pushbutton OVERSPEED TEST goes out.
– Pushbutton EMERGENCY STOP lights up.
– Pushbutton STOP lights up.
– Binary output for activation of a horn/flashing lamp is activated.
– LOP binary output “Emergency stop activated” is active.
– Various alarms are displayed.
– The emergency stop memory is set.
3. Release pushbutton OVERSPEED TEST.
4. Acknowledge alarms (see below).
5. Return plant to ready state.
6. Open flaps manually on engines with emergency air-shutoff flaps.
Result: Engine is ready for starting.

Overspeed test in engine room with engine running (option 1: test window
approached from above)
1. If pushbutton LOCAL MODE is not lit on LOP: Switch on Local mode (→ Page 46).
2. Press and hold down pushbutton OVERSPEED TEST.
3. Reduce speed (→ Page 50), until it is below the upper test window limit (1500 rpm for 50 Hz generator).
Result: Pushbutton OVERSPEED TEST lights up.
4. Increase speed (→ Page 50).
Result: An emergency engine stop is tripped on reaching the overspeed limit value.
• Engine Control Unit is switched off (ECU 4 only).
• On engines with emergency air-shutoff flaps: Flaps close.
• Engine is stopped by interrupting fuel injection.
• Pushbutton ENGINE SPEED INCREASE goes out.
• Pushbutton OVERSPEED TEST goes out.
• Pushbutton EMERGENCY STOP lights up.
• Pushbutton STOP lights up.
• Binary output for activation of a horn/flashing lamp is activated.
• LOP binary output “Emergency stop activated” is active.
• Various alarms are displayed.
• The emergency stop memory is set.
TIM-ID: 0000018127 - 002

5. Release pushbutton OVERSPEED TEST.

6. Acknowledge alarms (see below).
7. Return plant to ready state.
8. Open flaps manually on engines with emergency air-shutoff flaps.
Result: Engine is ready for starting.

E532300/01E 2014-11 | Operating Instructions | 55

 Overspeed test in engine room with engine running (option 2: test window
approached from below)
1. If pushbutton LOCAL MODE is not lit on LOP: Switch on Local mode (→ Page 46).
Note: The overspeed limit value is lowered to conserve the engine and the generator by reducing the engine
speed prior to the overspeed test.
2. Decrease speed (→ Page 50) until lower speed adjusting range limit is reached.
3. Press and hold down pushbutton OVERSPEED TEST.
Result: • Reduction of limit value is visible on LOP display (red limit value indicator on engine speed barchart).
• Pushbutton OVERSPEED TEST is lit as long as the speed is in the test window (1320 rpm to
1500 rpm for 50 Hz generator).
4. Increase speed (→ Page 50).
Result: An emergency engine stop is tripped on reaching the overspeed limit value.
• Engine Control Unit is switched off (ECU 4 only).
• On engines with emergency air-shutoff flaps: Flaps close.
• Engine is stopped by interrupting fuel injection.
• Pushbutton ENGINE SPEED INCREASE goes out.
• Pushbutton OVERSPEED TEST goes out.
• Pushbutton EMERGENCY STOP lights up.
• Pushbutton STOP lights up.
• Binary output for activation of a horn/flashing lamp is activated.
• LOP binary output “Emergency stop activated” is active.
• Various alarms are displayed.
• The emergency stop memory is set.
5. Release pushbutton OVERSPEED TEST.
6. Acknowledge alarms (see below).
7. Return plant to ready state.
8. Open flaps manually on engines with emergency air-shutoff flaps.
Result: Engine is ready for starting.

Alarm acknowledgment in engine room

1. If pushbutton LOCAL MODE is not lit on LOP: Switch on Local mode (→ Page 46).
2. Open Alarm Page on LOP display.
3. Consecutively for all alarms caused by the emergency stop:
a)
Use scroll keys F3 and F4 to select the alarm line.
b)
Use the F1 key to acknowledge the alarm.
Result: • Acknowledged alarm disappears from display.
After individual acknowledgment of all alarms caused by the emergency stop:
• Pushbutton EMERGENCY STOP goes out.
• Pushbutton STOP goes out.
• Binary output to control horn/flashing lamp is deactivated.
• LOP binary output “Emergency stop activated” is inactive.
• The emergency stop memory is reset.
• Engine Control Unit is switched back on (ECU 4 only).
TIM-ID: 0000018127 - 002

Alarm acknowledgment at control stand or by the plant

1. If pushbutton LOCAL MODE is lit on LOP: Switch off Local mode (→ Page 46).
2. Activate binary input “Acknowledge”. Ensure that no alarms are acknowledged unless their cause is
known.
Result: As for acknowledgment in engine room (see above).

56 | Operating Instructions | E532300/01E 2014-11

 Actions following emergency stop caused by overspeed test
1. Return plant to ready state.
2. Open flaps manually on engines with emergency air-shutoff flaps.
Result: Engine is ready for starting.
TIM-ID: 0000018127 - 002

E532300/01E 2014-11 | Operating Instructions | 57

 3.1.12 Safety system override – Override activation
NOTICE
Inadmissible operating status.
Severe damage to property!
• Use override function only in hazardous situations to ensure full capability in the event of engine
faults.

Note: The Override function involves a large number of operating states, which would normally lead to auto-
matic power reduction or engine shutdown, being ignored by the overall system:
• With the engine at a standstill:
Start interlocks are ignored.
• With the engine running:
Violations of engine limit values no longer lead to power reduction or engine shutdown.
Exception: Violation of the upper overspeed limit value still leads to shutdown.
Refer to the Engine Control Unit program listing for details of order-specific limit values which are
bypassed by the Override function.

Activating Override at the control stand or plant

Note: MTU refuses to accept warranty claims for engine damage incurred while the Override function is acti-
vated! Activation of the Override function is stored in the Engine Control Unit.
1. Activate LOP binary input “Safety system override” (pulse).
Result: • LOP binary output “Safety system override” is active.
• Binary output for horn/beacon is active.
• Engine runs in Override mode.
• Any malfunctions and alarm messages must be rectified manually.
2. Canceling horn/beacon (if applicable):
a) Activate LOP binary input ALARM/ACK either at the control stand or the plant.
b) Or open a page on the LOP display on which the F1 key at the bottom is assigned for “alarm ac-

knowledgment”: and press the F1 key.

Result: Binary output for horn/beacon is inactive.

TIM-ID: 0000017726 - 002

58 | Operating Instructions | E532300/01E 2014-11

 3.1.13 Safety system override cancellation – Deactivating override
Preconditions
☑The safety system is bypassed (override is activated.)

Deactivating override at the control stand or by the plant

1. Reactivate the active LOP binary input “Safety system override” (pulse).
Result: • LOP binary output “Safety system override” is inactive.
• Safety system override is canceled.
2. Make plant ready for operation.
TIM-ID: 0000017727 - 001

E532300/01E 2014-11 | Operating Instructions | 59

 3.2 Repair Work
3.2.1 Fuse on motherboard CIB 4 – Replacement
Preconditions
☑Engine shut down.
☑No operating voltage applied.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Fuse 3.0 A 0015318986 7
Fuse 7.5 A 0025310586 2
Fuse 20.0 A 0025310086 1
Fuse 30.0 A 0015318486 2

Determining faulty fuse

1. Pinpoint the appropriate fuse (→ Page 60).
2. Grasp the faulty fuse between finger and thumb and pull it out.

TIM-ID: 0000050424 - 001

Item Designation Value Fuse protection of

1 F1 20 A Not used – spare
2 F2 7.5 A Control panel binary signals (external) and display on LOP
3 F3 7.5 A CAN bus; Slots in SAM
4 F4 - Not used

60 | Operating Instructions | E532300/01E 2014-11

 Item Designation Value Fuse protection of
5 F5 - Not used
6 F17 3A Not used – spare
7 F49 3A Engine Monitoring Unit EMU (connector X35)
Not used – spare
8 F45 3A Display on LOP
9 F29 3A Not used – spare
10 F18 3A Speed demand and binary signals, PPC
11 F8 3A Binary and analog signals, engine room
12 F6 3A Spare current circuit
not used at present

Table 9: Printed circuit board CIB 4-02 – Fuses

Finding spare fuses

1. Locate correct replacement fuse.
2. Grasp the replacement fuse between finger
and thumb and pull it out.

Inserting a fuse
1. Place the replacement fuse carefully on the socket of the faulty fuse.
2. Press the fuse into the socket with one finger as far as it will go.
TIM-ID: 0000050424 - 001

E532300/01E 2014-11 | Operating Instructions | 61

 3.2.2 SAM fuse – Replacement
Preconditions
☑Engine shut down.
☑No operating voltage applied.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Fuse 15 A 0015319186 2

Locating a fuse
1 SAM
2 F2 for SAM supply —
3 F1 for SAM supply +

1. Locate appropriate fuse and replace both fuses if necessary.

2. Grasp the faulty fuse(s) between finger and thumb and pull out.
3. Determine cause of fuse tripping and remedy.

Inserting a new fuse

1. Carefully place new fuse(s) onto the plug-in socket(s).
2. Press fuse(s) with finger to the stop in their sockets.
TIM-ID: 0000008609 - 004

62 | Operating Instructions | E532300/01E 2014-11

 4 Appendix A
4.1 Conversion tables
Length
Unit A multiplied by factor = Unit B
in 25.4 = mm
ft 0.3048 =m
yd 0.9144 =m
stat. mile 1.609 = km
Nm 1.852 = km
yd 3 = ft
yd 36 = in

Unit B multiplied by factor = Unit A

mm 0.03937 = in
m 3.281 = ft
km 0.6215 = stat. mile

Area
Unit A multiplied by factor = Unit B
in 2 645.16 = mm2
ft2 0.0929 = m2
yd2 0.8361 = m2
stat. mile2 2.59 = km2

Unit B multiplied by factor Unit A

mm 2 0.00155 = in2
m2 10.764 = ft2
m2 1.1960 = yd2
km2 0.3861 = stat. mile2

Volume
Unit A multiplied by factor = Unit B
in 3 16387 = mm3
TIM-ID: 0000002173 - 016

ft3 0.02832 = m3
yd3 0.7646 = m3
gallon (U.S.) 3.785 = dm3
gallon (UK) 4.546 = dm3

Unit B multiplied by factor = Unit A

cm3 0.06102 = in3
m3 35.31 = ft3

E532300/01E 2014-11 | Appendix A | 63

 Unit B multiplied by factor = Unit A
dm 3 0.2642 = gallon (U.S.)
dm 3 0.22 = gallon (UK)

Volumetric flow
Unit A multiplied by factor = Unit B
gal/min (GPM, U.S.) 3.79 = l/min
gal/min (GPM, U.S.) 0.134 = ft3/min (cfm)
ft3/min (cfm) 1.70 = m3/h

Unit B multiplied by factor = Unit A

l/min 0.264 = gal/min (U.S.)
ft3/min (cfm) 7.48 = gal/min (U.S.)
m3/h 0.589 = ft3/min (cfm)

Velocity
Unit A multiplied by factor = Unit B
ft/s 0.3048 = m/s
stat. mile/h (mph) 1.609 = km/h
knot (UK) 1.852 = km/h

Unit B multiplied by factor = Unit B

m/s 3.281 = ft/s
km/h 0.6214 = stat. mile/h (mph)
km/h 0.54 = knot (UK)

Mass
Unit A multiplied by factor = Unit B
lb 0.4536 = kg
oz 28.35 =g
ton (imp.) 1.016 =t

Unit B multiplied by factor = Unit A

g 0.03527 = oz
kg 2.205 = lb
t 0.9842 = ton (imp.)
TIM-ID: 0000002173 - 016

Force
Unit A multiplied by factor = Unit B
lbf 0.4536 = kp
lbf 4.4482 =N
kp 9.80665 =N

64 | Appendix A | E532300/01E 2014-11

 Unit B multiplied by factor = Unit A
kp 2.205 = lbf
N 0.10197 = kp
N 0.2248 = lbf

Density
Unit A multiplied by factor = Unit B
slug/ft3 515.4 = kg/m3

Unit B multiplied by factor = Unit A

kg/m 3 0.00194 = slug/ft3

Torque
Unit A multiplied by factor = Unit B
lbf ft 1.3558 = Nm

Unit B multiplied by factor = Unit A

Nm 0.7376 = lbf ft

Pressure
Unit A multiplied by factor = Unit B
2
lbf/in (psi) 703.1 = kp/m2 (mmH2O)
lbf/in2 (psi) 0.06895 = bar
lbf/ft2 (psf) 47.88 = Pa
inHg 0.03386 = bar
inHg 345.3 = kp/m2 (mmH2O)

Unit B multiplied by factor = Unit A

atm 760 = mmHg
atm 1.0133 = bar
atm 10332 = kp/m2 (mmH2O)
atm 1.0332 = kp/cm2 (at)
atm 14.696 = lbf/in2 (psi)
bar 14.504 = lbf/in2 (psi)
Pa 0.0209 = lbf/ft2 (psf)

2nd moment of mass

TIM-ID: 0000002173 - 016

Unit A multiplied by factor = Unit B

slug ft 2 1.3558 = kg m2

Unit B multiplied by factor = Unit A

kg m 2 0.7376 = slug ft2

E532300/01E 2014-11 | Appendix A | 65

 Energy
Unit A multiplied by factor = Unit B
lbf ft 1.356 =J
kcal 4186.8 =J
BTU 1055 =J
CHU 1899 =J

Unit B multiplied by factor = Unit A

J 0.7376 = lbf ft
J 0.0002388 = kcal
J 0.0009478 = BTU
J 0.00052656 = CHU

Power
Unit A multiplied by factor = Unit B
PS 0.7355 = kW
HP 0.7457 = kW
BTU/s 1.054 = kW
kcal/h 1.163 =W
HP 550 = lbf ft/s

Unit B multiplied by factor = Unit A

kW 1.36 = PS
kW 1.341 = HP
kW 0.9487 = BTU/s
W 0.8598 = kcal/h
lbf ft/s 0.0018 = HP

Temperature
Celsius Kelvin
x °C - = x + 273.15 K
xK = x − 273.15 °C -
x °F = 5/9(x − 32) °C = 5/9(x − 32) + 273.15 K
x °R = 5/4x °C = (5/4x) + 273.15 K

Fahrenheit Réaumur
x °C = 9/5x + 32 °F = (4/5x) °R
TIM-ID: 0000002173 - 016

xK = 9/5(x − 273.15) + 32 °F = 4/5(x − 273.15) °R

x °F - = 4/9(x − 32) °R
x °R = (9/4x) + 32 °F -

Fuel consumption
Unit A multiplied by factor = Unit B
mile/gal (US) 0.4251 = km/l
gal/mile (US) 2.3527 = l/km

66 | Appendix A | E532300/01E 2014-11

 Unit B multiplied by factor = Unit A
km/l 2.3527 = mile/gal (US)
l/km 0.4251 = gal/mile (US)
TIM-ID: 0000002173 - 016

E532300/01E 2014-11 | Appendix A | 67

 4.2 List of abbreviations
Abbrevia- Meaning Explanation
tion
ADEC Advanced Diesel Engine Control Engine Control Unit
AL Alarm Alarm (general)
ANSI American National Standards Institute Association of American standardization organiza-
tions
ATL Abgasturbolader Exhaust turbocharger
BR Baureihe Series
BML Betriebsmittelleuchte Utility lamp
BV Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU Publication
No. A01061/..
CAN Controller Area Network Data bus system, bus standard
CoE CAN-over-Ethernet CAN-over-Ethernet connection
CPP Controllable Pitch Propeller
°C Degrees Celsius
DILA Diagnostic lamp
DIN Deutsches Institut für Normung e. V. German Standards Organization and identifier of Ger-
man standards (DIN = “Deutsche Industrie-Norm”)
DIS Display Unit Display panel
DL Default Lost Alarm: Default CAN bus failure
DTS Depot Test System Test system
ECS Engine Control System
ECU Engine Control Unit Engine governor
EDM Engine Data Module Memory module for engine data
EEPROM Electrically Erasable and Programma- Memory module
ble Read Only Memory
EIM Engine Interface Module Engine interface
EPROM Electrically Programmable Read Only Memory module
Memory
EMU Engine Monitoring Unit
EMC Electromagnetic Compatibility
ERCS Signal Foreign Control System Signal for RCS provided by shipyard. Non-MTU RCS.
ESD Electrostatic Discharge
ETC Electronic Transmission Controller J1939 message
ETK Ersatzteilkatalog Spare parts catalog
TIM-ID: 0000037513 - 007

ETH Ethernet Ethernet connection

FCU Flap Control Unit Control unit for exhaust flaps
FDH Field Data Handling
FPP Fixed Pitch Propeller
FRCS Foreign Remote Control System RCS provided by shipyard. Non-MTU RCS.
GND Ground
h Hour
HFST Hauptfahrstand Main Control Station, main control stand

68 | Appendix A | E532300/01E 2014-11

 Abbrevia- Meaning Explanation
tion
HI High Alarm: Measured value exceeds 1st maximum limit
HIHI High High Alarm: Measured value exceeds 2nd maximum limit
value
HRC Human Readable Code
HT High Temperature
Hz Hertz
ICFN ISO – Continuous rating – Fuel stop Power specification in accordance with DIN-ISO
power – Net 3046-7
IDM Interface Data Module Memory module for interface data
IEC International Electrotechnical Commis-
sion
IMO International Maritime Organization
I/O Input/Output
IP International Protection Protection against accidental contact, dust and water
as per DIN 40050
ISO International Standards Organization International umbrella organization for all national
standardization institutes
kg Kilogram
kΩ Kiloohm
LAN Local Area Network
LCD Liquid Crystal Display, Liquid Crystal
Device
LCU Local Control Unit LOP subassembly
LED Light Emitting Diode
LMU Local Monitoring Unit LOP subassembly
LO Low Alarm: Measured value lower than 1st minimum limit
value
LOLO Low Low Alarm: Measured value lower than 2nd minimum limit
value
LOP Local Operating Panel Control console, control panel
LOS Local Operating Station
MCD Marine Control Drive Remotely-controllable and regulated fluid coupling
MCS Monitoring and Control System
MD Missing Data No data available
MFD Multifunction Display
MG Message
TIM-ID: 0000037513 - 007

ML Meldeleuchte Signal lamp

MPU Microprocessing Unit Microprocessor (unit)
mm Millimeter
MTU Motoren- und Turbinen-Union
MΩ Megaohm
ms Millisecond
NFST Nebenfahrstand Slave control stand

E532300/01E 2014-11 | Appendix A | 69

 Abbrevia- Meaning Explanation
tion
NMEA National Marine Electronics Associa-
tion
OT Oberer Totpunkt Top Dead Center
P-xyz Pressure-xyz Pressure measuring point xyz
PAN Panel Control panel
PCU Propeller Control Unit
PCS Process Control System
PGN Parameter Group Number SAEJ1939 message
PPC Priming Pump Control
PVC Polyvinylchloride
PWR Power Power supply
RCS Remote Control System
RET Return
RIM Remote Interface Module Connection device for remote control units
RL Redundancy Lost Alarm: Redundant CAN bus failure
ROS Remote Operating Station Propulsion control lever for remote control
RP Rudder Propeller
SAE Society of Automotive Engineers U.S. standardization organization
SCU System bus Coupling Unit System bus coupler
SD Sensor Defect Alarm: Sensor failure
SDAF Shut Down Air Flaps Emergency air-shutoff flap(s)
SE System Error Operating system error
SILA Safety lamp
SMCS Smart Managed Compact Switch Network distributor
SMU Shaft Speed Monitoring Unit Shaft speed acquisition
SPN Suspect Parameter Number SAEJ1939 message
SPU System bus Processing Unit
SS Safety System Safety system alarm
SSK Schnellschlussklappe(n) Emergency air-shutoff flap(s)
SW Switch
T-xyz Temperature-xyz Temperature measuring point xyz
TD Transmitter Deviation Alarm: Sensor comparison fault
UT Unterer Totpunkt Bottom Dead Center
VS Voith Schneider Voith Schneider drive
TIM-ID: 0000037513 - 007

WJ Water Jet Water jet drive

WZK Werkzeugkatalog Tool catalog
50V_Iso - Insulation voltage 50V

70 | Appendix A | E532300/01E 2014-11

 4.3 MTU contact persons/service partners
Our worldwide sales network with its subsidiaries, sales offices, representatives and customer service
centers ensures fast and direct support on site and the high availability of our products.

Local support
Experienced and qualified specialists place their knowledge and expertise at your disposal.
For locally available support, go to the MTU Internet site: http://www.mtu-online.com

24h hotline
With our 24h hotline and the outstanding flexibility of our service staff, we are always ready to assist
you – either during operation, for preventive maintenance, corrective work in case of malfunction or
changed operating conditions, or for spare parts supply.
Your contact person in our Customer Assistance Center:
E-mail: [email protected]
Tel.: +49 7541 9077777
Fax: +49 7541 9077778
Asia/Pacific: +65 6100 2688
North and Latin America: +1 248 560 8000

Spare parts service

Fast, simple and correct identification of spare parts for your drive system or vehicle fleet. The right
spare part at the right time at the right place.
With this aim in mind, we can call on a globally networked spares logistics system, a central warehouse
at headquarters and on-site stores at our subsidiary companies, agencies and service workshops.
Your contact at Headquarters:
E-mail: [email protected]
Tel.: +49 7541 908555
Fax: +49 7541 908121
TIM-ID: 0000000873 - 015

E532300/01E 2014-11 | Appendix A | 71

 5 Appendix B
5.1 Index
A Local control – Activation/deactivation 46
Available upgrades and variants 11 Local Operating Panel
– Connections 28
C – Interfaces 28
Contact persons 71 Local Operating Panel LOP
Conversion tables 63 – Technical data 22
Local Operating Panel LOP 10 – Controls and displays 30
D Local Operating Panel LOP
Devices 11 – Functions 15
Display – Purpose 15
– Function keys 32 LOP
– Navigation 32 – Connections 28
– Screen pages 32 – Function keys 32
– Functions 15
E – Interfaces 28
ECU – Navigation 32
– Functions 19 – Purpose 15
– Purpose 19 – Screen pages 32
EIM – Technical data 22
– Functions 18 LOP – RS 422 serial interface 29
– Purpose 18
Emergency engine stop 52 M
EMU Monitored variables 11
– Functions 20 MTU contact persons 71
– Purpose 20
O
Engine
– Priming (PPC manual mode) 45 Override
Engine Control Unit – Activation 58
– Functions 19 Overspeed test 54
– Purpose 19
P
Engine Interface Module
– Functions 18 PPC
– Purpose 18 – Controls and indicators 44
Engine Monitoring Unit – Engine priming (manual mode) 45
– Functions 20 – Indicators 44
– Purpose 20 – Purpose 21
Engine speed – Change 50 Priming Pump Controller
Engine start 48 – Engine priming (manual mode) 45
Engine stop 51 Priming Pump Controller PPC
– Controls and indicators 44
F – Indicators 44
DCL-ID: 0000006665 - 002

Features 11 – Purpose 21
Fuse Purpose
– Replacement – Priming Pump Controller PPC 21
– Motherboard CIB 4 60
R
– SAM 62
Ready for operation – Activation/deactivation 47
H
S
Hotline 71
Safety notices, standards 10
L
List of abbreviations 68

72 | Appendix B | E532300/01E 2014-11

 Safety regulations
– Organizational requirements 5
– Personnel requirements 5
Safety requirements
– Important requirements 4
– Maintenance work 7
– Operation 6
– Repair work 7
– Safety notices, standards 10
– Startup 6
Safety system
– Override 58
Safety system override cancellation – Deactivating over-
ride 59
Service partners 71
Spare parts service 71
System overview 11

T
Technical data
– ECU 7 24
– EIM 23
– EMU 8 26
– LOP 10 22
– PPC 27
DCL-ID: 0000006665 - 002

E532300/01E 2014-11 | Appendix B | 73

Installation and Commissioning
Instructions
Electronic Equipment
GenoLine System
with LOP 10, ADEC and EIM
for Onboard Power Generators
Engine Series:
4000 M
Application: Marine

E532302/01E
© 2014 Copyright MTU Friedrichshafen GmbH
This publication is protected by copyright and may not be used in any way, whether in whole or in part, without the prior
written consent of MTU Friedrichshafen GmbH. This particularly applies to its reproduction, distribution, editing, transla-
tion, microfilming and storage or processing in electronic systems including databases and online services.
All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen
GmbH reserves the right to change, delete or supplement the information provided as and when required.
 Table of Contents
1 Safety
4.2 Start-Up 37
1.1 Important requirements for all products 4 4.2.1 Checks prior to startup 37
4.2.2 SAM device settings 39
1.2 Personnel and organizational requirements 5
1.3 Safety requirements for startup and 4.3 Settings 40
operation 6 4.3.1 CAN nodes – Configuration 40
1.4 Safety requirements for maintenance and 4.3.2 SAM – Node address setting 41
repair work 7 4.3.3 Minidialog – Settings 42
1.5 Standards for safety notices in the text 10 4.3.4 Diagnostics 51

2 Mechanical Installation 5 Repair Work

2.1 Local Operating Panel LOP 10 – Installation 11 5.1 Fuse on motherboard CIB 4 – Replacement 53
2.2 Priming Pump Controller PPC – Installation 13 5.2 SAM fuse – Replacement 55

3 Electrical Installation 6 Supplementary Technical Information

3.1 Scope of delivery of MTU cables; preparing 6.1 Local Operating Panel LOP 10 – Internal
Yard cables 14 design 56
3.2 Cable connector pin numbers 16 6.2 Supply voltages in LOP 10 – Distribution
3.3 Cables between devices and assemblies – and fuse protection 64
Routing 18 6.3 Serial RS 422 interface 66
3.4 Cable gland ICOTEK – Assembly 19
3.5 Terminal strips or terminal blocks (spring 7 Technical Data
terminals) – Preparation 21
3.6 Local Operating Panel LOP 10 – Connection 23 7.1 LOP 10 – Technical data 80
3.7 Engine Control Unit ECU 7 – Connection 25 7.2 EIM – Technical data 81
3.8 Engine Monitoring Unit EMU 8 – 7.3 ECU 7 – Technical data 82
Connection 26 7.4 EMU 8 – Technical data 84
3.9 Engine Interface Module EIM – Connection 27 7.5 PPC – Technical data 85
3.10 Fuel prefilter level sensors – Connection 28
3.11 PPC – Connection (single phase) 29 8 Appendix A
3.12 PPC – Connection (three phases) 31
8.1 Conversion tables 86
8.2 List of abbreviations 91
4 Initial Operation
8.3 MTU contact persons/service partners 94
4.1 Preparation 33
4.1.1 Checks prior to startup 33 9 Appendix B
4.1.2 LOP power supply – Check 35
9.1 Index 95
DCL-ID: 0000006833 - 002

E532302/01E 2014-11 | Table of Contents | 3

 1 Safety
1.1 Important requirements for all products
Nameplate
The product is identified by a nameplate, model designation or serial number which must match the
information on the title page of this manual.
Nameplate, model designation or serial number can be found on the product.

General information
This product may pose a risk of injury or damage in the following cases:
• Improper use
• Operation, maintenance and repair by unqualified personnel
• Changes or modifications
• Noncompliance with the safety instructions and warning notices

Intended use
The product is intended for use in accordance with its contractually-defined purpose as described in the
relevant technical documents only.
Intended use entails operation:
• Within the permissible operating parameters in accordance with the (→ Technical data)
• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubri-
cants Specifications of the manufacturer)
• With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU
contact/Service partner)
• In the original as-delivered configuration or in a configuration approved by the manufacturer in writ-
ing (including engine management/parameters)
• In compliance with all safety regulations and in accordance with all warning notices in this manual
• With maintenance work performed in accordance with the (→ Maintenance Schedule) throughout the
useful life of the product
• In compliance with the maintenance and repair instructions 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
repair
• By contracting only workshops authorized by the manufacturer to carry out repair and overhaul
Any other use shall be considered non-intended. Such improper use increases the risk of injury and
damage when working with the product. The manufacturer shall not be held liable for any damage re-
sulting from improper, non-intended use.

Changes or modifications
Unauthorized changes to the product represent a contravention of its intended use and compromise
TIM-ID: 0000040530 - 005

safety.
Changes or modifications shall only be considered to comply with the intended use when expressly au-
thorized by the manufacturer. The manufacturer shall not be held liable for any damage resulting from
unauthorized changes or modifications.

4 | Safety | E532302/01E 2014-11

 1.2 Personnel and organizational requirements
Organizational measures of the operator
This manual must be issued to all personnel involved in operation, maintenance, repair or transporta-
tion.
Keep this manual handy in the vicinity of the product such that it is accessible to operating, mainte-
nance, repair and transport personnel at all times.
Use this manual as a basis for instructing personnel on product operation and repair, whereby the safe-
ty-relevant instructions, in particular, must be read and understood.
This is particularly important in the case of personnel who only occasionally perform work on or around
the product. This personnel must be 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
• Qualified personnel specialized in mechanical and plant engineering
The operator must define the responsibilities of the personnel involved in operation, maintenance, re-
pair and transport.

Working clothes and personal protective equipment

Wear proper protective clothing for all work.
When working, always wear the necessary personal protective equipment (e.g. ear protectors, protec-
tive gloves, goggles, breathing protection). Observe the information on personal protective equipment
in the respective activity description.
TIM-ID: 0000040531 - 003

E532302/01E 2014-11 | Safety | 5

 1.3 Safety requirements for startup and operation
Safety requirements for startup
The product must be installed and accepted in accordance with manufacturers' specifications prior to
initial startup.
All the requisite regulatory approvals must have been granted and all startup requirements fulfilled prior
to initial startup.
Whenever the product is started, always ensure that:
• All maintenance and repair work has been completed.
• All loose parts have been removed from rotating machine components.
• Wearers of cardiac pacemakers or other active medical implants are well clear.
• The operating room is adequately ventilated.
• Exhaust pipework is leak-tight and routed to atmosphere.
• Battery terminals, generator terminals and cables are guarded to preclude accidental contact.
• All personnel is clear of the danger zone represented by moving parts.
Immediately after putting the product into operation, make sure that all control and display instruments
as well as the monitoring, signaling and alarm systems are working properly.

Safety requirements for operation

The operator must be familiar with the controls and displays.
The operator must be aware of the consequences of any operations he/she performs.
During operation, the display instruments and monitoring units must be constantly observed in regard
of present operating status, limit value violation and warning or alarm messages.

Malfunctions and emergency stop

Emergency procedures, in particular emergency stop, must be practiced on a regular basis.
Take the following steps if a system malfunction is detected or signaled by the system:
• Inform the duty supervisor(s).
• Evaluate the message.
• Respond to the emergency appropriately, e.g. execute an emergency stop.

Operation
Do not stay in the operating room when the product is running unless absolutely necessary and then as
briefly as possible.
Keep a safe distance away from the product whenever possible. Do not touch the product unless ex-
pressly instructed to do so.
Do not inhale exhaust gases emitted by the product.
Ensure that the following requirements have been fulfilled before starting the product:
• Ear protectors are worn.
• Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binding
TIM-ID: 0000040533 - 006

agent.

Operation of electrical equipment

Some components are live (high voltage) when electrical equipment is in operation.
Observe the safety instructions for these appliances.

6 | Safety | E532302/01E 2014-11

 1.4 Safety requirements for maintenance and repair work
Safety requirements before commencing maintenance and repair work
Have maintenance or repair work carried out by qualified and authorized personnel only.
Allow the product to cool down to less than 50°C (risk of explosion for oil vapors, fluids and lubricants,
risk of burning).
Relieve pressure in fluid and lubricant systems and compressed-air lines which are to be opened. Use
suitable collection vessels with a sufficient filling volume.
Ensure that the operating room is adequately ventilated when changing the oil or working on the fuel
system.
Do not perform maintenance or repair work when the product is running unless:
• expressly instructed to do so.
• the product is running in the low load range and only for as long as necessary to complete the task.
Lock-out the product to preclude undesired starting, e.g. start interlock.
Tag-out the product with a “Do Not Start” sign in the operation room or on the control facility.
Disconnect the battery. Lock the contactor.
Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic
starters are fitted.
Disconnect the control facility from the product.
For starters with pinions made of copper-beryllium alloy:
• Wear a respirator mask (filter class P3). Do not blow out the interior of the flywheel housing or the
starter with compressed air. Clean the interior of the flywheel housing with a class H dust extractor.
• Observe the safety data sheet.

Safety requirements during maintenance and repair work

Take special care when removing vent plugs or plug screws from the product. Hold a cloth over the
screw or plug to prevent discharge of highly pressurized liquids.
Take care when draining hot fluids and lubricants (risk of burning).
Use suitable and calibrated tools only. Observe the specified tightening torques during assembly or dis-
assembly.
Carry out work only on assembles and/or installations which are properly secured.
Never climb up on the lines.
Keep fuel injection lines and connections clean.
Always seal connections with caps or covers if a line is removed or opened.
Fit new seals when re-installing lines.
Avoid damaging lines, particularly the fuel lines.
TIM-ID: 0000040535 - 006

Ensure that all retainers and dampers are installed correctly.

Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent
contact with other components. Never route fuel or oil lines in the vicinity of hot components.
Do not touch elastomeric seals (e.g. Viton sealing rings) with your bare hands if they have a carbonized
or resinous appearance.
Observe the cooling time for components which have been heated for installation or removal (risk of
burning!).
Always use suitable ladders and work platforms when working above head-height. Ensure that compo-
nents or assemblies are placed on stable surfaces.

E532302/01E 2014-11 | Safety | 7

 Pay particular attention to cleanliness at all times.

Safety requirements after completing maintenance and repair work

Ensure that all personnel is clear of danger zones before cranking.
Check that all access ports/apertures which have been opened to facilitate working are closed again.
Check that all safety equipment has been installed and that all tools and loose parts have been re-
moved (especially the barring gear).
Ensure that no unattached parts have been left in/on the product (e.g. including rags and cable straps).

Welding work
Do not perform welding on the product or its attachments. Cover the product when performing welding
work in the vicinity.
Before commencing welding work:
• Switch off the master power supply switch.
• Disconnect the battery.
• Disconnect electronic and genset grounds.
Do not perform maintenance or repair work on the product when welding is in progress in its vicinity.
Risk of explosion or fire due to oil vapors and highly flammable process materials.
Do not use the product as a grounding terminal.
Do not route the welding cable over or near the wiring harnesses of the product. The welding current
may otherwise induce an interference voltage in the wiring harnesses which could conceivably damage
the electrical system.
Remove components (e.g. exhaust pipe) from the product before performing necessary welding work .

Hydraulic installation and removal

Check function and satisfactory condition of the jigs and fixtures to be used. Use only the specified jigs
and fixtures for hydraulic removal/installation.
Observe the max. permissible force-on pressure specified for the installation/removal jig.
Do not attempt to bend or exert force on HP lines.
Before starting work, pay attention to the following:
• Vent the installation/removal jig, the pumps and 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 hydraulic installation/removal jigs with central expansion pressure supply, screw the spindle into
the shaft end until correct sealing has been established.
During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of
the component to be installed/removed.

Working with batteries

TIM-ID: 0000040535 - 006

Observe the safety requirements of the battery manufacturer when working with batteries.
Gases released from the battery are explosive. Avoid sparks and naked flames.
Do not allow electrolyte (battery acid) to come into contact with skin or clothing.
Wear goggles and protective gloves.
Do not place tools on the battery.
Check polarity before connecting the cable to the battery. Battery polarity reversal may lead to injury by
the sudden discharge of acid or bursting of the battery unit.

8 | Safety | E532302/01E 2014-11

 Working on electrical/electronic assemblies
Always obtain the permission of the duty supervisor before commencing maintenance or repair work or
switching off any part of the electronic system required to do so.
De-energize the appropriate areas prior to working on assemblies.
Avoid damaging cabling during removal. When reconnecting, ensure that cabling cannot be damaged
during operation by:
• Contact with sharp edges
• Chafing on components
• Contact with hot surfaces.
Do not secure cabling to lines bearing fluids.
Do not use cable ties to secure cabling.
Always use connector pliers to tighten union nuts on connectors.
Subject the device and also the product to appropriate function testing whenever repair work has been
completed. In particular, check the function of the emergency stop feature.
Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Pack-
age faulty electronic components or assemblies properly before dispatching for repair:
• Moisture-proof
• Shock-proof
• Wrapped in antistatic foil if necessary.

Working with laser equipment

Always wear special laser-protection goggles when working with laser equipment (danger due to in-
tensely focused radiation).
Laser equipment must be fitted with the protective devices necessary for safe operation according to
type and application.
For conducting light-beam procedures and measurement work, only the following laser devices must be
used:
• Laser devices of classes 1, 2 or 3A.
• Laser devices of class 3B, which have maximum output in the visible wavelength range (400 nm to
700 nm), a maximum output of 5 mW, and in which the beam axis and surface are designed to pre-
vent any risk to the eyes.

Measuring component deviations

Workpieces, components and measuring instruments are within specified tolerances at a reference
temperature of 20°C.
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E532302/01E 2014-11 | Safety | 9

 1.5 Standards for safety notices in the text
DANGER
In the event of immediate danger.
Consequences: Death, serious or permanent injury!
• Remedial action.

WARNING
In the event of a situation involving potential danger.
Consequences: Death, serious or permanent injury!
• Remedial action.

CAUTION
In the event of a situation involving potential danger.
Consequences: Minor or moderate injuries!
• Remedial action.

NOTICE
In the event of a situation involving potentially adverse effects on the product.
Consequences: Material damage!
• Remedial action.
• Additional product information.

Safety notices
1. This manual with all safety instructions and safety notices must be issued to all personnel involved in
operation, maintenance, repair or transportation.
2. The higher level warning notice is used if several hazards apply at the same time. Warnings related to
personal injury shall be considered to include a warning of potential damage.

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10 | Safety | E532302/01E 2014-11

 2 Mechanical Installation
2.1 Local Operating Panel LOP 10 – Installation
Preconditions
☑The Local Operating Panel should be located in the engine room in the immediate vicinity of the en-
gine. Observe draw-out clearance dimensions.
☑Ensure that there is adequate space in front of the housing. The LOP display must be easily legible.
Ensure ease of access to operate the pushbuttons.
☑The front flap of the Local Operating Panel must be easily opened in the installed state.

Drilling bores
A 80.82 mm
B 390.82 mm
C 14.81 mm

1. Mark the eight bores to secure the Local Operating Panel LOP to the wall as illustrated in the figure. The
tolerance range is ±0.2 mm.
2. Drill bores with a diameter of 6 mm.

Installing LOP
Note: Never install the Local Operating Panel
without the plate with the shock dampers.
1. Unscrew the damper plate (2) at the rear of
the housing (1).
2. Bolt on the damper plate in the installation
location:
a) Fit eight M6 screws through the bores
in the shock dampers and the bores in
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the wall.
b) Screw a nut and washer A6.4 onto the
other end of each screw and tighten.
3. Hold the housing (1) of the LOP against the
damper plate and secure with the four
screws mentioned in (→ Step 1).
4. Tighten screws.

E532302/01E 2014-11 | Mechanical Installation | 11

 Fitting grounding cable
1. Route a cable with a cross-section of min.
4 mm2 or a grounding strap with a cross-
section of 6 mm2 to the ground connection.
2. Fit a ring lug (8 mm diameter) on the de-
vice end.
3. Secure the ring lug to the grounding stud
on the device as shown in the figure:
Nut (1) – spring washer (2) – washer (3) –
ring lug (4) – grounding stud (5) – hous-
ing (6)
4. Establish electrical connection between
grounding cable/strap and common
ground connection (specifics vary from
case to case).

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12 | Mechanical Installation | E532302/01E 2014-11

 2.2 Priming Pump Controller PPC – Installation
Preconditions
☑Space to next wall or other device below the housing is at least 150 mm.
☑At least 20 mm space on left and right.
☑Front door of PPC can be opened at front when installed.

Drilling bores
1. Mark out four mounting bores for housing
on designated wall in accordance with drill-
ing pattern, tolerance ±0.5 mm
2. Drill bores with a diameter of 6 mm.

Installing PPC
1. Open housing door.
2. Insert a screw through one of the mounting bores.
3. Push screw through bore in wall.
4. Fit washer, spring washer and nut on other side and tighten fingertight.
5. Proceed with other screws in the same way.
6. Align housing horizontally.
7. Tighten screws.
8. Close door.

Fitting grounding cable

1. Route a cable with a cross-section of at least 2.5 mm2 to the ground connection.
2. Fit wire-tip sleeve on device end.
3. Undo ground strap screws, slide grounding cable under and tighten screws.
4. Secure grounding cable to common ground connection.
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E532302/01E 2014-11 | Mechanical Installation | 13

 3 Electrical Installation
3.1 Scope of delivery of MTU cables; preparing Yard cables
Scope of delivery of MTU cables
The following prefabricated system cables are delivered:

Cable No. Comment, restriction Terminal 1 Terminal 2

in wiring Device, assembly Connector Connector Device, assembly
diagram No. on ca- No. on ca-
ble ble
W051 EIM X51 X22 CIB 4 in LOP
+ X001
+ X51.1
W014.7 "Flying connector" LOP X51.1 X1 PPC
When optional PPC is in-
cluded
W017 When optional PPC is in- AC power supply -- X2 PPC
cluded for PPC
W018 When optional PPC is in- Oil priming pump -- X3 PPC
cluded

Yard cabling
The following cables are numbered in the “schematic ship wiring diagram” and must be supplied by the
Yard:

Cable no. Comment, restriction Terminal 1 Terminal 2

in wiring Device, assembly Connector Connector Device, assembly
diagram No. on ca- No. on ca-
ble ble
W011.1 Fuel prefilter level -- X14 CIB 4 in LOP
sensor
W011.2 For double prefilter Fuel prefilter level -- X34 CIB 4 in LOP
sensor

All other cables to be supplied by the Yard are not numbered in the “schematic ship wiring diagram”.

Preparing Yard cables for connection to LOP connectors

Prepare the Yard cables which are connected to the connectors on motherboard CIB 4 in Local Operat-
ing Panel LOP 10 as follows:
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1. Determine cable route.

2. Determine cable length.
3. Determine cross section of cable (→ Wiring diagram).
4. Cut cables to size.
5. Use the connectors provided in the MTU scope of delivery “GenoLine connectors”. The connectors
are identified as “X…”; these numbers must match with the connector number on the CIB when
connecting the LOP (→ Page 56).
6. Strip cable insulation at the LOP end and fit the appropriate connector to the cable. Note connector
pin numbering in so doing (→ Page 16).
7. Prepare the cable at the other end as required (depending on the assembly connected there).

14 | Electrical Installation | E532302/01E 2014-11

 Preparing Yard cables for connection to LOP terminal strip
Prepare the Yard cables which are connected to the terminal strip in Local Operating Panel LOP 10 as
follows:
1. Determine cable route.
2. Determine cable length.
3. Determine cross section of cable (→ Wiring diagram).
4. Strip cable insulation at the LOP end; do not use end sleeves!
5. Prepare the cable at the other end as required (depending on the assembly etc. connected there).
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E532302/01E 2014-11 | Electrical Installation | 15

 3.2 Cable connector pin numbers
In many cases, cable cores must be connected to separately supplied connectors when installing and
connecting up MTU devices. The connector channel pin numbers are not always stated on the connec-
tor by the manufacturer. The figures below show the cable connectors together with the respective pin
numbers.

Wago cable connector

Type 769

Left: 4-pole; Front, e.g. connector number

X15
Right: 8-pole; Back page
a Notch for orientation

Type 231

Left: 3-pole; Front, e.g. connector number

X33
Right: 3-pole; Back page

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16 | Electrical Installation | E532302/01E 2014-11

 Weidmüller cable connector
Left: 16-pole; Front, e.g. connector num-
ber X30
Right: 16-pole; Back page
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E532302/01E 2014-11 | Electrical Installation | 17

 3.3 Cables between devices and assemblies – Routing
Preconditions
☑Local Operating Panel LOP is installed.
☑Priming Pump Controller PPC is installed (if realized as an option).
☑Cable channels etc. are installed.
☑Cables are long enough to allow connectors to be plugged in when all devices have been installed.

General information about cable routing

1. Route cables in the right direction. Connectors or cable ends are labeled with the numbers beginning
with X used in the description below to facilitate this.
2. Ensure that cables are routed neatly! Cover sharp edges along the cable route with suitable protectors
(edge protectors, anti-kink protectors for the cable etc.).
3. Secure all cables with suitable fixtures (cable clamps, cable ties etc.) at suitable points.
4. The routing instructions below only include the cables designated with a number “W...” in the “schemat-
ic ship wiring diagram”.

Regardless of engine series, starting method etc.

1. Route cable W101 between battery connection point (main power supply; after fuse) and LOP (terminal
strip X001, terminal Nos. 1 – 4).
2. Route cable W101 between battery connection point (emergency power supply; after fuse) and LOP
(terminal strip X001, terminal Nos. 5 – 8).
3. Route cable W051 between LOP (X22, X001 and X51.1) and Engine Interface Module EIM.
4. Route cable W011.1 between LOP (X14) and level sensor F070.1 at the fuel prefilter.
5. When a double prefilter is installed: Route cable W011.2 between LOP (X34) and level sensor F070.2 at
the fuel prefilter.

Additionally, for optional oil priming pump only

1. Route cable W014.7 between LOP ("flying connector" X51.1) and Priming Pump Control PPC (X1).
2. Route cable W017 between power source and PPC (X2).
3. Route cable W018 between PPC (X3) and oil priming pump.

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18 | Electrical Installation | E532302/01E 2014-11

 3.4 Cable gland ICOTEK – Assembly
Preconditions
☑Housing installed at installation location

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Calipers (→ Tools Catalog)
Suitable sealing plugs for all cables being routed in

Note: Plugs seal off all cable entries on delivery. These do not necessarily ensure the required degree of seal-
ing and strain relief for cables of varying thickness. Use a suitably sized sealing plug for each cable for
this reason.
Disassembly
1. Undo screws at top (2).
2. Undo screws (1).
3. Remove upper half (3) of cable entry.
4. The lower half (5) of the cable entry re-
mains on the housing.
5. Extract superfluous plugs (4) from the low-
er half of the cable entry (5).
6. Extract superfluous plugs (4) from the up-
per half of the cable entry (3).

Route cables into the housing

1. Distribute the cables over the various openings:
• Insert max. 10 cables into each opening.
• Distribute cables such that their respective routes are as short as possible inside the housing.
• Avoid crossing cables inside the housing.
• Shielded cables must always be located in the lower half of the cable entry.
2. Route all cables into the housing through the openings in the side panels.
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E532302/01E 2014-11 | Electrical Installation | 19

 Securing cables
1. Insert cables consecutively in the two
halves of the cable entry. Proceed as fol-
lows.
a) Measure cable diameter.
b) Select suitable sealing plug (1). The
opening in the sealing plug must be ap-
prox. 1 mm smaller than the diameter
of the cable. The diameter of the seal-
ing plug is written in one corner (2).
c) Fit sealing plug (1) on cable (3).
d) Slide sealing plug with cable into corre-
sponding slot (4) in the upper or lower
half of the cable entry. Always fit
shielded cables in the lower half of the
cable entry.
2. Fit sealing plugs at unused slots on each
half of the cable entry.

Assembling cable entry

1. Place the upper half of the cable entry on the lower half.
2. Insert screws (5) and tighten evenly.
3. Secure screws (6).

Grounding shielded cables

Note: A large grounding contact area is important to preclude electrical malfunctions.
1. Ensure that the shield of each shielded cable is applied to a tooth of the grounding comb in contact
with as large an area as possible.
2. Secure each shielded cable to the tooth with a cable tie.

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20 | Electrical Installation | E532302/01E 2014-11

 3.5 Terminal strips or terminal blocks (spring terminals) –
Preparation
Preconditions
☑Cables are routed properly.
☑Cables are long enough.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Actuator tool 0015383830 1

Cutting individual wires to size

1. Determine the terminal to which the wire concerned is to be connected (→ terminal diagram or wiring
diagram).
2. Cut each wire to a suitable length.

Connecting wires (illustration of terminal block and connector type are exam-
ples, delivered assemblies may vary)
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E532302/01E 2014-11 | Electrical Installation | 21

 1. Strip back the insulation on the first wire by approx. 8 mm.
2. For litz wires: Twist litz.
3. Do not fit wire-tip sleeves!
4. Route wire to the associated terminal (→ terminal diagram or wiring diagram).
Note: Never use metal-tipped screwdrivers as an actuator tool!
5. Press the actuator tool (1) firmly into the square hole (4) in the direction indicated by the arrow (a).
Bend the inscription tag (5) to one side if necessary.
6. Insert wire (2) into round hole (3).
7. Remove actuator tool.
8. Connect all other wires in the same way.

Final steps
1. Check firm seating of all connections which have been established.
2. Bundle individual wires appropriately with cable ties.
3. Remove all foreign bodies (bits of cable, pieces of cable tie etc.) from the housing.

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22 | Electrical Installation | E532302/01E 2014-11

 3.6 Local Operating Panel LOP 10 – Connection
Preconditions
☑LOP is installed.
☑Cables are routed.

Routing cables into the housing

1 SAM 3 Cable glands 5 Motherboard CIB 4

2 Grounding comb 4 Terminal block X001
1. Assign spaces in the cable entries: Consider the terminal points of the cables LOP by checking connec-
tor numbers (→ Page 56).
2. Secure the cables in the cable glands (→ Page 19).

Connecting cables to terminal strip X001 and motherboard CIB 4

1. Connect Yard and plant-specific cabling to terminal strip X001 (→ Page 21) (→ Wiring diagram).
2. Connect cables according to connector numbers in the pin sockets of motherboard CIB 4 (→ Page 56).
The connectors/sockets are protected against misconnection.
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3. Secure all cables in the housing with cable ties.

E532302/01E 2014-11 | Electrical Installation | 23

 Connecting the power supply
1. Connect cable W101 (main supply) to terminal strip X001:
• Core 1 (red) – Terminal 1
• Core 2 (red) – Terminal 2
• Core 3 (black) – Terminal 3
• Core 4 (black) – Terminal 4
2. Connect cable W102 (emergency supply) to terminal strip X001:
• Core 1 (red) – Terminal 7
• Core 2 (red) – Terminal 8
• Core 3 (black) – Terminal 5
• Core 4 (black) – Terminal 6
3. Secure all cores in the housing with cable ties.

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24 | Electrical Installation | E532302/01E 2014-11

 3.7 Engine Control Unit ECU 7 – Connection
Preconditions
☑Cables are routed properly
☑Cables are long enough

Connecting ECU
1. Fit cable clamps (7, 8).
2. Plug connector X1 (3) into socket X1 (6)
and engage clip.
3. Plug connector X3 (4) into socket X3 (5)
and engage clip.
4. Route cables over and away from the en-
gine governor.
5. Secure cables (7, 8) with cable clamps.
6. Install screws (1) with washers (2) and
tighten.
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E532302/01E 2014-11 | Electrical Installation | 25

 3.8 Engine Monitoring Unit EMU 8 – Connection
Preconditions
☑Cables are routed properly
☑Cables are long enough

Connecting EMU 8
Note: The cable to the engine may already be
connected on delivery. Omit the associated
activities in this case.
1. Unscrew cable clamps (10).
2. Plug connector X12 (4) into socket X12 (6)
and engage clip.
3. Plug connector X11 (5) into socket X11 (8)
and engage clip.
4. Secure cable (1) on device with cable
clamps (10) as shown.
5. Insert screws (2) with washers (3) into the
appropriate bores (7, 9) and tighten.
6. Secure connected cables at suitable points
on the engine.

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26 | Electrical Installation | E532302/01E 2014-11

 3.9 Engine Interface Module EIM – Connection
Preconditions
☑Cables are routed properly.
☑Cables are long enough.
☑Operating voltage switched on.

Connecting EIM
1. Remove protective caps (6) on sockets for
the 62-pole Tyco connectors (5).
2. Connect female connector X51 of cable
W511 (4) to EIM connector X51 and lock
with clip.
3. Screw screws (1) with washers (2) into ca-
ble clamps (3) on EIM.
4. Route cable W511 (4) via EIM and secure
with cable clamps (3) on EIM.
5. Connect female connector X52 (5) of cable
W052 (7) to EIM connector X52 and lock
with clip.
6. Route cable W052 (7) via EIM and secure
with cable clamps (3) on EIM.
7. Tighten screws (1) with washers (2) on ca-
ble clamps (3).
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E532302/01E 2014-11 | Electrical Installation | 27

 3.10 Fuel prefilter level sensors – Connection
Preconditions
☑Cables are routed properly
☑Cables are long enough

Connecting level sensor “Water in the fuel prefilter”

1. Route cable W011.1 (coming from terminal box CTB) to the connector of sensor F070 or F070.1.
2. Remove the connector at the filter.
3. Route the cable through the connector housing.
4. Remove approximately 3 cm of the outer casing of the cable.
5. Strip the three cores and connect to the connector as follows:
a) Core no. 1: +24 V DC supply to connector pin A
b) Core no. 2: Signal to connector pin C
c) Core no. 3: Ground supply to connector pin B
6. Assemble the connector.
7. Plug the connector into the fuel prefilter and tighten the union nut.

For double prefilter: Connecting 2nd “Water in fuel prefilter” level sensor
1. Route cable W011.2 (coming from terminal box CTB) to the connector of sensor F070.2.
2. Connect the level sensor of the second filter in the same way as the first filter.

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 3.11 PPC – Connection (single phase)
Preconditions
☑Cables are routed properly
☑Cables are long enough

Connectors on PPC

AC Supply voltage for PPC VSP Oil priming pump

Note: • The supply connection of cables W017 and W018 is represented schematically in the figure. This de-
pends greatly on the actual conditions on-board.
• The end of cable W014.7 which is not illustrated in the figure depends on the specifics of the auto-
mation system to which it is connected: It either has open cores or a suitable connector.
1. Remove cap covering connector socket X1 on PPC.
2. Plug connector X1 of cable W0014.7 into connector socket X1.
3. Remove cap covering connector socket X2 on PPC.
4. Plug connector X2 of cable W017 into connector socket X2.
5. Remove cap covering connector socket X3 on PPC.
6. Plug connector X3 of cable W018 into connector socket X3.
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E532302/01E 2014-11 | Electrical Installation | 29

 Connecting pump and supply voltage
1. Connect individual cores of cable W017 to supply voltage of oil priming pump.
a) Install two-pole power circuit breakers in all supply lines between connecting points and MTU cable.
b) Prepare cores:
• Core 1: L1
• Core 2: not used, insulate
• Core 3: not used, insulate
• Core 4: Neutral conductor
• Core yellow/green: Housing ground
2. Connect individual cores of cable W018 to oil priming pump:
• Core 1: U1/Z2
• Core 2: not used, insulate
• Core 3: not used, insulate
• Core 4: U2
• Core yellow/green: Housing ground

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30 | Electrical Installation | E532302/01E 2014-11

 3.12 PPC – Connection (three phases)
Preconditions
☑Cables are routed properly.
☑Cables are long enough.

Connectors on PPC

AC Supply voltage for PPC VSP Oil priming pump

Note: • The supply connection of cables W017 and W018 is represented schematically in the figure. This de-
pends greatly on the actual conditions on-board.
• The end of cable W014.7 which is not illustrated in the figure depends on the specifics of the auto-
mation system to which it is connected: It either has open cores or a suitable connector.
1. Remove cap covering connector socket X1 on PPC.
2. Plug connector X1 of cable W0014.7 into connector socket X1.
3. Remove cap covering connector socket X2 on PPC.
4. Plug connector X2 of cable W017 into connector socket X2.
5. Remove cap covering connector socket X3 on PPC.
6. Plug connector X3 of cable W018 into connector socket X3.
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 Connecting pump and supply voltage
1. Connect individual cores of cable W017 to supply voltage of oil priming pump.
a) Install two-pole power circuit breakers in all supply lines between connecting points and MTU cable.
b) Prepare cores:
• Core 1: L1
• Core 2: L2
• Core 3: L3
• Core 4: N, not used, insulate
• Core yellow/green: Housing ground
2. Connect individual cores of cable W018 to oil priming pump:
• Core 1: V1
• Core 2: U1
• Core 3: W1
• Core 4: N, not used, insulate
• Core yellow/green: Housing ground

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 4 Initial Operation
4.1 Preparation
4.1.1 Checks prior to startup

Note: The tasks listed below must be carried out in the order stated before switching on the operating voltage
for the first time:

Checking installation on engine

1. Check that engine is grounded.
2. Check that all cables are correctly connected to the starter; make sure that cables, spade lugs etc. do
not touch each other.
3. Check that the cables on the engine (to ECU, to EMU and to starter) are adequately secured. These
cables must not hang free at any point.
4. For configuration with Engine Interface Module EIM:Check that its cables have been properly connected
to the engine. These cables must not hang free at any point.

Checking device installation

1. Check that all devices are properly secured.
2. Check that the various devices are grounded.

Checking cable routing

1. Check all cables which are connected manually or routed inside housings:
a) Test all conductors.
b) Check that shielding is connected correctly.
2. Check that all cables are secured at suitable points.
3. Check that the cables are relieved of strain where necessary.
4. Check that bending radii of all cables have been respected.
5. Make sure that cables are never routed over sharp edges unless suitably protected against chafing.
6. Ensure that no cables can be sheared through when doors or flaps are closed.
7. Check that all cables are routed such that connector and cable designations are legible.
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 Checking cables at devices
1. Check that the connectors are properly connected at Engine Control Unit ECU and that the connectors
have been properly secured.
2. For configuration featuring additional Engine Monitoring Unit EMU: Check that the connectors are prop-
erly connected at the EMU and that the connectors have been properly secured.
3. For configuration with Engine Interface Module EIM:Check that the plug connectors are correctly con-
nected at the EIM and that the locking clips are engaged.
4. If Priming Pump Control PPC is installed: Check that the connectors are properly connected at the PPC
and that the locking clips have been engaged.
5. Check that all connectors on printed circuit board CIB 4 (on CCU or in LOP depending on configuration)
are properly connected: Check connector designations and proper seating, connector housing must be
pressed in fully and secured with screws.
6. For configuration with CCU: Check that all cables are properly secured at the mounting plate (strain
relief, shielding connected).
7. For configuration with LOP:
a) Check that all cables are properly installed in the cable glands.
b) Check that all cables are properly secured in the LOP (strain relief, shielding connected).
c) Check that all individual cores are firmly connected in terminal strip X001.
8. Check that all connectors are properly connected to the devices for the operator: Check connector des-
ignations and proper seating.
9. Check that all bus terminators and plugs are connected to the CAN bus.

Checking fuses in LOP

1. (→ Page 56)
2. Check that fuses have the right rating.
3. If not: Plug in a suitable fuse.

Checking external system power supply

1. Check that the CCU and LOP are connected to the batteries (main supply and possibly also emergency
supply).
2. Check that all cables are properly connected to the batteries and cannot cause short circuits:
a) Polarity correct
b) Cores properly secured
c) Core cross-sections adequate
3. Ensure adequate battery capacity.
4. If Priming Pump Control PPC is installed: Check that single- or three-phase AC voltage is properly con-
nected.

Checking supply voltage distribution in the system

1. Prepare multimeter for voltage measurement:
a) Plug test leads into the appropriate sockets.
b) Fit test prods.
c) Set voltage measuring range to min. 30 V.
2. Check that supply voltage is applied at fuses or connectors and lies in the tolerated range (→ Page 64).
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34 | Initial Operation | E532302/01E 2014-11

 4.1.2 LOP power supply – Check
Preconditions
☑Supply voltage is available.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
multimeter 0005362539 1
Test prod, red 0005385230 2
Test prod, black 0005385130 2
Test prod, red 0005385430 2
Test prod, black 0005385330 2
Small clip 0005385530 3
Small clip 0005385630 3
Cable set 0025314380 1
Insulating bushing 0005316682 2
Insulating bushing 0005316782 2

Checking ship-side supply volt-

age
1. Switch on ship-side power supply voltage.
2. Pull off connector X15 from CIB of the LOP.
3. Prepare multimeter for voltage measure-
ment:
a) Plug cables into corresponding sockets
b) Set voltage measuring range to mini-
mum of 30 V
4. Switch on ship-side power supply voltage.
5. Measure the voltage between positive
pin (1) and negative pin (3) of connector
X15. Specified value: voltage must be be-
tween 19.5 V and 30 V.
a) If the measured value deviates from
the specification, check ship-side pow-
er supply.
b) If voltage is not present, check cabling.
c) In case of wrong polarity, rectify cable
connections (→ Page 23)
6. Measure the voltage between positive
pin (2) and negative pin (4) of connector
X15. Specified value: voltage must be be-
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tween 19.5 V and 30 V.

a) If the measured value deviates from
the specification, check ship-side pow-
er supply.
b) If voltage is not present, check cabling.
c) In the case of reverse polarity, correct
cabling (→ Page 23).
7. Plug connector into X15 on CIB of LOP.
8. Switch on ship-side power supply voltage.

E532302/01E 2014-11 | Initial Operation | 35

 Checking internal supply voltag-
es
1. Open LOP door.
2. If required, carefully move the cores of the
connection field aside.

3. Check LEDs in accordance with the table below:

Item Finding Action
Motherboard V30 LED (green) for external CAN bus Replace fuse F3 (→ Page 53)
supply voltage is dark.
Motherboard V28 LED (green) for control stand sup- Replace fuse F2 (→ Page 53)
ply voltage is dark.
Motherboard V26 LED (green) for ECU supply volt- Replace fuse F1 (→ Page 53)
age is dark.

TIM-ID: 0000021876 - 001

36 | Initial Operation | E532302/01E 2014-11

 4.2 Start-Up
4.2.1 Checks prior to startup

Note: The tasks listed below must be carried out in the order stated before switching on the operating voltage
for the first time:

Checking installation on engine

1. Check that engine is grounded.
2. Check that all cables are correctly connected to the starter; make sure that cables, spade lugs etc. do
not touch each other.
3. Check that the cables on the engine (to ECU, to EMU and to starter) are adequately secured. These
cables must not hang free at any point.
4. For configuration with Engine Interface Module EIM:Check that its cables have been properly connected
to the engine. These cables must not hang free at any point.

Checking device installation

1. Check that all devices are properly secured.
2. Check that the various devices are grounded.

Checking cable routing

1. Check all cables which are connected manually or routed inside housings:
a) Test all conductors.
b) Check that shielding is connected correctly.
2. Check that all cables are secured at suitable points.
3. Check that the cables are relieved of strain where necessary.
4. Check that bending radii of all cables have been respected.
5. Make sure that cables are never routed over sharp edges unless suitably protected against chafing.
6. Ensure that no cables can be sheared through when doors or flaps are closed.
7. Check that all cables are routed such that connector and cable designations are legible.

Checking cables at devices

1. Check that the connectors are properly connected at Engine Control Unit ECU and that the connectors
have been properly secured.
2. For configuration featuring additional Engine Monitoring Unit EMU: Check that the connectors are prop-
erly connected at the EMU and that the connectors have been properly secured.
3. For configuration with Engine Interface Module EIM:Check that the plug connectors are correctly con-
nected at the EIM and that the locking clips are engaged.
4. If Priming Pump Control PPC is installed: Check that the connectors are properly connected at the PPC
and that the locking clips have been engaged.
5. Check that all connectors on printed circuit board CIB 4 (on CCU or in LOP depending on configuration)
are properly connected: Check connector designations and proper seating, connector housing must be
pressed in fully and secured with screws.
TIM-ID: 0000017553 - 002

6. For configuration with CCU: Check that all cables are properly secured at the mounting plate (strain
relief, shielding connected).
7. For configuration with LOP:
a) Check that all cables are properly installed in the cable glands.
b) Check that all cables are properly secured in the LOP (strain relief, shielding connected).
c) Check that all individual cores are firmly connected in terminal strip X001.
8. Check that all connectors are properly connected to the devices for the operator: Check connector des-
ignations and proper seating.
9. Check that all bus terminators and plugs are connected to the CAN bus.

E532302/01E 2014-11 | Initial Operation | 37

 Checking fuses in LOP
1. (→ Page 56)
2. Check that fuses have the right rating.
3. If not: Plug in a suitable fuse.

Checking external system power supply

1. Check that the CCU and LOP are connected to the batteries (main supply and possibly also emergency
supply).
2. Check that all cables are properly connected to the batteries and cannot cause short circuits:
a) Polarity correct
b) Cores properly secured
c) Core cross-sections adequate
3. Ensure adequate battery capacity.
4. If Priming Pump Control PPC is installed: Check that single- or three-phase AC voltage is properly con-
nected.

Checking supply voltage distribution in the system

1. Prepare multimeter for voltage measurement:
a) Plug test leads into the appropriate sockets.
b) Fit test prods.
c) Set voltage measuring range to min. 30 V.
2. Check that supply voltage is applied at fuses or connectors and lies in the tolerated range (→ Page 64).

TIM-ID: 0000017553 - 002

38 | Initial Operation | E532302/01E 2014-11

 4.2.2 SAM device settings
Preconditions
☑De-energize the SAM assembly by removing fuses F1 and F2 on the SAM assembly.

Startup procedure for new SAM device (from stock)

1. Insert compact flash card (CF-card) in the appropriate slot.
2. Reinsert fuses F1 and F2 in the appropriate fuseholders on the SAM assembly.
Result: Display shows:
• In the first line: “Startup error”
• In the second line: “No valid config.”
Note: SAM has no valid configuration data. The configuration data are stored redundantly in the OnBoard
Flash and on the CF-card.
3. Press any key.
Result: Configuration menu is started.
TIM-ID: 0000008294 - 001

E532302/01E 2014-11 | Initial Operation | 39

 4.3 Settings
4.3.1 CAN nodes – Configuration
Devices with CAN connection
The following devices feature a CAN interface and are thus assigned a CAN node number:
• Engine Control Unit ECU
• Engine Monitoring Unit EMU (if applicable)
• Engine Interface Module EIM
• Local Operating Panel LOP
• MTU display (integrated in LOP 10 in the case of GenoLine)

Node numbers
Device Node number
ECU 2
EMU 3
Display in LOP 4
LOP 7
EIM 31

TIM-ID: 0000021799 - 001

40 | Initial Operation | E532302/01E 2014-11

 4.3.2 SAM – Node address setting
Preconditions
☑Operating voltage applied.
☑SAM is accessible.
☑Engine is stopped and starting disabled.

Checking setting
1. Select “View Config page” by pressing “Ar-
row ↑” (2) or “Arrow ↓” (1) keys on printed
circuit board SAM.
2. Press ENTER key (4).
Result: • Display on first line e.g. CAN 1 FB 1
• Display on second line e.g. Nd: 7 Bd:
125
3. Select other settings with “Arrow ↑” (2)
and “Arrow ↓” (1) keys.
4. Compare the settings with the specified
values:
• CAN 1 Node = 07
• CAN 1 Baud = 125
• CAN 2 Node = 07
• CAN 2 Baud = 125
• CAN 3 COORD
• CAN 3 Node = 02 or 03 (obtained from
system parameters and cannot be ad-
justed)
• CAN 3 Baud = 125
• Serial Usage = NO TERMINAL
• Enable BDM = YES
• Source Download = NO
5. Correct any deviating settings (→ Step 2).

Minidialog SAM, changing node setting

1. Switch off operating voltage.
2. Press and hold down keys “ESC” (3) and “ENTER” (4).
3. Switch on operating voltage.
Result: Display shows “Configuration requested”.
4. Press “ENTER” key (4).
Result: The first value is displayed.
5. Press “ENTER” key (4) repeatedly until desired value is displayed.
a) Correct value with “Arrow ↑” (2) and “Arrow ↓” (1) keys.
b) Change other values in same way if necessary.
• Go to next value with “ENTER” (4) key.
TIM-ID: 0000007945 - 003

• Go to previous value with “ESC” (3) key.

c) Press “Enter” key (4) repeatedly until “EXIT and SAVE” appears in second line.
d) Select “SAVE” and confirm with “ENTER” (4), or;
Result: inputs are saved.
e) Select “EXIT” and confirm with “ESC” key (3).
Result: Inputs are not saved.

E532302/01E 2014-11 | Initial Operation | 41

 4.3.3 Minidialog – Settings
Preconditions
☑Operating voltage applied.
☑Engine is stopped and starting disabled.

Note: The settings are made with the mini-keys on the SAM module in Local Operating Panel LOP.

Entering a hexadecimal number

in SAM minidialog
1 ↓ key (scroll)
2 ↑ key (scroll)
3 ESC key (cancel)
4 ENTER key (enter, OK, confirm)

1. Press the ↑ or ↓ key repeatedly until ”Select Initial Page” appears on the display.
2. Press ENTER key.
3. Press the ↑ or ↓ key until “Password Page” appears on the display.
Note: The cursor is placed at the highest digit of the number when a page appears on which a hexadecimal
number is to be entered. The input can be terminated at any time by pressing the ESC key.
• Password for engine with ECU: Engine run time as a hexadecimal value
Proceed as follows to determine the engine run time: Go to “Monitor page” by pressing the ↑
or ↓ key.
• Password for engine without ECU: ACDC
4. Change the value displayed at this point by pressing the ↑ or ↓ key.
5. Press ENTER key.
Result: Value is confirmed. The cursor jumps to the next lower digit of the number.
6. Repeat steps for all digits of the number.
Result: The entire hexadecimal number is accepted when the lowest digit has been confirmed.

Note: The “Download completed” message only appears when the plant is switched on after it has been prop-
erly configured. Never start the engine for the first time before!

SAM node address setting

TIM-ID: 0000021808 - 002

u (→ Page 41)

42 | Initial Operation | E532302/01E 2014-11

 Setting engine type
1. Press the ↑ or ↓ key repeatedly until ”Select Parameter page” appears on the display.
2. Press ENTER key.
Result: Engine type is displayed in a second line.
3. Press the ↑ or ↓ key repeatedly until the appropriate engine type is displayed. Examples:
• 16 V 4000 M23
• 12 V 4000 M33
4. Press ENTER key.
Result: Selected engine type is displayed
Note: Perform step 5 after completing all settings.
5. Press the ↑ or ↓ key until “Save Changes? Exit-Yes” appears, confirm with Yes (Enter).

Entering classification
1. Press the ↑ or ↓ key repeatedly until ”Select Parameter page” appears on the display.
2. Press ENTER key.
3. Press the ↑ or ↓ key repeatedly until ”Classified” appears on the display.
4. Press ENTER key.
Result: The currently set value is displayed in the second line.
5. Set classification with the ↑ or ↓ keys. Possible values:
• No
• Yes
6. Press ENTER key, display shows ”Classified, YES”.
Note: Perform step 7 after completing all settings.
7. Press the ↑ or ↓ key until “Save Changes? Exit Yes” appears, confirm with Yes (ENTER).

Exhaust gas monitoring

1. Press the ↑ or ↓ key repeatedly until ”Select Parameter page” appears on the display.
2. Press ENTER key.
3. Press the ↑ or ↓ key repeatedly until ”Exhaust Gas Mon” appears on the display.
4. Press ENTER key.
Result: The currently set value is displayed in the second line.
5. Set exhaust gas monitoring with the ↑ or ↓ keys. Possible values:
• No
• Yes
6. Press ENTER key, display shows ”Exhaust Gas Moni, YES”.
Note: Perform step 7 after completing all settings.
7. Press the ↑ or ↓ key until “Save Changes? Exit Yes” appears, confirm with Yes (Enter).

Setting lube-oil refill pump

1. Press the ↑ or ↓ key repeatedly until ”Select Parameter page” appears on the display.
2. Press ENTER key.
3. Press the ↑ or ↓ key repeatedly until ”Oil Refill Pump” appears on the display.
4. Press ENTER key.
TIM-ID: 0000021808 - 002

Result: The currently set value is displayed in the second line.

5. Set lube-oil refill pump with the ↑ or ↓ keys. Possible values:
• No
• Yes
6. Press ENTER key, display shows ”Oil Refill Pump, YES”.
Note: Perform step 7 after completing all settings.
7. Press the ↑ or ↓ key until “Save Changes? Exit Yes” appears, confirm with Yes (Enter).

E532302/01E 2014-11 | Initial Operation | 43

 Setting nominal speed
1. Press the ↑ or ↓ key repeatedly until ”Select Parameter page” appears on the display.
2. Press ENTER key.
3. Press the ↑ or ↓ key repeatedly until ”Nominal Speed” appears on the display.
4. Press ENTER key.
Result: The currently set value is displayed in the second line.
5. Set nominal speed with the ↑ or ↓ keys. Possible values:
• 1500 rpm
• 1800 rpm
6. Press ENTER key, display shows ”Nominal Speed”.
Note: Perform step 7 after completing all settings.
7. Press the ↑ or ↓ key until “Save Changes? Exit-Yes” appears, confirm with Yes (Enter).

Setting display
1. Press the ↑ or ↓ key repeatedly until ”Select Parameter page” appears on the display.
2. Press ENTER key.
3. Press the ↑ or ↓ key repeatedly until ”MTU Display” appears on the display.
4. Press ENTER key.
Result: The currently set value is displayed in the second line.
5. Set display with the ↑ or ↓ keys. Possible values:
• YES
• NO
6. Press ENTER key, display shows ”MTU Display”.
Note: Perform step 7 after completing all settings.
7. Press the ↑ or ↓ key until “Save Changes? Exit-Yes” appears, confirm with Yes (Enter).

Setting oil priming pump

1. Press the ↑ or ↓ key repeatedly until “Select Parameter Page” appears on the display.
2. Press ENTER key.
3. Press the ↑ or ↓ key repeatedly until “Priming Pump” appears on the display.
4. Press ENTER key.
Result: The currently set value is displayed in the second line.
5. Set oil priming pump with the ↑ or ↓ keys. Possible values:
• YES
• NO
6. Press ENTER key, “Priming Pump, YES” appears on the display.
Note: Perform step 7 after completing all settings.
7. Press the ↑ or ↓ key until “Save Changes? Exit-Yes” appears, confirm with Yes (Enter).

Setting generator (24 V) / battery-charging generator

1. Press the ↑ or ↓ key repeatedly until “Select Parameter Page” appears on the display.
2. Press ENTER key.
3. Press the ↑ or ↓ key repeatedly until “Generator (24 V)” appears on the display.
TIM-ID: 0000021808 - 002

4. Press ENTER key.

Result: The currently set value is displayed in the second line.
5. Set generator/battery-charging generator with the ↑ or ↓ keys. Possible values:
• Yes
• No
6. Press ENTER key, “Generator (24 V), YES” appears on the display.
Note: Perform step 7 after completing all settings.
7. Press the ↑ or ↓ key until “Save Changes? Exit-Yes” appears, confirm with Yes (Enter).

44 | Initial Operation | E532302/01E 2014-11

 Setting air starter
1. Press the ↑ or ↓ key repeatedly until “Select Parameter Page” appears on the display.
2. Press ENTER key.
3. Press the ↑ or ↓ key repeatedly until “Start Air” appears on the display.
4. Press ENTER key.
Result: The currently set value is displayed in the second line.
5. Set air starter with the ↑ or ↓ keys. Possible values:
• Yes
• No
6. Press ENTER key, “Start Air, YES” appears on the display.
Note: Perform step 7 after completing all settings.
7. Press the ↑ or ↓ key until “Save Changes? Exit-Yes” appears, confirm with Yes (Enter).

Setting generator bearing DE (driving end)

1. Press the ↑ or ↓ key repeatedly until ”Select Parameter page” appears on the display.
2. Press ENTER key.
3. Press the ↑ or ↓ key repeatedly until ”Gen Bear DE” appears on the display.
4. Press ENTER key.
Result: The currently set value is displayed in the second line.
5. Set generator bearing DE with the ↑ or ↓ keys. Possible values:
• Yes
• No
6. Press ENTER key, display shows ”Gen Bear DE, YES”.
Note: Perform step 7 after completing all settings.
7. Press the ↑ or ↓ key until “Save Changes? Exit Yes” appears, confirm with Yes (Enter).

Setting first upper limit value for generator bearing temperature DE (driving
end)
1. Press the ↑ or ↓ key repeatedly until ”Select Parameter page” appears on the display.
2. Press ENTER key.
3. Press the ↑ or ↓ key repeatedly until ”U1L T-GenBearDE” appears on the display.
4. Press ENTER key.
Result: The currently set value is displayed in the second line.
5. Set first upper bearing temperature limit value with the ↑ or ↓ keys. Possible values:
• NONE
• 90 °C
• Manual setting
6. Press ENTER key, display shows ”U1L T-GenBearDE, 90 °C”.
Note: Perform step 7 after completing all settings.
7. Press the ↑ or ↓ key until “Save Changes? Exit Yes” appears, confirm with Yes (Enter).
TIM-ID: 0000021808 - 002

E532302/01E 2014-11 | Initial Operation | 45

 Setting second upper limit value for generator bearing temperature DE (driv-
ing end)
1. Press the ↑ or ↓ key repeatedly until ”Select Parameter page” appears on the display.
2. Press ENTER key.
3. Press the ↑ or ↓ key repeatedly until ”U2L T-GenBearDE” appears on the display.
4. Press ENTER key.
Result: The currently set value is displayed in the second line.
5. Set second upper bearing temperature limit value with the ↑ or ↓ keys. Possible values:
• NONE
• 95 °C
• Manual setting
6. Press ENTER key, display shows ”U2L T-GenBearDE, 95 °C”.
Note: Perform step 7 after completing all settings.
7. Press the ↑ or ↓ key until “Save Changes? Exit-Yes” appears, confirm with Yes (Enter).

Setting generator bearing NDE (free end)

1. Press the ↑ or ↓ key repeatedly until ”Select Parameter page” appears on the display.
2. Press ENTER key.
3. Press the ↑ or ↓ key repeatedly until ”Gen Bear NDE” appears on the display.
4. Press ENTER key.
Result: The currently set value is displayed in the second line.
5. Set generator bearing NDE with the ↑ or ↓ keys. Possible values:
• Yes
• No
6. Press ENTER key, display shows ”Gen Bear NDE, YES”.
Note: Perform step 7 after completing all settings.
7. Press the ↑ or ↓ key until “Save Changes? Exit Yes” appears, confirm with Yes (Enter).

Setting first upper limit value for generator bearing temperature NDE (free
end)
1. Press the ↑ or ↓ key repeatedly until ”Select Parameter page” appears on the display.
2. Press ENTER key.
3. Press the ↑ or ↓ key repeatedly until ”U1L T-GenBearNDE” appears on the display.
4. Press ENTER key.
Result: The currently set value is displayed in the second line.
5. Set first upper bearing temperature limit value with the ↑ or ↓ keys. Possible values:
• NONE
• 90 °C
• Manual setting
6. Press ENTER key, display shows ”U1L T-GenBearNDE, 90 °C”.
Note: Perform step 7 after completing all settings.
7. Press the ↑ or ↓ key until “Save Changes? Exit-Yes” appears, confirm with Yes (Enter).
TIM-ID: 0000021808 - 002

46 | Initial Operation | E532302/01E 2014-11

 Setting second upper limit value for generator bearing temperature NDE (free
end)
1. Press the ↑ or ↓ key repeatedly until ”Select Parameter page” appears on the display.
2. Press ENTER key.
3. Press the ↑ or ↓ key repeatedly until ”U2L T-GenBearNDE” appears on the display.
4. Press ENTER key.
Result: The currently set value is displayed in the second line.
5. Set second upper bearing temperature limit value with the ↑ or ↓ keys. Possible values:
• NONE
• 95 °C
• Manual setting
6. Press ENTER key, display shows ”U2L T-GenBearNDE, 95 °C”.
Note: Perform step 7 after completing all settings.
7. Press the ↑ or ↓ key until “Save Changes? Exit-Yes” appears, confirm with Yes (Enter).

Setting Generator Monitoring

1. Press the ↑ or ↓ key repeatedly until ”Select Parameter page” appears on the display.
2. Press ENTER key.
3. Press the ↑ or ↓ key repeatedly until ”Generator Monitoring" appears on the display.
4. Press ENTER key.
Result: The currently set value is displayed in the second line.
5. Set Generator Monitoring with the ↑ or ↓ keys. Possible values:
• Yes
• No
6. Press ENTER key, display shows ”Generator Monitoring”.
Note: Perform step 7 after completing all settings.
7. Press the ↑ or ↓ key until “Save Changes? Exit Yes” appears, confirm with Yes (Enter).

Setting first upper limit value for generator winding temperature

1. Press the ↑ or ↓ key repeatedly until ”Select Parameter page” appears on the display.
2. Press ENTER key.
3. Press the ↑ or ↓ key repeatedly until ”U1L T-Gen Wind” appears on the display.
4. Press ENTER key.
Result: The currently set value is displayed in the second line.
5. Set first upper winding temperature limit value with the ↑ or ↓ keys. Possible values:
• NONE
• 125 °C
• 140 °C
• 155 °C
• Manual setting
6. Press ENTER key, display shows ”U1L T-Gen Wind”.
Note: Perform step 7 after completing all settings.
7. Press the ↑ or ↓ key until “Save Changes? Exit Yes” appears, confirm with Yes (Enter).
TIM-ID: 0000021808 - 002

E532302/01E 2014-11 | Initial Operation | 47

 Setting second upper limit value for generator winding temperature
1. Press the ↑ or ↓ key repeatedly until ”Select Parameter page” appears on the display.
2. Press ENTER key.
3. Press the ↑ or ↓ key repeatedly until ”U2L T-Gen Wind” appears on the display.
4. Press ENTER key.
Result: The currently set value is displayed in the second line.
5. Set second upper winding temperature limit value with the ↑ or ↓ keys. Possible values:
• NONE
• 130 °C
• 145 °C
• 160 °C
• Manual setting
6. Press ENTER key, display shows ”U2L T-Gen Wind”.
Note: Perform step 7 after completing all settings.
7. Press the ↑ or ↓ key until “Save Changes? Exit-Yes” appears, confirm with Yes (Enter).

Setting generator outlet cooling air temperature monitoring

1. Press the ↑ or ↓ key repeatedly until ”Select Parameter page” appears on the display.
2. Press ENTER key.
3. Press the ↑ or ↓ key repeatedly until ”T-Cooling Air Outlet” appears on the display.
4. Press ENTER key.
Result: The currently set value is displayed in the second line.
5. Set cooling air temperature monitoring with the ↑ or ↓ keys. Possible values:
• NO
• YES
6. Press ENTER key, display shows ”T-Cooling Air Outlet, YES”.
Note: Perform step 7 after completing all settings.
7. Press the ↑ or ↓ key until “Save Changes? Exit-Yes” appears, confirm with Yes (Enter).

Setting first upper limit value for generator outlet cooling air temperature
1. Press the ↑ or ↓ key repeatedly until ”Select Parameter page” appears on the display.
2. Press ENTER key.
3. Press the ↑ or ↓ key repeatedly until ”U1L T-Cool Air Outlet” appears on the display.
4. Press ENTER key.
Result: The currently set value is displayed in the second line.
5. Set first upper cooling air temperature limit value with the ↑ or ↓ keys. Possible values:
• NO
• 85 °C
• Manual setting
6. Press ENTER key, display shows ”U1L T-Cool Air Outlet, 85 °C”.
Note: Perform step 7 after completing all settings.
7. Press the ↑ or ↓ key until “Save Changes? Exit-Yes” appears, confirm with Yes (Enter).
TIM-ID: 0000021808 - 002

48 | Initial Operation | E532302/01E 2014-11

 Setting second upper limit value for generator outlet cooling air temperature
1. Press the ↑ or ↓ key repeatedly until ”Select Parameter page” appears on the display.
2. Press ENTER key.
3. Press the ↑ or ↓ key repeatedly until ”U2L T-Cool Air Outlet” appears on the display.
4. Press ENTER key.
Result: The currently set value is displayed in the second line.
5. Set second upper cooling air temperature limit value with the ↑ or ↓ keys. Possible values:
• NO
• 90 °C
• Manual setting
6. Press ENTER key, display shows ”U2L T-Cool Air Outlet, 90 °C”.
Note: Perform step 7 after completing all settings.
7. Press the ↑ or ↓ key until “Save Changes? Exit-Yes” appears, confirm with Yes (Enter).

Setting generator inlet cooling air temperature monitoring

1. Press the ↑ or ↓ key repeatedly until ”Select Parameter page” appears on the display.
2. Press ENTER key.
3. Press the ↑ or ↓ key repeatedly until ”T-Cooling Air Inlet” appears on the display.
4. Press ENTER key.
Result: The currently set value is displayed in the second line.
5. Set cooling air temperature monitoring with the ↑ or ↓ keys. Possible values:
• NO
• YES
6. Press ENTER key, display shows ”T-Cooling Air Inlet, YES”.
Note: Perform step 7 after completing all settings.
7. Press the ↑ or ↓ key until “Save Changes? Exit-Yes” appears, confirm with Yes (Enter).

Setting first upper limit value for generator inlet cooling air temperature
1. Press the ↑ or ↓ key repeatedly until ”Select Parameter page” appears on the display.
2. Press ENTER key.
3. Press the ↑ or ↓ key repeatedly until ”U1L T-Cool Air Inlet” appears on the display.
4. Press ENTER key.
Result: The currently set value is displayed in the second line.
5. Set first upper cooling air temperature limit value with the ↑ or ↓ keys. Possible values:
• NO
• 85 °C
• Manual setting
6. Press ENTER key, display shows ”U1L T-Cool Air Inlet, 85 °C”.
Note: Perform step 7 after completing all settings.
7. Press the ↑ or ↓ key until “Save Changes? Exit-Yes” appears, confirm with Yes (Enter).

Setting second upper limit value for generator inlet cooling air temperature
1. Press the ↑ or ↓ key repeatedly until ”Select Parameter page” appears on the display.
TIM-ID: 0000021808 - 002

2. Press ENTER key.

3. Press the ↑ or ↓ key repeatedly until ”U2L T-Cool Air Inlet” appears on the display.
4. Press ENTER key.
Result: The currently set value is displayed in the second line.
5. Set second upper cooling air temperature limit value with the ↑ or ↓ keys. Possible values:
• NO
• 90 °C
• Manual setting
6. Press ENTER key, display shows ”U2L T-Cool Air Inlet, 90 °C”.
Note: Perform step 7 after completing all settings.
7. Press the ↑ or ↓ key until “Save Changes? Exit-Yes” appears, confirm with Yes (Enter).

E532302/01E 2014-11 | Initial Operation | 49

 Setting present generator power display
1. Press the ↑ or ↓ key repeatedly until ”Select Parameter page” appears on the display.
2. Press ENTER key.
3. Press the ↑ or ↓ key repeatedly until ”Act Power Displ” appears on the display.
4. Press ENTER key.
Result: The currently set value is displayed in the second line.
5. Set generator power display with the ↑ or ↓ keys. Possible values:
• NO
• YES
6. Press ENTER key, display shows ”Act Power Displ, YES”.
Note: Perform step 7 after completing all settings.
7. Press the ↑ or ↓ key until “Save Changes? Exit-Yes” appears, confirm with Yes (Enter).

Setting Test mode / Configuration mode

1. Press the ↑ or ↓ key repeatedly until ”Select Parameter page” appears on the display.
2. Press ENTER key.
3. Press the ↑ or ↓ key repeatedly until ”Test/Conf.Mode:” appears on the display.
4. Press ENTER key.
Result: The currently set value is displayed in the second line.
5. Set Test mode/Configuration mode with the ↑ or ↓ keys. Possible values:
• ON
• OFF
6. Press ENTER key, display shows ”Test/Conf.Mode, ON bzw. OFF”.
Note: Perform step 7 after completing all settings.
7. Press the ↑ or ↓ key until “Save Changes? Exit Yes” appears, confirm with Yes (Enter).

The following outputs are tested/activated consecutively on pressing the the “Acknowledge” key when
Test mode is active:
→ Engine speed 0 ... 10 V, the speed is increased by 100 rpm each time the “Acknowledge” key is
pressed (up to max. 3000 rpm).
→ Lube-oil pressure with 100 % (10 V)
→ Coolant temperature with 100 % (10 V)
→ Lube-oil temperature with 100 % (10 V)
→ Spare with 100 % (10 V)
→ “Start activated”
→ “Stop activated”
→ “Summary alarm”
→ “Nominal speed reached”
→ “Ready for start”
→ “Engine shutdown pending”
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→ “SISY override activated”

→ “Generator shutdown”
→ “Genset stop pending”
→ “Generator false start”

Table 1: Test mode procedure

50 | Initial Operation | E532302/01E 2014-11

 4.3.4 Diagnostics
Diagnostic lamp
A diagnostic lamp (LED DILA, green) is integrated in the housing of the Engine Interface Module (EIM).
It indicates the operating status of the EIM.
The DILA has the following functions:
• Diagnostic lamp lit:
EIM is OK
• Diagnostic lamp dark:
EIM supply voltage missing or diagnostic lamp activation is faulty
• Diagnostic lamp flashes:
Hardware or software error in EIM
The diagnostic lamp (DILA) signals the following states:

1 Time in seconds 4 Application loader active 7 No firmware

2 Timing: 1/8 s 5 External RAM faulty 8 Application crashed
3 Ready for operation 6 External FLASH faulty

Fuse lamp
TIM-ID: 0000017037 - 003

A second indicator is the fuse lamp SILA.

This is likewise integrated in the EIM housing. It indicates the status of the fuses.
An orange LED is provided to allow diagnosis of a “tripped fuse” fault directly at the unit as it is often
difficult to pinpoint a fault in the field without cabling diagrams.
This LED is activated by the controller.

E532302/01E 2014-11 | Initial Operation | 51

 Brief description of SILA:
• SILA dark
Norma operating state
• SILA flashes orange
One or more fuses have tripped
The fuse lamp (SILA) signals the following states:

1 Preamble 7 SLD current path failed 13 SDAF 1+2 current path

2 ECU current path failed (S6) failed (S12)*
(S1) 8 DDV current path failed 14 PIM current path failed
3 MCS current path failed (S7) (S13)*
(S2) 9 Gear monitoring current 15 Spare current path failed
4 EMU current path failed path failed (S8) (S14)*
(S3) 10 Emergency stop current * Not relevant for Series
5 Starter current path failed path failed –24V internal 1163 M04
(S4)* (S9)
6 VSP current path failed 11 ES pushbutton current
(S5) path failed –24V external
(S10)
12 Key switch current path
failed (S11)
TIM-ID: 0000017037 - 003

The failed current paths are signaled consecutively following the preamble (LED on for 4 seconds (1)).
There is a pause lasting 4 seconds in between.

52 | Initial Operation | E532302/01E 2014-11

 5 Repair Work
5.1 Fuse on motherboard CIB 4 – Replacement
Preconditions
☑Engine shut down.
☑No operating voltage applied.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Fuse 3.0 A 0015318986 7
Fuse 7.5 A 0025310586 2
Fuse 20.0 A 0025310086 1
Fuse 30.0 A 0015318486 2

Determining faulty fuse

1. Pinpoint the appropriate fuse (→ Page 53).
2. Grasp the faulty fuse between finger and thumb and pull it out.
TIM-ID: 0000050424 - 001

Item Designation Value Fuse protection of

1 F1 20 A Not used – spare
2 F2 7.5 A Control panel binary signals (external) and display on LOP
3 F3 7.5 A CAN bus; Slots in SAM

E532302/01E 2014-11 | Repair Work | 53

 Item Designation Value Fuse protection of
4 F4 - Not used
5 F5 - Not used
6 F17 3A Not used – spare
7 F49 3A Engine Monitoring Unit EMU (connector X35)
Not used – spare
8 F45 3A Display on LOP
9 F29 3A Not used – spare
10 F18 3A Speed demand and binary signals, PPC
11 F8 3A Binary and analog signals, engine room
12 F6 3A Spare current circuit
not used at present

Table 2: Printed circuit board CIB 4-02 – Fuses

Finding spare fuses

1. Locate correct replacement fuse.
2. Grasp the replacement fuse between finger
and thumb and pull it out.

Inserting a fuse
1. Place the replacement fuse carefully on the socket of the faulty fuse.
2. Press the fuse into the socket with one finger as far as it will go.
TIM-ID: 0000050424 - 001

54 | Repair Work | E532302/01E 2014-11

 5.2 SAM fuse – Replacement
Preconditions
☑Engine shut down.
☑No operating voltage applied.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Fuse 15 A 0015319186 2

Locating a fuse
1 SAM
2 F2 for SAM supply —
3 F1 for SAM supply +

1. Locate appropriate fuse and replace both fuses if necessary.

2. Grasp the faulty fuse(s) between finger and thumb and pull out.
3. Determine cause of fuse tripping and remedy.

Inserting a new fuse

1. Carefully place new fuse(s) onto the plug-in socket(s).
2. Press fuse(s) with finger to the stop in their sockets.
TIM-ID: 0000008609 - 004

E532302/01E 2014-11 | Repair Work | 55

 6 Supplementary Technical Information
6.1 Local Operating Panel LOP 10 – Internal design

1 SAM 3 Cable glands 5 Motherboard CIB 4

2 Grounding comb 4 Terminal block X001
Motherboard CIB 4 and the main assembly SAM (Service and Application Module) are located in the top
half of the housing. The electrical connections between CIB and SAM are already established on deliv-
ery. Electrical installation of the LOP (standard scope) is limited to connecting cables to the specified
connectors on the CIB.
Terminal strip X001 for all customer and plant-specific connections is located in the bottom half of the
housing.
TIM-ID: 0000049486 - 001

56 | Supplementary Technical Information | E532302/01E 2014-11

 Assignment of pin sockets on motherboard CIB 4

Item Designation Assignment

1 ST35 Multiple-pin connector
2 ST22 Multiple-pin connector
3 ST20 Multiple-pin connector
4 ST19 Multiple-pin connector
5 ST18 Multiple-pin connector
6 ST17 Multiple-pin connector
7 ST13 Multiple-pin connector
8 X33 Battery-charging generator
9 X15 24 V supply, LOP
10 X24 Starting valve (for air starting) or starter (for electric
starting)
11 X32 Emergency stop, wire break monitoring
12 X23 Optional CCB2 board (signals, CAN bus)
13 X31 Barring gear limit switch
TIM-ID: 0000049486 - 001

14 X14 Fuel prefilter level sensor 1

15 X30 Oil priming pump, generator power, bearing temper-
ature
16 X22 Optional CCB2 board (signals, CAN bus)
17 X21 Optional CCB2 board (signals, CAN bus)
18 X29 CAN bus termination resistor 121 Ω between
X29 / 1+5
19 X13 Pushbuttons, signal lamps

E532302/01E 2014-11 | Supplementary Technical Information | 57

 Item Designation Assignment
20 X20 Pushbuttons, signal lamps, emergency stop
21 X28 Not used
22 X12 Not used
23 X34 Fuel prefilter 2 level sensor (in case of double prefil-
ter)
24 X19 Not used
25 X27 Dimmer voltage for display instruments in control
room 2;
Jumper between X27 / 1+2 and X27 / 3+4 and
X27 / 5+7
26 X18 Not used
27 X11 Control room display instruments
28 X35 Engine Monitoring Unit EMU (power supply and CAN
bus); on classified systems only
29 X17 Generator monitoring (e.g. generator cooling air inlet
temperature, winding temperatures of W)
30 X10 Generator monitoring signals (e.g. U and V winding
temperatures)
31 X26 Generator monitoring (e.g. generator cooling air out-
let temperature)
32 X25 Key switch; jumper between X25 / 5+6
33 X16 Plant signals
34 X8 Starting-air pressure sensor (for air starting)
35 X9 Engine coolant level sensor
36 X7 Sensor “T-Riser too high”
37 X6 Speed demand, oil priming pump
38 X4 CAN extension 1 – not supported
39 X5 CANOpen
40 X3 CANOpen
41 X2 Not used
42 X1 Serial RS 422 interface

Table 3: Assignment of pin sockets on motherboard CIB 4

TIM-ID: 0000049486 - 001

58 | Supplementary Technical Information | E532302/01E 2014-11

 Pin numbering of pin sockets on motherboard CIB 4
1 Pin 1
2 Pin 4
3 Pin 3
4 Pin 8
5 Pin 24
6 Pin 12
7 Pin 13
8 Pin 6

The figure shows the position of significant pins in examples of various types of pin sockets.

Replaceable plug-in fuses on motherboard CIB 4

TIM-ID: 0000049486 - 001

Item Designation Value Fuse protection of

1 F1 20 A Not used – spare
2 F2 7.5 A Control panel binary signals (external) and display on LOP
3 F3 7.5 A CAN bus; slots in SAM
4 F4 - Not used

E532302/01E 2014-11 | Supplementary Technical Information | 59

 Item Designation Value Fuse protection of
5 F5 - Not used
6 F17 3A Not used – spare
7 F49 3A Not used
8 F45 3A Display on LOP
9 F29 3A Not used – spare
10 F18 3A Speed demand and binary signals, PPC
11 F8 3A Binary and analog signals, engine room
12 F6 3A Spare current circuit
Not used at present

Table 4: Printed circuit board CIB 4-02 fuses

Spare fuses on motherboard CIB 4

Six spare fuses (“SPARE”) are located at the top left corner of the motherboard.
TIM-ID: 0000049486 - 001

60 | Supplementary Technical Information | E532302/01E 2014-11

 Display elements on SAM and CIB 4

1 LEDs for CIB-4 functions 3 SAM minidisplay 5 LEDs for supply voltage
2 LEDs on plug-in circuit 4 LEDs for supply voltage
board CCB 2 (CANopen in- and status indication of re-
terface, option) lay K1
The indicators have the following meanings:
TIM-ID: 0000049486 - 001

E532302/01E 2014-11 | Supplementary Technical Information | 61

 Item LED no. On Color Meaning
1 V92 CIB 4 Green Not used.
V128 Green Emergency stop reset active.
V134 Green ECU switched off.
V113 Green Not used.
V122 Green Emergency stop tripped.
V87 Green Not used.
V38 Green EMU supply voltage applied.
V34 Green Distribution voltage for emergency stop pushbuttons
and emergency stop lamps applied.
V40 Green Supply voltage for priming pump control signals, gen-
erator signals applied.
V32 Green Supply voltage for external start interlock, overspeed
test, coolant leak, “engine running” relay and horn
applied.
V106 Green Not used.
V80 Green Relay 1 (K2) activated, generator switch “OFF”, HI-
HI Alarm T Winding
V99 Green Not used.
V82 Green Spare relay 2 (K3) activated.
V146 Green Horn/flashing lamp switched on, relay K12
4 V71 CIB Green “Power On” relay is activated (K1).
V42 Green Supply voltage for plant applied.
5 V30 CIB Green Supply voltage for CAN buses applied.
V28 Green Supply voltage for generator applied.
V26 Green ECU supply voltage applied.

Table 5: Printed circuit board CIB 4-02 – Meaning of LED indicators

Indicators on plug-in circuit board CCB 2 (option)

TIM-ID: 0000049486 - 001

The indicators have the following meanings:

62 | Supplementary Technical Information | E532302/01E 2014-11

 Item LED no. On Color Meaning
2 1 CCB 2 Yellow Indicator lamp CAN1 SAEJ1939
2 Yellow Indicator lamp CAN2 CANopen
3 Yellow Indicator lamp CAN Hi unit-pump system
4 Yellow Indicator lamp INFO
5 red Indicator lamp ERROR
6 green Indicator lamp RUN

Table 6: Meaning of the indicators on plug-in circuit board CCB 2 (option)

Replaceable fuses on SAM

Item Designation Value Fuse protection of

2 F2 15 A SAM power supply (negative)
3 F1 15 A SAM power supply (positive)

Table 7: SAM – Fuses

TIM-ID: 0000049486 - 001

E532302/01E 2014-11 | Supplementary Technical Information | 63

 6.2 Supply voltages in LOP 10 – Distribution and fuse protection
The +Ub supply voltage for the entire system is connected at the terminal strip in Local Operating Panel
LOP 10.
The supply voltages for the individual assemblies, devices and subsystems are protected by separate
fuses. The fuses are partly installed on motherboard CIB 4 and partly on the SAM module.

Item Supply of … Comment

M GenoLine system Main supply (M = Main)
E GenoLine system Emergency supply (E = Emergency)
1 Not used Reserve
2 Control panel binary signals (external)
3 Display on LOP
4 I/O plug-in circuit board in SAM, slot 1 Binary inputs / binary outputs, CAN bus
5 I/O plug-in circuit board in SAM, slot 2 Binary inputs / binary outputs, CAN bus
6 I/O plug-in circuit board in SAM, slot 3 Binary inputs / binary outputs, CAN bus
TIM-ID: 0000049487 - 001

7 Not used Reserve

8 Emergency stop pushbutton on LOP
9 Additional emergency stop inputs Reserve
10 Engine room binary signals
11 Barring device
12 Coolant level sensor (external)
13 Start-air pressure sensor
14 Not used

64 | Supplementary Technical Information | E532302/01E 2014-11

 Item Supply of … Comment
15 Speed demand
16 Not used
17 Relay K1 “Power on/off” for generator charging check
18 Not used Reserve

Table 8: Local Operating Panel LOP 10 – GenoLine power distribution

TIM-ID: 0000049487 - 001

E532302/01E 2014-11 | Supplementary Technical Information | 65

 6.3 Serial RS 422 interface
General information about the RS422 interface
The CCU and the LOP respectively are equipped with a RS422 interface to allow transmission of numer-
ous acquired and generated data (measured values, fault messages, control signals etc.).
The signals of all measurement points listed are always transmitted irrespective of the configuration of
the engine management system. Measuring points which, for example, are not supported in the stand-
ard scope of the automation system are encoded with the value Missing Data (MD).
Initialization is not necessary in order to start serial communication. No handshake mechanisms are
used. Serial data communication is realized in full-duplex mode. The data transmission rules described
in this chapter apply both to the transmission and reception of data.
Serial communication (transmission and reception) is realized cyclically in an infinite loop. The cycle
times for the transmission of all data blocks are specified. The minimum interval to be maintained be-
tween any two data blocks is 50 ms.
The data block order in the data cycle is determined by the specified block number.

Block 1: 100 measurands

Block 2: 100 measurands
Block 3: 50 measurands

The occurrence of alarms leads to a change in the data block order.

The data flow is monitored by the receiver concerned. The receiver generates a fault message on de-
tecting data transmission failure.
Data is transmitted in blocks whereby a differentiation is made between three different types of block
(xxh = number in hexadecimal format).
Block type Block type code
Analog measured value 03h
block
Binary measured value block 02h
Request block 01h

2 bytes are provided for block type identification (unsigned, Motorola memory format).
The data blocks are embedded in a data frame with an identical structure for each block type.

Start_1 Start_2 Block Block Frame Meas- ... Meas- Check- End_1 End_2
no. type size urand urand sum
1 byte 1 byte 2 byte 2 byte 4 byte X byte X byte 4 byte 1 byte 1 byte
Data block

Table 9: Data frame

TIM-ID: 0000049488 - 001

The beginning and end of the data frame are identified by the following values:

Start_1 ⇒ FAh
Start_2 ⇒ F5h
End_1 ⇒ AFh
End_2 ⇒ 5Fh

The block number (unsigned 2-byte integer value, Motorola memory format) which is determined by
MTU specifically for the order concerned follows the start code. The block number “0” is reserved for
the request block and is used both by the transmitter and the receiver.

66 | Supplementary Technical Information | E532302/01E 2014-11

 The “Frame Size” entry (unsigned 4-byte integer value, Motorola memory format) contains the number
of all bytes transmitted within the data frame, i.e. the number of bytes from Start_1 to End_2.
Between 25 and 100 measured values can be transmitted and received depending on the interface cou-
pler on the MTU device.
The interface of the third-party system should be designed to facilitate the reception and processing of
100 measurands.
The minimum number of measurands in a data block is 4 (block 1).
Transmitted data is assigned to the measuring points in accordance with the measuring-point list com-
piled by MTU. The defined order of the measurands must be strictly observed in order to ensure trou-
ble-free data transmission.
A checksum (unsigned 4-byte integer value, Motorola memory format) is transmitted after the data
block. The check sum incorporates the sum of all bytes commencing at “Start_1” and ending at the last
data byte prior to the checksum.
The data frame is terminated by the end code.
The end ID may only be checked after receiving the bytes indicated by “Frame Size” as it is possible
that the end ID appears when transmitting analog measured value blocks within the data block.

Analog measured value block

Start_1 Start_2 Block Block Frame Meas- ... Meas- Check- End_1 End_2
no. type size urand urand sum
1 byte 1 byte 2 byte 2 byte 4 byte X byte X byte 4 byte 1 byte 1 byte
Data block

Table 10: Basic structure of an analog measurand block (X … max. number of measurands)
Analog measurands are transmitted by signed 4-byte integer values in Motorola memory format. The
most significant byte of the integer value is transmitted first in this memory format.

Byte 4 Byte 3 Byte 2 Byte 1

Most significant byte Least significant byte
00h 00h 3Ah B8h

Table 11: Analog measured value “15032” corresponds to “3AB8h” in Motorola memory format
The measurands must be normalized in accordance with the measuring-point list specified by MTU.
The value 8000 0000h is transmitted in case of sensor defect. Missing data are identified by the value
7FFF FFFFh.
”Missing Data” does not represent a critical value. In this case there is simply no information about the
state of the measuring point. The connected third-party system must assume a safe state on receiving
from a measuring point signaling “Missing Data”.

Binary measured value block

TIM-ID: 0000049488 - 001

Start_1 Start_2 Block Block Frame Meas- ... Meas- Check- End_1 End_2
no. type size urand urand sum
1 byte 1 byte 2 byte 2 byte 4 byte X byte X byte 4 byte 1 byte 1 byte
Data block

Table 12: Basic structure of a binary measurand block (X … max. number of measurands)
Binary measured values are transmitted as signed 1-byte values:

E532302/01E 2014-11 | Supplementary Technical Information | 67

 01h ⇒ True
00h ⇒ False
80h ⇒ Sensor Defect
7Fh ⇒ Missing Data

Alarm messages
Transmission of the alarm block within a data cycle depends on the interface coupler used.
Generally the data cycle always begins with transmission of the alarm blocks (the number of alarm
blocks depends on the order concerned). The other data blocks are transmitted after the alarm blocks
in accordance with the specified block order.
Should an alarm occur during transmission of a data block, the transmission is duly completed. The da-
ta cycle recommences following a pause.
If an alarm becomes active in the period between the end of a data cycle and the start of the next data
cycle, the interface coupler responds immediately or after a pause.

Sequence of functions
• Alarm transmission
When an alarm occurs the corresponding binary measurand is set to 01h and transmitted in accord-
ance with the specification for the exchange of alarm messages.
The binary value remains at 01h as long as the alarm conditions are fulfilled, or, in the case of stored
alarms, until the alarm is reset.

The MTU system does not acknowledge alarms/horn from the third-party system. Any third-party sys-
tem connected must store and acknowledge alarms independently.

Request block
Start_1 Start_2 Block no. Block Frame Check- End_1 End_2
type size sum
1 byte 1 byte 2 byte 2 byte 4 byte 4 byte 1 byte 1 byte
FAh F5h 00h 01h 10h 200h AFh 5Fh

Table 13: Basic structure of the request block

The request block is preset. It is not a fixed part of the data cycle.
The request block is used to request all data blocks on detecting faulty data transmission, i.e. the re-
ceiver terminates the current data cycle and starts a new data cycle on receiving a request block.
It is transmitted when no valid data blocks are received over a period of 3 s.
The period between any two request blocks must be at least 500 ms. This mechanism applies both to
the interface coupler and the third-party system.
The interface coupler detects a timeout and generates a fault message if no valid data is received after
TIM-ID: 0000049488 - 001

transmitting four request blocks.

Interface parameters
The LOP supports full-duplex mode and provides electrical isolation.
The transmission parameters of the RS422 interface are:
Baud rate: 9600
Data bits: 8

68 | Supplementary Technical Information | E532302/01E 2014-11

 Stop bit: 1
Parity: No parity

Classification of measurands and data blocks

The data transmission cycle times have the following values (“transmission” and “reception” defined
from the interface coupler's viewpoint):
• Transmission block: 95 ms
• Reception block: 100 ms
• Pause between the various data blocks: 50 ms

Identification letters for fault messages

Each fault message is preceded by two letters followed by a blank. The meaning of these identification
letters is defined as follows:
• MG (Message)
Is followed by an informative message indicating impaired engine operation (operator error, etc.).
• AL (Alarm)
The fault message which follows indicates a fault in the electronic system or engine, or inadmissible
engine operating values.
• HI (High) and LO (Low)
Admissible limit values defined by MTU have been violated. This is usually the result of a mechanical
fault at the engine. This type of fault must be rectified immediately.
• SS (Safety System)
Indicates safety channels:
Engine management system ECS-5 takes action to protect the engine if admissible upper or lower
limit values continue to be violated. These measures may range between a request to reduce power
and engine shutdown depending on the nature and severity of the limit value violation, .
• TD (Transmitter Deviation)
This is an are alarm output for analog (redundant) measuring points, where measured values are reg-
istered by two different systems, indicating an excessive deviation between the two measured val-
ues.

"Unit" column in the tables

The entries in the "Unit" column of the following tables are partly in English and have the following
meaning:
degC = ° = Degrees Celsius
h = Hours
rpm = min–1 = (revolutions) per minute
krpm = 1000 (revolutions) per minute
digit = digit per digit (e. g. in hexadecimal representation)

"Remark" column in the tables

The entries in the "Remark" column of the following tables have the following meaning:
1) Order-related or optional
TIM-ID: 0000049488 - 001

4) Series 4000 only (without EMU)

5) Series 4000 only (with EMU)
6) Series 4000 only (with EMU and EIM)
7) Generator signals

E532302/01E 2014-11 | Supplementary Technical Information | 69

 Transmission values – Block 1
General information:
• Block number: 1
• Block type: Binary
• Direction: Reception
Analog value
Seri- PV No. range
al Sys. In- Min. Max. Start
no. no. dex Process Variable Unit Scaling phys. phys. value
1 600 911 Start Command RS 422
2 600 912 Stop Command RS 422
3 600 914 Override RS 422

Transmission values – Block 2

General information:
• Block number: 2
• Block type: Alarm
• Direction: Transmit
Analog value
Seri- PV No. range
al Sys. In- Min. Max. Start
no. no. dex Process Variable Unit Scaling phys. phys. value
SS Autom. Power Reduct. ac-
1 410 9 tive 0 1 0
2 410 29 LO P-Lube Oil (ECU) 0 1 0
3 410 30 SS P-Lube Oil (ECU) 0 1 0
4 410 34 HI P-Crankcase 0 1 0
5 410 35 SS P-Crankcase 0 1 0
6 410 39 LO P-Coolant 0 1 0
7 410 40 SS P-Coolant 0 1 0
8 410 47 LO P-Fuel 0 1 0
9 410 48 SS P-Fuel 0 1 0
10 410 50 LO P-Charge Air (a) 0 1 0
11 410 133 HI T-Charge Air 0 1 0
12 410 168 SS T-Charge Air 0 1 0
13 410 54 HI P-Oil Filter Difference 0 1 0
14 410 55 LO Coolant Level 0 1 0
15 410 56 HI Fuel Leakage 0 1 0
TIM-ID: 0000049488 - 001

16 410 58 HI ETC 1 Speed 0 1 0

17 410 70 SS ETC 1 Overspeed 0 1 0
18 410 60 HI ETC 2 Speed 0 1 0
19 410 71 SS ETC 2 Overspeed 0 1 0
20 410 64 LO P-Fuel (Common Rail) 0 1 0
21 410 65 HI P-Fuel (Common Rail) 0 1 0
22 410 116 AL ECU Defect 0 1 0
23 410 122 LO ECU Power Supply Voltage 0 1 0

70 | Supplementary Technical Information | E532302/01E 2014-11

 Analog value
Seri- PV No. range
al Sys. In- Min. Max. Start
no. no. dex Process Variable Unit Scaling phys. phys. value
LOLO ECU Power Supply Volt-
24 410 270 age 0 1 0
25 410 123 HI ECU Power Supply Voltage 0 1 0
26 410 271 HIHI ECU Power Supply Voltage 0 1 0
27 410 129 HI T-Coolant (ECU) 0 1 0
28 410 130 SS T-Coolant (ECU) 0 1 0
29 410 143 HI T-Lube Oil 0 1 0
30 410 144 SS T-Lube Oil 0 1 0
31 410 147 HI T-Exhaust Combined A 0 1 0
32 410 296 SS T-Exhaust Combined A 0 1 0
33 410 150 HI T-Exhaust Combined B 0 1 0
34 410 297 SS T-Exhaust Combined B 0 1 0
35 410 170 HI T-ECU 0 1 0
36 410 177 SS Engine Speed too low 0 1 0
AL ECU Error/Check Error
37 410 178 Code 0 1 0
38 410 185 AL Common Rail Leakage 0 1 0
39 410 187 AL ETC 2 Idle Speed High 0 1 0
40 410 188 HI ETC Speed Difference 0 1 0
41 410 189 AL ETC 2 Cut in Fail 0 1 0
42 410 200 HIHI T-Fuel 0 1 0
43 410 294 HI T-Charge Air Seq Ctrl Valve 0 1 0
44 410 295 SS T-Charge Air Seq Ctrl Valve 0 1 0
45 410 299 HI T-Fuel 0 1 0
46 412 29 LO P-Lube Oil (EMU) 0 1 0
47 412 30 SS P-Lube Oil (EMU) 0 1 0
48 412 129 HI T-Coolant (EMU) 0 1 0
49 412 130 SS T-Coolant (EMU) 0 1 0
50 412 301 HI T-Exhaust A1 0 1 0
51 412 302 HI T-Exhaust A2 0 1 0
52 412 303 HI T-Exhaust A3 0 1 0
53 412 304 HI T-Exhaust A4 0 1 0
54 412 305 HI T-Exhaust A5 0 1 0
TIM-ID: 0000049488 - 001

55 412 306 HI T-Exhaust A6 0 1 0

56 412 307 HI T-Exhaust A7 0 1 0
57 412 308 HI T-Exhaust A8 0 1 0
58 412 311 HI T-Exhaust B1 0 1 0
59 412 312 HI T-Exhaust B2 0 1 0
60 412 313 HI T-Exhaust B3 0 1 0
61 412 314 HI T-Exhaust B4 0 1 0
62 412 315 HI T-Exhaust B5 0 1 0

E532302/01E 2014-11 | Supplementary Technical Information | 71

 Analog value
Seri- PV No. range
al Sys. In- Min. Max. Start
no. no. dex Process Variable Unit Scaling phys. phys. value
63 412 316 HI T-Exhaust B6 0 1 0
64 412 317 HI T-Exhaust B7 0 1 0
65 412 318 HI T-Exhaust B8 0 1 0
66 412 401 LO T-Exhaust A1 0 1 0
67 412 402 LO T-Exhaust A2 0 1 0
68 412 403 LO T-Exhaust A3 0 1 0
69 412 404 LO T-Exhaust A4 0 1 0
70 412 405 LO T-Exhaust A5 0 1 0
71 412 406 LO T-Exhaust A6 0 1 0
72 412 407 LO T-Exhaust A7 0 1 0
73 412 408 LO T-Exhaust A8 0 1 0
74 412 411 LO T-Exhaust B1 0 1 0
75 412 412 LO T-Exhaust B2 0 1 0
76 412 413 LO T-Exhaust B3 0 1 0
77 412 414 LO T-Exhaust B4 0 1 0
78 412 415 LO T-Exhaust B5 0 1 0
79 412 416 LO T-Exhaust B6 0 1 0
80 412 417 LO T-Exhaust B7 0 1 0
81 412 418 LO T-Exhaust B8 0 1 0
82 412 503 LO P-Raw Water 0 1 0
83 412 510 SS Request Power Reduction 0 1 0
84 412 512 AL Exhaust Monitoring Fail 0 1 0
85 412 513 AL Press Monitoring Fail (EMU) 0 1 0
86 412 516 AL Security Channel Def EMU 0 1 0
87 412 518 TD T-Coolant 0 1 0
88 412 519 TD P-Lube Oil 0 1 0
89 412 309 HI T-Exhaust A9 0 1 0
90 412 310 HI T-Exhaust A10 0 1 0
91 412 319 HI T-Exhaust B9 0 1 0
92 412 320 HI T-Exhaust B10 0 1 0
93 412 409 LO T-Exhaust A9 0 1 0
94 412 410 LO T-Exhaust A10 0 1 0
TIM-ID: 0000049488 - 001

95 412 419 LO T-Exhaust B9 0 1 0

96 412 420 LO T-Exhaust B10 0 1 0

Transmission values – Block 3

General information:
• Block number: 3
• Block type: Alarm
• Direction: Transmit

72 | Supplementary Technical Information | E532302/01E 2014-11

 Analog value
Seri- PV No. range
al Sys. In- Min. Max. Start
no. no. dex Process Variable Unit Scaling phys. phys. value
1 412 6 SS Overspeed (EMU) 0 1 0
2 414 354 MG External Start Interlock 0 1 0
4 414 360 AL Barring Gear Engaged 0 1 0
5 414 431 HI T-Riser (switch) 0 1 0
6 414 489 SS Security Shutdown 0 1 0
7 414 490 SS Emergency Stop 0 1 0
8 414 591 AL Diff Protection Tripped 0 1 0
9 414 593 AL Coolant Leakage Generator 0 1 0
10 414 553 HI T-Winding L1 0 1 0
11 414 554 HIHI T-Winding L1 0 1 0
12 414 558 HI T-Winding L2 0 1 0
13 414 559 HIHI T-Winding L2 0 1 0
14 414 563 HI T-Winding L3 0 1 0
15 414 564 HIHI T-Winding L3 0 1 0
16 414 355 MG Not Ready for Operation 0 1 0
17 414 356 MG Starter Not Ready 0 1 0
18 414 487 AL Emerg. Stop Circuit Fail 0 1 0
19 410 3 SS Overspeed (ECU) 0 1 0
20 414 352 MG Barring Gear Engaged 0 1 0
21 414 588 HI T-Cooling Air Inlet Gen 0 1 0
22 414 589 HIHI T-Cooling Air Inlet Gen 0 1 0

Transmission values – Block 4

General information:
• Block number: 4
• Block type: Alarm
• Direction: Transmit
Analog value
Seri- PV No. range
al Sys. In- Min. Max. Start
no. no. dex Process Variable Unit Scaling phys. phys. value
1 414 408 AL Priming Pump Fail 0 1 0
2 414 411 AL Water in Fuel Prefilter 0 1 0
TIM-ID: 0000049488 - 001

3 414 416 AL Battery Charger Failure 0 1 0

4 414 421 LO P-Start Air 0 1 0
5 414 470 AL Override Activated 0 1 0
6 414 573 HI T-Bearing Driven End 0 1 0
7 414 574 HIHI T-Bearing Driven End 0 1 0
8 414 578 HI T-Bearing Non Driven End 0 1 0
9 414 579 HIHI T-Bearing Non Driven End 0 1 0
10 414 583 HI T-Cooling Air Outlet 0 1 0

E532302/01E 2014-11 | Supplementary Technical Information | 73

 Analog value
Seri- PV No. range
al Sys. In- Min. Max. Start
no. no. dex Process Variable Unit Scaling phys. phys. value
11 414 584 HIHI T-Cooling Air Outlet 0 1 0
12 416 20 AL Safety System Fail (EMU) 0 1 0
13 416 810 AL Shutdown expected 0 1 0
14 414 427 HI P-Exhaust Back 0 1 0
15 414 511 AL Lube Oil Refill Tank empty 0 1 0
16 414 423 LOLO P-Start Air/Start Term. 0 1 0

Transmission values – Block 5

General information:
• Block number: 5
• Block type: Binary
• Direction: Transmit
Analog value
Seri- PV No. range
al Sys. In- Min. Max. Start
no. no. dex Process Variable Unit Scaling phys. phys. value
1 410 1 Stop Activated 0 1 1
2 410 68 Engine Running 0 1 0
3 410 69 ETC 2 Cut In 0 1 0
4 410 78 Generator Load On 0 1 0
5 410 190 AL Shutdown expected 0 1 0
6 410 290 Coolant Level Switch 0 1 0
7 410 291 Fuel Leakage Level Switch 0 1 0
8 414 1 Combined Alarm Red (Prio 2) 0 1 0
9 414 2 Combined Alarm Yellow (Prio 3) 0 1 0
10 414 265 ML LOP Start 0 1 0
11 414 270 ML LOP Stop 0 1 0
12 414 290 ML Ready for Start 0 1 0
13 414 594 Priming Pump Automatic Mode 0 1 0
14 416 11 Override Activated (Display) 0 1 0
15 414 405 Priming Pump On 0 1 0

Transmission values – Block 6

TIM-ID: 0000049488 - 001

General information:
• Block number: 6
• Block type: Analog
• Direction: Transmit

74 | Supplementary Technical Information | E532302/01E 2014-11

 Analog value
Seri- PV No. range
al Sys. In- Min. Max. Start
no. no. dex Process Variable Unit Scaling phys. phys. value
1 410 2 Engine Speed (ECU) rpm 10 0 3000
2 410 26 P-Lube Oil (ECU) bar 100000 0 10
3 410 27 L1L P-Lube Oil (ECU) bar 100000 0 10
4 410 28 L2L P-Lube Oil (ECU) bar 100000 0 10
mba
5 410 31 P Crankcase r 100 -70 70
mba
6 410 32 U1L P-Crankcase r 100 -70 70
mba
7 410 33 U2L P-Crankcase r 100 -70 70
8 410 36 P-Coolant bar 100000 0 6
9 410 37 L1L P-Coolant bar 100000 0 6
10 410 38 L2L P-Coolant bar 100000 0 6
11 410 46 P Fuel bar 100000 0 15
12 410 49 P-Charge Air (a) bar 100000 0 5
13 410 163 LL P-Charge Air (a) bar 100000 0 5
krp
14 410 57 ETC 1 Speed m 10000 0 100
krp
15 410 160 U1L ETC 1 Speed m 10000 0 100
krp
16 410 172 U2L ETC 1 Speed m 10000 0 100
krp
17 410 59 ETC 2 Speed m 10000 0 100
krp
18 410 161 U1L ETC 2 Speed m 10000 0 100
krp
19 410 173 U2L ETC 2 Speed m 10000 0 100
2147
4836
20 410 75 ECU Failure Codes digit 1 0 47
1431
21 410 115 ECU Operat.Hours sec 1 0 655
deg
22 410 126 T-Coolant (ECU) C 100 -20 120
TIM-ID: 0000049488 - 001

deg
23 410 127 U1L T-Coolant (ECU) C 100 -20 120
deg
24 410 128 U2L T-Coolant (ECU) C 100 -20 120
deg
25 410 131 T Charge Air C 100 -20 120
deg
26 410 132 U1L T-Charge Air C 100 -20 120
deg
27 410 167 L2H T-Charge Air C 100 -20 120

E532302/01E 2014-11 | Supplementary Technical Information | 75

 Analog value
Seri- PV No. range
al Sys. In- Min. Max. Start
no. no. dex Process Variable Unit Scaling phys. phys. value
deg
28 410 140 T Lube Oil C 100 -20 120
deg
29 410 141 L1H T-Lube Oil C 100 -20 120
deg
30 410 142 L2H T-Lube Oil C 100 -20 120
deg
31 410 145 T-Exhaust Combined A C 100 0 1000
deg
32 410 146 U1L T-Exhaust Combined A C 100 0 1000
deg
33 410 261 U2L T-Exhaust Combined A C 100 0 1000
deg
34 410 148 T-Exhaust Combined B C 100 0 1000
deg
35 410 149 U1L T-Exhaust Combined B C 100 0 1000
deg
36 410 262 U2L T-Exhaust Combined B C 100 0 1000
deg
37 410 151 T Intake Air C 100 -20 120
deg
38 410 152 T Fuel C 100 -20 120
39 410 158 L1L P-Fuel bar 100000 0 15
40 410 159 L2L P-Fuel bar 100000 0 15
41 410 162 UL Engine Speed (ECU) rpm 10 0 3000
deg
42 410 199 U2L T-Fuel C 100 -20 120
43 410 216 Injection in Relation to DBR % 1000 0 100
deg
44 410 258 T-Charge Air Seq Ctrl Valve C 100 0 1000
deg
45 410 259 U1L T-Charge Air Seq Ctr Valve C 100 0 1000
deg
46 410 260 U2L T-Charge Air Seq Ctr Valve C 100 0 1000
deg
47 410 298 U1L T-Fuel C 100 -20 120
TIM-ID: 0000049488 - 001

48 410 300 UL T-ECU

49 412 2 Engine Speed (EMU) rpm 10 0 3000
50 412 26 P-Lube Oil (EMU) bar 100000 0 10
51 412 27 L1L P-Lube Oil (EMU) bar 100000 0 10
52 412 28 L2L P-Lube Oil (EMU) bar 100000 0 10
deg
53 412 126 T-Coolant (EMU) C 100 -20 120
deg
54 412 127 U1L T-Coolant (EMU) C 100 -20 120

76 | Supplementary Technical Information | E532302/01E 2014-11

 Analog value
Seri- PV No. range
al Sys. In- Min. Max. Start
no. no. dex Process Variable Unit Scaling phys. phys. value
deg
55 412 128 U2L T-Coolant (EMU) C 100 -20 120
56 412 162 UL Engine Speed rpm 10 0 3000
deg
57 412 201 T-Exhaust A1 C 100 0 1000
deg
58 412 202 T-Exhaust A2 C 100 0 1000
deg
59 412 203 T-Exhaust A3 C 100 0 1000
deg
60 412 204 T-Exhaust A4 C 100 0 1000
deg
61 412 205 T-Exhaust A5 C 100 0 1000
deg
62 412 206 T-Exhaust A6 C 100 0 1000
deg
63 412 207 T-Exhaust A7 C 100 0 1000
deg
64 412 208 T-Exhaust A8 C 100 0 1000
deg
65 412 211 T-Exhaust B1 C 100 0 1000
deg
66 412 212 T-Exhaust B2 C 100 0 1000
deg
67 412 213 T-Exhaust B3 C 100 0 1000
deg
68 412 214 T-Exhaust B4 C 100 0 1000
deg
69 412 215 T-Exhaust B5 C 100 0 1000
deg
70 412 216 T-Exhaust B6 C 100 0 1000
deg
71 412 217 T-Exhaust B7 C 100 0 1000
deg
72 412 218 T-Exhaust B8 C 100 0 1000
deg
73 412 221 T-Exhaust Mean C 100 0 1000
TIM-ID: 0000049488 - 001

deg
74 412 225 L1L T-Exhaust C 100 0 1000
75 412 501 P-Raw Water bar 100000 0 6
76 412 502 LL P-Raw Water bar 100000 0 6
deg
77 414 550 T-Winding Generator L1 C 100 0 200
deg
78 414 551 U1L T-Winding L1 C 100 0 200

E532302/01E 2014-11 | Supplementary Technical Information | 77

 Analog value
Seri- PV No. range
al Sys. In- Min. Max. Start
no. no. dex Process Variable Unit Scaling phys. phys. value
deg
79 414 552 U2L T-Winding L1 C 100 0 200
deg
80 414 555 T-Winding Generator L2 C 100 0 200
deg
81 414 556 U1L T-Winding L2 C 100 0 200
deg
82 414 557 U2L T-Winding L2 C 100 0 200
deg
83 414 560 T-Winding Generator L3 C 100 0 200
deg
84 414 561 U1L T-Winding L3 C 100 0 200
deg
85 414 562 U2L T-Winding L3 C 100 0 200
86 410 119 Actual Fuel Consumption l/h 1000 0 3000 0
87 410 120 Trip Fuel Consumption l 10 0 1430 0
0000
0
88 410 121 Total Fuel Consumption l 10 0 1430 0
0000
0
89 410 198 Mean Trip Fuel Consumption l/h 1000 0 3000 0
90 412 209 T-Exhaust A9 deg 100 0 1000 0
C
91 412 210 T-Exhaust A10 deg 100 0 1000 0
C
92 412 219 T-Exhaust B9 deg 100 0 1000 0
C
93 412 220 T-Exhaust B10 deg 100 0 1000 0
C
94 414 571 U1L T-Bearing Driven End deg 100 0 120 0
C
95 414 572 U2L T-Bearing Driven End deg 100 0 120 0
C
96 414 576 U1L T-Bearing Non Driven End deg 100 0 120 0
C
97 414 577 U2L T-Bearing Non Driven End deg 100 0 120 0
TIM-ID: 0000049488 - 001

C
98 414 585 T-Cooling Air Inlet Generator deg 100 0 120 0
C
99 414 586 U1L T-Cooling Air Inlet Gen deg 100 0 120 0
C
100 414 587 U2L T-Cooling Air Inlet Gen deg 100 0 120 0
C

78 | Supplementary Technical Information | E532302/01E 2014-11

 Transmission values – Block 7
General information:
• Block number: 7
• Block type: Analog
• Direction: Transmit
Analog value
Seri- PV No. range
al Sys. In- Min. Max. Start
no. no. dex Process Variable Unit Scaling phys. phys. value
1 412 504 P-Oil Re-Fill Pump bar 100000 0 6
2 412 505 LL P-Oil Re-Fill Pump bar 100000 0 6
3 414 420 P-Start Air bar 100000 0 50
4 414 422 LL P-Start Air bar 100000 0 50
deg
5 414 570 T-Bearing Driven End Generator C 100 0 120
T-Bear. Non Driven End Gener- deg
6 414 575 at C 100 0 120
deg
7 414 580 T-Cooling Air Outlet Generator C 100 0 120
8 414 595 Gen Actual Power in KW kW 1000 0 3000
9 414 424 L2L P-Start Air bar 100000 0 50 0
TIM-ID: 0000049488 - 001

E532302/01E 2014-11 | Supplementary Technical Information | 79

 7 Technical Data
7.1 LOP 10 – Technical data
Term Unit Value
Dimensions
(10 mm free space is required
around all 3 axes when installed
on shock absorbers)
WxHxD mm 500 x 500 x 243
(without shock absorbers)
WxHxD mm 500 x 500 x 294
(with shock absorbers, door
closed)
WxHxD mm 500 x 500 x approx. 794
(with shock absorbers, door
open)
Weight kg 32
Current consumption A Typ. 15,
max. 30,
temporary 80
Operating voltage VDC 24, +30%, –25%
EMC protection IEC 60533 standard
Insulation resistance IEC 92-504 (550 VAC / 1 min)
Operational ambient temperature °C +5 to +55
Storage temperature °C -10 to 70
Relative air humidity % 5 to 95, non-condensing
Shock resistance 15 g / 11 ms (half-sine shock pulse) IEC 68-2-27
5 g / 30 ms (half-sine shock pulse) DIN EN 61373
Vibrostability
2 to 13 Hz xpp = ± 1.0 mm
13 to 150 Hz a= ±0.7 g
Degree of protection IP 54 as per DIN 40050
Installation position Wall-mounting, vertical
(NL90 as per DIN 16257)
TIM-ID: 0000017715 - 003

80 | Technical Data | E532302/01E 2014-11

 7.2 EIM – Technical data
Term Unit Value
Dimensions
LxWxH mm 254 x 193 x 103
Draw-out clearance upwards mm 157
Draw-out clearance in longitudi- mm Max. 100
nal direction
Weight kg 4.4
Power consumption A 0.12 to 40
(without starter)
Heat dissipation W Max. 25
Operating voltage VDC 16 to 32 (operation) (STANAG 1008, Ed. 9 : 2004) (Marine,
on-board genset)
16 to 32 (operation) (DIN EN 50155 : 2004) (Rail)
12 to 16.8 (dialog)
Supply impedance Ω 0.15
Ri(power source) + Rcable
Grounding Required, via grounding strip
EMC protection IEC 60533: 1999 (Marine)
DIN EN 50121-3-2 : 2007 (Rail)
DIN EN 50155 : 2004 (Rail)
DIN EN 61000-6-2 : 2006 (CE classification industrial/
immunity)
DIN EN 61000-6-4 : 2007 (CE classification industrial/
emissions)
Insulation resistance IEC 60092-504 : 2001
Ri > 10 MΩ (IEC 60092-504
Utest = 50 VDC
Operational ambient temperature °C -30 to +85
Storage temperature °C -40 to +85
Relative air humidity % 0 to 95, condensing
Shock resistance 15g / 11 ms (half-sine shock pulse)
Vibrostability
5 to 25 Hz xpp = ± 1.6 mm
25 to 100 Hz a = ±4 g
Degree of protection
Mated IP 69K as per IEC 60529 / DIN 40050
Not mated IP 20 as per IEC 60529 / DIN 40050
TIM-ID: 0000020235 - 003

With connector protection cap IP 54 as per IEC 60529 / DIN 40050

Installation position As desired
MTBF h 20000 (at an ambient temperature of 75 °C)

Table 14: EIM – Technical data

E532302/01E 2014-11 | Technical Data | 81

 7.3 ECU 7 – Technical data
Term Unit Value
Housing material AlSi10Mg
Dimensions (length x width x mm 361 x 315 x 63
height)
Draw-out clearance (height) mm 135
Weight kg 5.5
(without cable connection)
Installation position As desired
Operating voltage VDC 20 to 32 (operation, injection without power reduction)
16.8 to 20 (operation, injection with power reduction)
11 to 16.8 (interactive mode, without injection)
(EN 50155; STANAG 1008)
Supply impedance Ω 0.25 (max.)
(Ri, voltage source + Rline + Rcontact)
Power consumption A 0.2 to 17 (typical)
24 (maximum, at 24 V DC)
5AppAC / 200 to 400 Hz
approx. 7 mA at ignition OFF
approx. 250 mA at ignition ON (without injection)
Heat dissipation W 35 (max.)
Grounding Required, via grounding strip
EMC protection IEC 60533: 1999 (Marine)
EN 50121-3-2: 2001 (Rail)
EN 50155: 2004 (Rail)
EN 61000-6-2: 2002 (CE classification industrial)
EN 61000-6-4: 2004 (CE classification industrial)
EN 55025: 2003 (C&I international)
EN 13309: 2000 (C&I international)
DIN ISO 7637-2: 2002 (C&I international)
DIN ISO 7637-3: 1995 (C&I international)
Dielectric strength 10 MΩ (IEC 60092-504)
Utest ≥ 50 VDC (device removed for test)
500 V DC (EN 50155)
ESD protection EN 61000-4-2: 2002, IEC 61000-4-2 (CE, railway and na-
val)
ISO 10605: 2001 (C&I international)
Operational ambient temperature °C –40 to +75
Storage temperature range °C -40 to +85
Housing temperature °C 105 (maximum; for at most 30 min.)
TIM-ID: 0000016864 - 003

Relative air humidity % 0 to 95, condensing

Degree of protection Plugged in: IP69K (IEC 60529, DIN 40050)
Not plugged in: IP 20
With connector protective cap: IP 54
Shock resistance 15 g (11 ms period) (IEC 68-2-27)

82 | Technical Data | E532302/01E 2014-11

 Term Unit Value
Vibrostability 3.7 g*ms; 31.5 to 150 Hz 11 g peak (IEC 60068-2-6)
0.00057 g2/Hz at 5 Hz
0.06 g2/Hz at 31.5 Hz
0.06 g2/Hz at 150 Hz
0.00057 g2/Hz at 1000 Hz
0.00057 g2/Hz at 1500 Hz
MTBF h 20000 (at an ambient temperature of 75 °C)

Table 15: ECU 7 – Technical data

TIM-ID: 0000016864 - 003

E532302/01E 2014-11 | Technical Data | 83

 7.4 EMU 8 – Technical data
Term Unit Value
Housing material AlSi10Mg
Dimensions (length x width x mm 318 x 263 x approx. 70
height)
Draw-out clearance (height) mm 116
Weight (without cable connec- kg 3.3
tion)
Installation position As desired
Operating voltage VDC 16.8 to 32 (operation) (STANAG 1008, Ed. 8: 1994)
11 to 16.8 (dialog)
Supply impedance Ω 0.25 (max.)
Power consumption A 0.1 to 3.5 (typical)
5.5 (max., at 24 VDC)
Heat dissipation W 6 (max.)
Load impedance, switching out- Ω 32 to 20000
puts
Grounding Required, via grounding strip
EMC protection IEC 60533: 1999 (Marine)
MIL-STD-461E: 1999 (surface ships)
EN 50121-3-2: 2001 (Rail)
EN 50155: 2004 (Rail)
EN 61000-6-2: 2002 (CE classification industrial)
EN 61000-6-4: 2004 (CE classification industrial)
Dielectric strength > 2 MΩ (IEC 60092-504)
Utest ≥ 50 VDC (device removed for test)
ESD protection EN 61000-4-2: 2002, IEC 61000-4-2
Operational ambient temperature °C –40 to 75
Storage temperature °C -40 to +85
Housing temperature °C 80 (max.)
Relative air humidity % 0 to 95, condensing
Protection (mated) IP69K (IEC 60529, DIN 40050)
Shock resistance 15 g (11 ms period) (IEC 68-2-27)
Vibrostability 3.7 grms; 31.5 to 150 Hz: 11 g peak (IEC 60068-2-6)
0.00057 g2/Hz at 5 Hz
0.06 g2/Hz at 31.5 Hz
0.06 g2/Hz at 150 Hz
0.00057 g2/Hz at 1000 Hz
TIM-ID: 0000016808 - 004

0.00057 g2/Hz at 1500 Hz

MTBF h 20000 (at 75° ambient temperature)

Table 16: Technical data – EMU 8

84 | Technical Data | E532302/01E 2014-11

 7.5 PPC – Technical data
Term Unit Value
Dimensions (length x width x mm Approx. 280 x 200 x 136
height)
Draw-out clearance (longitudinal mm Approx. 125
direction)
Weight kg Approx. 3.5
(without cable connection)
Installation position As desired
Operational ambient temperature °C –25 to +55
Storage temperature °C -35 to +70
Relative air humidity % 0 to 95, condensing
Degree of protection IP 65 (DIN 40050)
Shock resistance 10 g (semi-sinusoidal shock, duration 11 ms)
Vibrostability 2 to 12.8 Hz: xpp = 3 mm
12.8 to 100 Hz: a = ± 1 g
EMC protection IEC 801
Operating voltage (PPC) VDC 24; +30% / –25%
PPC 5
Oil priming pump operating volt- 3-phase, 400 V, 50 Hz
age
Oil priming pump power W 750
Oil priming pump rated current A 2.0
PPC 6
Oil priming pump operating volt- 1-phase, 230 V, 50 Hz
age
Oil priming pump power W 1100
Oil priming pump rated current A 7.5
PPC 7
Oil priming pump operating volt- 3-phase, 230 V, 60 Hz
age
Oil priming pump power W 900
Oil priming pump rated current A 4.0
PPC 8
Oil priming pump operating volt- 3-phase, 440 V, 60 Hz
age
Oil priming pump power W 900
TIM-ID: 0000016795 - 006

Oil priming pump rated current A 2.0

Table 17: PPC – Technical data

E532302/01E 2014-11 | Technical Data | 85

 8 Appendix A
8.1 Conversion tables
Length
Unit A multiplied by factor = Unit B
in 25.4 = mm
ft 0.3048 =m
yd 0.9144 =m
stat. mile 1.609 = km
Nm 1.852 = km
yd 3 = ft
yd 36 = in

Unit B multiplied by factor = Unit A

mm 0.03937 = in
m 3.281 = ft
km 0.6215 = stat. mile

Area
Unit A multiplied by factor = Unit B
in 2 645.16 = mm2
ft2 0.0929 = m2
yd2 0.8361 = m2
stat. mile2 2.59 = km2

Unit B multiplied by factor Unit A

mm 2 0.00155 = in2
m2 10.764 = ft2
m2 1.1960 = yd2
km2 0.3861 = stat. mile2

Volume
Unit A multiplied by factor = Unit B
in 3 16387 = mm3
TIM-ID: 0000002173 - 016

ft3 0.02832 = m3
yd3 0.7646 = m3
gallon (U.S.) 3.785 = dm3
gallon (UK) 4.546 = dm3

Unit B multiplied by factor = Unit A

cm3 0.06102 = in3
m3 35.31 = ft3

86 | Appendix A | E532302/01E 2014-11

 Unit B multiplied by factor = Unit A
dm 3 0.2642 = gallon (U.S.)
dm 3 0.22 = gallon (UK)

Volumetric flow
Unit A multiplied by factor = Unit B
gal/min (GPM, U.S.) 3.79 = l/min
gal/min (GPM, U.S.) 0.134 = ft3/min (cfm)
ft3/min (cfm) 1.70 = m3/h

Unit B multiplied by factor = Unit A

l/min 0.264 = gal/min (U.S.)
ft3/min (cfm) 7.48 = gal/min (U.S.)
m3/h 0.589 = ft3/min (cfm)

Velocity
Unit A multiplied by factor = Unit B
ft/s 0.3048 = m/s
stat. mile/h (mph) 1.609 = km/h
knot (UK) 1.852 = km/h

Unit B multiplied by factor = Unit B

m/s 3.281 = ft/s
km/h 0.6214 = stat. mile/h (mph)
km/h 0.54 = knot (UK)

Mass
Unit A multiplied by factor = Unit B
lb 0.4536 = kg
oz 28.35 =g
ton (imp.) 1.016 =t

Unit B multiplied by factor = Unit A

g 0.03527 = oz
kg 2.205 = lb
t 0.9842 = ton (imp.)
TIM-ID: 0000002173 - 016

Force
Unit A multiplied by factor = Unit B
lbf 0.4536 = kp
lbf 4.4482 =N
kp 9.80665 =N

E532302/01E 2014-11 | Appendix A | 87

 Unit B multiplied by factor = Unit A
kp 2.205 = lbf
N 0.10197 = kp
N 0.2248 = lbf

Density
Unit A multiplied by factor = Unit B
slug/ft3 515.4 = kg/m3

Unit B multiplied by factor = Unit A

kg/m 3 0.00194 = slug/ft3

Torque
Unit A multiplied by factor = Unit B
lbf ft 1.3558 = Nm

Unit B multiplied by factor = Unit A

Nm 0.7376 = lbf ft

Pressure
Unit A multiplied by factor = Unit B
2
lbf/in (psi) 703.1 = kp/m2 (mmH2O)
lbf/in2 (psi) 0.06895 = bar
lbf/ft2 (psf) 47.88 = Pa
inHg 0.03386 = bar
inHg 345.3 = kp/m2 (mmH2O)

Unit B multiplied by factor = Unit A

atm 760 = mmHg
atm 1.0133 = bar
atm 10332 = kp/m2 (mmH2O)
atm 1.0332 = kp/cm2 (at)
atm 14.696 = lbf/in2 (psi)
bar 14.504 = lbf/in2 (psi)
Pa 0.0209 = lbf/ft2 (psf)

2nd moment of mass

TIM-ID: 0000002173 - 016

Unit A multiplied by factor = Unit B

slug ft 2 1.3558 = kg m2

Unit B multiplied by factor = Unit A

kg m 2 0.7376 = slug ft2

88 | Appendix A | E532302/01E 2014-11

 Energy
Unit A multiplied by factor = Unit B
lbf ft 1.356 =J
kcal 4186.8 =J
BTU 1055 =J
CHU 1899 =J

Unit B multiplied by factor = Unit A

J 0.7376 = lbf ft
J 0.0002388 = kcal
J 0.0009478 = BTU
J 0.00052656 = CHU

Power
Unit A multiplied by factor = Unit B
PS 0.7355 = kW
HP 0.7457 = kW
BTU/s 1.054 = kW
kcal/h 1.163 =W
HP 550 = lbf ft/s

Unit B multiplied by factor = Unit A

kW 1.36 = PS
kW 1.341 = HP
kW 0.9487 = BTU/s
W 0.8598 = kcal/h
lbf ft/s 0.0018 = HP

Temperature
Celsius Kelvin
x °C - = x + 273.15 K
xK = x − 273.15 °C -
x °F = 5/9(x − 32) °C = 5/9(x − 32) + 273.15 K
x °R = 5/4x °C = (5/4x) + 273.15 K

Fahrenheit Réaumur
x °C = 9/5x + 32 °F = (4/5x) °R
TIM-ID: 0000002173 - 016

xK = 9/5(x − 273.15) + 32 °F = 4/5(x − 273.15) °R

x °F - = 4/9(x − 32) °R
x °R = (9/4x) + 32 °F -

Fuel consumption
Unit A multiplied by factor = Unit B
mile/gal (US) 0.4251 = km/l
gal/mile (US) 2.3527 = l/km

E532302/01E 2014-11 | Appendix A | 89

 Unit B multiplied by factor = Unit A
km/l 2.3527 = mile/gal (US)
l/km 0.4251 = gal/mile (US)

TIM-ID: 0000002173 - 016

90 | Appendix A | E532302/01E 2014-11

 8.2 List of abbreviations
Abbrevia- Meaning Explanation
tion
ADEC Advanced Diesel Engine Control Engine Control Unit
AL Alarm Alarm (general)
ANSI American National Standards Institute Association of American standardization organiza-
tions
ATL Abgasturbolader Exhaust turbocharger
BR Baureihe Series
BML Betriebsmittelleuchte Utility lamp
BV Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU Publication
No. A01061/..
CAN Controller Area Network Data bus system, bus standard
CoE CAN-over-Ethernet CAN-over-Ethernet connection
CPP Controllable Pitch Propeller
°C Degrees Celsius
DILA Diagnostic lamp
DIN Deutsches Institut für Normung e. V. German Standards Organization and identifier of Ger-
man standards (DIN = “Deutsche Industrie-Norm”)
DIS Display Unit Display panel
DL Default Lost Alarm: Default CAN bus failure
DTS Depot Test System Test system
ECS Engine Control System
ECU Engine Control Unit Engine governor
EDM Engine Data Module Memory module for engine data
EEPROM Electrically Erasable and Programma- Memory module
ble Read Only Memory
EIM Engine Interface Module Engine interface
EPROM Electrically Programmable Read Only Memory module
Memory
EMU Engine Monitoring Unit
EMC Electromagnetic Compatibility
ERCS Signal Foreign Control System Signal for RCS provided by shipyard. Non-MTU RCS.
ESD Electrostatic Discharge
ETC Electronic Transmission Controller J1939 message
ETK Ersatzteilkatalog Spare parts catalog
TIM-ID: 0000037513 - 007

ETH Ethernet Ethernet connection

FCU Flap Control Unit Control unit for exhaust flaps
FDH Field Data Handling
FPP Fixed Pitch Propeller
FRCS Foreign Remote Control System RCS provided by shipyard. Non-MTU RCS.
GND Ground
h Hour
HFST Hauptfahrstand Main Control Station, main control stand

E532302/01E 2014-11 | Appendix A | 91

 Abbrevia- Meaning Explanation
tion
HI High Alarm: Measured value exceeds 1st maximum limit
HIHI High High Alarm: Measured value exceeds 2nd maximum limit
value
HRC Human Readable Code
HT High Temperature
Hz Hertz
ICFN ISO – Continuous rating – Fuel stop Power specification in accordance with DIN-ISO
power – Net 3046-7
IDM Interface Data Module Memory module for interface data
IEC International Electrotechnical Commis-
sion
IMO International Maritime Organization
I/O Input/Output
IP International Protection Protection against accidental contact, dust and water
as per DIN 40050
ISO International Standards Organization International umbrella organization for all national
standardization institutes
kg Kilogram
kΩ Kiloohm
LAN Local Area Network
LCD Liquid Crystal Display, Liquid Crystal
Device
LCU Local Control Unit LOP subassembly
LED Light Emitting Diode
LMU Local Monitoring Unit LOP subassembly
LO Low Alarm: Measured value lower than 1st minimum limit
value
LOLO Low Low Alarm: Measured value lower than 2nd minimum limit
value
LOP Local Operating Panel Control console, control panel
LOS Local Operating Station
MCD Marine Control Drive Remotely-controllable and regulated fluid coupling
MCS Monitoring and Control System
MD Missing Data No data available
MFD Multifunction Display
MG Message
TIM-ID: 0000037513 - 007

ML Meldeleuchte Signal lamp

MPU Microprocessing Unit Microprocessor (unit)
mm Millimeter
MTU Motoren- und Turbinen-Union
MΩ Megaohm
ms Millisecond
NFST Nebenfahrstand Slave control stand

92 | Appendix A | E532302/01E 2014-11

 Abbrevia- Meaning Explanation
tion
NMEA National Marine Electronics Associa-
tion
OT Oberer Totpunkt Top Dead Center
P-xyz Pressure-xyz Pressure measuring point xyz
PAN Panel Control panel
PCU Propeller Control Unit
PCS Process Control System
PGN Parameter Group Number SAEJ1939 message
PPC Priming Pump Control
PVC Polyvinylchloride
PWR Power Power supply
RCS Remote Control System
RET Return
RIM Remote Interface Module Connection device for remote control units
RL Redundancy Lost Alarm: Redundant CAN bus failure
ROS Remote Operating Station Propulsion control lever for remote control
RP Rudder Propeller
SAE Society of Automotive Engineers U.S. standardization organization
SCU System bus Coupling Unit System bus coupler
SD Sensor Defect Alarm: Sensor failure
SDAF Shut Down Air Flaps Emergency air-shutoff flap(s)
SE System Error Operating system error
SILA Safety lamp
SMCS Smart Managed Compact Switch Network distributor
SMU Shaft Speed Monitoring Unit Shaft speed acquisition
SPN Suspect Parameter Number SAEJ1939 message
SPU System bus Processing Unit
SS Safety System Safety system alarm
SSK Schnellschlussklappe(n) Emergency air-shutoff flap(s)
SW Switch
T-xyz Temperature-xyz Temperature measuring point xyz
TD Transmitter Deviation Alarm: Sensor comparison fault
UT Unterer Totpunkt Bottom Dead Center
VS Voith Schneider Voith Schneider drive
TIM-ID: 0000037513 - 007

WJ Water Jet Water jet drive

WZK Werkzeugkatalog Tool catalog
50V_Iso - Insulation voltage 50V

E532302/01E 2014-11 | Appendix A | 93

 8.3 MTU contact persons/service partners
Our worldwide sales network with its subsidiaries, sales offices, representatives and customer service
centers ensures fast and direct support on site and the high availability of our products.

Local support
Experienced and qualified specialists place their knowledge and expertise at your disposal.
For locally available support, go to the MTU Internet site: http://www.mtu-online.com

24h hotline
With our 24h hotline and the outstanding flexibility of our service staff, we are always ready to assist
you – either during operation, for preventive maintenance, corrective work in case of malfunction or
changed operating conditions, or for spare parts supply.
Your contact person in our Customer Assistance Center:
E-mail: [email protected]
Tel.: +49 7541 9077777
Fax: +49 7541 9077778
Asia/Pacific: +65 6100 2688
North and Latin America: +1 248 560 8000

Spare parts service

Fast, simple and correct identification of spare parts for your drive system or vehicle fleet. The right
spare part at the right time at the right place.
With this aim in mind, we can call on a globally networked spares logistics system, a central warehouse
at headquarters and on-site stores at our subsidiary companies, agencies and service workshops.
Your contact at Headquarters:
E-mail: [email protected]
Tel.: +49 7541 908555
Fax: +49 7541 908121
TIM-ID: 0000000873 - 015

94 | Appendix A | E532302/01E 2014-11

 9 Appendix B
9.1 Index
C LOP
Cable connector pin numbers 16 – Connection 23
Cable gland ICOTEK – Assembly 19 – Installation 11
Cables – Internal design 56
– Routing 18 – Power supply check 35
CAN bus – Supply voltage 64
– Node numbers 40 – Technical data 80
Checks
M
– Prior to startup 33, 37
Connecting wires Minidialog on SAM
– Spring terminals 21 – Setting 42
Connection MTU cables
– Engine Interface Module EIM 27 – Scope of delivery 14
– PPC MTU contact persons 94
– Single phase 29
N
Contact persons 94
Conversion tables 86 Node address SAM
– Setting 41
D Node numbers
Devices – Devices on CAN bus 40
– Node numbers on CAN bus 40
P
Diagnostics 51
Power supply check
E – LOP 35
ECU 7 PPC
– Connection 25 – Connection
EMU 8 – Single phase 29
– Connection 26 – three phases 31
Engine Control Unit ECU 7 – Installation 13
– Connection 25 Priming Pump Controller
Engine Monitoring Unit EMU 8 – Connection
– Connection 26 – Single phase 29
– three phases 31
F – Installation 13
Fuel prefilter level sensors
R
– Connection 28
Fuse RS 422 66
– Replacement RS 422 serial interface 66
– Motherboard CIB 4 53
S
– SAM 55
Safety notices, standards 10
DCL-ID: 0000006833 - 002

H Safety regulations
Hotline 94 – Organizational requirements 5
– Personnel requirements 5
L Safety requirements
List of abbreviations 91 – Important requirements 4
Local Operating Panel LOP – Maintenance work 7
– Connection 23 – Operation 6
– Installation 11 – Repair work 7
– Internal design 56 – Safety notices, standards 10
– Supply voltage 64 – Startup 6
– Technical data 80

E532302/01E 2014-11 | Appendix B | 95

 SAM
– Minidialog 42
– Node address setting 41
– Setting 42
SAM device settings 39
Scope of delivery
– MTU cables 14
Service partners 94
Spare parts service 94
Spring terminals
– Connecting wires 21
Startup
– Checks prior to 33, 37

T
Technical data
– ECU 7 82
– EIM 81
– EMU 8 84
– LOP 10 80
– PPC 85
Terminal block
– Connecting wires 21
Terminal strip
– Connecting wires 21

Y
Yard cables
– Preparation 14

DCL-ID: 0000006833 - 002

96 | Appendix B | E532302/01E 2014-11

MTU_ValueService
Technical Documentation

Data protocols
J1939 and CANopen

for GenoLine LOP 10

(Engine management systems
MDEC and ADEC/EIM)

Application: Marine

E532303/00E
Printed in Germany
E 2010 Copyright MTU Friedrichshafen GmbH
Diese Veröffentlichung einschließlich aller seiner Teile ist urheberrechtlich geschützt. Jede Verwertung oder Nutzung bedarf der vorherigen
schriftlichen Zustimmung der MTU Friedrichshafen GmbH. This applies, in particular, to reproduction, dissemination, editing, translation, mi-
crofilming and storage and / or processing in electronic systems, including databases and online utilities.
Das Handbuch ist zur Vermeidung von Störungen oder Schäden beim Betrieb zu beachten und daher vom Betreiber dem jeweiligen War-
tungs- und Bedienungspersonal zur Verfügung zu stellen.
Änderungen bleiben vorbehalten.

Printed in Germany
E 2010 Copyright MTU Friedrichshafen GmbH
This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior written permission of
MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, microfilming and storage or processing on
electronic systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage during operation.
Subject to alterations and amendments.

Impremé en Allemagne
E 2010 Copyright MTU Friedrichshafen GmbH
Tout droit réservé pour cet ouvrage dans son intégralité. Toute utilisation ou exploitation requiert au préalable l’accord écrit de MTU Fried-
richshafen GmbH. Ceci s’applique notamment à la reproduction, la diffusion, la modification, la traduction, l’archivage sur microfiches, la
mémorisation et / ou le traitement sur des systèmes électroniques, y compris les bases de données et les services en ligne.
Le manuel devra être observé en vue d’éviter des incidents ou des endommagements pendant le service. Aussi recommandons--nous à
l’exploitant de le mettre à la disposition du personnel chargé de l’entretien et de la conduite.
Modifications réservées.

Impreso en Alemania
E 2010 Copyright MTU Friedrichshafen GmbH
Esta publicación se encuentra protegida, en toda su extensión, por los derechos de autor. Cualquier utilización de la misma, así como su
reproducción, difusión, transformación, traducción, microfilmación, grabación y/o procesamiento en sistemas electrónicos, entre los que se
incluyen bancos de datos y servicios en línea, precisa de la autorización previa de MTU Friedrichshafen GmbH.
El manual debe tenerse presente para evitar fallos o daños durante el servicio, y, por dicho motivo, el usario debe ponerlo a disposición del
personal de mantenimiento y de servicio.
Nos reservamos el derecho de introducir modificaciones.

Stampato in Germania
E 2010 Copyright MTU Friedrichshafen GmbH
Questa pubblicazione è protetta dal diritto d’autore in tutte le sue parti. Ciascun impiego od utilizzo, con particolare riguardo alla riprodu-
zione, alla diffusione, alla modifica, alla traduzione, all’archiviazione in microfilm ed alla memorizzazione od all’elaborazione in sistemi elet-
tronici, comprese banche dati e servizi on line, deve essere espressamente autorizzato per iscritto dalla MTU Friedrichshafen GmbH.
II manuale va consultato per evitare anomalie o guasti durante il servizio, per cui va messo a disposizione dall’ utente al personale addetto
alla manutenzione e alla condotta.
Con riserva di modifiche.

Printed in Germany
© 2010 Copyright MTU Friedrichshafen GmbH
A presente publicação, inclusive todas as suas partes, está protegida pelo direito autoral. Qualquer aproveitamento ou uso exige a
autorização prévia e por escrito da MTU Friedrichshafen GmbH.
Isto diz respeito em particular à reprodução, divulgação, tratamento, tradução, microfilmagem, e a memorização e/ou processamento em
sistemas eletrônicos, inclusive bancos de dados e serviços on--line.
Para evitar falhas ou danos durante a operação, os dizeres do manual devem ser respeitados. Quem explora o equipamento
economicamente consequentemente deve colocá--lo à disposição do respetivo pessoal da conservação, e à dispositção dos operadores.
Salvo alterações.
Data protocols J1939 and CANopen -- GenoLine LOP 10 Part 1
Table of contents Page I

1 Transmission values as per J1939 standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1.1 Message structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1.2 Identifier message structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1.3 PDU message structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1.4 Node and baud rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.2 SPN-PV mapping – Explanation of table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Explanation of signal ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Examples of table presentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Explanation of table columns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.3 SPN-PV mapping – Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.4 Standard PGN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

1.5 Proprietary PGN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2 Transmission values as per CANopen standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

2.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

2.2 CANopen: PDO tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Explanation of table columns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Receiving objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Transmission objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

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Page II Table of contents

(Leerseite)

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Data protocols J1939 and CANopen -- GenoLine LOP 10 Part 1
J1939: General information Page 1

1 Transmission values as per J1939 standard

1.1 General information

1.1.1 Message structure

A CAN message is structured as follows:

¯ 29 bit CAN identifier
¯ Statement of the length of the data field
¯ Up to 8 data bytes (J1939/21)

MTU also uses data packets with less than 8 data bytes, therefore an evaluation of the data field length is vi-
tal.

1.1.2 Message structure identifier

The 29 bit CAN identifier consists of the following components:

¯ Message priority
This is preset to 6 for all PGNs
¯ PGN (Parameter Group Number)
This number is structured as follows:
-- EDP -- defines the structure of the CAN identifier and is always set to zero for J1939 mes-
sages
-- DP -- bit for the extension of the subsequent PDU (Process Data Unit) format field
-- PF -- PDU format
Field to distinguish between communication services. Together with other constituents of
the PGN, it allows to describe the subsequent data field. Messages sent to all nodes (bro-
adcast) are in PDU1 format (PDU format field > 239). Messages only sent to individual de-
vices (peer to peer) are PDU2 format (PDU format field < 240)
-- PS -- PDU Specific (DA or GE)
The definition of this data field depends on the PDU format. For PDU1 format the specific
field is the target address (DA). For PDU2 format this data field contains the group exten-
sion (GE).
DA: Target address to which a message is transmitted.
GE: Forms the parameter group together with the PF.

¯ Source address
This is a unique device address with 8 bits (0...253).

The structure of the identifier therefore appears as follows:

28 ... 26 25 24 23 ... 16 15 ... 8 7 ... 0

Priority PGN (Parameter Group Number) Source address
Res DP PF DA/GE

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Part 1 Data protocols J1939 and CANopen -- GenoLine LOP 10
Page 2 J1939: General information

Abbreviations:
¯ DA: Destination Address
¯ DP: Data Page
¯ EDP: Extended Data Page
¯ GE: Group Extension
¯ LSB: Least Significant Bit
¯ PDU: Protocol Data Unit
¯ PF: PDU Format
¯ PGN: Parameter Group Number
¯ PS: PDU Specific
¯ Res: Reserved

1.1.3 PDU message structure

The maximum length of the data field is 8 bytes. However, MTU also uses shorter data fields to reduce the
volume of data transmitted, or longer messages transmitted by transport protocol (e.g. DM1, DM2, TTI2,
EC1, see also SAE J1939S21). Therefore the Dlc (Data length code) must be evaluated.

A request message then has, for example, the following structure (see also SAE J1939--21 Section 5.2.7.1
“Data from 0 to 8 Bytes”):

29 bit identifier Dlc PDU data field

28 ... 26 25 24 23 ... 16 15 ... 8 7 ... 0 3 d0 d1 d2
Priority PGN (Parameter Group Number) Source ad-
dress
Res DP PF DA/DG Requested PGN

1.1.4 Nodes and baud rate

The following node and baud rate settings apply:

¯ SAM: Node no.: 2
¯ Baud rate: 250 kB
¯ Deterministic

Note on the process variables PV

The System Index can vary for the two applications MDEC and ADEC. The system number varies depen-
ding on the application engineering. The PV Number of the process variables comprises a System Index and
a System Number. These PV Numbers vary on the basis of the information given above. Their purpose is
exclusively to provide a rough orientation. The designations (e.g. engine speed, stop or start) are uniquely
assigned.

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J1939: SPN--PV mapping -- Explanation of table Page 3

1.2 SPN-PV mapping – Explanation of table

Explanation of signal ranges

The table below defines the usable signal ranges (source: SAE J1939--71, January 2008).

The value ranges summarized under ”Fault indicator” have the following meanings:
¯ The relevant data are currently unavailable.
¯ Fault in sensor
¯ Fault in subsystem
¯ Fault in module
The ”Unavailable” ranges are indicated when a data request is made for an inexistant signal or if the requested signal is not supported in this module.

”Not requested” summarizes ranges for which no responses are expected from the receiving device, or if receiving devices transmit a response without a request.

Range name Numeric 1 byte 2 bytes 4 bytes ASCII

representa-
tion
Valid signal Decimal 0 -- 250 0 -- 64 255 0 -- 4 211 081 215 1 -- 254

Hexadecimal

Parameter--specific information Decimal 251 64 256 -- 64 511 4 211 081 216 -- 4 227 858 431 none

Hexadecimal

Reserved for future bits Decimal 252 -- 253 64 512 -- 65 023 4 227 858 432 -- 4 261 412 863 none

Hexadecimal

Fault indicator Decimal 254 65 024 -- 65 279 4 261 412 864 -- 4 278 190 079 0

Hexadecimal

Unavailable or not requested Decimal 255 65 280 -- 65 535 4 278 190 080 -- 4 294 967 294 255

Hexadecimal

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Page 4 J1939: SPN--PV mapping -- Explanation of table

Examples of table presentation

PGN Operating range
T PV Index PV Name CAN Mux J1939 Name SPN PGN S K. Byte Bit Data Normalization X--value Y--value Unit Explanation
/ ID MCS / SPN Name / No Off- Off- lengt table X
R MCS P . set set h:

Example: Binary signal

R PV600902 Stop Com- 1029 1 Auxiliary 970 61441 S 10 4 5 2 Binary X--Y table 0 0 Norm range Lower limit
mand J1939 Engine Shut- value
down Switch
1 1 Norm range Upper limit
value
2 --2147483647 SD Sensor
Defect
3 2147483647 MD Missing
Data

Example: Analog signal

T PV410026 P--Lube Oil 1001 0 Engine oil 100 65263 S 2 4 0 8 Pressure --2147483647 254 kPa SD Sensor
(ECU) pressure 4kPa/bit Defect
--1 254 kPa SD Sensor
Defect
0 0 kPa Norm range Lower limit
value
1000000 250 kPa Norm range Upper limit
value
1000001 250 kPa Overflow

2147483646 250 kPa Overflow

2147483647 255 kPa MD Missing

Data

The “SPN--PV mapping” table below only lists the values of the norm range, i.e. upper and lower limit values.

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J1939: SPN--PV mapping -- Explanation of table Page 5

Explanation of table columns

¯ T/R Direction (T: Transmit; R: Receive)
¯ PV Index Process variable, unique number
¯ PV Name Process variable, denomination
¯ CAN ID MCS CAN identifier, MCS (Monitoring and Control System)
¯ Mux MCS Multiplexer, MCS (Monitoring and Control System)
¯ J1939 Name / SPN Name Name in J1939 protocol (may deviate from “PV Name”, as it is defined in the SAE standard)
¯ SPN Suspect Parameter Number (unique identification of parameters or other elements of a control unit)
¯ PGN Parameter Group Number (takes account of priority, repetition rate, data length and transmission type)
¯ S/P S: PGN is standard; P: PGN is proprietary
¯ K. No. Channel number
¯ Byte Offset Offset (bytes)
¯ Bit Offset Offset (bits)
¯ Data length Number of bytes or words to be transmitted
¯ Normalization table Format and scaling of expected data
¯ X--value Maximum value in X--direction
¯ Y--value Maximum value in Y--direction
¯ Unit X Unit (X--axis)
¯ Explanation (This column only applies to the sample table above.)

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Page 6 J1939: SPN--PV mapping -- Table

1.3 SPN-PV mapping – Table

PGN Operating range
T PV Index PV Name CAN Mux J1939 Name / SPN Name SPN PGN S K. Byte Bit Data Normalization X-- Y-- Unit
/ ID MCS / No Off- Off- lengt table value value X
R MCS P . set set h:
R PV600902 Stop Command J1939 1029 1 Auxiliary Engine Shutdown 970 61441 S 10 4 5 2 Binary X--Y table 0 0
Switch
1 1

R PV600904 Override J1939 1029 2 Engine Shutdown Override 1237 65265 S 10 8 7 2 Binary X--Y table 0 0
Switch
1 1

R PV600901 Start Command J1939 1029 0 Engine Start 0 65325 P 10 1 1 2 Binary X--Y table 0 0
1 1

T PV410002 Engine Speed (ECU) 1000 1 Engine Speed 190 61444 S 2 4 0 16 Speed 0.125 rpm/bit 0 0 rpm
80320 64255 rpm

T PV410026 P--Lube Oil (ECU) 1001 0 Engine Oil Pressure 100 65263 S 2 4 0 8 Pressure 4kPa/bit 0 0 kPa
1000000 250 kPa

T PV410031 P--Crankcase 1001 5 Crankcase Pressure 101 65263 S 2 5 0 16 Pressure 128kPa/bit --250000 0 kPa
251000 64128 kPa

T PV410036 P--Coolant 1001 10 Coolant Pressure 109 65263 S 2 7 0 8 Pressure 2kPa/bit 0 0 kPa
500000 250 kPa

T PV410046 P--Fuel 1001 20 Engine Fuel Delivery 94 65263 S 2 1 0 8 Pressure 4kPa/bit 0 0 kPa
Pressure
1000000 250 kPa

T PV410049 P--Charge Air (a) 1001 23 Engine Turbocharger Boost 102 65270 S 2 2 0 8 Pressure 2kPa/bit 0 0 kPa
Pressure
500000 250 kPa

T PV410056 HI Fuel Leakage 1002 5 Fuel Leakage 1 1239 65169 S 2 1 1 2 Binary X--Y table 0 0
1 1

T PV410057 ETC 1 Speed 1002 6 Turbocharger 1 Speed 103 65245 S 2 2 0 16 Speed 4 rpm/bit 0 0 rpm
2570200 64255 rpm

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Data protocols J1939 and CANopen -- GenoLine LOP 10 Part 1
J1939: SPN--PV mapping -- Table Page 7

PGN Operating range

T PV Index PV Name CAN Mux J1939 Name / SPN Name SPN PGN S K. Byte Bit Data Normalization X-- Y-- Unit
/ ID MCS / No Off- Off- lengt table value value X
R MCS P . set set h:
T PV410059 ETC 2 Speed 1002 8 Engine Turbocharger 2 1169 65179 S 2 2 0 16 Speed 4 rpm/bit 0 0 rpm
Speed
2570200 64255 rpm

T PV410115 ECU Operat.Hours 1004 14 Total Engine Hours 247 65253 S 2 1 0 32 Hours 0.05 hr/bit 0 0 h
1073741 21474 h
82 83640
T PV410126 T--Coolant (ECU) 1005 0 Engine Coolant Temperature 110 65262 S 2 1 0 8 Temp. 1 deg C/bit --4000 0 degC
--40C offset
21000 250 degC

T PV410131 T--Charge Air 1005 5 Turbocharger 1 Compressor 2629 64979 S 2 1 0 16 Temperature 0.03125 --27300 0 degC
Outlet Temperature deg C/bit
173500 64255 degC

T PV410140 T--Lube Oil 1005 14 Engine Oil Temperature 175 65262 S 2 3 0 16 Temperature 0.03125 --27300 0 degC
deg C/bit
173500 64255 degC

T PV410145 T--Exhaust Combined A 1005 19 Engine Exhaust Exhaust Gas 2434 65031 S 2 3 0 16 Temperature 0.03125 --27300 0 degC
Temperature -- Left Manifold deg C/bit
173500 64255 degC

T PV410148 T--Exhaust Combined B 1005 22 Engine Exhaust Exhaust Gas 2433 65031 S 2 1 0 16 Temperature 0.03125 --27300 0 degC
Temperature -- Right Manifold deg C/bit
173500 64255 degC

T PV410151 T--Intake Air 1006 0 Intake Manifold 1 Tempera- 105 65270 S 2 3 0 8 Temp. 1 deg C/bit --4000 0 degC
ture --40C offset
21000 250 degC

T PV410152 T--Fuel 1006 1 Fuel Temperature 174 65262 S 2 2 0 8 Temp. 1 deg C/bit --4000 0 degC
--40C offset
21000 250 degC

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Page 8 J1939: SPN--PV mapping -- Table

PGN Operating range

T PV Index PV Name CAN Mux J1939 Name / SPN Name SPN PGN S K. Byte Bit Data Normalization X-- Y-- Unit
/ ID MCS / No Off- Off- lengt table value value X
R MCS P . set set h:
T PV410169 T--ECU 1006 18 Engine ECU Temperature 1136 65188 S 2 3 0 16 Temperature 0.03125 --27300 0 degC
deg C/bit
173500 64255 degC

T PV412026 P--Lube Oil (EMU) 1016 0 Transmission Oil Pressure 127 65272 S 2 4 0 8 Pressure 16 kPa/bit 0 0 kPa
4000000 250 kPa

T PV412126 T--Coolant (EMU) 1016 1 Auxiliary Temperature 1 441 65164 S 2 1 0 8 Temp. 1 deg C/bit --4000 0 degC
--40C offset
21000 250 degC

T PV412201 T--Exhaust A1 1025 16 Exhaust Gas Port 1 Tempera- 1137 65187 S 2 1 0 16 Temperature 0.03125 --27300 0 degC
ture deg C/bit
173500 64255 degC

T PV412202 T--Exhaust A2 1025 17 Exhaust Gas Port 2 Tempera- 1138 65187 S 2 3 0 16 Temperature 0.03125 --27300 0 degC
ture deg C/bit
173500 64255 degC

T PV412203 T--Exhaust A3 1025 18 Engine Exhaust Gas Port 3 1139 65187 S 2 5 0 16 Temperature 0.03125 --27300 0 degC
Temperature deg C/bit
173500 64255 degC

T PV412204 T--Exhaust A4 1025 19 Engine Exhaust Gas Port 4 1140 65187 S 2 7 0 16 Temperature 0.03125 --27300 0 degC
Temperature deg C/bit
173500 64255 degC

T PV412205 T--Exhaust A5 1025 20 Engine Exhaust Gas Port 5 1141 65186 S 2 1 0 16 Temperature 0.03125 --27300 0 degC
Temperature deg C/bit
173500 64255 degC

T PV412206 T--Exhaust A6 1025 21 Engine Exhaust Gas Port 6 1142 65186 S 2 3 0 16 Temperature 0.03125 --27300 0 degC
Temperature deg C/bit
173500 64255 degC

T PV412207 T--Exhaust A7 1025 22 Engine Exhaust Gas Port 7 1143 65186 S 2 5 0 16 Temperature 0.03125 --27300 0 degC
Temperature deg C/bit
173500 64255 degC

E MTU -- 10.2010 -- E532303/00E

Data protocols J1939 and CANopen -- GenoLine LOP 10 Part 1
J1939: SPN--PV mapping -- Table Page 9

PGN Operating range

T PV Index PV Name CAN Mux J1939 Name / SPN Name SPN PGN S K. Byte Bit Data Normalization X-- Y-- Unit
/ ID MCS / No Off- Off- lengt table value value X
R MCS P . set set h:
T PV412208 T--Exhaust A8 1025 23 Engine Exhaust Gas Port 8 1144 65186 S 2 7 0 16 Temperature 0.03125 --27300 0 degC
Temperature deg C/bit
173500 64255 degC

T PV412211 T--Exhaust B1 1025 24 Engine Exhaust Gas Port 11 1147 65185 S 2 5 0 16 Temperature 0.03125 --27300 0 degC
Temperature deg C/bit
173500 64255 degC

T PV412212 T--Exhaust B2 1017 0 Engine Exhaust Gas Port 12 1148 65185 S 2 7 0 16 Temperature 0.03125 --27300 0 degC
Temperature deg C/bit
173500 64255 degC

T PV412213 T--Exhaust B3 1017 1 Engine Exhaust Gas Port 13 1149 65184 S 2 1 0 16 Temperature 0.03125 --27300 0 degC
Temperature deg C/bit
173500 64255 degC

T PV412214 T--Exhaust B4 1017 2 Engine Exhaust Gas Port 14 1150 65184 S 2 3 0 16 Temperature 0.03125 --27300 0 degC
Temperature deg C/bit
173500 64255 degC

T PV412215 T--Exhaust B5 1017 3 Engine Exhaust Gas Port 15 1151 65184 S 2 5 0 16 Temperature 0.03125 --27300 0 degC
Temperature deg C/bit
173500 64255 degC

T PV412216 T--Exhaust B6 1017 4 Engine Exhaust Gas Port 16 1152 65184 S 2 7 0 16 Temperature 0.03125 --27300 0 degC
Temperature deg C/bit
173500 64255 degC

T PV412217 T--Exhaust B7 1017 5 Exhaust Gas Port 17 Tempe- 1153 65183 S 2 1 0 16 Temperature 0.03125 --27300 0 degC
rature deg C/bit
173500 64255 degC

T PV412218 T--Exhaust B8 1017 6 Exhaust Gas Port 18 Tempe- 1154 65183 S 2 3 0 16 Temperature 0.03125 --27300 0 degC
rature deg C/bit
173500 64255 degC

E532303/00E -- 10.2010 -- E MTU

Part 1 Data protocols J1939 and CANopen -- GenoLine LOP 10
Page 10 J1939: SPN--PV mapping -- Table

PGN Operating range

T PV Index PV Name CAN Mux J1939 Name / SPN Name SPN PGN S K. Byte Bit Data Normalization X-- Y-- Unit
/ ID MCS / No Off- Off- lengt table value value X
R MCS P . set set h:
T PV412221 T--Exhaust Mean 1024 5 Engine Exhaust Gas Tempe- 173 65270 S 2 6 0 16 Temperature 0.03125 --27300 0 degC
rature deg C/bit
173500 64255 degC

T PV414411 AL Water in Fuel Prefilter 1019 22 Water In Fuel Indicator 97 65279 S 2 1 1 2 Binary X--Y table 0 0
1 1

T PV414420 P--Start Air 1013 13 Air Start Pressure 82 65246 S 2 1 0 8 Pressure 4kPa/bit 0 0 kPa
1000000 250 kPa

T PV414550 T--Winding U Generator 1013 20 Alternator Winding 1 Tempe- 1124 65191 S 2 3 0 8 Temp. 1 deg C/bit --4000 0 degC
rature --40C offset
21000 250 degC

T PV414555 T--Winding V Generator 1013 21 Alternator Winding 2 Tempe- 1125 65191 S 2 4 0 8 Temp. 1 deg C/bit --4000 0 degC
rature --40C offset
21000 250 degC

T PV414560 T--Winding W Generator 1013 22 Alternator Winding 3 Tempe- 1126 65191 S 2 5 0 8 Temp. 1 deg C/bit --4000 0 degC
rature --40C offset
21000 250 degC

T PV414570 T--Bearing Driven End 1013 23 Alternator Bearing 1 Tempe- 1122 65191 S 2 1 0 8 Temp. 1 deg C/bit --4000 0 degC
Generator rature --40C offset
21000 250 degC

T PV414575 T--Bear. Non Driven End 1013 24 Alternator Bearing 2 Tempe- 1123 65191 S 2 2 0 8 Temp. 1 deg C/bit --4000 0 degC
Generat rature --40C offset
21000 250 degC

T PV414580 T--Cooling Air Outlet 1014 0 Auxiliary Temperature 2 442 65164 S 2 2 0 8 Temp. 1 deg C/bit --4000 0 degC
Generator --40C offset
21000 250 degC

T PV414595 Gen Actual Power in KW 1021 11 Electrical Load 1204 65171 S 2 1 0 16 0--32,127.5 kW 0 0 kW
0.5 kW/bit
3212750 64255 kW
0

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Data protocols J1939 and CANopen -- GenoLine LOP 10 Part 1
J1939: SPN--PV mapping -- Table Page 11

PGN Operating range

T PV Index PV Name CAN Mux J1939 Name / SPN Name SPN PGN S K. Byte Bit Data Normalization X-- Y-- Unit
/ ID MCS / No Off- Off- lengt table value value X
R MCS P . set set h:
T PV410001 Stop Activated 1000 0 Stop Activated 65297 S 2 1 5 2 Binary X--Y table 0 0
1 1

T PV410027 L1L P--Lube Oil (ECU) 1001 1 L1L P--Lube Oil Limit 0 65300 P 2 1 0 8 Pressure 4kPa/bit 0 0 kPa
1000000 250 kPa

T PV410028 L2L P--Lube Oil (ECU) 1001 2 L2L P--Lube Oil Limit 0 65300 P 2 2 0 8 Pressure 4kPa/bit 0 0 kPa
1000000 250 kPa

T PV410032 U1L P--Crankcase 1001 6 U1L P--Crankcase 0 65300 P 2 5 0 8 Pressure 4kPa/bit 0 0 kPa
1000000 250 kPa

T PV410033 U2L P--Crankcase 1001 7 U2L P--Crankcase 0 65300 P 2 6 0 8 Pressure 4kPa/bit 0 0 kPa
1000000 250 kPa

T PV410034 HI P--Crankcase 1001 8 HI P--Crankcase 65297 P 2 1 1 2 Binary X--Y table 0 0

1 1

T PV410035 SS P--Crankcase 1001 9 HIHI P--Crankcase 65297 P 2 1 3 2 Binary X--Y table 0 0

1 1

T PV410037 L1L P--Coolant 1001 11 L1L P--Coolant after Pump 0 65301 P 2 1 0 8 Pressure 2kPa/bit 0 0 kPa
500000 250 kPa

T PV410038 L2L P--Coolant 1001 12 L2L P--Coolant after Pump 0 65301 P 2 2 0 8 Pressure 2kPa/bit 0 0 kPa
500000 250 kPa

T PV410039 LO P--Coolant 1001 13 LO P--Coolant 65297 P 2 2 1 2 Binary X--Y table 0 0

1 1

T PV410040 SS P--Coolant 1001 14 LOLO P--Coolant 65297 P 2 2 3 2 Binary X--Y table 0 0

1 1

T PV410060 HI ETC 2 Speed 1002 9 HI ETC 2 Speed 65297 P 2 1 7 2 Binary X--Y table 0 0
1 1

E532303/00E -- 10.2010 -- E MTU

Part 1 Data protocols J1939 and CANopen -- GenoLine LOP 10
Page 12 J1939: SPN--PV mapping -- Table

PGN Operating range

T PV Index PV Name CAN Mux J1939 Name / SPN Name SPN PGN S K. Byte Bit Data Normalization X-- Y-- Unit
/ ID MCS / No Off- Off- lengt table value value X
R MCS P . set set h:
T PV410068 Engine Running 1002 17 Engine Running 65297 P 2 2 5 2 Binary X--Y table 0 0
1 1

T PV410069 ETC 2 Cut In 1002 18 ETC 2 Cut In 65297 P 2 2 7 2 Binary X--Y table 0 0
1 1

T PV410071 SS ETC 2 Overspeed 1002 20 SS ETC 2 Overspeed 65297 P 2 3 1 2 Binary X--Y table 0 0
1 1

T PV410075 ECU Failure Codes 1002 24 Actual Failure Codes 0 65284 P 2 1 0 16 0--255 pro byte 1:1 0 0
65535 65535

T PV410078 Rated Speed Reached 1003 2 Rated Speed Reached 65297 P 2 3 3 2 Binary X--Y table 0 0
1 1

T PV410127 U1L T--Coolant (ECU) 1005 1 U1L T--Coolant 0 65302 P 2 1 0 8 Temp. 1 deg C/bit --4000 0 degC
--40C offset
21000 250 degC

T PV410128 U2L T--Coolant (ECU) 1005 2 U2L T--Coolant 0 65302 P 2 2 0 8 Temp. 1 deg C/bit --4000 0 degC
--40C offset
21000 250 degC

T PV410132 U1L T--Charge Air 1005 6 U1L T--Charge Air 0 65302 P 2 3 0 16 Temperature 0.03125 --27300 0 degC
deg C/bit
173500 64255 degC

T PV410141 L1H T--Lube Oil 1005 15 U1L T--Lube Oil 0 65303 P 2 1 0 16 Temperature 0.03125 --27300 0 degC
deg C/bit
173500 64255 degC

T PV410142 L2H T--Lube Oil 1005 16 U2L T--Lube Oil 0 65303 P 2 3 0 16 Temperature 0.03125 --27300 0 degC
deg C/bit
173500 64255 degC

T PV410146 U1L T--Exhaust Combined A 1005 20 UL T--Exhaust A 0 65305 P 2 5 0 16 Temperature 0.03125 --27300 0 degC
deg C/bit
173500 64255 degC

E MTU -- 10.2010 -- E532303/00E

Data protocols J1939 and CANopen -- GenoLine LOP 10 Part 1
J1939: SPN--PV mapping -- Table Page 13

PGN Operating range

T PV Index PV Name CAN Mux J1939 Name / SPN Name SPN PGN S K. Byte Bit Data Normalization X-- Y-- Unit
/ ID MCS / No Off- Off- lengt table value value X
R MCS P . set set h:
T PV410149 U1L T--Exhaust Combined B 1005 23 UL T--Exhaust B 0 65305 P 2 7 0 16 Temperature 0.03125 --27300 0 degC
deg C/bit
173500 64255 degC

T PV410158 L1L P--Fuel 1006 7 L1L P--Fuel 0 65304 P 2 1 0 8 Pressure 4kPa/bit 0 0 kPa
1000000 250 kPa

T PV410159 L2L P--Fuel 1006 8 L2L P--Fuel 0 65304 P 2 3 0 16 Pressure 4kPa/bit 0 0 kPa
1000000 250 kPa

T PV410160 U1L ETC 1 Speed 1006 9 U1L Charger speed ETC1 0 65307 P 2 1 0 16 Speed 4 rpm/bit 0 0 rpm
2570200 64255 rpm

T PV410161 U1L ETC 2 Speed 1006 10 U1L Charger speed ETC2 0 65328 P 2 1 0 16 Speed 4 rpm/bit 0 0 rpm
2570200 64255 rpm

T PV410162 UL Engine Speed (ECU) 1006 11 UL Engine Speed 0 65307 P 2 7 0 16 Speed 0.125 rpm/bit 0 0 rpm
80320 64255 rpm

T PV410163 LL P--Charge Air (a) 1006 12 L1L P--Charger A--Side 0 65304 P 2 5 0 16 Pressure 2kPa/bit 0 0 kPa
500000 250 kPa

T PV410167 L2H T--Charge Air 1006 16 U2L T--Charge Air 0 65302 P 2 5 0 16 Temperature 0.03125 --27300 0 degC
deg C/bit
173500 64255 degC

T PV410172 U2L ETC 1 Speed 1006 21 U2L Charger Speed ETC1 0 65307 P 2 3 0 16 Speed 4 rpm/bit 0 0 rpm
2570200 64255 rpm

T PV410173 U2L ETC 2 Speed 1006 22 U2L Charger Speed ETC2 0 65328 P 2 3 0 16 Speed 4 rpm/bit 0 0 rpm
2570200 64255 rpm

T PV410187 AL ETC 2 Idle Speed High 1007 11 AL ETC 2 Idle Speed High 0 65297 P 2 3 5 2 Binary X--Y table 0 0
1 1

T PV410188 HI ETC Speed Difference 1007 12 HI ETC Speed Difference 0 65297 P 2 3 7 2 Binary X--Y table 0 0
1 1

E532303/00E -- 10.2010 -- E MTU

Part 1 Data protocols J1939 and CANopen -- GenoLine LOP 10
Page 14 J1939: SPN--PV mapping -- Table

PGN Operating range

T PV Index PV Name CAN Mux J1939 Name / SPN Name SPN PGN S K. Byte Bit Data Normalization X-- Y-- Unit
/ ID MCS / No Off- Off- lengt table value value X
R MCS P . set set h:
T PV410189 AL ETC 2 Cut in Fail 1007 13 AL ETC 2 Cut in Fail 0 65297 P 2 4 1 2 Binary X--Y table 0 0
1 1

T PV410190 AL Shutdown expected 1007 14 AL Shutdown expected 0 65297 P 2 4 3 2 Binary X--Y table 0 0
1 1

T PV410199 U2L T--Fuel 1007 23 U2L T--Fuel 0 65303 P 2 6 0 8 Temp. 1 deg C/bit --4000 0 degC
--40C offset
21000 250 degC

T PV410258 T--Charge Air Seq Ctrl Valve 1010 7 T--Charge Air Seq Ctrl Valve 0 65329 P 2 1 0 16 Temperature 0.03125 --27300 0 degC
deg C/bit
173500 64255 degC

T PV410259 U1L T--Charge Air Seq Ctr 1010 8 U1L T--Charge Air Seq Ctr 0 65329 P 2 3 0 16 Temperature 0.03125 --27300 0 degC
Valve Valve deg C/bit
173500 64255 degC

T PV410260 U2L T--Charge Air Seq Ctr 1010 9 U2L T--Charge Air Seq Ctr 0 65329 P 2 5 0 16 Temperature 0.03125 --27300 0 degC
Valve Valve deg C/bit
173500 64255 degC

T PV410261 U2L T--Exhaust Combined A 1010 10 U2L T--Exhaust A 0 65330 P 2 1 0 16 Temperature 0.03125 --27300 0 degC
deg C/bit
173500 64255 degC

T PV410262 U2L T--Exhaust Combined B 1010 11 U2L T--Exhaust B 0 65330 P 2 3 0 16 Temperature 0.03125 --27300 0 degC
deg C/bit
173500 64255 degC

T PV410291 Fuel Leakage Level Switch 1011 15 Fuel Leakage Level Switch 65297 P 2 4 5 2 Binary X--Y table 0 0
1 1

T PV410294 HI T--Charge Air Seq Ctrl 1011 18 HI T--Charge Air Seq Ctrl 65297 P 2 5 1 2 Binary X--Y table 0 0
Valve Valve
1 1

E MTU -- 10.2010 -- E532303/00E

Data protocols J1939 and CANopen -- GenoLine LOP 10 Part 1
J1939: SPN--PV mapping -- Table Page 15

PGN Operating range

T PV Index PV Name CAN Mux J1939 Name / SPN Name SPN PGN S K. Byte Bit Data Normalization X-- Y-- Unit
/ ID MCS / No Off- Off- lengt table value value X
R MCS P . set set h:
T PV410295 SS T--Charge Air Seq Ctrl 1011 19 SS T--Charge Air Seq Ctrl 65297 P 2 5 3 2 Binary X--Y table 0 0
Valve Valve
1 1

T PV410298 U1L T--Fuel 1011 22 U1L T--Fuel 0 65303 P 2 5 0 8 Temp. 1 deg C/bit --4000 0 degC
--40C offset
21000 250 degC

T PV410300 UL T--ECU 1011 24 U1L T--ECU 0 65305 P 2 3 0 16 Temperature 0.03125 --27300 0 degC
deg C/bit
173500 64255 degC

T PV412002 Engine Speed (EMU) 1016 7 Engine Speed Crankshaft 0 65307 P 2 5 0 16 Speed 0.125 rpm/bit 0 0 rpm
EMU
80320 64255 rpm

T PV412006 SS Overspeed (EMU) 1016 8 SS Overspeed EMU 65297 P 2 4 7 2 Binary X--Y table 0 0
1 1

T PV412027 L1L P--Lube Oil (EMU) 1016 11 L1L P--Lube Oil EMU 0 65331 P 2 1 0 8 Pressure 4kPa/bit 0 0 kPa
1000000 250 kPa

T PV412028 L2L P--Lube Oil (EMU) 1016 12 L2L P--Lube Oil EMU 0 65331 P 2 2 0 8 Pressure 4kPa/bit 0 0 kPa
1000000 250 kPa

T PV412029 LO P--Lube Oil (EMU) 1016 13 LO P--Lube Oil (EMU) 65297 P 2 5 5 2 Binary X--Y table 0 0
1 1

T PV412030 SS P--Lube Oil (EMU) 1016 14 SS P--Lube Oil (EMU) 65297 P 2 5 7 2 Binary X--Y table 0 0
1 1

T PV412127 U1L T--Coolant (EMU) 1016 17 U1L T--Coolant (EMU) 0 65331 P 2 3 0 8 Temp. 1 deg C/bit --4000 0 degC
--40C offset
21000 250 degC

T PV412128 U2L T--Coolant (EMU) 1016 18 U2L T--Coolant (EMU) 0 65331 P 2 4 0 8 Temp. 1 deg C/bit --4000 0 degC
--40C offset
21000 250 degC

E532303/00E -- 10.2010 -- E MTU

Part 1 Data protocols J1939 and CANopen -- GenoLine LOP 10
Page 16 J1939: SPN--PV mapping -- Table

PGN Operating range

T PV Index PV Name CAN Mux J1939 Name / SPN Name SPN PGN S K. Byte Bit Data Normalization X-- Y-- Unit
/ ID MCS / No Off- Off- lengt table value value X
R MCS P . set set h:
T PV412129 HI T--Coolant (EMU) 1016 19 HI T--Coolant (EMU) 65297 P 2 6 1 2 Binary X--Y table 0 0
1 1

T PV412130 SS T--Coolant (EMU) 1016 20 SS T--Coolant (EMU) 65297 P 2 6 3 2 Binary X--Y table 0 0
1 1

T PV412162 UL Engine Speed EMU 1016 21 UL Engine Speed Internal 0 65328 P 2 5 0 16 Speed 0.125 rpm/bit 0 0 rpm
EMU
80320 64255 rpm

T PV412224 U1L T--Exhaust 1024 6 U1L T--Exhaust 0 65330 P 2 5 0 16 Temperature 0.03125 --27300 0 degC
deg C/bit
173500 64255 degC

T PV412225 L1L T--Exhaust 1024 7 L1L T--Exhaust 0 65330 P 2 7 0 16 Temperature 0.03125 --27300 0 degC
deg C/bit
173500 64255 degC

T PV412501 P--Raw Water 1016 2 P--Raw Water 0 65331 P 2 5 0 8 Pressure 4kPa/bit 0 0 kPa
1000000 250 kPa

T PV412502 LL P--Raw Water 1016 24 L1L P--Raw Water 0 65331 P 2 6 0 8 Pressure 4kPa/bit 0 0 kPa
1000000 250 kPa

T PV412503 LO P--Raw Water 1022 0 LO P--Raw Water 65297 P 2 7 5 2 Binary X--Y table 0 0
1 1

T PV412505 LL P--Oil Re--Fill Pump 1022 1 L1L P--Oil Re--Fill Pump 0 65331 P 2 8 0 8 Pressure 4kPa/bit 0 0 kPa
1000000 250 kPa

T PV412506 LO P--Oil Re--Fill Pump 1022 2 LO P--Oil Re--Fill Pump 65297 P 2 7 7 2 Binary X--Y table 0 0
1 1

T PV412510 SS Request Power Reduction 1022 4 SS Request Power Reduction 65297 P 2 8 1 2 Binary X--Y table 0 0
1 1

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Data protocols J1939 and CANopen -- GenoLine LOP 10 Part 1
J1939: SPN--PV mapping -- Table Page 17

PGN Operating range

T PV Index PV Name CAN Mux J1939 Name / SPN Name SPN PGN S K. Byte Bit Data Normalization X-- Y-- Unit
/ ID MCS / No Off- Off- lengt table value value X
R MCS P . set set h:
T PV412512 AL Exhaust Monitoring Fail 1022 15 AL Exhaust Monitoring Fail 0 65332 P 2 7 3 2 Binary X--Y table 0 0
1 1

T PV412513 AL Press Monitoring Fail 1022 6 AL Press Monitoring Fail 0 65297 P 2 8 3 2 Binary X--Y table 0 0
(EMU) (EMU)
1 1

T PV412516 AL Security Channel Def 1022 8 AL Security Channel Def 0 65297 P 2 8 5 2 Binary X--Y table 0 0
EMU EMU
1 1

T PV412518 TD T--Coolant 1022 9 TD T--Coolant 0 65282 P 2 2 1 2 Binary X--Y table 0 0

1 1

T PV412519 TD P--Lube Oil 1022 10 TD P--Lube Oil 0 65282 P 2 2 3 2 Binary X--Y table 0 0
1 1

T PV414216 Injection in Rel. to DBR Scali 1026 19 Injection in Relation to DBR 65328 P 2 7 0 16 2 Byte 1:1 Range 0 0
0 to 64255
64255 64255

T PV414265 ML LOP Start 1019 2 ML LOP Start 0 65332 P 2 1 1 2 Binary X--Y table 0 0
1 1

T PV414270 ML LOP Stop 1019 3 ML LOP Stop 0 65332 P 2 1 3 2 Binary X--Y table 0 0
1 1

T PV414290 ML Ready for Start 1019 4 ML Ready for Start/Stop 0 65332 P 2 1 5 2 Binary X--Y table 0 0
1 1

T PV414408 AL Priming Pump Fail 1019 21 AL Priming Pump Fail 0 65332 P 2 1 7 2 Binary X--Y table 0 0
1 1

T PV414422 LL P--Start Air 1020 0 LL P--Start Air 0 65333 P 2 1 0 8 Pressure 4kPa/bit 0 0 kPa
1000000 250 kPa

E532303/00E -- 10.2010 -- E MTU

Part 1 Data protocols J1939 and CANopen -- GenoLine LOP 10
Page 18 J1939: SPN--PV mapping -- Table

PGN Operating range

T PV Index PV Name CAN Mux J1939 Name / SPN Name SPN PGN S K. Byte Bit Data Normalization X-- Y-- Unit
/ ID MCS / No Off- Off- lengt table value value X
R MCS P . set set h:
T PV414435 HI T--Riser (switch) 1020 1 HI T--Riser (switch) 65282 P 2 1 1 2 Binary X--Y table 0 0
1 1

T PV414490 SS Emergency Stop 1013 17 SS SwB Emergency Stop 0 65282 P 2 1 7 2 Binary X--Y table 0 0
1 1

T PV414540 WB SwB monitoring Emerg. 1013 19 WB SwB monitoring Emerg. 0 65282 P 2 3 1 2 Binary X--Y table 0 0
Stop Stop
1 1

T PV414551 U1L T--Winding U 1020 6 U1L T--Winding U 0 65333 P 2 2 0 8 Temp. 1 deg C/bit --4000 0 degC
--40C offset
21000 250 degC

T PV414552 U2L T--Winding U 1020 7 U2L T--Winding U 0 65333 P 2 3 0 8 Temp. 1 deg C/bit --4000 0 degC
--40C offset
21000 250 degC

T PV414553 HI T--Winding U 1020 8 HI T--Winding U 0 65332 P 2 2 1 2 Binary X--Y table 0 0

1 1

T PV414554 HIHI T--Winding U 1020 9 HIHI T--Winding U 0 65332 P 2 2 3 2 Binary X--Y table 0 0
1 1

T PV414556 U1L T--Winding V 1020 10 U1L T--Winding V 0 65333 P 2 4 0 8 Temp. 1 deg C/bit --4000 0 degC
--40C offset
21000 250 degC

T PV414557 U2L T--Winding V 1020 11 U2L T--Winding V 0 65333 P 2 5 0 8 Temp. 1 deg C/bit --4000 0 degC
--40C offset
21000 250 degC

T PV414558 HI T--Winding V 1020 12 HI T--Winding V 0 65332 P 2 2 5 2 Binary X--Y table 0 0

1 1

T PV414559 HIHI T--Winding V 1020 13 HIHI T--Winding V 0 65332 P 2 2 7 2 Binary X--Y table 0 0
1 1

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Data protocols J1939 and CANopen -- GenoLine LOP 10 Part 1
J1939: SPN--PV mapping -- Table Page 19

PGN Operating range

T PV Index PV Name CAN Mux J1939 Name / SPN Name SPN PGN S K. Byte Bit Data Normalization X-- Y-- Unit
/ ID MCS / No Off- Off- lengt table value value X
R MCS P . set set h:
T PV414561 U1L T--Winding W 1020 14 U1L T--Winding W 0 65333 P 2 6 0 8 Temp. 1 deg C/bit --4000 0 degC
--40C offset
21000 250 degC

T PV414562 U2L T--Winding W 1020 15 U2L T--Winding W 0 65333 P 2 7 0 8 Temp. 1 deg C/bit --4000 0 degC
--40C offset
21000 250 degC

T PV414563 HI T--Winding W 1020 16 HI T--Winding W 0 65332 P 2 3 1 2 Binary X--Y table 0 0

1 1

T PV414564 HIHI T--Winding W 1020 17 HIHI T--Winding W 0 65332 P 2 3 3 2 Binary X--Y table 0 0
1 1

T PV414573 HI T--Bearing Driven End 1020 20 HI T--Bearing Driven End 0 65332 P 2 3 5 2 Binary X--Y table 0 0
1 1

T PV414574 HIHI T--Bearing Driven End 1020 21 HIHI T--Bearing Driven End 0 65332 P 2 3 7 2 Binary X--Y table 0 0
1 1

T PV414578 HI T--Bearing Non Driven End 1020 24 HI T--Bearing Non Driven End 0 65332 P 2 4 1 2 Binary X--Y table 0 0
1 1

T PV414579 HIHI T--Bearing Non Driven 1021 0 HIHI T--Bearing Non Driven 0 65332 P 2 4 3 2 Binary X--Y table 0 0
End End
1 1

T PV414583 HI T--Cooling Air Outlet 1021 3 HI T--Cooling Air Outlet 0 65332 P 2 4 5 2 Binary X--Y table 0 0
1 1

T PV414584 HIHI T--Cooling Air Outlet 1021 4 HIHI T--Cooling Air Outlet 0 65332 P 2 4 7 2 Binary X--Y table 0 0
1 1

T PV414591 AL Diff Protection Tripped 1021 9 AL Diff Protection Tripped 0 65332 P 2 5 1 2 Binary X--Y table 0 0
1 1

E532303/00E -- 10.2010 -- E MTU

Part 1 Data protocols J1939 and CANopen -- GenoLine LOP 10
Page 20 J1939: SPN--PV mapping -- Table

PGN Operating range

T PV Index PV Name CAN Mux J1939 Name / SPN Name SPN PGN S K. Byte Bit Data Normalization X-- Y-- Unit
/ ID MCS / No Off- Off- lengt table value value X
R MCS P . set set h:
T PV414593 AL Coolant Leakage 1021 10 AL Coolant Leakage 0 65332 P 2 5 3 2 Binary X--Y table 0 0
Generator Generator
1 1

T PV414594 Priming Pump Automatic 1014 4 Priming Pump Automatic 0 65332 P 2 5 5 2 Binary X--Y table 0 0
Mode Mode
1 1

T PV416010 Combined Alarm (ECU) 1023 3 Combined Alarm (ECU) 0 65332 P 2 6 1 2 Binary X--Y table 0 0
1 1

T PV416011 Override Activated (Display) 1023 4 Override Activated (Display) 0 65332 P 2 6 3 2 Binary X--Y table 0 0
1 1

T PV416020 AL Safety System Fail (EMU) 1023 5 AL Safety System Fail (EMU) 0 65332 P 2 6 5 2 Binary X--Y table 0 0
1 1

T PV416032 Priming Pump On 1023 6 Priming Pump On 0 65332 P 2 6 7 2 Binary X--Y table 0 0
1 1

T PV416810 AL Shutdown expected 1023 8 AL Shutdown expected 2 0 65332 P 2 7 1 2 Binary X--Y table 0 0
1 1

T PV616019 MCC1 Alarm Acknowledge 1023 13 Alarm Acknowledge 65297 P 2 8 7 2 Binary X--Y table 0 0
for ML
1 1

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Data protocols J1939 and CANopen -- GenoLine LOP 10 Part 1
J1939: Standard PGN Page 21

1.4 Standard PGN

Explanation of columns:
¯ PDU--F Protocol Description Unit Format
¯ PDU--S Protocol Description Unit Specific (target address)

Name SPN PGN PDU--F PDU--S Data Normalization table Out-- Prenorm Prenorm Func- Func- Func- PDOs
type of-- -- -- tion tion tion
[bit] limit lower li- upper limit acti- Data 1 Data 2
value mit value value vate

AAI / Auxiliary Temperature 1 441 65164 254 140 8 Temp. 1 deg C/bit --40C offset 1 --1 255 0 0 0 1

AAI / Auxiliary Temperature 2 442 65164 254 140 8 Temp. 1 deg C/bit --40C offset 1 --1 255 0 0 0 1

AIR2 / Air Start Pressure 82 65246 254 222 8 Pressure 4kPa/bit 0 --1 1000 0 0 0 1

AT / Alternator Bearing 1 Temperature 1122 65191 254 167 8 Temp. 1 deg C/bit --40C offset 1 --1 65536 0 0 0 1

AT / Alternator Bearing 2 Temperature 1123 65191 254 167 8 Temp. 1 deg C/bit --40C offset 1 --1 65536 0 0 0 1

AT / Alternator Winding 1 Temperature 1124 65191 254 167 8 Temp. 1 deg C/bit --40C offset 0 --1 256 0 0 0 1

AT / Alternator Winding 2 Temperature 1125 65191 254 167 8 Temp. 1 deg C/bit --40C offset 0 --1 256 0 0 0 1

AT / Alternator Winding 3 Temperature 1126 65191 254 167 8 Temp. 1 deg C/bit --40C offset 0 --1 256 0 0 0 1

CCVS / Engine Shutdown Override Switch 1237 65265 254 241 2 Binary XY_table 0 --1 4 0 0 0 1

CCVS / Engine Shutdown Override Switch 1237 65265 254 241 2 Binary XY_table 0 --1 4 0 0 0 1

EBC1 / Auxiliary Engine Shutdown Switch 970 61441 240 1 2 Binary XY_table 0 --1 4 0 0 0 1

EEC1 / Engine Speed 190 61444 240 4 16 Speed 0.125 rpm/bit 0 --1 65535 0 0 0 1

EES / Electrical Load 1204 65171 254 147 16 0--32,127.5 kW 0.5 kW/bit 65535 --1 65535 0 0 0 1

EFL/P1 / Coolant Pressure 109 65263 254 239 8 Pressure 2kPa/bit 1 --1 501 0 0 0 1

EFL/P1 / Crankcase Pressure 101 65263 254 239 16 Pressure 128kPa/bit 1 --1 64256 0 0 0 1

EFL/P1 / Engine Fuel Delivery Pressure 94 65263 254 239 8 Pressure 4kPa/bit 0 --1 255 0 0 0 1

EFL/P1 / Engine Oil Pressure 100 65263 254 239 8 Pressure 4kPa/bit 0 --1 255 0 0 0 1

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Part 1 Data protocols J1939 and CANopen -- GenoLine LOP 10
Page 22 J1939: Standard PGN

Name SPN PGN PDU--F PDU--S Data Normalization table Out-- Prenorm Prenorm Func- Func- Func- PDOs
type of-- -- -- tion tion tion
[bit] limit lower li- upper limit acti- Data 1 Data 2
value mit value value vate

EPT3 / Engine Exhaust Gas Port 11 Tempera- 1147 65185 254 161 16 Temperature 0.03125 deg C/bit 1 --1 65536 0 0 0 1
ture

EPT3 / Engine Exhaust Gas Port 12 Tempera- 1148 65185 254 161 16 Temperature 0.03125 deg C/bit 1 --1 65536 0 0 0 1
ture

EPT5 / Exhaust Gas Port 17 Temperature 1153 65183 254 159 16 Temperature 0.03125 deg C/bit 1 --1 65536 0 0 0 1

EPT5 / Exhaust Gas Port 18 Temperature 1154 65183 254 159 16 Temperature 0.03125 deg C/bit 1 --1 65536 0 0 0 1

ET / Engine Exhaust Exhaust Gas Temperature 2434 65031 254 7 16 Temperature 0.03125 deg C/bit 0 --1 65536 0 0 0 1
-- Left Manifold

ET / Engine Exhaust Exhaust Gas Temperature 2433 65031 254 7 16 Temperature 0.03125 deg C/bit 0 --1 65536 0 0 0 1
-- Right Manifold

ET1 / Exhaust Gas Port 1 Temperature 1137 65187 254 163 16 Temperature 0.03125 deg C/bit 0 --1 64257 0 0 0 1

ET1 / Exhaust Gas Port 2 Temperature 1138 65187 254 163 16 Temperature 0.03125 deg C/bit 0 --1 64257 0 0 0 1

ET1 / Engine Coolant Temperature 110 65262 254 238 8 Temp. 1 deg C/bit --40C offset 0 --1 255 0 0 0 1

ET1 / Fuel Temperature 174 65262 254 238 8 Temp. 1 deg C/bit --40C offset 0 --1 255 0 0 0 1

ET1 / Engine Exhaust Gas Port 3 Temperature 1139 65187 254 163 16 Temperature 0.03125 deg C/bit 1 --1 65536 0 0 0 1

ET1 / Engine Exhaust Gas Port 4 Temperature 1140 65187 254 163 16 Temperature 0.03125 deg C/bit 1 --1 65536 0 0 0 1

ET1 / Engine Oil Temperature 175 65262 254 238 16 Temperature 0.03125 deg C/bit 0 --1 64257 0 0 0 1

ET2 / Engine ECU Temperature 1136 65188 254 164 16 Temperature 0.03125 deg C/bit 0 --1 64257 0 0 0 1

FL / Fuel Leakage 1 1239 65169 254 145 2 Binary XY_table 3 --1 4 0 0 0 1

HOURS / Total Engine Hours 247 65253 254 229 32 Hours 0.05 hr/bit 0 0 210554060 0 0 0 1

IC1 / Engine Turbocharger Boost Pressure 102 65270 254 246 8 Pressure 2kPa/bit 0 --1 255 0 0 0 1

IC1 / Intake Manifold 1 Temperature 105 65270 254 246 8 Temp. 1 deg C/bit --40C offset 0 --1 255 0 0 0 1

IC1 / Engine Exhaust Gas Temperature 173 65270 254 246 16 Temperature 0.03125 deg C/bit 0 --1 65536 0 0 0 1

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Data protocols J1939 and CANopen -- GenoLine LOP 10 Part 1
J1939: Standard PGN Page 23

Name SPN PGN PDU--F PDU--S Data Normalization table Out-- Prenorm Prenorm Func- Func- Func- PDOs
type of-- -- -- tion tion tion
[bit] limit lower li- upper limit acti- Data 1 Data 2
value mit value value vate

TC / Turbocharger 1 Speed 103 65245 254 221 16 Speed 4 rpm/bit 0 --1 2570200 0 0 0 1

TCI1 / Engine Turbocharger 2 Speed 1169 65179 254 155 16 Speed 4 rpm/bit 1 --1 65536 0 0 0 1

TCI6 / Turbocharger 1 Compressor Outlet 2629 64979 253 211 16 Temperature 0.03125 deg C/bit 0 --1 65536 0 0 0 1
Temperature

TF / Transmission Oil Pressure 127 65272 254 248 8 Pressure 16 kPa/bit 0 --1 256 0 0 0 1

WFI / Water In Fuel Indicator 97 65279 254 255 2 Binary XY_table 0 --1 4 0 0 0 1

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Page 24 J1939: Proprietary PGN

1.5 Proprietary PGN

Explanation of columns:
¯ PDU--F Protocol Description Unit Format
¯ PDU--S Protocol Description Unit Specific (target address)

Name SPN PGN PDU--F PDU--S Data Normalization table Out--of--limit Prenorm Prenorm Func- Func- Func- PDOs
type value -- -- tion tion tion
[bit] lower limit upper limit acti- Data 1 Data 2
value value vate

IN_J1939 / Engine Start 0 65325 255 45 2 Binary XY_table 0 --1 4 0 0 0 1

Prop_Po / HI T--Riser (switch) 65282 255 2 2 Binary XY_table 3 --1 4 0 0 0 1

Prop_Po / SS SwB Emergency Stop 0 65282 255 2 2 Binary XY_table --2147483647 --2147483646 2147483646 0 0 0 1

Prop_Po / TD P--Lube Oil 0 65282 255 2 2 Binary XY_table --2147483647 --2147483646 2147483646 0 0 0 1

Prop_Po / TD T--Coolant 0 65282 255 2 2 Binary XY_table --2147483647 --2147483646 4 0 0 0 1

Prop_Po / WB SwB monitoring Emerg. Stop 0 65282 255 2 2 Binary XY_table --2147483647 --2147483646 2147483646 0 0 0 1

PropA / Actual Failure Codes 0 65284 255 4 16 0--255 pro byte 1:1 0 --1 4 0 0 0 1

PropF / AL Coolant Leakage Generator 0 65332 255 52 2 Binary XY_table 0 --2147483646 4 0 0 0 1

PropF / AL Diff Protection Tripped 0 65332 255 52 2 Binary XY_table 0 --2147483646 4 0 0 0 1

PropF / AL Exhaust Monitoring Fail 0 65332 255 52 2 Binary XY_table 0 --2147483646 4 0 0 0 1

PropF / AL Priming Pump Fail 0 65332 255 52 2 Binary XY_table --2147483647 --2147483646 2147483646 0 0 0 1

PropF / AL Safety System Fail (EMU) 0 65332 255 52 2 Binary XY_table 0 --2147483646 4 0 0 0 1

PropF / AL Shutdown expected 2 0 65332 255 52 2 Binary XY_table 0 --2147483646 4 0 0 0 1

PropF / Combined Alarm (ECU) 0 65332 255 52 2 Binary XY_table 0 --2147483646 4 0 0 0 1

PropF / Gen Actual Power 0 65332 255 52 2 Binary XY_table 0 --2147483646 4 0 0 0 1

PropF / HI T--Bearing Driven End 0 65332 255 52 2 Binary XY_table 0 --2147483646 4 0 0 0 1

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Data protocols J1939 and CANopen -- GenoLine LOP 10 Part 1
J1939: Proprietary PGN Page 25

Name SPN PGN PDU--F PDU--S Data Normalization table Out--of--limit Prenorm Prenorm Func- Func- Func- PDOs
type value -- -- tion tion tion
[bit] lower limit upper limit acti- Data 1 Data 2
value value vate

PropF / HI T--Bearing Non Driven End 0 65332 255 52 2 Binary XY_table 0 --2147483646 4 0 0 0 1

PropF / HI T--Cooling Air Outlet 0 65332 255 52 2 Binary XY_table 0 --2147483646 4 0 0 0 1

PropF / HI T--Winding U 0 65332 255 52 2 Binary XY_table 0 --2147483646 4 0 0 0 1

PropF / HI T--Winding V 0 65332 255 52 2 Binary XY_table 0 --2147483646 4 0 0 0 1

PropF / HI T--Winding W 0 65332 255 52 2 Binary XY_table 0 --2147483646 4 0 0 0 1

PropF / HIHI T--Bearing Driven End 0 65332 255 52 2 Binary XY_table 0 --2147483646 4 0 0 0 1

PropF / HIHI T--Bearing Non Driven End 0 65332 255 52 2 Binary XY_table 0 --2147483646 4 0 0 0 1

PropF / HIHI T--Cooling Air Outlet 0 65332 255 52 2 Binary XY_table 0 --2147483646 4 0 0 0 1

PropF / HIHI T--Winding U 0 65332 255 52 2 Binary XY_table 0 --2147483646 4 0 0 0 1

PropF / HIHI T--Winding V 0 65332 255 52 2 Binary XY_table 0 --2147483646 4 0 0 0 1

PropF / HIHI T--Winding W 0 65332 255 52 2 Binary XY_table 0 --2147483646 4 0 0 0 1

PropF / L1L P--Lube Oil EMU 0 65331 255 51 8 Pressure 4kPa/bit 0 0 255 0 0 0 1

PropF / L1L P--Lube Oil Limit 0 65300 255 20 8 Pressure 4kPa/bit 0 0 255 0 0 0 1

PropF / L1L P--Oil Re--Fill Pump 0 65331 255 51 8 Pressure 4kPa/bit 0 0 255 0 0 0 1

PropF / L1L P--Raw Water 0 65331 255 51 8 Pressure 4kPa/bit 0 0 255 0 0 0 1

PropF / L2L P--Lube Oil EMU 0 65331 255 51 8 Pressure 4kPa/bit 0 0 255 0 0 0 1

PropF / L2L P--Lube Oil Limit 0 65300 255 20 8 Pressure 4kPa/bit 0 0 255 0 0 0 1

PropF / LL P--Start Air 0 65333 255 53 8 Pressure 4kPa/bit 0 0 255 0 0 0 1

PropF / ML LOP Start 0 65332 255 52 2 Binary XY_table --2147483647 --2147483646 2147483646 0 0 0 1

PropF / ML LOP Stop 0 65332 255 52 2 Binary XY_table --2147483647 --2147483646 2147483646 0 0 0 1

PropF / ML Ready for Start/Stop 0 65332 255 52 2 Binary XY_table --2147483647 --2147483646 2147483646 0 0 0 1

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Page 26 J1939: Proprietary PGN

Name SPN PGN PDU--F PDU--S Data Normalization table Out--of--limit Prenorm Prenorm Func- Func- Func- PDOs
type value -- -- tion tion tion
[bit] lower limit upper limit acti- Data 1 Data 2
value value vate

PropF / Override Activated (Display) 0 65332 255 52 2 Binary XY_table 0 --2147483646 4 0 0 0 1

PropF / P--Raw Water 0 65331 255 51 8 Pressure 4kPa/bit 0 0 255 0 0 0 1

PropF / Priming Pump Automatic Mode 0 65332 255 52 2 Binary XY_table 0 --2147483646 4 0 0 0 1

PropF / Priming Pump On 0 65332 255 52 2 Binary XY_table 0 --2147483646 4 0 0 0 1

PropF / U1L P--Crankcase 0 65300 255 20 8 Pressure 4kPa/bit 0 --1 65536 0 0 0 1

PropF / U1L T--Coolant (EMU) 0 65331 255 51 8 Temp. 1 deg C/bit 0 0 255 0 0 0 1
--40C offset

PropF / U1L T--Winding U 0 65333 255 53 8 Temp. 1 deg C/bit 0 0 255 0 0 0 1

--40C offset

PropF / U1L T--Winding V 0 65333 255 53 8 Temp. 1 deg C/bit 0 0 255 0 0 0 1

--40C offset

PropF / U1L T--Winding W 0 65333 255 53 8 Temp. 1 deg C/bit 0 0 255 0 0 0 1

--40C offset

PropF / U2L P--Crankcase 0 65300 255 20 8 Pressure 4kPa/bit 0 --1 65536 0 0 0 1

PropF / U2L T--Coolant (EMU) 0 65331 255 51 8 Temp. 1 deg C/bit 0 0 255 0 0 0 1
--40C offset

PropF / U2L T--Winding U 0 65333 255 53 8 Temp. 1 deg C/bit 0 0 255 0 0 0 1

--40C offset

PropF / U2L T--Winding V 0 65333 255 53 8 Temp. 1 deg C/bit 0 0 255 0 0 0 1

--40C offset

PropF / U2L T--Winding W 0 65333 255 53 8 Temp. 1 deg C/bit 0 0 255 0 0 0 1

--40C offset

PropG / L1L P--Coolant after Pump 0 65301 255 21 8 Pressure 2kPa/bit 0 0 255 0 0 0 1

PropG / L2L P--Coolant after Pump 0 65301 255 21 8 Pressure 2kPa/bit 0 0 255 0 0 0 1

PropH / T--Charge Air Seq Ctrl Valve 0 65329 255 49 16 Temperature 0.03125 0 --1 65536 0 0 0 1
deg C/bit

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J1939: Proprietary PGN Page 27

Name SPN PGN PDU--F PDU--S Data Normalization table Out--of--limit Prenorm Prenorm Func- Func- Func- PDOs
type value -- -- tion tion tion
[bit] lower limit upper limit acti- Data 1 Data 2
value value vate

PropH / U1L T--Charge Air 0 65302 255 22 16 Temperature 0.03125 0 --1 65536 0 0 0 1
deg C/bit

PropH / U1L T--Charge Air Seq Ctr Valve 0 65329 255 49 16 Temperature 0.03125 0 --1 65536 0 0 0 1
deg C/bit

PropH / U1L T--Coolant 0 65302 255 22 8 Temp. 1 deg C/bit 0 0 255 0 0 0 1

--40C offset

PropH / U2L T--Charge Air 0 65302 255 22 16 Temperature 0.03125 0 --1 65536 0 0 0 1
deg C/bit

PropH / U2L T--Charge Air Seq Ctr Valve 0 65329 255 49 16 Temperature 0.03125 0 --1 65536 0 0 0 1
deg C/bit

PropH / U2L T--Coolant 0 65302 255 22 8 Temp. 1 deg C/bit 0 0 255 0 0 0 1

--40C offset

PropI / U1L T--Fuel 0 65303 255 23 8 Temp. 1 deg C/bit 0 0 255 0 0 0 1

--40C offset

PropI / U1L T--Lube Oil 0 65303 255 23 16 Temperature 0.03125 0 --1 65536 0 0 0 1
deg C/bit

PropI / U2L T--Fuel 0 65303 255 23 8 Temp. 1 deg C/bit 0 0 255 0 0 0 1

--40C offset

PropI / U2L T--Lube Oil 0 65303 255 23 16 Temperature 0.03125 0 --1 65536 0 0 0 1
deg C/bit

PropJ / L1L P--Charger A--Side 0 65304 255 24 16 Pressure 2kPa/bit 0 --1 65536 0 0 0 1

PropJ / L1L P--Fuel 0 65304 255 24 8 Pressure 4kPa/bit 0 --1 65536 0 0 0 1

PropJ / L2L P--Fuel 0 65304 255 24 16 Pressure 4kPa/bit 0 --1 65536 0 0 0 1

PropK / L1L T--Exhaust 0 65330 255 50 16 Temperature 0.03125 0 --1 65536 0 0 0 1

deg C/bit

PropK / U1L T--ECU 0 65305 255 25 16 Temperature 0.03125 0 --1 65536 0 0 0 1

deg C/bit

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Page 28 J1939: Proprietary PGN

Name SPN PGN PDU--F PDU--S Data Normalization table Out--of--limit Prenorm Prenorm Func- Func- Func- PDOs
type value -- -- tion tion tion
[bit] lower limit upper limit acti- Data 1 Data 2
value value vate

PropK / U1L T--Exhaust 0 65330 255 50 16 Temperature 0.03125 0 --1 65536 0 0 0 1

deg C/bit

PropK / U2L T--Exhaust A 0 65330 255 50 16 Temperature 0.03125 0 --1 65536 0 0 0 1

deg C/bit

PropK / U2L T--Exhaust B 0 65330 255 50 16 Temperature 0.03125 0 --1 65536 0 0 0 1

deg C/bit

PropK / UL T--Exhaust A 0 65305 255 25 16 Temperature 0.03125 0 --1 65536 0 0 0 1

deg C/bit

PropK / UL T--Exhaust B 0 65305 255 25 16 Temperature 0.03125 0 --1 65536 0 0 0 1

deg C/bit

PropM / Engine Speed Crankshaft EMU 0 65307 255 27 16 Speed 0.125 rpm/bit 0 --1 2147483646 0 0 0 1

PropM / Injection in Relation to DBR 65328 255 48 16 2 Byte 1:1 Range 0 to --2147483647 --2147483646 2147483646 0 0 0 1
64255

PropM / U1L Charger speed ETC1 0 65307 255 27 16 Speed 4 rpm/bit 0 --1 65536 0 0 0 1

PropM / U1L Charger speed ETC2 0 65328 255 48 16 Speed 4 rpm/bit 0 --1 65536 0 0 0 1

PropM / U2L Charger Speed ETC1 0 65307 255 27 16 Speed 4 rpm/bit 0 --1 65536 0 0 0 1

PropM / U2L Charger Speed ETC2 0 65328 255 48 16 Speed 4 rpm/bit 0 --1 65536 0 0 0 1

PropM / UL Engine Speed 0 65307 255 27 16 Speed 0.125 rpm/bit 0 --1 2147483646 0 0 0 1

PropM / UL Engine Speed Internal EMU 0 65328 255 48 16 Speed 0.125 rpm/bit 0 --1 2147483646 0 0 0 1

PropZ / AL ETC 2 Cut in Fail 0 65297 255 17 2 Binary XY_table --2147483647 --2147483646 2147483646 0 0 0 1

PropZ / AL ETC 2 Idle Speed High 0 65297 255 17 2 Binary XY_table --2147483647 --2147483646 2147483646 0 0 0 1

PropZ / AL Press Monitoring Fail (EMU) 0 65297 255 17 2 Binary XY_table --2147483647 --2147483646 2147483646 0 0 0 1

PropZ / AL Security Channel Def EMU 0 65297 255 17 2 Binary XY_table --2147483647 --2147483646 2147483646 0 0 0 1

PropZ / AL Shutdown expected 0 65297 255 17 2 Binary XY_table --2147483647 --2147483646 2147483646 0 0 0 1

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Data protocols J1939 and CANopen -- GenoLine LOP 10 Part 1
J1939: Proprietary PGN Page 29

Name SPN PGN PDU--F PDU--S Data Normalization table Out--of--limit Prenorm Prenorm Func- Func- Func- PDOs
type value -- -- tion tion tion
[bit] lower limit upper limit acti- Data 1 Data 2
value value vate

PropZ / Alarm Acknowledge 65297 255 17 2 Binary XY_table 3 --1 4 0 0 0 1

PropZ / Engine Running 65297 255 17 2 Binary XY_table --2147483647 --2147483646 4 0 0 0 1

PropZ / ETC 2 Cut In 65297 255 17 2 Binary XY_table --2147483647 --2147483646 4 0 0 0 1

PropZ / Fuel Leakage Level Switch 65297 255 17 2 Binary XY_table --2147483647 --2147483646 4 0 0 0 1

PropZ / HI ETC 2 Speed 65297 255 17 2 Binary XY_table --2147483647 --2147483646 2147483646 0 0 0 1

PropZ / HI ETC Speed Difference 0 65297 255 17 2 Binary XY_table --2147483647 --2147483646 2147483646 0 0 0 1

PropZ / HI P--Crankcase 65297 255 17 2 Binary XY_table 0 --2147483646 4 1

PropZ / HI T--Charge Air Seq Ctrl Valve 65297 255 17 2 Binary XY_table --2147483647 --2147483646 4 0 0 0 1

PropZ / HI T--Coolant (EMU) 65297 255 17 2 Binary XY_table 3 --1 4 0 0 0 1

PropZ / HIHI P--Crankcase 65297 255 17 2 Binary XY_table 0 --2147483646 4 0 0 0 1

PropZ / LO P--Coolant 65297 255 17 2 Binary XY_table --2147483647 --2147483646 4 0 0 0 1

PropZ / LO P--Lube Oil (EMU) 65297 255 17 2 Binary XY_table --2147483647 --2147483646 4 0 0 0 1

PropZ / LO P--Oil Re--Fill Pump 65297 255 17 2 Binary XY_table --2147483647 --2147483646 4 0 0 0 1

PropZ / LO P--Raw Water 65297 255 17 2 Binary XY_table 3 --1 4 0 0 0 1

PropZ / LOLO P--Coolant 65297 255 17 2 Binary XY_table --2147483647 --2147483646 4 0 0 0 1

PropZ / Rated Speed Reached 65297 255 17 2 Binary XY_table --2147483647 --2147483646 4 0 0 0 1

PropZ / SS ETC 2 Overspeed 65297 255 17 2 Binary XY_table --2147483647 --2147483646 4 0 0 0 1

PropZ / SS Overspeed EMU 65297 255 17 2 Binary XY_table --2147483647 --2147483646 4 0 0 0 1

PropZ / SS P--Lube Oil (EMU) 65297 255 17 2 Binary XY_table --2147483647 --2147483646 4 0 0 0 1

PropZ / SS Request Power Reduction 65297 255 17 2 Binary XY_table 0 --2147483646 4 1

PropZ / SS T--Charge Air Seq Ctrl Valve 65297 255 17 2 Binary XY_table --2147483647 --2147483646 4 0 0 0 1

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Part 1 Data protocols J1939 and CANopen -- GenoLine LOP 10
Page 30 J1939: Proprietary PGN

Name SPN PGN PDU--F PDU--S Data Normalization table Out--of--limit Prenorm Prenorm Func- Func- Func- PDOs
type value -- -- tion tion tion
[bit] lower limit upper limit acti- Data 1 Data 2
value value vate

PropZ / SS T--Coolant (EMU) 65297 255 17 2 Binary XY_table 3 --1 4 0 0 0 1

PropZ / Stop Activated 65297 255 17 2 Binary XY_table --2147483647 --2147483646 2147483646 0 0 0 1

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Data protocols J1939 and CANopen -- GenoLine LOP 10 Part 1
CANopen: General information Page 31

2 Transmission values in accordance with CANopen standard

2.1 General information

PDOs

The Process Data Objects (referred to below as PDOs) which may be up to 8 bytes long having a total of
64 bits can transmit the following values:
¯ Binary values
¯ Analog values
¯ Diagnostic messages
¯ Binary setpoints/values
¯ Analog setpoints/values

Physical specifications
¯ CAN specification: ISO11898, CAN 2.0A/B, electrically isolated, 3 core
¯ The following values are set for node number and baud rate on the GenoLine LOP 10:
-- Node no.: 2
-- Baud rate: 125 kB
¯ 11 bit identifier
¯ Start/stop CANopen devices

CANopen NMT and communication

¯ CANopen specification: DS301 V 4.01
¯ The MTU system operates as a slave and waits to be started by a master.
¯ Static mapping, dynamic mapping is not supported.
¯ SDOs are not supported
¯ No write access to the object directory via SDOs
¯ Support of standard PDOs
¯ Transmitted data format: Intel format
¯ NMT monitoring is realized exclusively by means of a heartbeat.
-- Heartbeat Producer Time: 500 ms
¯ Transmission Type 255
-- Inhibit Time: 250 ms
-- Event Time 20 s
¯ Analog values are transmitted in Unsigned32 format
¯ Boolean values are transmitted in Boolean format

IMPORTANT:

MTU uses data packages with less than 8 data bytes. The definition is recorded in the
DCF/EDS file compiled by MTU (supplied on request).

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Page 32 CANopen: General information

Missing data detection, Missing Data (MD)/Sensor Defect (SD)

The following values are transmitted in case of faults:

¯ Analog values:
-- MD value: 0x7FFFFFFF
-- SD value: 0x80000001
¯ Boolean values
The standard dictates that in the case of PDOs which transmit binary values, bytes 0 to 3 con-
tain the user data and bytes 4 to 7 the status values:

Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Byte 6 Byte 7 Byte 8

MV MV MV MV MD/SD MD/SD MD/SD MD/SD
status status status status

Example:
Measured value in byte 1 is 0
The associated status is given in byte 5:
0 for measured value is OK
1 for measured value is MD/SD

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Data protocols J1939 and CANopen -- GenoLine LOP 10 Part 1
CANopen: PDO tables Page 33

2.2 CANopen: PDO tables

Explanation of table columns

¯ T/R Direction (T: Transmit; R: Receive)
¯ PV Index Process variable, unique number
¯ PV Name Process variable, denomination
¯ CAN ID MCS CAN identifier, MCS (Monitoring and Control System)
¯ Mux MCS Multiplexer, MCS (Monitoring and Control System)
¯ Index Index to object directory for CANopen
¯ Subindex Subindex to object directory for CANopen
¯ Pos. in PG Position in telegram (Start byte)
¯ CAN ID CANopen CAN identifier in CANopen protocol

Receiving objects

=321+A002--A002 -- CAN input

T/R PV Index PV Name CAN ID Mux MCS Index Subindex Pos. in PG CAN ID
MCS CANopen
R PV600901 Start Command CAN Open 1026 19 0xA500 0x2 4 0x201
R PV600902 Stop Command CAN OPEN 1026 20 0xA500 0x4 12 0x201
R PV600904 Override CAN OPEN 1026 21 0xA500 0x6 20 0x201

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Page 34 CANopen: PDO tables

Transmission objects

=321+A002--A002 -- CAN output

T/R PV Index PV Name CAN ID Mux MCS Index Subindex Pos. in PG CAN ID
MCS CANopen
T PV410001 Stop Activated 1000 0 0xA080 0x2 4 0x181
T PV410002 Engine Speed (ECU) 1000 1 0xA1C0 0x1 0 0x185
T PV410009 SS Autom. Power Reduct. active 1000 8 0xA080 0x4 12 0x181
T PV410026 P--Lube Oil (ECU) 1001 0 0xA1C0 0x2 4 0x185
T PV410027 L1L P--Lube Oil (ECU) 1001 1 0xA1C0 0x3 8 0x186
T PV410028 L2L P--Lube Oil (ECU) 1001 2 0xA1C0 0x4 12 0x186
T PV410029 LO P--Lube Oil (ECU) 1001 3 0xA080 0x6 20 0x181
T PV410030 SS P--Lube Oil (ECU) 1001 4 0xA080 0x8 28 0x181
T PV410031 P--Crankcase 1001 5 0xA1C0 0x5 16 0x187
T PV410032 U1L P--Crankcase 1001 6 0xA1C0 0x6 20 0x187
T PV410033 U2L P--Crankcase 1001 7 0xA1C0 0x7 24 0x188
T PV410034 HI P--Crankcase 1001 8 0xA080 0xA 36 0x181
T PV410035 SS P--Crankcase 1001 9 0xA080 0xC 44 0x181
T PV410036 P--Coolant 1001 10 0xA1C0 0x8 28 0x188
T PV410037 L1L P--Coolant 1001 11 0xA1C0 0x9 32 0x189
T PV410038 L2L P--Coolant 1001 12 0xA1C0 0xA 36 0x189
T PV410039 LO P--Coolant 1001 13 0xA080 0xE 52 0x181
T PV410040 SS P--Coolant 1001 14 0xA080 0x10 60 0x181
T PV410046 P--Fuel 1001 20 0xA1C0 0xB 40 0x18A
T PV410047 LO P--Fuel 1001 21 0xA080 0x12 68 0x181
T PV410048 SS P--Fuel 1001 22 0xA080 0x14 76 0x181
T PV410049 P--Charge Air (a) 1001 23 0xA1C0 0xC 44 0x18A
T PV410050 LO P--Charge Air (a) 1001 24 0xA080 0x16 84 0x181
T PV410054 HI P--Oil Filter Difference 1002 3 0xA080 0x18 92 0x181
T PV410055 LO Coolant Level 1002 4 0xA080 0x1A 100 0x181

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CANopen: PDO tables Page 35

T/R PV Index PV Name CAN ID Mux MCS Index Subindex Pos. in PG CAN ID
MCS CANopen
T PV410056 HI Fuel Leakage 1002 5 0xA080 0x1C 108 0x181
T PV410057 ETC 1 Speed 1002 6 0xA1C0 0xD 48 0x18B
T PV410058 HI ETC 1 Speed 1002 7 0xA080 0x1E 116 0x181
T PV410059 ETC 2 Speed 1002 8 0xA1C0 0xE 52 0x18B
T PV410060 HI ETC 2 Speed 1002 9 0xA080 0x20 124 0x181
T PV410064 LO P--Fuel (Common Rail) 1002 13 0xA080 0x22 132 0x181
T PV410065 HI P--Fuel (Common Rail) 1002 14 0xA080 0x24 140 0x181
T PV410068 Engine Running 1002 17 0xA080 0x26 148 0x181
T PV410069 ETC 2 Cut In 1002 18 0xA080 0x28 156 0x181
T PV410070 SS ETC 1 Overspeed 1002 19 0xA080 0x2A 164 0x181
T PV410071 SS ETC 2 Overspeed 1002 20 0xA080 0x2C 172 0x181
T PV410075 ECU Failure Codes 1002 24 0xA1C0 0xF 56 0x18C
T PV410078 Generator Load On 1003 2 0xA080 0x2E 180 0x181
T PV410115 ECU Operat.Hours 1004 14 0xA1C0 0x10 60 0x18C
T PV410116 AL ECU Defect 1004 15 0xA080 0x30 188 0x181
T PV410122 LO ECU Power Supply Voltage 1004 21 0xA080 0x32 196 0x181
T PV410123 HI ECU Power Supply Voltage 1004 22 0xA080 0x34 204 0x181
T PV410126 T--Coolant (ECU) 1005 0 0xA1C0 0x11 64 0x18D
T PV410127 U1L T--Coolant (ECU) 1005 1 0xA1C0 0x12 68 0x18D
T PV410128 U2L T--Coolant (ECU) 1005 2 0xA1C0 0x13 72 0x18E
T PV410129 HI T--Coolant (ECU) 1005 3 0xA080 0x36 212 0x181
T PV410130 HIHI T--Coolant (ECU) 1005 4 0xA080 0x38 220 0x181
T PV410131 T--Charge Air 1005 5 0xA1C0 0x14 76 0x18E
T PV410132 U1L T--Charge Air 1005 6 0xA1C0 0x15 80 0x18F
T PV410133 HI T--Charge Air 1005 7 0xA080 0x3A 228 0x181
T PV410140 T--Lube Oil 1005 14 0xA1C0 0x16 84 0x18F
T PV410141 L1H T--Lube Oil 1005 15 0xA1C0 0x17 88 0x190

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Page 36 CANopen: PDO tables

T/R PV Index PV Name CAN ID Mux MCS Index Subindex Pos. in PG CAN ID
MCS CANopen
T PV410142 L2H T--Lube Oil 1005 16 0xA1C0 0x18 92 0x190
T PV410143 HI T--Lube Oil 1005 17 0xA080 0x3C 236 0x181
T PV410144 SS T--Lube Oil 1005 18 0xA080 0x3E 244 0x181
T PV410145 T--Exhaust Combined A 1005 19 0xA1C0 0x19 96 0x191
T PV410146 U1L T--Exhaust Combined A 1005 20 0xA1C0 0x1A 100 0x191
T PV410147 HI T--Exhaust Combined A 1005 21 0xA080 0x40 252 0x181
T PV410148 T--Exhaust Combined B 1005 22 0xA1C0 0x1B 104 0x192
T PV410149 U1L T--Exhaust Combined B 1005 23 0xA1C0 0x1C 108 0x192
T PV410150 HI T--Exhaust Combined B 1005 24 0xA080 0x42 260 0x182
T PV410151 T--Intake Air 1006 0 0xA1C0 0x1D 112 0x193
T PV410152 T--Fuel 1006 1 0xA1C0 0x1E 116 0x193
T PV410158 L1L P--Fuel 1006 7 0xA1C0 0x1F 120 0x194
T PV410159 L2L P--Fuel 1006 8 0xA1C0 0x20 124 0x194
T PV410160 U1L ETC 1 Speed 1006 9 0xA1C0 0x21 128 0x195
T PV410161 U1L ETC 2 Speed 1006 10 0xA1C0 0x22 132 0x195
T PV410162 UL Engine Speed (ECU) 1006 11 0xA1C0 0x23 136 0x196
T PV410163 L1L P--Charge Air (a) 1006 12 0xA1C0 0x24 140 0x196
T PV410167 U2L T--Charge Air 1006 16 0xA1C0 0x25 144 0x197
T PV410168 SS T--Charge Air 1006 17 0xA080 0x44 268 0x182
T PV410170 HI T--ECU 1006 19 0xA080 0x46 276 0x182
T PV410172 U2L ETC 1 Speed 1006 21 0xA1C0 0x26 148 0x197
T PV410173 U2L ETC 2 Speed 1006 22 0xA1C0 0x27 152 0x198
T PV410177 SS Engine Speed too low 1007 1 0xA080 0x48 284 0x182
T PV410178 AL ECU Error/Check Error Code 1007 2 0xA080 0x4A 292 0x182
T PV410185 AL Common Rail Leakage 1007 9 0xA080 0x4C 300 0x182
T PV410187 HI ETC 2 Idle Speed 1007 11 0xA080 0x4E 308 0x182
T PV410188 HI ETC Speed Difference 1007 12 0xA080 0x50 316 0x182

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CANopen: PDO tables Page 37

T/R PV Index PV Name CAN ID Mux MCS Index Subindex Pos. in PG CAN ID
MCS CANopen
T PV410189 AL ETC 2 Cut in Fail 1007 13 0xA080 0x52 324 0x182
T PV410199 U2L T--Fuel 1007 23 0xA1C0 0x28 156 0x198
T PV410200 HIHI T--Fuel 1007 24 0xA080 0x56 340 0x182
T PV410216 Injection in Relation to DBR 1008 15 0xA1C0 0x29 160 0x199
T PV410258 T--Charge Air Seq Ctrl Valve 1010 7 0xA1C0 0x2A 164 0x199
T PV410259 U1L T--Charge Air Seq Ctr Valve 1010 8 0xA1C0 0x2B 168 0x19A
T PV410260 U2L T--Charge Air Seq Ctr Valve 1010 9 0xA1C0 0x2C 172 0x19A
T PV410261 U2L T--Exhaust Combined A 1010 10 0xA1C0 0x2D 176 0x19B
T PV410262 U2L T--Exhaust Combined B 1010 11 0xA1C0 0x2E 180 0x19B
T PV410270 LOLO ECU Power Supply Voltage 1010 19 0xA080 0x58 348 0x182
T PV410271 HIHI ECU Power Supply Voltage 1010 20 0xA080 0x5A 356 0x182
T PV410290 Coolant Level Switch 1011 14 0xA080 0x5C 364 0x182
T PV410291 Fuel Leakage Level Switch 1011 15 0xA080 0x5E 372 0x182
T PV410294 HI T--Charge Air Seq Ctrl Valve 1011 18 0xA080 0x60 380 0x182
T PV410295 SS T--Charge Air Seq Ctrl Valve 1011 19 0xA080 0x62 388 0x182
T PV410296 SS T--Exhaust Combined A 1011 20 0xA080 0x64 396 0x182
T PV410297 SS T--Exhaust Combined B 1011 21 0xA080 0x66 404 0x182
T PV410298 U1L T--Fuel 1011 22 0xA1C0 0x2F 184 0x19C
T PV410299 HI T--Fuel 1011 23 0xA080 0x68 412 0x182
T PV410300 UL T--ECU 1011 24 0xA1C0 0x30 188 0x19C
T PV412002 Engine Speed (EMU) 1027 4 0xA1C0 0x31 192 0x19D
T PV412006 SS Overspeed (EMU) 1027 7 0xA080 0x6A 420 0x182
T PV412026 P--Lube Oil (EMU) 1027 8 0xA1C0 0x32 196 0x19D
T PV412027 L1L P--Lube Oil (EMU) 1027 9 0xA1C0 0x33 200 0x19E
T PV412028 L2L P--Lube Oil (EMU) 1027 10 0xA1C0 0x34 204 0x19E
T PV412029 LO P--Lube Oil (EMU) 1027 11 0xA080 0x6C 428 0x182
T PV412030 SS P--Lube Oil (EMU) 1027 12 0xA080 0x6E 436 0x182

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Page 38 CANopen: PDO tables

T/R PV Index PV Name CAN ID Mux MCS Index Subindex Pos. in PG CAN ID
MCS CANopen
T PV412126 T--Coolant (EMU) 1027 14 0xA1C0 0x35 208 0x19F
T PV412127 U1L T--Coolant (EMU) 1027 15 0xA1C0 0x36 212 0x19F
T PV412128 U2L T--Coolant (EMU) 1027 16 0xA1C0 0x37 216 0x1A0
T PV412129 HI T--Coolant (EMU) 1027 17 0xA080 0x70 444 0x182
T PV412130 SS T--Coolant (EMU) 1027 18 0xA080 0x72 452 0x182
T PV412162 UL Engine Speed 1027 19 0xA1C0 0x38 220 0x1A0
T PV412201 T--Exhaust A1 1028 0 0xA1C0 0x39 224 0x1A1
T PV412202 T--Exhaust A2 1028 1 0xA1C0 0x3A 228 0x1A1
T PV412203 T--Exhaust A3 1028 2 0xA1C0 0x3B 232 0x1A2
T PV412204 T--Exhaust A4 1028 3 0xA1C0 0x3C 236 0x1A2
T PV412205 T--Exhaust A5 1028 4 0xA1C0 0x3D 240 0x1A3
T PV412206 T--Exhaust A6 1028 5 0xA1C0 0x3E 244 0x1A3
T PV412207 T--Exhaust A7 1028 6 0xA1C0 0x3F 248 0x1A4
T PV412208 T--Exhaust A8 1028 7 0xA1C0 0x40 252 0x1A4
T PV412211 T--Exhaust B1 1028 10 0xA1C0 0x41 256 0x1A5
T PV412212 T--Exhaust B2 1028 11 0xA1C0 0x42 260 0x1A5
T PV412213 T--Exhaust B3 1028 12 0xA1C0 0x43 264 0x1A6
T PV412214 T--Exhaust B4 1028 13 0xA1C0 0x44 268 0x1A6
T PV412215 T--Exhaust B5 1028 14 0xA1C0 0x45 272 0x1A7
T PV412216 T--Exhaust B6 1028 15 0xA1C0 0x46 276 0x1A7
T PV412217 T--Exhaust B7 1028 16 0xA1C0 0x47 280 0x1A8
T PV412218 T--Exhaust B8 1028 17 0xA1C0 0x48 284 0x1A8
T PV412225 L1L T--Exhaust 1028 24 0xA1C0 0x4B 296 0x1AA
T PV412501 P--Raw Water 1032 9 0xA1C0 0x4C 300 0x1AA
T PV412502 LL P--Raw Water 1032 10 0xA1C0 0x4D 304 0x1AB
T PV412503 LO P--Raw Water 1032 11 0xA080 0x74 460 0x182
T PV412504 P--Oil Re--Fill Pump 1032 12 0xA1C0 0x4E 308 0x1AB

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CANopen: PDO tables Page 39

T/R PV Index PV Name CAN ID Mux MCS Index Subindex Pos. in PG CAN ID
MCS CANopen
T PV412505 LL P--Oil Re--Fill Pump 1032 13 0xA1C0 0x4F 312 0x1AC
T PV412506 LO P--Oil Re--Fill Pump 1032 14 0xA080 0x76 468 0x182
T PV412510 SS Request Power Reduction 1032 16 0xA080 0x78 476 0x182
T PV412512 AL Exhaust Monitoring Fail 1032 18 0xA080 0x7A 484 0x182
T PV412513 AL Press Monitoring Fail (EMU) 1032 19 0xA080 0x7C 492 0x182
T PV412516 AL Security Channel Def EMU 1032 22 0xA080 0x7E 500 0x182
T PV412518 TD T--Coolant 1032 24 0xA080 0x80 508 0x182
T PV412519 TD P--Lube Oil 1033 0 0xA080 0x82 516 0x183
T PV414001 Combined Alarm Red (Prio 2) 1026 1 0xA080 0x84 524 0x183
T PV414002 Combined Alarm Yellow (Prio 3) 1026 2 0xA080 0x86 532 0x183
T PV414265 ML LOP Start 1019 0 0xA080 0x88 540 0x183
T PV414270 ML LOP Stop 1040 9 0xA080 0x8A 548 0x183
T PV414290 ML Ready for Start 1019 3 0xA080 0x8C 556 0x183
T PV414354 MG External Start Interlock 1040 14 0xA080 0x8E 564 0x183
T PV414355 MG Not Ready for Operation 1040 16 0xA080 0x90 572 0x183
T PV414360 AL Barring Gear Engaged 1040 19 0xA080 0x92 580 0x183
T PV414380 Shutdown expected 1026 15 0xA080 0x54 332 0x182
T PV414405 Priming Pump On 1040 23 0xA080 0xD4 844 0x184
T PV414408 AL Priming Pump Fail 1041 0 0xA080 0x94 588 0x183
T PV414411 AL Water in Fuel Prefilter 1019 24 0xA080 0x96 596 0x183
T PV414416 AL Battery Charger Failure 1041 13 0xA080 0x98 604 0x183
T PV414420 P--Start Air 1040 10 0xA1C0 0x50 316 0x1AC
T PV414421 LO P--Start Air 1040 12 0xA080 0x9A 612 0x183
T PV414422 LL P--Start Air 1040 11 0xA1C0 0x51 320 0x1AD
T PV414431 HI T--Riser (switch) 1020 4 0xA080 0x9C 620 0x183
T PV414470 AL Override Activated 1020 5 0xA080 0x9E 628 0x183
T PV414489 SS Security Shutdown 1041 8 0xA080 0xA0 636 0x183

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Page 40 CANopen: PDO tables

T/R PV Index PV Name CAN ID Mux MCS Index Subindex Pos. in PG CAN ID
MCS CANopen
T PV414490 SS Emergency Stop 1041 5 0xA080 0xA2 644 0x183
T PV414540 WB SwB monitoring Emerg. Stop 1018 15 0xA080 0xA6 660 0x183
T PV414550 T--Winding U Generator 1017 20 0xA1C0 0x52 324 0x1AD
T PV414551 U1L T--Winding U 1020 9 0xA1C0 0x53 328 0x1AE
T PV414552 U2L T--Winding U 1020 10 0xA1C0 0x54 332 0x1AE
T PV414553 HI T--Winding U 1020 11 0xA080 0xAA 676 0x183
T PV414554 HIHI T--Winding U 1020 12 0xA080 0xAC 684 0x183
T PV414555 T--Winding V Generator 1017 21 0xA1C0 0x55 336 0x1AF
T PV414556 U1L T--Winding V 1020 13 0xA1C0 0x56 340 0x1AF
T PV414557 U2L T--Winding V 1020 14 0xA1C0 0x57 344 0x1B0
T PV414558 HI T--Winding V 1020 15 0xA080 0xAE 692 0x183
T PV414559 HIHI T--Winding V 1020 16 0xA080 0xB0 700 0x183
T PV414560 T--Winding W Generator 1017 22 0xA1C0 0x58 348 0x1B0
T PV414561 U1L T--Winding W 1020 17 0xA1C0 0x59 352 0x1B1
T PV414562 U2L T--Winding W 1020 18 0xA1C0 0x5A 356 0x1B1
T PV414563 HI T--Winding W 1020 19 0xA080 0xB2 708 0x183
T PV414564 HIHI T--Winding W 1020 20 0xA080 0xB4 716 0x183
T PV414570 T--Bearing Driven End Generator 1017 23 0xA1C0 0x5B 360 0x1B2
T PV414573 HI T--Bearing Driven End 1020 23 0xA080 0xB6 724 0x183
T PV414574 HIHI T--Bearing Driven End 1020 24 0xA080 0xB8 732 0x183
T PV414575 T--Bear. Non Driven End Generat 1017 24 0xA1C0 0x5C 364 0x1B2
T PV414578 HI T--Bearing Non Driven End 1021 2 0xA080 0xBA 740 0x183
T PV414579 HIHI T--Bearing Non Driven End 1021 3 0xA080 0xBC 748 0x183
T PV414580 T--Cooling Air Outlet Generator 1018 0 0xA1C0 0x5D 368 0x1B3
T PV414583 HI T--Cooling Air Outlet 1021 6 0xA080 0xBE 756 0x183
T PV414584 HIHI T--Cooling Air Outlet 1021 7 0xA080 0xC0 764 0x183
T PV414591 AL Diff Protection Tripped 1021 12 0xA080 0xC2 772 0x184

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CANopen: PDO tables Page 41

T/R PV Index PV Name CAN ID Mux MCS Index Subindex Pos. in PG CAN ID
MCS CANopen
T PV414593 AL Coolant Leakage Generator 1021 13 0xA080 0xC4 780 0x184
T PV414594 Priming Pump Automatic Mode 1018 4 0xA080 0xC6 788 0x184
T PV414595 Gen Actual Power in KW 1021 14 0xA1C0 0x5E 372 0x1B3
T PV414601 AL Power Amplifier 1 Failure 1021 15 0xA080 0xC8 796 0x184
T PV414602 AL Power Amplifier 2 Failure 1021 16 0xA080 0xCA 804 0x184
T PV414603 AL Status Transistor Outputs 1021 17 0xA080 0xCC 812 0x184
T PV416010 Combined Alarm (ECU) 1022 6 0xA080 0xCE 820 0x184
T PV416011 Override Activated (Display) 1022 7 0xA080 0xD0 828 0x184
T PV416020 AL Safety System Fail (EMU) 1022 8 0xA080 0xD2 836 0x184
T PV416810 AL Shutdown expected 1022 12 0xA080 0xD6 852 0x184

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Page 42 CANopen: PDO tables

(Leerseite)

E MTU -- 10.2010 -- E532303/00E

 LEROY SOMER DATA SHEET SECTION 1

ALTERNATOR MANUAL

1. MACHINE TECHNICAL DATA

1.1 General characteristics

Project Sinopacific
Type A52.2 M60 Engine drive
Serial Nr 605809
Synchronous Triphased
Connections Star
Machine axis Horizontal
Rated output 1850 KVA
Voltage 690 V
Frequency 60 Hz
Power Factor 0.8
Polarity 4
Speed 1800 rpm
Machine protection IP55
Terminal box protection IP 55
Insulation H
Temperatue rise F
Generator air gap 3.5 mm
Exciter air gap 1 mm
Ambient temperature 50 °C
Cooling IC 8 A1 W7
Weight of rotor 1395 Kg
Total weight 4950 Kg

1.2 Excitation - Regulation

Excitation AREP + PMI
AVR type AVR hors fourniture LS

1.3 Stator protections

Space heater (W) 500
under(V) 230
Stator winding sensor 6 x PT100

SECTION 1 Page 2
 LEROY SOMER DATA SHEET SECTION 1

ALTERNATOR MANUAL

1.6 Roller/ball bearing technical data

Drive Non drive
End side End side
Type 6232 6226

Insulated bearing

PERIODICITY OF LUBRICATION
Lubricant type Grease SHELL GADUS S3 V220C2 Grease SHELL GADUS S3 V220C2
Quantity of lubricant 70 g 50 g
Each (hours) 1 500 1 500

A continuous greasing system is recomended for low re-greasing period

1.7 Drive end bearing Protection

Bearing sensor (thrust) 1 x PT100

1.8 Non drive end bearing Protection

Bearing sensor (thrust) 1 x PT100

SECTION 1 Page 3
 LEROY SOMER DATA SHEET SECTION 1

ALTERNATOR MANUAL

1.10 Cooler characteristics

Manufacturer LHERMITTE
Type Air to Water
Rejected power 68 kw
Water quality sea water
Water flow (+0 . +20%) 11.5 m3/h
Water inlet temperature 40 °C
Water outlet temperature 45 °C
Water pressure loss 0.08 bar
Water design pressure 6 bar
Water lines test pressure 9 bar

COMPOSITION
Internal end plate (outer air tube) Naval brass
External end plate (inner water tube) Naval brass
Iner tubes consist of Cupronickel
Outer tube consist of Copper
Blades consist of Copper
Water headers consist of Steel + coating

2. SPARE PARTS

2.1 To order spare parts

1-Identify the machine Serial Number
on the name plate (eg : 605 513)
2- Identify the part number using the attached
drawings and give a description

2.2 Recommanded spare parts

Rotating diodes 3 SKN130/12
Rotating diodes 3 SKR130/12
Anti friction bearing 1 6232
Anti friction bearing 1 6226

SECTION 1 Page 4
 ALTERNATOR MANUAL
SERVICING & OPERATING

605809 S3_4994_d_en.doc SECTION 3 Page 1

 LEROY SOMER SERVICING & OPERATING

ALTERNATOR MANUAL

TABLE OF CONTENTS

2.9.0.2 Description Air/Water double tube

1. GENERAL INFORMATION 5 exchanger 10
2.9.0.3 Description of Air/Water single tube
1.1 INTRODUCTION 5 exchanger 11
1.1.0 General points 5 2.9.1 Water Cooler operating condition 11
1.1.1 Safety notes 5 2.9.1.1 "Standard" operation with water 11
1.1.2 Conditions of use 5 2.9.1.2 "Emergency" operation without water 11
1.1.2.1 Generalities 5 2.9.2 Cooler protection devices 12
1.1.2.2 Vibratory analysis 5 2.9.2.1 Leak detection (float system) 12
1.2 GENERAL DESCRIPTION 6 2.9.2.2 Water temperature sensor (optional) 12
1.2.1 Generator 6 2.9.2.3 Water filtering 12
1.2.2 Excitation system 6 2.10 Not applicable 12
2.11 Not applicable 12
2. DESCRIPTION OF SUB-ASSEMBLIES 7
2.12 TRANSPORT LOCKING SYSTEM 12
2.1 STATOR 7
2.1.1 Electric machine armature 7
2.1.2 Excitation field winding 7 3. INSTALLATION 13
2.1.3 Stator protection 7 3.1 TRANSPORT AND STORAGE 13
2.1.3.1 Heating resistor 7 3.1.1 Transport 13
2.1.3.2 Stator winding temperature sensor 7 3.1.2 Storage warehouse 13
2.1.3.3 Stator air sensor 7 3.1.3 Maritime packing 13
2.1.3.4 Bearing vibration sensor 8 3.1.4 Unpacking and installation 14
2.2 ROTOR 8 3.1.5 Storage measures of antifriction bearings 14
2.2.1 Revolving field-coil 8 3.1.6.1 General points 14
2.2.2 Excitation armature 8 3.1.6.2 Short term storage 14
2.2.3 Fan (machines: IC 0 A1) 8 3.1.6.3 Long term storage 14
2.2.4 Rotating diode bridge 8 3.1.6 Not applicable 14
2.2.5 Balancing 9 3.1.7 Storage measures of water cooled
machines 14
2.3 TERMINAL BOX 9
2.3.0 Description 9 3.2 INSTALLATION OF THE MACHINE 15
2.3.1 Automatic voltage regulator (AVR) 9 3.2.1 Fitting the coupling (double-bearing
machine only) 15
2.4 NAMEPLATES 9 3.2.2 Fitting the stator 15
2.4.1. Main nameplate 9
2.4.2. Lubrication nameplate 9 3.3 MACHINE ALIGNMENT 15
2.4.3. Rotation direction nameplate 9 3.3.1 Alignment general points 15
3.3.1.1 General points 15
2.5 ANTI FRICTION BEARING 10 3.3.1.2 Shaft elevation caused by Thermal
2.5.0 Description of antifriction bearings 10 elevation 16
2.5.1 Antifriction bearing protection devices 10 3.3.1.3 Not applicable 16
2.6 Not applicable 10 3.3.1.4 Shaft elevation of Anti-friction bearing
machine 16
2.7 Not applicable 10 3.3.1.5 Generator check before alignment 16
3.3.1.6 Alignment procedure"Double
2.8 Not applicable 10
concentricity" alignment method 16
2.9 WATER COOLER (CACW) 10 3.3.2 Two bearings machine alignment (flanged)
2.9.0 Description of the cooler 10 17
2.9.0.1 General points 10 3.3.2.1 Machines without axial end play (standard)
17

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 LEROY SOMER SERVICING & OPERATING

ALTERNATOR MANUAL
3.3.2.2 Machines with axial end play 17 5.2.1 General points 30
5.2.2 Double bearing machine 30
3.4 ELECTRICAL CONNECTIONS 18 5.2.3 Single bearing machine 30
3.4.0. General points 18
3.4.1 Phase-sequence 18 5.3 ANTI FRICTION-BEARINGS 30
3.4.1.1 Standard units ; IEC 34-8 18 5.3.1 General points 30
3.4.1.2 On request ; NEMA 19 5.3.2 Cleaning bearings from old grease 30
3.4.2 Insulating distances 19 5.3.3 Cleaning bearings assembly area 31
3.4.3 Added products in the terminal box 19 5.3.4 Bearing removal 31
5.3.5 Bearing re-assembly 31
3.5 WATER COOLER INSTALLATION 20
5.4 Not applicable 31
4. START-UP 20 5.5 LUBRICANTS 32
4.1 ELECTRICAL START-UP INSPECTION 20 5.5.1 Greases 32
4.1.0 General points 20 5.5.2 Oils 32
4.1.1 Winding Insulation 20 5.5.2.1 General 32
4.1.2 Electrical connections 20 5.5.2.2 Synthetic oils 33
4.1.3 Parallel operation 20 5.5.2.3 Mineral oils 33
4.1.3.1 Definition of parallel operation 20 5.5.2.4 Oil filtering and pollution 33
4.1.3.2 Possibility of parallel operation 20 5.6 WATER COOLER 33
4.1.3.3 Parallel coupling 21 5.6.1 Maintenance of the water-cooler 33
4.2 MECHANICAL START-UP INSPECTION 21 5.6.1.1 General points 33
4.2.0 General points 21 5.6.1.2 Cleaning 34
4.2.0.1 Alignment ; fixing ; prime mover 21 5.6.1.3 Leak detection for a double-tube
4.2.0.2 Cooling 21 exchanger 34
4.2.0.3 Lubrication 21 5.6.2 Servicing the water-cooler 34
4.2.1 Anti friction bearing machines start up 21 5.6.2.1 Cooler removal 34
4.2.2 Not applicable 21 5.6.2.2 Cooler re-assembly 34
4.2.3 water cooler Start-up 21 5.7 Not applicable 34
4.2.4 Vibrations 21
5.8 BOLT TIGHTENING 34
4.3 START-UP SEQUENCE 22 5.8.0 General 34
4.3.1 Static checks 22 5.8.1 Steel screw in steel tapping 34
4.3.2 Rotating checks 22 5.8.2 Plugs 35
4.3.2.0 Rotor speed rate of rise (Standard unit) 22 5.8.3 Electrical contact 35
4.3.2.1 Rotating checks not excited 22 5.8.4 Rotating diodes 35
4.3.2.2 Rotating checks at no load excited 22 5.8.5 Synthetic parts 35
4.3.2.3 Generator and site safety parameters 22
4.3.2.4 Rotating checks at full load 22 5.9 ELECTRICAL MEASURING
4.3.3 Generator start up check list 23 INSTRUMENTS 35
5.9.1 Instruments used 35
5. MAINTENANCE AND SERVICING 27 5.10 WINDINGS INSULATION CHECK 35
5.10.0 General 35
5.0 GENERAL 27
5.10.1 Insulation measure 35
5.1 MAINTENANCE SCHEDULE 28 5.10.2 Polarization index 36
5.1.0 Not applicable 28
5.1.1 Stator 28
5.11 ROTATING DIODE BRIDGE TEST 37
5.1.2 Rotor 28 5.12 CLEANING THE WINDINGS 37
5.1.3 Terminal box 28 5.12.0 General points 37
5.1.4 Not applicable 28 5.12.1 Coil-cleaning products 37
5.1.5 Anti friction bearing 28 5.12.2 Cleaning operation 37
5.1.6 Machine cooler 28
5.1.7 Rubber dampers 29 5.13 DRYING THE WINDING 38
5.1.8 Not applicable 29 5.13.0 General points 38
5.1.9 Not applicable 29 5.13.1 Drying method 38
5.1.10 Protection devices 29 5.13.1.1 General points 38
5.13.1.2 Drying generator in a stopped position 38
5.2 AIR GAP CHECK 30 5.13.1.3 Drying generator in rotation 38

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5.14 RE-VARNISHING 39

10. TYPICAL ASSEMBLIES AND DRAWINGS

40
10.1 MACHINE CUT VIEWS 40
10.1.1 Machine type A52 40
10.1.1 Machine type A60 ; A62 41
10.2 ANTI FRICTION BEARING ASSEMBLY 42
10.2.1 Machine type A52.2 42

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Any operating condition other than those specified by the
1. GENERAL INFORMATION original tender must receive a Leroy Somer agreement
Any modification of the machine structure must receive a
Leroy Somer agreement
1.1 INTRODUCTION
1.1.2.2 Vibratory analysis
1.1.0 General points It is the responsibility of the gen set manufacturer to
This manual provides installation, operating and ensure that the different assembled system will be
maintenance instructions for synchronous machines. It vibratory compatible.(ISO 8528-9 and BS5000-3)
also describes the basic construction of these machines. It is the responsibility of the gen set manufacturer to
This manual is general ; it applies to an entire group of ensure that the shaft line torsional analysis has been done
synchronous generators. Additionally, in order to make and accepted by the different parties (ISO 3046)
information-finding easier, Section 1, "Characteristics and
Performance", has been included, describing the machine CAUTION :
completely (type of construction, type of bearing, EXCEEDING THE VIBRATORY LEVEL ALLOWED BY
protection index, and so forth...); this will enable you to THE STANDARD ISO 8528-9 & BS5000-3 MAY CREATE
determine exactly the chapters which apply to your HEAVY DAMAGES (BEARING DAMAGE, STRUCURE
machine. CRACKS …).
This synchronous machine has been designed for a EXCEEDING THE TORSIONAL VIBRATORY LEVEL OF
maximum length of service. To achieve this, it is necessary THE SHAFT LINE (ex: ABS, LLOYD …) MAY CREATE
to pay special attention to the chapter concerning the HEAVY DAMAGES (CRANKSHAFT FAILURE ,
periodic maintenance schedule for the machines. GENERATOR SHAFT FAILURE, …)

1.1.1 Safety notes Refer to chapter 2.1.3.4 for further information about the
accepted vibration level of the standard ISO 8528-9 and
The warnings "DANGER, CAUTION, NOTE" are used to BS5000-3
draw the user’s attention to different points:

DANGER :
THIS WARNING IS USED WHEN AN OPERATION,
PROCEDURE, OR USE MAY CAUSE PERSONAL
INJURY OR LOSS OF LIFE

CAUTION :
THIS WARNING IS USED WHEN AN OPERATION,
PROCEDURE, OR USE MAY CAUSE DAMAGE TO OR
DESTRUCTION OF EQUIPMENT

NOTE :
This warning is used when an operation, procedure, or
delicate installation requires clarification.

1.1.2 Conditions of use

1.1.2.1 Generalities
A machine must only be installed, operated, by qualified
and trained persons.
Any technical engineer operating, maintaining this machine
must be allowed to practice in regard with local working
laws (eg: to be certified to operate on high voltage
devices…)
Any product (sealing compound; cleaning product…) used
during any maintenance or servicing must be in
accordance with local regulation and environmental
standard
A machine can only be operated for the duty foreseen by
its original tender.
The main data of this machine are summarized in "Section
1" of this manual

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1.2 GENERAL DESCRIPTION

1.2.1 Generator
The synchronous generator is an alternating-current
machine, without ring or brush. The machine is cooled by
the flow of air through the machine.
For a better comprehension, use the drawings of chapter
10.
The Automatic Voltage Regulator (item 6) supplies the
exciter field (static part ; item 1) in DC current.
The Exciter works as a reversed alternator.
The Exciter armature (rotating part ; item 2) generate a
three-phase current which supplies the Rotating diodes
bridge (rotating part ; item 3)
The Rotating diodes bridge (rotating part ; item 3) rectifies
the three phases current in DC current which supplies the
Revolving field (rotating part ; item 4)
The Revolving field (rotating part ; item 4) excites the
Alternator armature (static part ; item 5) which generates a
three phases current

5 1
3
4 2

1- Excitation field winding

2- Excitation armature
3- Rotating diodes bridge
4- Revolving field
5- Alternator armature
6- Automatic Voltage Regulator

1.2.2 Excitation system

The excitation system is fitted at the Non Drive End side

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2.1.3.2 Stator winding temperature sensor
2. DESCRIPTION OF SUB-ASSEMBLIES The temperature sensors are located in the zone assumed
to be the hottest part of the machine. The sensors are
connected to a terminal box.
2.1 STATOR Depending on the temperature rise of the machine, the
temperature of the sensors should not exceed a maximum
2.1.1 Electric machine armature of :
The alternator stator (armature) is a stacking of low losses
steel laminations assembled under pressure. The stator TEMP. RISE ALARM TRIP
coils are inserted and blocked in the slots, then class
impregnated with varnish and polymerised (VPI system).
Power (KVA) < 5000 > 5000 < 5000 > 5000
(b) (a)
B 130 °C 125 °C 135 °C 130 °C
3
F 155 °C 150 °C 160 °C 155 °C
2 4 H 175 °C 170 °C 180 °C 175 °C

(c) To improve the machine protection we recommend to set

the alarm point following effective site conditions:
5
Alarm temperature (*) = Highest recorded temp + 10°K
1 Trip temperature (*) = Alarm temperature + 5 °K
(*) do not pass over the values of the previous table.
1 - Stator
(*)Highest recorded temp: Temperature measured at
2 - Rotor
the site in the worst temperature condition at the stator
3 - Exciter
temperature sensor
4 - Rotating diodes
a - Stator Air inlet (cold air) E.g.: a class B machine reached 110°C during a factory
b - Stator air exhaust (warmed air) heat run test. Set the alarm temperature to 120°C instead
c – Rotating diodes air cooling of 130°C as indicated in the previous chart. Set the
emergency shutdown to 115°C instead of 135°C as
indicated in the previous chart.
2.1.2 Excitation field winding
The excitation field winding comprises a wound solid 2.1.3.3 Stator air sensor
element. As an option an RTD or thermostat can measure the stator
The excitation is flanged on the rear end shield of the air inlet temperature (cold air)
machine. Stator air inlet temperature; Alarm points and shutdown:
• alarm Nominal air inlet stator + 5 K
2.1.3 Stator protection • shutdown 80°C

2.1.3.1 Heating resistor Stator air outlet temperature; Alarm points and shutdown:
• alarm Nominal air inlet stator + 35K
The heating element avoids internal condensation during • shutdown Nominal air inlet stator + 40K
the shutdown periods. It is connected to the main terminal
box strip. The heating resistor is switched on as soon as NOTE :
the machine is shut down. For an open drip proof machine the nominal air
temperature entering the stator corresponds to the ambiant
The electrical characteristics are provided in Section 1
temperature
"Technical Characteristics".
NOTE :
If quickly restarting after a stop Inhibit the stator air sensor
safety "alarm" for few seconds (no more than 30 s) during
the machine start up;
NOTE:
For a water cooled machine (CACW) the nominal air
entering the stator may be approximated as following:
Tair entering stator = Twater entering cooler + 15°K

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2.2.3 Fan (machines: IC 0 A1)
2.1.3.4 Bearing vibration sensor
The synchronous machine is characterized by a self-
This chapter concerns the setting of seismic probes. For ventilation system. A centrifugal fan is mounted between
setting of proximity probes refer to chapter 2.2.6.1 the revolving field coil and the front bearing.
The vibration level of the machines is directly linked to the Air intake is at the rear of the machine and the exhaust on
duty and to the site characteristics. the drive end side.
We propose the following adjustment: The fan consists of a hub, which is keyed and heat-shrunk
Vibration Alarm (*) = Site Highest Vibration level + 50% onto the shaft. The flange is made of welded steel,
Vibration Trip = Vibration Alarm + 50% attached to the hub with hexagonal head-cap screws. The
(*) do not pass over the values of the following chart ventilation effect is obtained through, inclined blades. The
air is exhausted by centrifugation. The air inlet and outlet
The machines are engineered to be able to withstand the
must remains free during operation
vibration level specified by the standard ISO8528-9 and
BS5000-3
2.2.4 Rotating diode bridge
Maximum levels for : reciprocating Internal combustion
engines The rectifier bridge, comprising six diodes, is placed at the
rear of the machine. The rotating bridge is made of fiber
Nominal speed kVA Generator vibration level glass with a printed circuit to connect the diodes together.
(rpm) (nominal conditions) This bridge is supplied with alternating current by the
excitation armature and supplies direct current to the
Overall Any harmonics revolving field-coil. The diodes are protected against over
(mm/s rms)
(2–1000 Hz)
voltage by rotating resistors, or by varistors. These
resistors (or varistors) are mounted in parallel with the
1300 à 2199 > 250 < 20 revolving field-coil.
< 0.5 mm ; pp
721 à 1299 ≥ 250 < 20
(5 – 8 Hz) 2
> < 18
1250 1 + 3
< 9 mm/s ; rm
≤ 720 > < 15 (8 – 200 Hz)
1250
< 10 (*)
(*) generator on concrete base
-

Maximum levels for : Turbines 1 - Field

2 - Rotating resistors / varistors
Turbines Max advised : 4.5
(overall ; mm/s rms) 3 - Exciter armature
(hydraulic ; gaz ; steam)

The inner and outer rings are connected to the revolving

field-coil
2.2 ROTOR
1
2.2.1 Revolving field-coil
The Revolving field is a salient pole type, without any fixing
device as dove tail, cap bolt …
2
The revolving field is heat-shrunk onto the shaft

2.2.2 Excitation armature

The excitation armature is constructed by stacking
magnetic steel laminations. These steel laminations are
held in place by rivets.
The excitation armature is keyed and heat-shrunk onto the 1 - Outer ring
shaft. 2 - Inner ring
The windings are enamelled copper wires, class "F" The diode fastening screws must be tightened to the
insulation (or "H", depending on the customer's request or correct torque.
size of the machine).

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CAUTION :
THE ROTATING DIODE FASTENING SCREWS MUST
BE TIGHTENED USING A TORQUE WRENCH 2.4 NAMEPLATES
CALIBRATED TO THE RECOMMENDED TORQUE.
2.4.1. Main nameplate
The main nameplate is fitted to the stator. It gives the
2.2.5 Balancing manufacturer's electrical characteristics, the type of
The complete rotor has been balanced according to machine and its serial number. The serial number is
ISO8221 standard in order to obtain a residual imbalance necessary for any contact with the factory
less than : For machines with anti-friction bearings lubrication
Gen set : Class G2.5 parameters are indicated.
Turbine : Class G1
The shaft end is cold-stamped to indicate the type of 2.4.2. Lubrication nameplate
balancing (as per ISO8221)
The machines with Sleeve bearings have a lubrication
H : balancing with Half-key carried out as
plate attached to the bearing, indicating:
standard
• Type of bearing
F : balancing with Full key (done on request)
• Oil change frequency
N : balancing without key (done on request)
• Oil capacity of bearing
The balancing is carried out in two planes. • Oil viscosity.
The first is on the fan. It is recommended, when the fan is
The machines with anti-friction bearings have the
refitted (after servicing) to respect the initial indexing.
lubrication parameters indicated on the main nameplate
The second is at the Non Drive End side.
fixed on the stator, indicating :
The coupling must be balanced to fit the generator rotor • Type of bearing
balancing. • Grease-change frequency
• Quantity of grease
• Grease type
2.3 TERMINAL BOX
2.4.3. Rotation direction nameplate
2.3.0 Description Located on the stator an arrow indicates the direction of
Use the attached Terminal box drawing rotation.
The openings provide access to the terminals.
The gland plates are made of non-magnetic materials in
order to avoid circulating currents.
If accessories not supplied by Leroy Somer have to be
installed in the terminal box (CT’s, VT’s, Shunt …) refer to
chapter.3.4.3

2.3.1 Automatic voltage regulator (AVR)

When the automatic voltage regulator is located in the
terminal box, it is fitted on a separate plate, insulated from
vibration by means of dampers. The operation of the
regulator is explained in Section 3.

CAUTION :
RUBBER DAMPERS MUST BE CHECKED
PERIODICALLY AND REPLACED EVERY FIVE YEARS

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2.5 ANTI FRICTION BEARING 2.9 WATER COOLER (CACW)

2.5.0 Description of antifriction bearings 2.9.0 Description of the cooler

The bearings ensure the rotor rotation guiding and axial 2.9.0.1 General points
location
The purpose of the cooler is to remove machine heat
The bearings are protected from ambiant dust by labyrinth losses (mechanical, ohmic etc). The exchanger is located
seals and are of replaceable type. on the top of the machine.
The bearings must be lubricated regularly. The old grease Normal operation:
is forced out at the lower part of the bearings by the force The internal air goes through the exchanger, transferring
of the new grease being injected. the heat and then goes back to the machine.

CAUTION:
2.5.1 Antifriction bearing protection devices WHEN THE HOUSING INSTALLED WITH VIBRATION
As an option, the bearing may be equipped with RTD or DAMPERS, THE DAMPERS MUST BE PERIODICALLY
PTC sensors (customer’s choice) to detect eventual CHECKED AND CHANGED EACH FIVE YEARS.
overheating
For special use in warm surroundings where the CAUTION:
temperature of the bearings exceeds the authorised limit THE COOLER MUST BE FULLY OPERATIONAL AS
(for a bearing known to be in good condition), contact us. SOON AS THE MACHINE IS ROTATING (EVEN IF THE
Bearing; Alarm points and shutdown: MACHINE IS RUN AT NO LOAD !)
• alarm 90°C (194°F)
• shutdown 95°C (203°F) 2.9.0.2 Description Air/Water double tube exchanger
To improve the machine protection we recommend to set The internal air flow is moved by a fan fixed on the
the alarm point following effective site conditions: machine shaft. The internal cooling air circulates through
the machine and through the air-cooler in a closed circuit.
Alarm temperature (*) = Highest recorded temp + 15°K
The internal air circulation can be created through natural
(*) do not pass over the values of the previous chart.
ventilation (machine class IC 8 A1 W7) or through
E.g. : At site the common bearing temperature is 60°C. Set separate ventilation (machine class IC 8 A6 W7).
the alarm temperature to 75°C instead of 90°C as
Eg : machine class IC 8 A1 W7
indicated in the previous chart
air 1 air
NOTE:
Specific dedicated devices based on the analysis of the
vibration signal are able to monitor bearings behavior
air
2.6 Not applicable

2.7 Not applicable

1 – Air to Water cooler
2.8 Not applicable The double-tube technique keeps the cooling circuit from
being affected by possible water leakage. The double tube
provides a high safety level. In case of leakage, the water
goes from the inside of the internal tube to the coaxial
space between the two tubes. The water is drained axially
to a leakage chamber where it may activate a sensor.
An exchanger comprises a fin-tube block containing :
• a steel frame.
• a fin-tube block crimped mechanically to the tubes.
The tube bundle is roll-expanded in the end plates (parts 3
and 4)
The water distribution in the tubes is provided by two
removable water boxes (part 5). A water box is equipped
with collars for fitting the inlet and outlet lines. Neoprene
seals ensure watertightness between the water boxes and
the end plates.

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A
2.9.1 Water Cooler operating condition
B 1
2
2.9.1.1 "Standard" operation with water
CAUTION:
WATER SUPPLY MUST BE EFFECTIVE AS SOON AS
C THE GENERATOR IS ROTATING UNTIL THE
COMPLETE SHAFT LINE STOP

3 5 CAUTION:
6 4 WATER SUPPLY MUST BE STOPPED AS SOON AS
THE GENERATOR IS STOPPED TO AVOID IMPORTING
1 - Internal tube CONDENSATION INTO THE GENERATOR
2 - External tube with internal grooving and with External
fins Condensation trouble may appears when using too cold
3 - Internal end plate water. Condensation trouble can be managed by the help
4 - External end plate of psychrométric diagram (Mollier diagram).
5 - Water header Water thermostatic valve monitored by the generator air
6 – Leakage drain plug temperature to regulate the water flow can help to fix the
A - Air B - Leakage C – Water problem.

2.9.0.3 Description of Air/Water single tube exchanger 2.9.1.2 "Emergency" operation without water
The internal air flow is moved by a fan fixed on the As an option the machines can be engineered to be able to
machine shaft. The internal cooling air circulates through operate in an "Emergency" mode without water flow
the machine and through the air-cooler in a closed circuit. Only machines engineered for this operation case can
The internal air circulation can be created through natural operate without water flow.
ventilation (machine class IC 8 A1 W7) or through
CAUTION :
separate ventilation(machine class IC 8 A6 W7).
THIS OPERATING CONDITION CORRESPOND TO A
An exchanger comprises a fin-tube block containing POWER DERATED OPERATING MODE
• a steel frame
• a fin-tube block crimped mechanically onto the tubes. In such case the machine operate in "open drip proof"
• The tube bundle is roll-expanded in the end plates mode (cooling ensured by ambient air, with a protection
The water distribution in the tubes is provided by two water level IP23)
boxes. One water box is equipped with collars for fitting the
inlet and outlet water lines. Neoprene seals provide CAUTION :
watertightness between the water boxes and the end AIR INLET AND OUTLET FLAPS LOCATED AT THE
plates. NON DRIVE END AND DRIVE END SIDE OF THE
MACHINE MUST BE OPEN
A 1 (Concerned openings are marked by specific labels)
before running the shaft line

2 3

1 - Tube with fins

2 - End plate
3 - Water header
A - Air B – Water

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2.9.2 Cooler protection devices
2.9.2.2 Water temperature sensor (optional)
2.9.2.1 Leak detection (float system) A temperature sensor may be installed into the water inlet
A magnet float activates a switch located in the float flow of the cooler.
guiding rod Proposal of adjustment of the water inlet sensor :
Alarm temperature (*) = Water site temp max + 5 °K
Trip temperature (*) = Alarm temperature + 5 °K
A
x 2.9.2.3 Water filtering
1 Water filtering is not ensured by Leroy Somer.
y Water filtering must be better than 300 µ
z
2 2.10 Not applicable

2.11 Not applicable

1 - Guide rod
2 - Magnetic float
A – No potential contacts 2.12 TRANSPORT LOCKING SYSTEM
x - Blue y - Brown z – Black Certain type of Machines may have their rotor locked
during transport.
The locking systems are red painted
The locking systems must be removed just before the
alternator final installation and re install if the alternator is
later re transported.
CAUTION:
THE ROTOR LOCKING SYTEM MUST REMAIN IN
PLACE IF THE ALTERNATOR IS SUBJECT TO BE
TRANSPORTED.

CAUTION:
THE ROTOR LOCKING FIXING SCREW MUST BE
TIGHTENED TO THE NOMINAL RECOMMENDED
TORQUE.

The Locking system fixing screws must be correctly

tightened. A too low torque can conduce to an insufficient
locking effect

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Non Drive End bearing; Locking system examples:
3. INSTALLATION
1

3.1 TRANSPORT AND STORAGE

2
3.1.1 Transport
3
During the transport the intermittent shocks level applied to
2
the machines must remains below 30 m/s
Machines equipped with anti friction bearing must have
3 their rotor locked during the transport to avoid "false
brineling" problem
Machine temperature must remains within the range -20°C
to +70°C. Stay down to -40°C during few hours is admitted.
1 3 The machine must be protected against bad weather
conditions and condensation.
Machines must not be handled at temperature below -20°C
2 3
3.1.2 Storage warehouse
The machine must be stored in clean and dry premises
which are not subject to abrupt changes in temperature or
to high humidity (75% maximum)
CAUTION:
1 - Cable THE HEATING RESISTOR MUST BE CONTINUOUSLY
2 – Red label out of the alternator indicating a Locking
SWITCHED ON
system
3 – Rotor locking system Storage at an ambient temperature of +5 to +45° C is
recommended.
The machine must not be subject to vibrations higher than
1mm/s rms

3.1.3 Maritime packing

The synchronous machine is carefully packed in a wooden
crate, then hermetically sealed.
In any case the generator must be store in a warehouse
(refer to chapter 3.1.2)
This packing provides access to the dessicant for periodic
change (every 18 months)
CAUTION :
BREAKING THE HERMETIC PROTECTIVE FILM
DISCHARGES LEROY SOMER OF ITS LONG STORAGE
GUARANTEE

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3.1.6.3 Long term storage

3.1.4 Unpacking and installation
When a sleeve bearing machine has to be stopped for
DANGER : more than one year:
THE DEDICATED LIFTING HOOKS MUST BE USED TO Drain the bearing. Place a "Silicagel" gag inside the
LIFT THE MACHINE WITH SLINGS (ONE HOOK AT bearing oil sump (it is necessary to open the bearing
EACH CORNER OF THE MACHINE) housing to proceed)
Rotors of machines with Sleeve bearings and single- Place an adhesive strip along the parting lines of the
bearing machines, are blocked during transportation so as housing.
to avoid any movement. Withdraw the retaining bars. The
Pour the recommended protecting agent through the oil
retaining bar is screwed to the end of the shaft and to the
filling hole of the bearing (around 50 cc). Turn the shaft
front support.
several times in order to spread the product evenly
CAUTION : throughout the bearing.
TRANSPORT LOCKING DEVICES PAINTED RED OR CAUTION:
WITH RED STICKER MUST BE REMOVED. A VISIT OF THE BEARING (research of corrosion
The end of the shaft is protected from corrosion. Clean it marks) MUST BE DONE AT LEAST ONCE PER YEAR
before coupling.
CAUTION:
The heating resistor must be switched on at all times.
BEFORE START UP IT WILL BE NECESSARY TO
Before starting the machine up again, it will be necessary REMOVE THE "SILICAGEL" BAG AND TAPES
to carry out a start-up inspection.

3.1.5 Storage measures of antifriction bearings 3.1.6 Not applicable

This chapter must be taken in consideration if a machine is
stopped more than 6 months. 3.1.7 Storage measures of water cooled machines
After 6 months of stop; grease by injecting two time the For water-coolers, the water flow must be shut off. If the
grease volume used for a standard maintenance. water is not treated and if there is likelihood of freezing, the
exchanger must be drained.
Then, each 3 months turn the machine shaft line of few
turns while injecting a standard grease volume

3.1.6.1 General points

CAUTION:
FOR MINERAL OIL WE RECOMMEND THE USE OF
TECTYL PRODUCTS FROM "VALVOLINE GmbH" SUCH
AS TYPE "511 M"
FOR SYNTHETIC OIL WE RECOMMEND THE USE OF
"JELT 003400" SPRAY FROM "ITW SPRAYTEC"

NOTE :
It is possible to start the machine up without removing the
recommended protective coating.

3.1.6.2 Short term storage

When a sleeve bearing machine has to be stopped for
more than one month and less than one year:
Do not drain the bearing oil
Pour the recommended protecting agent through the oil
filling hole of the bearing (around 50 cc). Turn the shaft
several times in order to spread the product evenly
throughout the bearing.

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3.2 INSTALLATION OF THE MACHINE 3.3 MACHINE ALIGNMENT

3.2.1 Fitting the coupling (double-bearing machine 3.3.1 Alignment general points
only)
3.3.1.1 General points
The coupling must be balanced separately before
assembly on the machine shaft. Refer to the balancing The alignment aims to obtain the driving shaft and the
instructions in chapter 2.2.5. driven shaft coaxial when operating at the nominal
conditions (machine rotating; at its operating temperature)
The shrinking of the half coupling onto the electrical
machine shaft end must be chosen, by the gen-set The machine must be aligned according to the Leroy
manufacturer, in such way as it should be removable for Somer standard and adhere to the manufacturer's
maintenance (e.g.: bearing change) alignment standard for the drive machine and coupling
tolerance
When heating the machine has its shaft line which grow
3.2.2 Fitting the stator
up. Between stop and rotation the shaft axis location inside
Four plates on the frame enable the unit to be fitted to a its bearing is different. The total axis height elevation is
skid. composed of the thermal elevation and of the bearing
The fixing bolts must support the forces created by the elevation.
static and dynamic loads.
CAUTION:
The machine may be positioned by means of 4 dowel pins.
THE ALIGNMENT MUST BE DONE TAKING IN
The dowel pins make later realignment easier. (The use of
CONSIDERATION OF THE SHAFT THERMAL GROWTH
pins is optional).
CORRECTION
The machine may be aligned through the use of 4 jacking-
screws. These jacking-screws allow the machine to be The correct locating of the parts must be obtained by
positioned according to the various axes. inserting shims under the machine feet.
The double-bearing machines are mounted with bearings
(ball or roller) or Sleeve bearings. The axial clearance of
the bearings (if the machine has Sleeve bearings) must be
distributed as well as possible, taking into account the axial
thermal expansion. The Anti friction-bearing machines with
a positioning bearing (standard machine) do not have axial
play.
The machines are delivered with the rotor mechanically
centered (axially and radially) in relation to the stator.

CAUTION :
THE ALIGNMENT STANDARDS OF MANUFACTURERS
OF DRIVE MACHINES ARE FREQUENTLY MORE
ACCURATE THAN THOSE OF LEROY SOMER

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3.3.1.2 Shaft elevation caused by Thermal elevation simultaneously, the measurement is not affected by the
error resulting from run out of the two shaft ends.
∆ H (mm) =λ (°K-1) . H(m) . ∆T(°K)
H(m) = Height of the machine axis
∆T= frame temperature elevation = 30°C C1
λ = Coefficient of steel elongation = 0.012 °K-1

3.3.1.3 Not applicable 12h B

3.3.1.4 Shaft elevation of Anti-friction bearing machine

9h
Caused by thermal growth of the anti friction bearing.itself
A
"2" 3h

Y ° 0,01 mm
6h C2

L
"1"
1 - cold, in rotation, or stopped
2 - hot, in rotation, or stopped The "C1" and "C2" micrometers are located at an angular
difference of 180°.
3.3.1.5 Generator check before alignment More the distance "L" is long better should be the
Check the generator shaft end run out. sensitivity to detect the angular error
Total Indicator Reading must be within 0.04 mm
The reading should be performed 4 times for the "C1" and
NOTE: "C2" micrometers : at 12h, 3h, 6h, 9h
RUN OUT CHECK CAN BE NOT FEASABLE ON It is recommended to record the results and draw the axes
SLEEVE BEARING MACHINE BECAUSE OF THE TOO for better evaluation, as explained below. Interpretation of
HIGH NECESSARY BREAK AWAY TORQUE NEEDED measurements by means of an example.
TO TURN THE ROTOR Values given in millimeters. The reading is considered
positive (+) when the micrometer stylus is pushed inwards.

3.3.1.6 Alignment procedure"Double concentricity"

alignment method
NOTE:
LASER DEVICES CAN MAKE THE JOB EASIER THAN
WITH THE SHOWN PROCEDURE

This method is not sensitive to axial movements.(the

alignment methods using axial measure may often be
perturbed by small axial movement of the rotor)
It is possible to check the alignment with the coupling
installed.
Equipment required :
Two rigid brackets. The rigidity of the two brackets is very
important.
Two micrometers
Implementation :
During the measures, both shafts must turn simultaneously
in the same direction. (For example : the coupling installed
with its screws untightened). By turning both shafts

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MEASUREMENTS In the both planes the parallelism error is:
+ 1.34 52 + 9 2 = 0.103mm or 16 2 + 47 2 = 0.496 mm (not
C1 C2 acceptable)
+ 0.90
+ 0.70 3.3.2 Two bearings machine alignment (flanged)
12h B
3.3.2.1 Machines without axial end play (standard)
+ 0.164
The alignment must take the tolerances of the coupling
9h into account.
+ 0.86 A 3h
+ 1.04 CAUTION:
+ 0.102
A MISALIGNMENT EVEN IF ACCEPTABLE BY THE
6h L=400 COUPLING MUST NOT CREATE STRESSES LEVEL
+ 1.00 NOT ACCEPTABLE BY THE BEARING
Measurements referring to the vertical plane: Shafts alignment limits to follow:
Considering the vertical plane "C1" : The vertical action
towards the top of shaft "A" on the micrometer is dominant.
In the plane "C1" the axis "A" is higher than axis "B” Angular error
( 0.9 – 0.1 ) / 2 = - 0.05 mm
0.01 mm
In the vertical plane "C2", the vertical action towards the
0.08 mm 100 mm
top of shaft "B" on the micrometer is greater.
parallelism error
In the plane "C2" the axis "B" is higher than axis "A"
( 0.134 – 0.102 ) / 2 = 0.16 mm To check the alignment, there are different methods: the
"double concentricity" method is described in the
The respective position of the axes is as follows: "alignment procedure" chapter 3.3.1.6.

3.3.2.2 Machines with axial end play

C1 The alignment must be performed using the same method
B as for a machine having no axial end play.
A The assembler should ensure that the generator shaft will
be properly located (centered) and the shaft line should be
0.16 hold in place while in operation
C2 CAUTION:
0.05
THE ROTOR AXIAL LOCATION MUST BE CHECKED TO
Regarding the vertical plane the angular alignment error is: AVOID ANY MAGNETIC OFFSET
( 0.16 + 0.05 ) *100 / 400 = 0.0525 mm/100mm (not
acceptable) CAUTION:
Measurements referring to the horizontal axis: THE FAN THRUST OF THE GENERATOR MUST BE
In the plane "C1" the axis "B" is further to the right than "A” HELD THROUGH THE COUPLING.
( 0.104 – 0.86 ) / 2 = 0.09 mm
A needle fitted on the drive end side bearing must face a
In the plane "C2" the axis "B" is further to the left than "A” groove machined on the shaft. If the needle is missing the
( 0.70 - 1.64 ) / 2 = - 0.47 mm distance "A" (distance from the groove up to the first
The representation of the shafts is as follows: bearing part) is stamped on the shaft enabling checking.
Example for a sleeve bearing machine :
C1
B
A
0.47
1
C2
0.09

Regarding the horizontal plane the angular error is:

( 0.47 + 0.09 ) *100/ 400 = 0.14 mm/100mm (not
acceptable) "A"

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3.4.1 Phase-sequence
3.4 ELECTRICAL CONNECTIONS
3.4.1.1 Standard units ; IEC 34-8
3.4.0. General points Except by special request of the customer, the phase-
The installation must comply with the electrical schematics sequence is carried out using the IEC 34-8 standard.
attached in Section 5 An arrow located on the front bearing indicates the
Check that all the protection devices are correctly direction of rotation.
connected and in good working order. In the terminal box a specific marking plate indicates the
The assembler has the responsibility to mechanically and specific generator phase sequence.
electrically protect the generator within the best practice
rules and to secure any operation over the defined tender
(respect of capability curve ; overspeed …) Clockwise rotation viewed Counter clockwise rotation
from the shaft drive end viewed from the shaft
For low-voltage machines, power supply cables must be drive end
connected directly to the machine terminals (without
adding washers etc) The phases are marked: The phases are marked:
U1, V1, W1. U1, V1, W1.
For high-voltage machines, power supply cables should be
connected to separate terminals or to current transformer Viewed from the front of Viewed from the front of
terminals. the terminal box the the terminal box the
terminals are : terminals are :
NOTE: U1, V1, W1 U1, V1, W1
THE GLAND PLATE IS MADE OF NON MAGNETIC
The installer connects : The installer connects :
MATERIAL.
L1 --> U1 L3 --> U1
L2 --> V1 L2 --> V1
CAUTION
L3 --> W1 L1 --> W1
DO NOT ADD WASHERS TO THE POWER SUPPLY
CABLE TERMINALS OTHER THAN THOSE USED BY
THE MANUFACTURER OF THE ELECTRIC MACHINE

Check that the lugs are tightened.(refer to chapter 5.8)

U2 V2 W2 U2 V2 W2
CAUTION
ALL CURRENT TRANSFORMERS MUST BE
CONNECTED OR SHUNTED

CAUTION
THE VOLTAGE TRANSFORMER MUST NEVER BE
SHUNTED
U1 V1 W1 U1 V1 W1
CAUTION
THE INSTALLED POWER CABLES MUST BE FIXED
AND SUPPORTED IN SUCH A WAY AS TO BE ABLE TO
WITHSTAND THE VIBRATION LEVEL REACHED BY
THE GENERATOR IN OPERATION (refer to chapter L1 L2 L3 L3 L2 L1
2.1.3.4)

The power cables must not stress (push, pull, bend ...) the
generator terminals

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3.4.1.2 On request ; NEMA

3.4.2 Insulating distances
An arrow located on the front bearing indicates the
direction of rotation. Products not delivered by Leroy Somer and then installed
in the terminal box must meet the electrical insulating
In the terminal box a specific marking plate indicates the distances.
specific generator phase sequence.
This applies to power cables and lugs, and to added
transformers, etc.
Counter clockwise rotation Clockwise rotation viewed Nominal Voltage 500 V 1 KV 2 KV 3 KV
viewed from the stator from the stator connection
connection (NEMA) (NEMA) Phase-Phase in 25 30 40 60
the air (mm)
(Clockwise rotation viewed (Counter clockwise
from the shaft drive end rotation viewed from the Phase-Earth in the 25 30 40 60
following IEC) shaft drive end following air (mm)
IEC)
Phase-Phase 25 30 40 70
The cables are marked: The cables are marked: Creeping (mm)
U1, V1, W1. U1, V1, W1. Phase-Earth 25 30 40 70
The terminals are marked The terminals are marked Creeping (mm)
: :
T3, T2, T1 T3, T2, T1
Viewed from the front of Viewed from the front of Nominal Voltage 5 KV 7,5KV 12,5KV 15 KV
the terminal box the the terminal box the Phase-Phase in 120 180 190 190
cables are : cables are : the air (mm)
U1, V1, W1 U1, V1, W1
Phase-Earth in the 90 120 125 125
The installer connects : The installer connects : air (mm)
L1 --> (U1) T3 L3 --> (U1) T3 Phase-Phase 120 180 190 190
L2 --> (V1) T2 L2 --> (V1) T2 Creeping (mm)
L3 --> (W1) T1 L1 --> (W1) T1
Phase-Earth 120 180 190 190
Creeping (mm)

T6 T5 T4 T6 T5 T4 3.4.3 Added products in the terminal box

This may apply to site added customer CTs ; VTs etc.
Leroy Somer must be informed if some appliances have to
be installed in the generator terminal box.
The products not delivered by Leroy Somer and then
U1 V1 W1
installed in the terminal box must meet the electrical
U1 V1 W1 insulating distances. Refer to chapter 3.4.2
1
T3 T2 T1 The installed appliances must be able to withstand
T3 T2 T1 vibration.

L1 L2 L3 L3 L2 L1

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3.5 WATER COOLER INSTALLATION 4. START-UP

Assembly example:
1 Outlet flange 4.1 ELECTRICAL START-UP INSPECTION
2 Inlet flange
3 Water cooler
4.1.0 General points
4 Connecting flange
5 Tap Electrical connections (auxiliaries, safeties and power
6 Flexible junction connections) must comply with the schematics provided.
7 Pipe Refer to Section 5 to get the concerned schematics
8 Draining and de aeration
9 Water leakage detector DANGER:
CHECK THAT ALL SAFETY EQUIPMENT OPERATES
CORRECTLY.

4.1.1 Winding Insulation

The insulation and the polarization index must be
measured on start up and then as per chapter 5.1.0
recommendation.
To measure the insulation (refer to chapter 5.10)

4.1.2 Electrical connections

The phases must be connected directly to the machine
links (with no spacers or washers, etc).
Make sure that the lugs are sufficiently tightened.

CAUTION:
Water pipes must be connected stress free ALL CURRENT TRANSFORMERS MUST BE
Water pipes must be able to expand without restraint CONNECTED BEFORE START UP. IF CURRENT
TRANSFORMER NOT USED ITS OUTPUT MUST BE
CAUTION: SHORTED
FOR MACHINE SUPPORTING A VIBRATION LEVEL
HIGHER THAN 5 MM/S RMS WE RECOMMEND THE
USE OF HYDRAULIC FLEXIBLE JUNCTION 4.1.3 Parallel operation

A pressure limitor must be installed on the system to 4.1.3.1 Definition of parallel operation
protect the complete assembly against abnormal over • Between machines
pressure Operation mode named by Leroy Somer "1F"
At least two alternators are connected in parallel to supply
a load
The Automatic Voltage Regulator is in voltage regulation
mode
A droop Current Transformer is necessary to share the
reactive load
• With the mains
Operation mode named by Leroy Somer "2F"
At least one alternator is connected in parallel with the
mains (Public electricity network)
The Automatic Voltage Regulator is in Power Factor
regulation mode

4.1.3.2 Possibility of parallel operation

CAUTION:
PARALLEL OPERATION CAN ONLY BE USED FOR
ALTERNATOR ENGINEERED FOR SUCH OPERATION

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4.2.2 Not applicable
4.1.3.3 Parallel coupling
CAUTION: 4.2.3 water cooler Start-up
A WRONG SYNCHRONIZATION CAN LEAD TO MAIN If the cooler has been stocked for more than 6 months,
DAMAGES (HIGH MECHANICAL OVERTORQUE AND recheck the correct tightening of the water boxes .The
st
OVER CURRENT) tightening must be done in 4 steps (1 step , tightening at
nd
¼ of the nominal torque ; 2 step , tightening at 1/2 of the
During synchronization the following values must not be rd
nominal torque ; 3 step , tightening at 3/4 of the nominal
overpass: torque ; final step ; tightening at 4/4 of the nominal torque).
Max frequency shift : 0,1 Hz The tightening must be done "diagonally" using a torque
Max phase offset : 10° (electrical angle) wrench (torque following chapter 5.8.1)
Max voltage (phase - neutral) between machines : "diagonally" tightening principle :
(at phase offset =0) 5 % of the nominal voltage
In case of wrong synchronization, or mains micro
interruption inducing a fault over the indicated limits Leroy
Somer will not be considered as responsible of the
damages.

4.2 MECHANICAL START-UP INSPECTION Make sure that the safety devices are operating.
Connect the supply and return lines.
4.2.0 General points Fill with water, whilst carefully draining the circuit.
4.2.0.1 Alignment ; fixing ; prime mover
CAUTION: (machine with motorized fan only)
The installation must comply with the manufacturer’s
WE RECOMMEND THAT THE FREE OPERATION OF
installation rules for drive machine (alignment, mounting).
THE FAN BE CHECKED (NO FRICTION, NO
An arrow at the drive end, end shield, indicates the BLOCKING).
direction of rotation.

4.2.0.2 Cooling CAUTION:

BEFORE START-UP, CHECK THE CLEANLINESS OF
The air inlet and exhaust must be unobstructed.
THE COOLER FINS.
The cooling auxiliaries (water circulation in the cooler, etc)
must be operating. Start up the installation (if the other sub-assemblies allow
this).
4.2.0.3 Lubrication
Load the machine (KVA); adjust the water flow-rate to
Lubrication must be carried out as per chapter 5. Lubricant obtain the rated flow-rate (refer to Section 1).
quantity and periodicity as per Section 1
Check the water tightness of the lines and of the
exchanger.
4.2.1 Anti friction bearing machines start up
Check that the temperatures comply with the
The bearings are pre-lubricated in the factory, but before recommended temperatures.
they are put into service, it is necessary to re grease in
order to fill the free spaces in the greasing circuit and to
evacuate the storage grease. 4.2.4 Vibrations
The vibration measurement must be taken on each
CAUTION bearing in the three directions. The measured levels must
UPON START-UP, GREASE THE MACHINE WHILE IT IS be lower than the specified values indicated in the chapter
RUNNING. 2.1.3.4
Adjust the sensor as per chapter 2.1.3.4
Record the temperature of the bearings during the initial
operating hours. Poor lubrication can cause abnormal
heating.
If the bearing hisses, lubricate it immediately. Some
bearings may make a clattering noise if they do not
operate at normal temperature. This may occur if the
weather is very cold or when the machine is operating
under abnormal temperature conditions (start-up phase,
for example). The bearings will become quieter after
having reached their normal operating temperature.

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Load the generator step by step. :
Check the excitation current at 25%of the rated load
4.3 START-UP SEQUENCE Check the excitation current at 100%of the rated load
The generator start up (commissioning) must follow the At the nominal speed (full load) measure the vibrations.
following sequences: Check that the vibration level is in accordance with the
generator duty (as per chapter 2.1.3.4).
4.3.1 Static checks
Machine fixing as per chapter 4.2
Alignment as per chapter 3.3
Cooling as per chapter 4.2.0.2 & 4.2.3
Bearing lubrication as per chapter 4.2.2
Electrical connections as per chapter 4.1.2
Winding insulation as per chapter 5.10

4.3.2 Rotating checks

4.3.2.0 Rotor speed rate of rise (Standard unit)
There is no restriction regarding the rate of rise of the rotor
spin up from stop to nominal speed
There is no restriction regarding the load rate of rise

4.3.2.1 Rotating checks not excited

Run the generator without excitation by steps to verify the
bearings temperature as per chapter 2.5.1 or 2.6.2
At the nominal speed (not excited) measure the vibrations.
Check that the vibration level is in accordance with the
generator duty (as per chapter 2.1.3.4).

4.3.2.2 Rotating checks at no load excited

In AVR manual mode; Voltage adjustment; check the
excitation current value (refer to Section 4 for the AVR
manual and to Section 2 for the generator test report)
In AVR automatic mode; Voltage adjustments; Voltage
range; check the excitation current value value (refer to
Section 4 for the AVR manual and to Section 2 for the
generator test report)
At the nominal speed (excited) measure the vibrations.
Check that the vibration level is in accordance with the
generator duty (as per chapter 2.1.3.4).

4.3.2.3 Generator and site safety parameters

Proceed to the site safeties adjustment (over voltage relay,
over current relay, differential protection; negative
sequence relay...). The setting points are not in Leroy
Somer scope of supply.
The settings must comply with the generator data sheet
(eg: capability curve; thermal damage curve …)
Check the synchronizer setting following chapter 4.1.3.3
For any operation at a speed exceeding the nominal range
(generally the main frequency +3%) the generator
excitation must be shut off (refer to the electrical
schematics)

4.3.2.4 Rotating checks at full load

Operating In parallel with the mains
Adjust the Power Factor

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4.3.3 Generator start up check list

TYPE SERIAL N°

Voltage V Frequency Hz Speed rpm

Output Power kVA Power Factor

STATIC CHECKS

Mechanical checks
• Direction of Rotation (refer to Section1) Clock Wise or Anti-clock Wise
• Mechanical Fixing of the generator (refer to chapter 4.2) ________________________________________
• Coupling - Alignment to the engine (refer to chapter 3.3) ________________________________________
• Cooling : Coolant flow (refer to Section1 ; chapter 4.2.0.2 & 4.2.3) _________________________________
• Air inlet and exhaust free ___________________________________________________
• Bearing lubrication : Sleeve Bearings Lubrication (flow ; level ; oil type) (refer to Section1 & chapter 4.2.2) __
Or Anti-friction Bearings Greasing (refer to Section1 & chapter 4.2.1)
Temperature sensors (correct readings) (refer to Section1 & chapter 2.5.1 & 2.6.2) __
• Space Heaters (refer to Section1) ___________________________________________________

Type of AVR : 1F 2F 3F

Electrical connections between alternator, AVR and main panel : (refer to Section 4 & drawing Section 5)
• Output power cables connections following phase order (refer to chapter 3.4.1) ______________________
• Terminal box connections ________________________________________
• AVR detection voltage ________________________________________
• Supply power and excitation terminals ________________________________________
• Network detection (3F only) ________________________________________
• Command signals (equalisation and synchronisation for 2F and 3F) ________________________________
• Excitation polarity and booster ________________________________________
• Protective devices : (Bearing oil level fault detectors; Temperature sensors, etc) ______________________
• External accessories (e.g.. remote potentiometer) ________________________________________

ALL CURRENT TRANSFORMERS MUST BE CONNECTED

Windings insulation
Winding temp:…….°C Voltage 1 minute 10 minutes Polarisation
(MΩ) (MΩ) index
3 Phases / Ground
"U" /Ground
Static parts

"V" /Ground
"W" /Ground
"U" / "V"
"U" / "W"
Exciter field / Ground
Rotor / Ground ≤ 500 V
Rotatin
g parts

Exciter armature / Ground ≤ 500 V

Rotating resistances ≤ 500 V
Rotating diodes ≤ 500 V

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All works must be carried out by a qualified and authorized person.

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ROTATING CHECKS

WITH EXCITATION - AT NO LOAD CONDITIONS

• Verification of the bearings temperature (refer to chapter 2.5.1 or 2.6.2) °C ______________

• In manual mode : Voltage adjustment ___________________________________

Excitation current check ___________________________________

• In automatic mode : Voltage Setting (referring to nominal voltage) ________________________

Excitation current check ________________________

• Parallel coupling : Adjustment to parallel operation (3F) ________________________

A FAULTY SYNCHRONISING CAN BE THE ORIGIN OF DAMAGES (HIGH MECHANICAL OVER-TORQUE)

• Maximum acceptable values for synchronisation to the mains :
Maximum frequency shift 0,1 Hz _________________________
Maximum Phase offset 10 ° _________________________
Maximum voltage (P.N.) difference 5% of Un _________________________

Control / Adjustment of the site safety Parameters

• Over-voltage, _____________________________________________________________
• Over-current (by short-circuit on stator in separate excitation mode), _________________________
• Negative sequence relay, _____________________________________________________________
• Over-speed, _____________________________________________________________
• Differential protection (in static conditions), _____________________________________
• Other protective device. _____________________________________________________________

CHECK THAT ALL SAFETY EQUIPMENT OPERATES CORRECTLY

WITH EXCITATION - LOADED

Take the load gradually from 0 to 100% in steps of 25%
Record for each step (refer to Section 1):
• Electrical output (KW)
• POWER FACTOR
• Voltage (V)
• Current (A)
• Excitation Current / voltage
• Winding temperature
Time KW pf Volts I (A) I (ex) U1 (°C) V1 (°C) W1 (°C)

• Bearings temperature (if thrust sensor available, please record its value)
Time DE Thrust (°C) DE Radial (°C) NDE Radial (°C)

• Oil inlet temperature (if applicable ; refer to Section 1)

• Oil flows (if applicable ; refer to Section 1)
• Bearings vibrations (mm/s) (refer to chapter 2.1.3.4)
DE-V DE-H DE-A DE-V DE-H DE-A

All works must be carried out by a qualified and authorized person.

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5. MAINTENANCE AND SERVICING

5.0 GENERAL
DANGER :
BEFORE ANY WORK ON THE GENERATOR, MAKE
SURE THAT THE START-UP CANNOT BE ACTIVATED
BY ANY MANUAL OR AUTOMATIC SIGNAL.
CHECK THAT ALL LOCKS ARE ENGAGED AND
FOLLOW THE SITE SAFETY PROCEDURES

DANGER:
BEFORE WORKING ON THE MACHINE, MAKE SURE
THAT YOU HAVE UNDERSTOOD THE OPERATING
PRINCIPLES OF THE SYSTEM. IF NECESSARY, REFER
TO THE APPROPRIATE CHAPTERS IN THIS MANUAL.

To obtain additional information on the maintenance of

sub-assemblies, refer to the chapters dealing with the sub-
assemblies concerned.
When a defective part is replaced with a spare part, make
sure that it is in good condition.
For any electrical work use electrical schematics for
assistance
The whole machine must be kept clean.

CAUTION :
ALL THE CLEANING PERIODS INDICATED IN THIS
MANUAL MAY BE CHANGED (INCREASED OR
DECREASED) ACCORDING TO SITE CONDITIONS

The air inlet and air outlet surfaces must be maintained

clean (Louvers can be cleaned as per the filters) refer to
chapter 5.7.1.

CAUTION :
DIRT ENTERING THE MACHINE MAY POLLUTE AND
THUS REDUCE THE ELECTRICAL INSULATION

CAUTION :
ANY PRODUCT (SEALING COMPOUND, CLEANING
PRODUCT…) USED DURING MAINTENANCE OR
SERVICING MUST BE IN ACCORDANCE WITH LOCAL
REGULATION AND ENVIRONMENTAL STANDARD

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5.1 MAINTENANCE SCHEDULE

5.1.0 Not applicable

5.1.1 Stator
Hours Comments Task duration
Winding temperature 24 Daily operation, (without gen stop)Refer to 2.1.3.2
Insulation 8000 (*1) Refer to 5.10
4hrs
Polarisation index 8000 (*1) Refer to 5.10.4
Bolts tightening 8000 (*1) Refer to 5.8 2 hrs
Winding visual inspection 8000 (*1) Refer to 5.10 1 hr
Stator RTD function 8000 (*1) Refer to 2.1.3.2
Cleaning air inlet and outlet 1000 (*1) Refer to 5.7

5.1.2 Rotor
Insulation 8000 (*1) Refer to 5.10
0.5 hr
Polarisation index 8000 (*1) Refer to 5.10.4
Winding visual inspection 8000 (*1)
Cleaning diodes 8000 (*1)
Diodes and varistor check 8000 (*1) 0.5 hr
Diodes tightening 8000 (*1)

5.1.3 Terminal box

Cleaning 8000 (*1) 0.5 hr
Regulator assembly & supports 8000 (*1) Applicable if mounted in the terminal box
Bolts tightening 8000 (*1) 1.5 hrs

5.1.4 Not applicable

5.1.5 Anti friction bearing

Following technical specification in "Section 1"
Re greasing See lub plate; Or every 6 months whichever come first
Bearing temperature 24 Daily operation, (without gen stop)Refer to 2.5.1

5.1.6 Machine cooler

Following technical specification in "Section 1"
Leakage level 24 Daily operation, (without gen stop)Refer to 5.6.1.3 &
2.9.2.1
Water temperature 24 Daily operation, (without gen stop)Refer to 2.9.2.2
Cleaning of the fins 8000 Cleaning following site conditions; Refer to 5.6.1.2 2 hrs

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5.1.7 Rubber dampers
Rubber dampers 8000 Refer 2.3.1

5.1.8 Not applicable

5.1.9 Not applicable

5.1.10 Protection devices

Protection devices 8000 (*1)

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5.2 AIR GAP CHECK 5.3 ANTI FRICTION-BEARINGS

5.2.1 General points 5.3.1 General points

The air gap measurement is not always possible because
NOTE:
of a lack of access. When the air gap can be reached the
Few international studies report that more than 80% of the
measure can be distorted because of paint and resin
coating on the checked surfaces. anti friction bearing installed worldwide for any duty are
prematurely damaged because of lubrication trouble.
To preserve your machine we recommend to closely fulfill
5.2.2 Double bearing machine the recommendations of this manual.
Verification of the air gap is not necessary. The rotor is
mechanically centered by its construction. Even after They must be lubricated regularly with the same type of
dismantling and reassembling the machine, the rotor will grease as used in the factory. For information concerning
return to its position without verification of the air gap. the lubrication quantity and interval, refer to Section 1:
The exciter air gap of generators type A60 and A62 can be "Characteristics and Performance".
adjusted on site.
CAUTION:
5.2.3 Single bearing machine LUBRICATION MUST BE CARRIED OUT AS PER
When the machine is delivered, the rotor is mechanically SECTION 1 OR AT LEAST EVERY 6 MONTHS
centered in the stator (see chapter on alignment). After WHICHEVER COME FIRST
dismantling the machine, it will be necessary to center the
rotor in the stator, by using the two half-shells (delivered NOTE:
with the machine) as explained in the chapter 3.3.3. After a regreasing the bearing temperature may increase
If you do not have 1/2 shells, use a dial indicator to check of 10 to 20°C
the concentricity between the shaft (machined surface) This temporary temperature increase may stay few tens of
and the front end shield (machined surface). hours

NOTE:
For re greasing period lower than 2000 hours we
recommend to install a continuous greasing system to limit
the maintenance operators visit
These type of system must be disable during machine stop
The grease contained in these systems must not be stored
over a period of 1 year

5.3.2 Cleaning bearings from old grease

This note is applicable when the type of grease is
changed.
Dismantle the machine in order to get to the bearing
Remove the old grease with a palette knife.
Clean the lubricator and the grease removal tube.
For greater cleaning efficiency, use a brush with solvent.

NOTE:
Used solvent must be in accordance with local regulation
and environmental standard.

DANGER:
THE PROHIBITED SOLVENTS ARE:
CHLORINATED SOLVENT
(TRICHLORETHYLENE,TRICHLOROETHANE) WHICH
BECOMES ACID
FUEL-OIL (EVAPORATES TOO SLOWLY)
GASOLINE CONTAINING LEAD
BENZINE (TOXIC)

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After cleaning ensure that the bearing becomes perfectly
dry. 5.3.5 Bearing re-assembly
Fill the bearing with the new grease. A bearing can be refitted if it is known to be in perfect
condition. As far as possible we recommend to use a
Re-assemble the cage and the parts, which have been
brand new bearing
dismantled, filling them with grease (2/3 of the empty
spaces must be filled with new grease) Before refitting a bearing, carefully clean the surface of the
bearing and the other parts of the bearing.
Use a grease pump to complete the bearing lubrication
(while machine running) Measure the shaft diameter to check it is within the
recommended tolerances.
5.3.3 Cleaning bearings assembly area To install the bearing on the shaft, it is necessary to heat
Bearing life is directly impacted by the cleanliness of the the bearing. The heat source may be an oven or a space
lubricant. The dirt must not enter or pollute the bearings. heater (the use of oil baths is not recommended). The use
of an induction bearing heater is recommended.
Excess of grease must be removed before operation in
order to avoid pollution of the environment as well as the CAUTION:
alternator NEVER HEAT A BEARING TO MORE THAN 125°C
Periodically: (257°F)
clean the labyrinth seals outside face. Remove the excess
Push the bearing up to the shaft shoulder, and check after
of grease which may appears onto the shaft.
cooling that the inner ring is still in contact with the
Remove the excess of dry old grease from the bearing
shoulder. Lubricate using the recommended grease. Fill
exhaust channel (use a clean blade)
the bearing covers with new grease
After removing the old grease check that a small fresh
volume of grease will plug the exhaust channel (to avoid
pollution coming back to the bearing) 5.4 Not applicable
5.3.4 Bearing removal
The inner bearing race is mounted, shrunk onto the shaft.
The outer bearing race is free, or slightly tightened, on the
hub (depending on the type of bearing). To remove the
bearing from the shaft, it is necessary to use a dedicated
hub-puller to avoid damaging the surface of the shaft.
Typical bearing drawing assembly is joined in chapter 10

CAUTION:
CLEANLINESS IS IMPERATIVE

NOTE:
Heat the bearing during the pulling operation is
recommended to prevent the shaft from being scored.

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5.5.2 Oils
5.5 LUBRICANTS
5.5.2.1 General
5.5.1 Greases We do not have any special recommendation regarding
Recommended lubricant: any mineral oil manufacturer.
SHELL GADUS S3 V220C2 (lithium complex base). The used oil must comply with the requested viscosity
SHELL RETINAX LX2 (lithium complex base). (refer to Section 1).
For frequent cold starting (lower than -15°C) without oil
Recommendation for a substitution grease choice :: sump heater, please contact us. A new oil viscosity may be
Mineral oil or PAO (SHC) advised.
Base (soap ) grade NLGI 2
Use a non-foaming mineral oil, without additives. If an oil
Lithium complex base
containing additives has to be used, make sure that the
Base oil viscosity at 40°C: 100 to 200 mm2/s
supplier confirms the chemical compatibility of the oil and
Dye penetration test (DIN 51817) : 2% minimum
the lead anti-friction properties.
Use of grease which do not fit to the recomended figure
Viscosity data (for information) :
(substitution grease) :
Mineral oil or PAO (SHC) x y
Base (soap ) grade NLGI 2
Lithium base 850 42
Base oil viscosity at 40°C: 100 to 200 mm2/s (high 775 40
viscosity preferred) 700 38
680
Dye penetration test (DIN 51817) : 2% minimum 625 36
550 34
Greases recognized as possible substitution grease: 500 140 32
SKF LGWA2 450 460 30
CASTROL LMX NLGI2 400 28
TOTAL Multis complex EP2 365 26
315 320 24
CAUTION : 280 22
THE USE OF A SUBSTITUTION GREASE CONDUCE TO 240 20
REDUCE THE RE GREASING PERIOD OF 30% 205 220 90 50
18
175 16
NOTE: 140 150 40 14
Lithium and complex lithium soap can be mixed 115 85 12
100 30
Lithium complex and calcium lithium soap can be mixed 85 10
60 68 80
In case of change of grease brand it is recommended to 20 8
40 46 6
proceed to a massive greasing to waste the previous 32 75 10W
20 22 4
grease. 10 0W & 5W 2

NOTE:
A B C
Mixing different types of grease never give as result an x - CST at 40°C
addition of the good greases properties ! Mixing of different y - CST at 100°C
types of grease must be done only after getting the grease A - ISO (VG)
supplier agreement or after cleaning the bearing from the B - SAE J306c Transmissions
old grease C - SAE J300d motors

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5.5.2.2 Synthetic oils 5.5.2.3 Mineral oils

Since the synthetic lubricants are not standardized, no Mineral oils containing special additives (diesel engine oils)
guarantee can be given regarding their chemical and must have a Total Base Number (marked TBN or BN)
mechanical behavior. Some synthetic lubricant may strictly below 40 mgKOH/g
become acid and destroys bearing parts (white metal, oil
ring, sight indicator..) in a short time 5.5.2.4 Oil filtering and pollution
If synthetic oil has to be used; during the first 2000 hours Following indications are related to the maximum
of use the lubricant should be checked at short intervals. acceptable oil pollution level and to the oil filtering level
(filter efficiency) which has to be installed to obtain a clean
Synthetic oils group concerns : oil
Synthetic hydrocarbons (SHC)
Poly-Alpha-Olefins (PAO) Refer to Section 1 to get data about the used bearing
Esther (Diester/Polyolester) The viscosity change must remains within +/- 10% of a
Phosporic ester / Phosphoric triarylester fresh oil lubricant
Polyglycols / Polyalkylglycols Acid Number (TAN) : must not exceed 2
Biodegradable lubricants Acidity change must remains (TAN) +/- 0.5 mg KOH/g of a
White oils fresh oil lubricant
Humidity ratio must remains below 0.05 %
CAUTION:
This paragraph applies to bearings designed for high axial
SYNTHETIC OILS MAY BE USED WITHOUT "LS"
thrust (tilting pads technology as used in bearings type
APPROVALONLY IF USED LUBRICANT ARE ISSUED
.....A).or oil lubricated anti friction bearing :
FROM THE FOLLOWING LIST Maximum acceptable pollution:
Authorized synthetic oils without "LS" special agreement: following ISO 4406 : 17/15/12
following NAS 1638 classe 7
viscosité Type
(cSt ; 40°C)
Filtering level to ensure :
following ISO 16889 : β 10 ( c ) = 100 (filtering 10µ)
KLUBER 32 Summit SH 32
44 Summit SH 46 This paragraph applies to standard bearings with low axial
62 Summit SH 68 thrust , self lub or oil circulation (as types E..Z.K ; E..Z.Q) :
81 Summit SH 100 Maximum acceptable pollution:
following ISO 4406 : 18/16/13
MOBIL 31 SHC 624 following NAS 1638 class 9
65 SHC 626
Filtering level to ensure (oil circulation bearing):
SHELL 32 Madrella Oil AS 32
48 Madrella Oil AS 46 following ISO 16889 : β 25 ( c ) = 100 (filtering 25µ)
68 Madrella Oil AS 68

5.6 WATER COOLER

5.6.1 Maintenance of the water-cooler

5.6.1.1 General points
A regular cooler clogging will have the result to a regular
winding temperature increasing.
The loss of performance of the cooler can come from a
clogging effect of the water tubes or by dust on the cooler
fins
Dust on the cooler fins has to cleaned using a soft brush.
The cooler tubes cleaning period is mainly function of the
water purity
In case of used of non recirculated water with risk (eg: river
water with algae passing trough the cooler) we recommend
the tubes are inspected after one year of operation. The
Inspection should be scheduled following any observed dirt
level.

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5.6.1.2 Cleaning 5.6.2 Servicing the water-cooler
Stop the machine.
5.6.2.1 Cooler removal
Cut off the power supply by isolating the inlet and outlet The cooler unit is slid into its housing. It is possible to
lines, and drain the water. remove the cooler from the housing without removing the
Disconnect the leak sensor (option with double-tube water boxes. The cooler is fastened to the housing via a
cooler), and make sure that there are no leaks. series of screws on the housing.
Remove the water headers on each side of the machine. Remove the supply and return pipes.
Rinse and brush each water box. Provide two supports to hold the cooler when it comes out
of its housing.
Remove the cooler using slings that can be attached to the
connecting flanges.

5.6.2.2 Cooler re-assembly

Carry out the operations of the "Cooler Removal" chapter
in the reverse order. Be careful to push the cooler
completely into its housing before tightening the fastening
screws of the cooler to the casing.

5.7 Not applicable

5.8 BOLT TIGHTENING

5.8.0 General
It is recommended to use a Liquid thread lock compound
on any fixing screws, or plugs (except for electrical contact)
1 - Water header, water connecting side which have been untighten or dismantled during any
2 - Gasket operation.
3 - Internal end plate A medium strength thread locker as or similar as "Loctite
4 - Cooler structure 242" ; or "Omnifit 100M" (from Henkel)
5 - Fins
6 - Gasket 5.8.1 Steel screw in steel tapping
7 - Water header, blind side If no torque value is specified into the concerned chapter
the following values can be used for fixation of parts metal
NOTE:
onto metal
Do not use a hard wire brush as this will remove the
protective oxidation layer which has formed on the Bolt : Steel / Steel
surfaces of the water boxes. Clean each tube with a metal (with medium strength thread locker)
scraper. Rinse in soft water.
Ø nominal Torque Ø nominal Torque
Keep the leakage chamber dry (double-tube water-cooler (mm) (N.m) (mm) (N.m)
only) 3 1,0 18 222
Proceed to a gasket change 4 2,3 20 313
5 4.6 22 430
5.6.1.3 Leak detection for a double-tube exchanger 6 7.9 24 540
If a leak is detected, it is necessary to ascertain its origin 8 19.2 27 798
immediately and repair it. 10 37.7 30 1083
Remove the two water boxes, apply a slight positive 12 64.9 33 1467
pressure in the leakage chamber and thus between the 14 103 36 1890
two tubes (only concerns double-tube coolers). 16 160
If a tube is damaged plug it at BOTH ends. Use a tapered
plug. The plug should preferably be made of salt-water
resistant aluminum bronze or of a synthetic material.

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5.8.2 Plugs 5.9 ELECTRICAL MEASURING
If no torque value is specified into the concerned chapter INSTRUMENTS
the following values can be used for plugs tightening
5.9.1 Instruments used
Steel and copper alloy Plugs
(medium strength thread locker) - AC voltmeter 0-600 Volts
- DC voltmeter 0-150 Volts
Ø nominal Torque Ø nominal Torque - Ohmmeter 10E-3 to 10 ohms
(inches) (N.m) (inches) (N.m) - Megohmmeter 1 to 100 MOhms / 500 Volts
G3/8 30 G1 ¼ 160 - AC Ammeter 0- 4500 A
G1/2 40 G1 ½ 230 - DC Ammeter 0-150 A
G3/4 60 G2 320 - Frequency meter 0-80 Hz
G1 110 G2 ½ 500 Low resistance can be measured by means of an
appropriate ohmmeter or by using a Kelvin or Wheatstone
bridge.
5.8.3 Electrical contact NOTE :
If no torque value is specified into the concerned chapter The identification of the equipment polarity may differ from
the following values can be used for brass (or copper alloy) one ammeter to another.
clean and dry threads.

CAUTION :
5.10 WINDINGS INSULATION CHECK
THE USE OF ANY COMPOUND ONTO ELECTRICAL
CONTACT THREAD IS FORBIDDEN
5.10.0 General
Thread M5 M6 M8 M10 M12 M14 M16 The insulation resistance enables the status of the
machine insulating to be verified.
Torque 2.5 4 8 20 35 57 87
The following measurements can be taken at any time
[N.m]
without any damage to machine insulating material.
The insulation check must be done :
- Before the start up
5.8.4 Rotating diodes
- After a long standstill
CAUTION : - As soon as an abnormal operation occurs.
THE ROTATING DIODE FASTENING SCREWS MUST - At maintenance intervals (refer to chapter 5.1)
BE TIGHTENED USING A TORQUE WRENCH
If the measurement indicates a poor result we advise
CALIBRATED TO THE RECOMMENDED
contacting our Service department.
TORQUE.WITHOUT USING ANY THREAD COMPOUND
To perform the measurement the generator must be
Diode Tightening torque stopped.

SKx 100/..xx 10 N.m If the insulation resistance is less than that required, it is
necessary, to clean and to dry the machine (refer to
SKx 130/..xx 10 N.m chapter 5.13).
SKx 240/..xx 30 N.m DANGER :
BEFORE ANY WORK THE RULES CONCERNING THE
SAFETY OF MATERIALS AND PERSONS MUST BE
5.8.5 Synthetic parts APPLIED (TOTAL LOCKING OF THE GENERATOR
This applies to parts made of light synthetic raw material FUNCTIONS, GROUNDING OF THE PHASES …)
(plastic covers; fiber glass covers; fiber glass fan air
shroud …)
5.10.1 Insulation measure
CAUTION : Disconnect the three phases at the generator terminals.
THE USE OF A THREAD LOCK COMPOUND IS
IMPERATIVE CAUTION
ALL ACCESSORIES MUST BE DISCONNECTED (AVR ,
Thread M8 M10 M12 M14 M16 EMC FILTER ;;;)
REFER TO THE ELECTRICAL SCHEMATICS TO
Torque 15 15 15 15 15 IDENTIFY THE ACCESSORIES TO DISCONNECT
[N.m]

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The measurement has to be taken between one phase
and the earth. Reading is done after 1 minute of test 5.10.2 Polarization index
Test voltage Criteria The polarization index enables the status of the machine
(VDC) (MΩ ; 40°C) insulating to be verified and gives an indication of the
pollution of the winding.
Stator: U ≤ 3 kV 500 200 A poor polarization index may be corrected by a cleaning
Stator: 3 kV< U ≤ 6.6 kV 2500 1000 and drying of the winding
The following measurements can be taken at any time
Stator: U > 6.6 kV 5000 1000 without any damage to the machine insulating material.
Rotor 500 100 CAUTION
Exciter (Stator & Rotor) 500 100 ALL ACCESSORIES MUST BE DISCONNECTED (AVR ,
EMC FILTER…)
Excitation auxiliary 250 100 REFER TO THE ELECTRICAL SCHEMATICS TO
windings (AREP) IDENTIFY THE ACCESSORIES TO DISCONNECT
PMG (stator) 100 100
NOTE:
Heating element 500 100 It must be done using a stable DC source.
Use a specific polarization index appliance (refer to
Resistance Temperature 500 100 chapter 5.10.1 for the correct applied voltage)
Detectors
Proceed for each phase
Open the winding star point
If the insulation resistance is not measured with a tested
element à 40°C a corrective factor has to be used
Rm 40°C= Rt x Kt40
Rt Measured insulation resistance
Kt40 Corrective factor
Curve LV for generator voltage ≤ 3 kV
Curve HV for generator voltage > 3 kV
100

LV
Kt40°C

10 Apply the requested voltage

HV After 1 minute record the Insulating resistance "R 1 min"
After 10 minutes record the Insulating resistance "R 10 min"
1
R (t =10minutes)
ip =
R (t =1minute)
0,1

(°C) polarization index Diagnostic

0,01 ip < 1 Poor

-10 0 1 2 3 4 5 6 7 8 9 10 110
2 < ip < 1 Monitored
If the minimum insulation level is not reached, dry the
windings (refer to chapter 5.13) 2 < ip < 4 Good
ip > 4 Very good

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CAUTION:
DO NOT USE TRICHLORETHYLENE,
5.11 ROTATING DIODE BRIDGE TEST PERCHLORETHYLENE, OR TRICHLORETHANE
Carry out the test using a D.C. source as indicated below.
A diode in good condition should allow the current to flow Avoid mixtures sold under various trademarks which often
only in the anode-to-cathode direction. contain white spirit (which evaporates too slowly) or
chlorinated products (which are likely to become acidified).
Disconnect the diodes before the test.
3 ... 48 volts CAUTION:
DO NOT USE TOO STRONG ALKALINE PRODUCTS.
- + THEY ARE DIFFICULT TO RINSE AND CAUSE
REDUCTION OF INSULATION RESISTANCE BY FIXING
1 2
THE HUMIDITY

5.12.2 Cleaning operation

Use a soft alkaline product or a dedicated cleaning agent
1 - Anode We recommend the use of the cleaning agent "ASOREL
2 - Cathode CN" from "Rhône Chimie Industrie" ; 07300 Tournon ;
France. This cleaning agent do not make the rinsing
operation imperative.
Diode type Positive Negative
It is essential to avoid entry of cleaning agents and dirt into
SKR diode housing diode wire the slots. Apply the product with a brush, sponging
frequently in order to avoid accumulation in the housing.
SKN diode wire diode housing
After cleaning, a rinsing operation is imperative. Hot soft
water (less than 80°C) used under pressure (less than 20
When reassembling ensure that the diodes are tightened bars) can be used.
to the correct torque
CAUTION:
AFTER CLEANING THE GENERATOR, DRYING IS
5.12 CLEANING THE WINDINGS IMPERATIVE TO RECOVER THE CORRECT WINDING
INSULATION
5.12.0 General points
The cleaning of the winding is a heavy service operation
which has to be engaged only if necessary.
The cleaning of the windings become necessary as soon
as the insulation resistance and/or the polarization index
are not satisfactory (refer to chapter 5.10.2)

5.12.1 Coil-cleaning products

A long term efficient cleaning can only be done in a work
Shop if equipped with specialized devices. A site cleaning,
because less efficient, can be considered only for a
transient period.

CAUTION :
USED CLEANING AGENT MUST BE IN ACCORDANCE
WITH LOCAL REGULATION AND ENVIRONMENTAL
STANDARD

CAUTION:
SOLVENTS, WHICH ARE HIGHLY CHLORINATED AND
SUBJECT TO HYDROLYSIS IN DAMP ATMOSPHERES
ARE PROHIBITED. THEY QUICKLY BECOME
ACIDIFIED, PRODUCING CORROSIVE AND
CONDUCTIVE HYDROCHLORIC ACID.

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5.13.1.3 Drying generator in rotation

5.13 DRYING THE WINDING CAUTION
THIS OPERATION MUST BE DONE BY A QUALIFIED
5.13.0 General points OPERATOR
All electric machines must be stored under dry conditions.
If a machine is placed in damp surroundings, it must be Disconnect the machine from the mains
dried before it is put into service. Units operating Short circuit the machine stator at the machine terminals
intermittently or placed in areas with high temperature
variations, are exposed to dampness and must be dried Disconnect the Voltage regulator. If booster current
very thoroughly if necessary. transformer used, short-circuit the booster.
Run the machine at its nominal speed (to air cool the
5.13.1 Drying method machine) with cooling system in operation.
Energized the machine (exciter field) using an separate ex
5.13.1.1 General points
citation source. Use a DC source (batteries ...).
During the drying operation measure the winding insulation
and the polarization index each 12 hours. Install an amp meter on excitation supply line.
To survey the insulation progress, record the measured Adjust the excitation current to get 2/3 of the nominal
values and plot the obtained progress function of the time. excitation current (refer to name plate data or alternator
test report)
When the insulation value becomes constant, the machine
can be considered as dry. Warm up during 4 hours, stop and leave it to cool down
(winding temperature < 50°C)
When the resistance is constant, it may be assumed that
the machine is dry. This operation may take up to 72 Check the winding insulation and the polarization index
hours, depending on the size of the machine and on the If necessary conduce other drying period...
degree of dampness.
U1 E
CAUTION: U2
TAKE FIRE-PREVENTION MEASURES DURING THE V1 S R
DRYING OF THE MACHINE. V2
W1
ALL THE CONNECTIONS MUST BE TIGHTENED. W2

5.13.1.2 Drying generator in a stopped position + -

The procedure " Drying generator in rotation" should be A
preferred to the following one if it is possible to run the DC
generator at its nominal speed
Several thermometers must be positioned onto the winding
S - Stator
and the temperature must not exceed 75°C (167°F). If one
R - Rotor
of the thermometers exceeds this value, immediately
E - Exciter
reduce the heating effect.
Dry by using an external source of heat, for example,
heaters; lamps; or hot air blowers.
Leave openings to exhaust the damp air.

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5.14 RE-VARNISHING
CAUTION:
RE VARNISHING MUST ONLY BE CONSIDERED IF
ABSOLUTLY NECESSARY. A RE VARNISHING
OPERATION DONE ON A WINDING STILL DIRTY OR
NOT PERFECTLY DRY MAY CONDUCE TO A
DEFINITIVE LOSS OF INSULATION

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10. TYPICAL ASSEMBLIES AND DRAWINGS

10.1 MACHINE CUT VIEWS

10.1.1 Machine type A52

1 Rotor 10 Polar wheel
2 Bearing (drive end) 11 Balancing disc
3 Fan hub 12 Exciter field
4 Drive end shield 13 Exciter armature
5 Fan 14 Non drive end shield
6 Fan screen 15 Bearing (non drive end)
7 Stator winding 16 Rotating resistances
8 Stator ribs 17 Rotating diodes
9 Stator lamination 18 Diode bridge cover

4 5 6 7 8 9 10 11 12 13 14

15

16

17
1

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10.1.1 Machine type A60 ; A62

1 Rotor 10 Polar wheel
2 Bearing (drive end) 11 Balancing disc
3 Fan hub 12 Exciter field
4 Drive end shield 13 Exciter armature
5 Fan 14 Non drive end shield
6 Fan screen 15 Bearing (non drive end)
7 Stator winding 16 Rotating resistances
8 Stator ribs 17 Rotating diodes
9 Stator lamination

4 5 6 7 8 9 10 11 12 13 14

18 17
2

15

16

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10.2 ANTI FRICTION BEARING ASSEMBLY

10.2.1 Machine type A52.2

2 1

4
1

Ø 210 K6

Ø 140 n5
3

6 3.5
3
1
Ø 290 H6

Ø 160 n5

2
3

5
Ø 230 H6

Ø 130 n5

Bearing assembly "Power plant"

Drive end Non drive end
1 End cover 1 End shield
2 End cover fixing screw 2 End cover
3 Ball bearing 6232 MC3 3 End cover fixing screw
4 End shield 4 Roller bearing NU 1028 MC3

Bearing assembly " Marine "

Drive end Non drive end
1 End cover 1 End shield
2 End cover fixing screw 2 End cover
3 Ball bearing 6232 MC3 3 End cover fixing screw
4 End shield 4 Bearing pre load spring
5 Ball bearing 6226 C3
6 O-Ring

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v. 1.01

SYNCHRONOUS ALTERNATOR

Project Sinopacific

Serial Nr 605809

Type A52.2 M60

Power 1850 KVA
Voltage 690 V
Power Factor 0.8
Frequency 60 Hz
Speed 1800 rpm

ALTERNATOR MANUAL
LEROY SOMER MANUAL TABLE OF CONTENTS SECTION 0

ALTERNATOR MANUAL

SECTION 0 MANUAL TABLE OF CONTENTS

WARNING

SECTION 1 DATA SHEET

SPARE PARTS LIST

SECTION 2 TEST REPORT

(AVR Settings)

SECTION 3 SERVICING & OPERATING

SECTION 4 AUTOMATIC VOLTAGE REGULATOR

SECTION 5 DRAWINGS ATTACHED

Dedicated manuals for specific equipement

SECTION 0 Page 1
LEROY SOMER MANUAL TABLE OF CONTENTS SECTION 0

ALTERNATOR MANUAL

FOREWORD

WARNING

THIS INSTALLATION AND MAINTENANCE MANUAL

CONCERNS A COMPLETE RANGE OF MACHINES.

SECTION 1 OF THIS MANUAL "DATA SHEET "

ENABLES YOU TO IDENTIFY THE CONSTITUTIVE
ELEMENTS OF YOUR PARTICULAR MACHINE

SECTION 0 Page 2
LEROY SOMER DATA SHEET SECTION 1

ALTERNATOR MANUAL

SECTION 1

DATA SHEET
SPARE PARTS LIST

SECTION 1 Page 0
LEROY SOMER DATA SHEET SECTION 1

ALTERNATOR MANUAL

TABLE OF CONTENTS

1. MACHINE TECHNICAL DATA

1.1 General characteristics

1.2 Excitation - Regulation

1.3 Stator protections

1.4 Not applicable

1.5 Not applicable

1.6 Roller/ball bearing technical data

1.7 Drive end bearing Protection

1.8 Non drive end bearing Protection

1.9 Not applicable

1.10 Cooler characteristics

2. SPARE PARTS

2.1 To order spare parts

2.2 Recommanded spare parts

SECTION 1 Page 1
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1. MACHINE TECHNICAL DATA

1.1 General characteristics

Project Sinopacific
Type A52.2 M60 Engine drive
Serial Nr 605809
Synchronous Triphased
Connections Star
Machine axis Horizontal
Rated output 1850 KVA
Voltage 690 V
Frequency 60 Hz
Power Factor 0.8
Polarity 4
Speed 1800 rpm
Machine protection IP55
Terminal box protection IP 55
Insulation H
Temperatue rise F
Generator air gap 3.5 mm
Exciter air gap 1 mm
Ambient temperature 50 °C
Cooling IC 8 A1 W7
Weight of rotor 1395 Kg
Total weight 4950 Kg

1.2 Excitation - Regulation

Excitation AREP + PMI
AVR type AVR hors fourniture LS

1.3 Stator protections

Space heater (W) 500
under(V) 230
Stator winding sensor 6 x PT100

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1.6 Roller/ball bearing technical data

Drive Non drive
End side End side
Type 6232 6226

Insulated bearing

PERIODICITY OF LUBRICATION
Lubricant type Grease SHELL GADUS S3 V220C2 Grease SHELL GADUS S3 V220C2
Quantity of lubricant 70 g 50 g
Each (hours) 1 500 1 500

A continuous greasing system is recomended for low re-greasing period

1.7 Drive end bearing Protection

Bearing sensor (thrust) 1 x PT100

1.8 Non drive end bearing Protection

Bearing sensor (thrust) 1 x PT100

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1.10 Cooler characteristics

Manufacturer LHERMITTE
Type Air to Water
Rejected power 68 kw
Water quality sea water
Water flow (+0 . +20%) 11.5 m3/h
Water inlet temperature 40 °C
Water outlet temperature 45 °C
Water pressure loss 0.08 bar
Water design pressure 6 bar
Water lines test pressure 9 bar

COMPOSITION
Internal end plate (outer air tube) Naval brass
External end plate (inner water tube) Naval brass
Iner tubes consist of Cupronickel
Outer tube consist of Copper
Blades consist of Copper
Water headers consist of Steel + coating

2. SPARE PARTS

2.1 To order spare parts

1-Identify the machine Serial Number
on the name plate (eg : 605 513)
2- Identify the part number using the attached
drawings and give a description

2.2 Recommanded spare parts

Rotating diodes 3 SKN130/12
Rotating diodes 3 SKR130/12
Anti friction bearing 1 6232
Anti friction bearing 1 6226

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SECTION 2

TEST REPORT
(AVR Settings)

SECTION 2 Page 0
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SECTION 3

SERVICING & OPERATING

SECTION 3 Page 0
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SERVICING & OPERATING

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TABLE OF CONTENTS

2.9.0.2 Description Air/Water double tube

1. GENERAL INFORMATION 5 exchanger 10
2.9.0.3 Description of Air/Water single tube
1.1 INTRODUCTION 5 exchanger 11
1.1.0 General points 5 2.9.1 Water Cooler operating condition 11
1.1.1 Safety notes 5 2.9.1.1 "Standard" operation with water 11
1.1.2 Conditions of use 5 2.9.1.2 "Emergency" operation without water 11
1.1.2.1 Generalities 5 2.9.2 Cooler protection devices 12
1.1.2.2 Vibratory analysis 5 2.9.2.1 Leak detection (float system) 12
1.2 GENERAL DESCRIPTION 6 2.9.2.2 Water temperature sensor (optional) 12
1.2.1 Generator 6 2.9.2.3 Water filtering 12
1.2.2 Excitation system 6 2.10 Not applicable 12
2.11 Not applicable 12
2. DESCRIPTION OF SUB-ASSEMBLIES 7
2.12 TRANSPORT LOCKING SYSTEM 12
2.1 STATOR 7
2.1.1 Electric machine armature 7
2.1.2 Excitation field winding 7 3. INSTALLATION 13
2.1.3 Stator protection 7 3.1 TRANSPORT AND STORAGE 13
2.1.3.1 Heating resistor 7 3.1.1 Transport 13
2.1.3.2 Stator winding temperature sensor 7 3.1.2 Storage warehouse 13
2.1.3.3 Stator air sensor 7 3.1.3 Maritime packing 13
2.1.3.4 Bearing vibration sensor 8 3.1.4 Unpacking and installation 14
2.2 ROTOR 8 3.1.5 Storage measures of antifriction bearings 14
2.2.1 Revolving field-coil 8 3.1.6.1 General points 14
2.2.2 Excitation armature 8 3.1.6.2 Short term storage 14
2.2.3 Fan (machines: IC 0 A1) 8 3.1.6.3 Long term storage 14
2.2.4 Rotating diode bridge 8 3.1.6 Not applicable 14
2.2.5 Balancing 9 3.1.7 Storage measures of water cooled
machines 14
2.3 TERMINAL BOX 9
2.3.0 Description 9 3.2 INSTALLATION OF THE MACHINE 15
2.3.1 Automatic voltage regulator (AVR) 9 3.2.1 Fitting the coupling (double-bearing
machine only) 15
2.4 NAMEPLATES 9 3.2.2 Fitting the stator 15
2.4.1. Main nameplate 9
2.4.2. Lubrication nameplate 9 3.3 MACHINE ALIGNMENT 15
2.4.3. Rotation direction nameplate 9 3.3.1 Alignment general points 15
3.3.1.1 General points 15
2.5 ANTI FRICTION BEARING 10 3.3.1.2 Shaft elevation caused by Thermal
2.5.0 Description of antifriction bearings 10 elevation 16
2.5.1 Antifriction bearing protection devices 10 3.3.1.3 Not applicable 16
2.6 Not applicable 10 3.3.1.4 Shaft elevation of Anti-friction bearing
machine 16
2.7 Not applicable 10 3.3.1.5 Generator check before alignment 16
3.3.1.6 Alignment procedure"Double
2.8 Not applicable 10
concentricity" alignment method 16
2.9 WATER COOLER (CACW) 10 3.3.2 Two bearings machine alignment (flanged)
2.9.0 Description of the cooler 10 17
2.9.0.1 General points 10 3.3.2.1 Machines without axial end play (standard)
17

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3.3.2.2 Machines with axial end play 17 5.2.1 General points 30
5.2.2 Double bearing machine 30
3.4 ELECTRICAL CONNECTIONS 18 5.2.3 Single bearing machine 30
3.4.0. General points 18
3.4.1 Phase-sequence 18 5.3 ANTI FRICTION-BEARINGS 30
3.4.1.1 Standard units ; IEC 34-8 18 5.3.1 General points 30
3.4.1.2 On request ; NEMA 19 5.3.2 Cleaning bearings from old grease 30
3.4.2 Insulating distances 19 5.3.3 Cleaning bearings assembly area 31
3.4.3 Added products in the terminal box 19 5.3.4 Bearing removal 31
5.3.5 Bearing re-assembly 31
3.5 WATER COOLER INSTALLATION 20
5.4 Not applicable 31
4. START-UP 20 5.5 LUBRICANTS 32
4.1 ELECTRICAL START-UP INSPECTION 20 5.5.1 Greases 32
4.1.0 General points 20 5.5.2 Oils 32
4.1.1 Winding Insulation 20 5.5.2.1 General 32
4.1.2 Electrical connections 20 5.5.2.2 Synthetic oils 33
4.1.3 Parallel operation 20 5.5.2.3 Mineral oils 33
4.1.3.1 Definition of parallel operation 20 5.5.2.4 Oil filtering and pollution 33
4.1.3.2 Possibility of parallel operation 20 5.6 WATER COOLER 33
4.1.3.3 Parallel coupling 21 5.6.1 Maintenance of the water-cooler 33
4.2 MECHANICAL START-UP INSPECTION 21 5.6.1.1 General points 33
4.2.0 General points 21 5.6.1.2 Cleaning 34
4.2.0.1 Alignment ; fixing ; prime mover 21 5.6.1.3 Leak detection for a double-tube
4.2.0.2 Cooling 21 exchanger 34
4.2.0.3 Lubrication 21 5.6.2 Servicing the water-cooler 34
4.2.1 Anti friction bearing machines start up 21 5.6.2.1 Cooler removal 34
4.2.2 Not applicable 21 5.6.2.2 Cooler re-assembly 34
4.2.3 water cooler Start-up 21 5.7 Not applicable 34
4.2.4 Vibrations 21
5.8 BOLT TIGHTENING 34
4.3 START-UP SEQUENCE 22 5.8.0 General 34
4.3.1 Static checks 22 5.8.1 Steel screw in steel tapping 34
4.3.2 Rotating checks 22 5.8.2 Plugs 35
4.3.2.0 Rotor speed rate of rise (Standard unit) 22 5.8.3 Electrical contact 35
4.3.2.1 Rotating checks not excited 22 5.8.4 Rotating diodes 35
4.3.2.2 Rotating checks at no load excited 22 5.8.5 Synthetic parts 35
4.3.2.3 Generator and site safety parameters 22
4.3.2.4 Rotating checks at full load 22 5.9 ELECTRICAL MEASURING
4.3.3 Generator start up check list 23 INSTRUMENTS 35
5.9.1 Instruments used 35
5. MAINTENANCE AND SERVICING 27 5.10 WINDINGS INSULATION CHECK 35
5.10.0 General 35
5.0 GENERAL 27
5.10.1 Insulation measure 35
5.1 MAINTENANCE SCHEDULE 28 5.10.2 Polarization index 36
5.1.0 Not applicable 28
5.1.1 Stator 28
5.11 ROTATING DIODE BRIDGE TEST 37
5.1.2 Rotor 28 5.12 CLEANING THE WINDINGS 37
5.1.3 Terminal box 28 5.12.0 General points 37
5.1.4 Not applicable 28 5.12.1 Coil-cleaning products 37
5.1.5 Anti friction bearing 28 5.12.2 Cleaning operation 37
5.1.6 Machine cooler 28
5.1.7 Rubber dampers 29 5.13 DRYING THE WINDING 38
5.1.8 Not applicable 29 5.13.0 General points 38
5.1.9 Not applicable 29 5.13.1 Drying method 38
5.1.10 Protection devices 29 5.13.1.1 General points 38
5.13.1.2 Drying generator in a stopped position 38
5.2 AIR GAP CHECK 30 5.13.1.3 Drying generator in rotation 38

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5.14 RE-VARNISHING 39

10. TYPICAL ASSEMBLIES AND DRAWINGS

40
10.1 MACHINE CUT VIEWS 40
10.1.1 Machine type A52 40
10.1.1 Machine type A60 ; A62 41
10.2 ANTI FRICTION BEARING ASSEMBLY 42
10.2.1 Machine type A52.2 42

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Any operating condition other than those specified by the
1. GENERAL INFORMATION original tender must receive a Leroy Somer agreement
Any modification of the machine structure must receive a
Leroy Somer agreement
1.1 INTRODUCTION
1.1.2.2 Vibratory analysis
1.1.0 General points It is the responsibility of the gen set manufacturer to
This manual provides installation, operating and ensure that the different assembled system will be
maintenance instructions for synchronous machines. It vibratory compatible.(ISO 8528-9 and BS5000-3)
also describes the basic construction of these machines. It is the responsibility of the gen set manufacturer to
This manual is general ; it applies to an entire group of ensure that the shaft line torsional analysis has been done
synchronous generators. Additionally, in order to make and accepted by the different parties (ISO 3046)
information-finding easier, Section 1, "Characteristics and
Performance", has been included, describing the machine CAUTION :
completely (type of construction, type of bearing, EXCEEDING THE VIBRATORY LEVEL ALLOWED BY
protection index, and so forth...); this will enable you to THE STANDARD ISO 8528-9 & BS5000-3 MAY CREATE
determine exactly the chapters which apply to your HEAVY DAMAGES (BEARING DAMAGE, STRUCURE
machine. CRACKS …).
This synchronous machine has been designed for a EXCEEDING THE TORSIONAL VIBRATORY LEVEL OF
maximum length of service. To achieve this, it is necessary THE SHAFT LINE (ex: ABS, LLOYD …) MAY CREATE
to pay special attention to the chapter concerning the HEAVY DAMAGES (CRANKSHAFT FAILURE ,
periodic maintenance schedule for the machines. GENERATOR SHAFT FAILURE, …)

1.1.1 Safety notes Refer to chapter 2.1.3.4 for further information about the
accepted vibration level of the standard ISO 8528-9 and
The warnings "DANGER, CAUTION, NOTE" are used to BS5000-3
draw the user’s attention to different points:

DANGER :
THIS WARNING IS USED WHEN AN OPERATION,
PROCEDURE, OR USE MAY CAUSE PERSONAL
INJURY OR LOSS OF LIFE

CAUTION :
THIS WARNING IS USED WHEN AN OPERATION,
PROCEDURE, OR USE MAY CAUSE DAMAGE TO OR
DESTRUCTION OF EQUIPMENT

NOTE :
This warning is used when an operation, procedure, or
delicate installation requires clarification.

1.1.2 Conditions of use

1.1.2.1 Generalities
A machine must only be installed, operated, by qualified
and trained persons.
Any technical engineer operating, maintaining this machine
must be allowed to practice in regard with local working
laws (eg: to be certified to operate on high voltage
devices…)
Any product (sealing compound; cleaning product…) used
during any maintenance or servicing must be in
accordance with local regulation and environmental
standard
A machine can only be operated for the duty foreseen by
its original tender.
The main data of this machine are summarized in "Section
1" of this manual

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1.2 GENERAL DESCRIPTION

1.2.1 Generator
The synchronous generator is an alternating-current
machine, without ring or brush. The machine is cooled by
the flow of air through the machine.
For a better comprehension, use the drawings of chapter
10.
The Automatic Voltage Regulator (item 6) supplies the
exciter field (static part ; item 1) in DC current.
The Exciter works as a reversed alternator.
The Exciter armature (rotating part ; item 2) generate a
three-phase current which supplies the Rotating diodes
bridge (rotating part ; item 3)
The Rotating diodes bridge (rotating part ; item 3) rectifies
the three phases current in DC current which supplies the
Revolving field (rotating part ; item 4)
The Revolving field (rotating part ; item 4) excites the
Alternator armature (static part ; item 5) which generates a
three phases current

5 1
3
4 2

1- Excitation field winding

2- Excitation armature
3- Rotating diodes bridge
4- Revolving field
5- Alternator armature
6- Automatic Voltage Regulator

1.2.2 Excitation system

The excitation system is fitted at the Non Drive End side

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2.1.3.2 Stator winding temperature sensor
2. DESCRIPTION OF SUB-ASSEMBLIES The temperature sensors are located in the zone assumed
to be the hottest part of the machine. The sensors are
connected to a terminal box.
2.1 STATOR Depending on the temperature rise of the machine, the
temperature of the sensors should not exceed a maximum
2.1.1 Electric machine armature of :
The alternator stator (armature) is a stacking of low losses
steel laminations assembled under pressure. The stator TEMP. RISE ALARM TRIP
coils are inserted and blocked in the slots, then class
impregnated with varnish and polymerised (VPI system).
Power (KVA) < 5000 > 5000 < 5000 > 5000
(b) (a)
B 130 °C 125 °C 135 °C 130 °C
3
F 155 °C 150 °C 160 °C 155 °C
2 4 H 175 °C 170 °C 180 °C 175 °C

(c) To improve the machine protection we recommend to set

the alarm point following effective site conditions:
5
Alarm temperature (*) = Highest recorded temp + 10°K
1 Trip temperature (*) = Alarm temperature + 5 °K
(*) do not pass over the values of the previous table.
1 - Stator
(*)Highest recorded temp: Temperature measured at
2 - Rotor
the site in the worst temperature condition at the stator
3 - Exciter
temperature sensor
4 - Rotating diodes
a - Stator Air inlet (cold air) E.g.: a class B machine reached 110°C during a factory
b - Stator air exhaust (warmed air) heat run test. Set the alarm temperature to 120°C instead
c – Rotating diodes air cooling of 130°C as indicated in the previous chart. Set the
emergency shutdown to 115°C instead of 135°C as
indicated in the previous chart.
2.1.2 Excitation field winding
The excitation field winding comprises a wound solid 2.1.3.3 Stator air sensor
element. As an option an RTD or thermostat can measure the stator
The excitation is flanged on the rear end shield of the air inlet temperature (cold air)
machine. Stator air inlet temperature; Alarm points and shutdown:
• alarm Nominal air inlet stator + 5 K
2.1.3 Stator protection • shutdown 80°C

2.1.3.1 Heating resistor Stator air outlet temperature; Alarm points and shutdown:
• alarm Nominal air inlet stator + 35K
The heating element avoids internal condensation during • shutdown Nominal air inlet stator + 40K
the shutdown periods. It is connected to the main terminal
box strip. The heating resistor is switched on as soon as NOTE :
the machine is shut down. For an open drip proof machine the nominal air
temperature entering the stator corresponds to the ambiant
The electrical characteristics are provided in Section 1
temperature
"Technical Characteristics".
NOTE :
If quickly restarting after a stop Inhibit the stator air sensor
safety "alarm" for few seconds (no more than 30 s) during
the machine start up;
NOTE:
For a water cooled machine (CACW) the nominal air
entering the stator may be approximated as following:
Tair entering stator = Twater entering cooler + 15°K

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2.2.3 Fan (machines: IC 0 A1)
2.1.3.4 Bearing vibration sensor
The synchronous machine is characterized by a self-
This chapter concerns the setting of seismic probes. For ventilation system. A centrifugal fan is mounted between
setting of proximity probes refer to chapter 2.2.6.1 the revolving field coil and the front bearing.
The vibration level of the machines is directly linked to the Air intake is at the rear of the machine and the exhaust on
duty and to the site characteristics. the drive end side.
We propose the following adjustment: The fan consists of a hub, which is keyed and heat-shrunk
Vibration Alarm (*) = Site Highest Vibration level + 50% onto the shaft. The flange is made of welded steel,
Vibration Trip = Vibration Alarm + 50% attached to the hub with hexagonal head-cap screws. The
(*) do not pass over the values of the following chart ventilation effect is obtained through, inclined blades. The
air is exhausted by centrifugation. The air inlet and outlet
The machines are engineered to be able to withstand the
must remains free during operation
vibration level specified by the standard ISO8528-9 and
BS5000-3
2.2.4 Rotating diode bridge
Maximum levels for : reciprocating Internal combustion
engines The rectifier bridge, comprising six diodes, is placed at the
rear of the machine. The rotating bridge is made of fiber
Nominal speed kVA Generator vibration level glass with a printed circuit to connect the diodes together.
(rpm) (nominal conditions) This bridge is supplied with alternating current by the
excitation armature and supplies direct current to the
Overall Any harmonics revolving field-coil. The diodes are protected against over
(mm/s rms)
(2–1000 Hz)
voltage by rotating resistors, or by varistors. These
resistors (or varistors) are mounted in parallel with the
1300 à 2199 > 250 < 20 revolving field-coil.
< 0.5 mm ; pp
721 à 1299 ≥ 250 < 20
(5 – 8 Hz) 2
> < 18
1250 1 + 3
< 9 mm/s ; rm
≤ 720 > < 15 (8 – 200 Hz)
1250
< 10 (*)
(*) generator on concrete base
-

Maximum levels for : Turbines 1 - Field

2 - Rotating resistors / varistors
Turbines Max advised : 4.5
(overall ; mm/s rms) 3 - Exciter armature
(hydraulic ; gaz ; steam)

The inner and outer rings are connected to the revolving

field-coil
2.2 ROTOR
1
2.2.1 Revolving field-coil
The Revolving field is a salient pole type, without any fixing
device as dove tail, cap bolt …
2
The revolving field is heat-shrunk onto the shaft

2.2.2 Excitation armature

The excitation armature is constructed by stacking
magnetic steel laminations. These steel laminations are
held in place by rivets.
The excitation armature is keyed and heat-shrunk onto the 1 - Outer ring
shaft. 2 - Inner ring
The windings are enamelled copper wires, class "F" The diode fastening screws must be tightened to the
insulation (or "H", depending on the customer's request or correct torque.
size of the machine).

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CAUTION :
THE ROTATING DIODE FASTENING SCREWS MUST
BE TIGHTENED USING A TORQUE WRENCH 2.4 NAMEPLATES
CALIBRATED TO THE RECOMMENDED TORQUE.
2.4.1. Main nameplate
The main nameplate is fitted to the stator. It gives the
2.2.5 Balancing manufacturer's electrical characteristics, the type of
The complete rotor has been balanced according to machine and its serial number. The serial number is
ISO8221 standard in order to obtain a residual imbalance necessary for any contact with the factory
less than : For machines with anti-friction bearings lubrication
Gen set : Class G2.5 parameters are indicated.
Turbine : Class G1
The shaft end is cold-stamped to indicate the type of 2.4.2. Lubrication nameplate
balancing (as per ISO8221)
The machines with Sleeve bearings have a lubrication
H : balancing with Half-key carried out as
plate attached to the bearing, indicating:
standard
• Type of bearing
F : balancing with Full key (done on request)
• Oil change frequency
N : balancing without key (done on request)
• Oil capacity of bearing
The balancing is carried out in two planes. • Oil viscosity.
The first is on the fan. It is recommended, when the fan is
The machines with anti-friction bearings have the
refitted (after servicing) to respect the initial indexing.
lubrication parameters indicated on the main nameplate
The second is at the Non Drive End side.
fixed on the stator, indicating :
The coupling must be balanced to fit the generator rotor • Type of bearing
balancing. • Grease-change frequency
• Quantity of grease
• Grease type
2.3 TERMINAL BOX
2.4.3. Rotation direction nameplate
2.3.0 Description Located on the stator an arrow indicates the direction of
Use the attached Terminal box drawing rotation.
The openings provide access to the terminals.
The gland plates are made of non-magnetic materials in
order to avoid circulating currents.
If accessories not supplied by Leroy Somer have to be
installed in the terminal box (CT’s, VT’s, Shunt …) refer to
chapter.3.4.3

2.3.1 Automatic voltage regulator (AVR)

When the automatic voltage regulator is located in the
terminal box, it is fitted on a separate plate, insulated from
vibration by means of dampers. The operation of the
regulator is explained in Section 3.

CAUTION :
RUBBER DAMPERS MUST BE CHECKED
PERIODICALLY AND REPLACED EVERY FIVE YEARS

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2.5 ANTI FRICTION BEARING 2.9 WATER COOLER (CACW)

2.5.0 Description of antifriction bearings 2.9.0 Description of the cooler

The bearings ensure the rotor rotation guiding and axial 2.9.0.1 General points
location
The purpose of the cooler is to remove machine heat
The bearings are protected from ambiant dust by labyrinth losses (mechanical, ohmic etc). The exchanger is located
seals and are of replaceable type. on the top of the machine.
The bearings must be lubricated regularly. The old grease Normal operation:
is forced out at the lower part of the bearings by the force The internal air goes through the exchanger, transferring
of the new grease being injected. the heat and then goes back to the machine.

CAUTION:
2.5.1 Antifriction bearing protection devices WHEN THE HOUSING INSTALLED WITH VIBRATION
As an option, the bearing may be equipped with RTD or DAMPERS, THE DAMPERS MUST BE PERIODICALLY
PTC sensors (customer’s choice) to detect eventual CHECKED AND CHANGED EACH FIVE YEARS.
overheating
For special use in warm surroundings where the CAUTION:
temperature of the bearings exceeds the authorised limit THE COOLER MUST BE FULLY OPERATIONAL AS
(for a bearing known to be in good condition), contact us. SOON AS THE MACHINE IS ROTATING (EVEN IF THE
Bearing; Alarm points and shutdown: MACHINE IS RUN AT NO LOAD !)
• alarm 90°C (194°F)
• shutdown 95°C (203°F) 2.9.0.2 Description Air/Water double tube exchanger
To improve the machine protection we recommend to set The internal air flow is moved by a fan fixed on the
the alarm point following effective site conditions: machine shaft. The internal cooling air circulates through
the machine and through the air-cooler in a closed circuit.
Alarm temperature (*) = Highest recorded temp + 15°K
The internal air circulation can be created through natural
(*) do not pass over the values of the previous chart.
ventilation (machine class IC 8 A1 W7) or through
E.g. : At site the common bearing temperature is 60°C. Set separate ventilation (machine class IC 8 A6 W7).
the alarm temperature to 75°C instead of 90°C as
Eg : machine class IC 8 A1 W7
indicated in the previous chart
air 1 air
NOTE:
Specific dedicated devices based on the analysis of the
vibration signal are able to monitor bearings behavior
air
2.6 Not applicable

2.7 Not applicable

1 – Air to Water cooler
2.8 Not applicable The double-tube technique keeps the cooling circuit from
being affected by possible water leakage. The double tube
provides a high safety level. In case of leakage, the water
goes from the inside of the internal tube to the coaxial
space between the two tubes. The water is drained axially
to a leakage chamber where it may activate a sensor.
An exchanger comprises a fin-tube block containing :
• a steel frame.
• a fin-tube block crimped mechanically to the tubes.
The tube bundle is roll-expanded in the end plates (parts 3
and 4)
The water distribution in the tubes is provided by two
removable water boxes (part 5). A water box is equipped
with collars for fitting the inlet and outlet lines. Neoprene
seals ensure watertightness between the water boxes and
the end plates.

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A
2.9.1 Water Cooler operating condition
B 1
2
2.9.1.1 "Standard" operation with water
CAUTION:
WATER SUPPLY MUST BE EFFECTIVE AS SOON AS
C THE GENERATOR IS ROTATING UNTIL THE
COMPLETE SHAFT LINE STOP

3 5 CAUTION:
6 4 WATER SUPPLY MUST BE STOPPED AS SOON AS
THE GENERATOR IS STOPPED TO AVOID IMPORTING
1 - Internal tube CONDENSATION INTO THE GENERATOR
2 - External tube with internal grooving and with External
fins Condensation trouble may appears when using too cold
3 - Internal end plate water. Condensation trouble can be managed by the help
4 - External end plate of psychrométric diagram (Mollier diagram).
5 - Water header Water thermostatic valve monitored by the generator air
6 – Leakage drain plug temperature to regulate the water flow can help to fix the
A - Air B - Leakage C – Water problem.

2.9.0.3 Description of Air/Water single tube exchanger 2.9.1.2 "Emergency" operation without water
The internal air flow is moved by a fan fixed on the As an option the machines can be engineered to be able to
machine shaft. The internal cooling air circulates through operate in an "Emergency" mode without water flow
the machine and through the air-cooler in a closed circuit. Only machines engineered for this operation case can
The internal air circulation can be created through natural operate without water flow.
ventilation (machine class IC 8 A1 W7) or through
CAUTION :
separate ventilation(machine class IC 8 A6 W7).
THIS OPERATING CONDITION CORRESPOND TO A
An exchanger comprises a fin-tube block containing POWER DERATED OPERATING MODE
• a steel frame
• a fin-tube block crimped mechanically onto the tubes. In such case the machine operate in "open drip proof"
• The tube bundle is roll-expanded in the end plates mode (cooling ensured by ambient air, with a protection
The water distribution in the tubes is provided by two water level IP23)
boxes. One water box is equipped with collars for fitting the
inlet and outlet water lines. Neoprene seals provide CAUTION :
watertightness between the water boxes and the end AIR INLET AND OUTLET FLAPS LOCATED AT THE
plates. NON DRIVE END AND DRIVE END SIDE OF THE
MACHINE MUST BE OPEN
A 1 (Concerned openings are marked by specific labels)
before running the shaft line

2 3

1 - Tube with fins

2 - End plate
3 - Water header
A - Air B – Water

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2.9.2 Cooler protection devices
2.9.2.2 Water temperature sensor (optional)
2.9.2.1 Leak detection (float system) A temperature sensor may be installed into the water inlet
A magnet float activates a switch located in the float flow of the cooler.
guiding rod Proposal of adjustment of the water inlet sensor :
Alarm temperature (*) = Water site temp max + 5 °K
Trip temperature (*) = Alarm temperature + 5 °K
A
x 2.9.2.3 Water filtering
1 Water filtering is not ensured by Leroy Somer.
y Water filtering must be better than 300 µ
z
2 2.10 Not applicable

2.11 Not applicable

1 - Guide rod
2 - Magnetic float
A – No potential contacts 2.12 TRANSPORT LOCKING SYSTEM
x - Blue y - Brown z – Black Certain type of Machines may have their rotor locked
during transport.
The locking systems are red painted
The locking systems must be removed just before the
alternator final installation and re install if the alternator is
later re transported.
CAUTION:
THE ROTOR LOCKING SYTEM MUST REMAIN IN
PLACE IF THE ALTERNATOR IS SUBJECT TO BE
TRANSPORTED.

CAUTION:
THE ROTOR LOCKING FIXING SCREW MUST BE
TIGHTENED TO THE NOMINAL RECOMMENDED
TORQUE.

The Locking system fixing screws must be correctly

tightened. A too low torque can conduce to an insufficient
locking effect

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Non Drive End bearing; Locking system examples:
3. INSTALLATION
1

3.1 TRANSPORT AND STORAGE

2
3.1.1 Transport
3
During the transport the intermittent shocks level applied to
2
the machines must remains below 30 m/s
Machines equipped with anti friction bearing must have
3 their rotor locked during the transport to avoid "false
brineling" problem
Machine temperature must remains within the range -20°C
to +70°C. Stay down to -40°C during few hours is admitted.
1 3 The machine must be protected against bad weather
conditions and condensation.
Machines must not be handled at temperature below -20°C
2 3
3.1.2 Storage warehouse
The machine must be stored in clean and dry premises
which are not subject to abrupt changes in temperature or
to high humidity (75% maximum)
CAUTION:
1 - Cable THE HEATING RESISTOR MUST BE CONTINUOUSLY
2 – Red label out of the alternator indicating a Locking
SWITCHED ON
system
3 – Rotor locking system Storage at an ambient temperature of +5 to +45° C is
recommended.
The machine must not be subject to vibrations higher than
1mm/s rms

3.1.3 Maritime packing

The synchronous machine is carefully packed in a wooden
crate, then hermetically sealed.
In any case the generator must be store in a warehouse
(refer to chapter 3.1.2)
This packing provides access to the dessicant for periodic
change (every 18 months)
CAUTION :
BREAKING THE HERMETIC PROTECTIVE FILM
DISCHARGES LEROY SOMER OF ITS LONG STORAGE
GUARANTEE

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3.1.6.3 Long term storage

3.1.4 Unpacking and installation
When a sleeve bearing machine has to be stopped for
DANGER : more than one year:
THE DEDICATED LIFTING HOOKS MUST BE USED TO Drain the bearing. Place a "Silicagel" gag inside the
LIFT THE MACHINE WITH SLINGS (ONE HOOK AT bearing oil sump (it is necessary to open the bearing
EACH CORNER OF THE MACHINE) housing to proceed)
Rotors of machines with Sleeve bearings and single- Place an adhesive strip along the parting lines of the
bearing machines, are blocked during transportation so as housing.
to avoid any movement. Withdraw the retaining bars. The
Pour the recommended protecting agent through the oil
retaining bar is screwed to the end of the shaft and to the
filling hole of the bearing (around 50 cc). Turn the shaft
front support.
several times in order to spread the product evenly
CAUTION : throughout the bearing.
TRANSPORT LOCKING DEVICES PAINTED RED OR CAUTION:
WITH RED STICKER MUST BE REMOVED. A VISIT OF THE BEARING (research of corrosion
The end of the shaft is protected from corrosion. Clean it marks) MUST BE DONE AT LEAST ONCE PER YEAR
before coupling.
CAUTION:
The heating resistor must be switched on at all times.
BEFORE START UP IT WILL BE NECESSARY TO
Before starting the machine up again, it will be necessary REMOVE THE "SILICAGEL" BAG AND TAPES
to carry out a start-up inspection.

3.1.5 Storage measures of antifriction bearings 3.1.6 Not applicable

This chapter must be taken in consideration if a machine is
stopped more than 6 months. 3.1.7 Storage measures of water cooled machines
After 6 months of stop; grease by injecting two time the For water-coolers, the water flow must be shut off. If the
grease volume used for a standard maintenance. water is not treated and if there is likelihood of freezing, the
exchanger must be drained.
Then, each 3 months turn the machine shaft line of few
turns while injecting a standard grease volume

3.1.6.1 General points

CAUTION:
FOR MINERAL OIL WE RECOMMEND THE USE OF
TECTYL PRODUCTS FROM "VALVOLINE GmbH" SUCH
AS TYPE "511 M"
FOR SYNTHETIC OIL WE RECOMMEND THE USE OF
"JELT 003400" SPRAY FROM "ITW SPRAYTEC"

NOTE :
It is possible to start the machine up without removing the
recommended protective coating.

3.1.6.2 Short term storage

When a sleeve bearing machine has to be stopped for
more than one month and less than one year:
Do not drain the bearing oil
Pour the recommended protecting agent through the oil
filling hole of the bearing (around 50 cc). Turn the shaft
several times in order to spread the product evenly
throughout the bearing.

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3.2 INSTALLATION OF THE MACHINE 3.3 MACHINE ALIGNMENT

3.2.1 Fitting the coupling (double-bearing machine 3.3.1 Alignment general points
only)
3.3.1.1 General points
The coupling must be balanced separately before
assembly on the machine shaft. Refer to the balancing The alignment aims to obtain the driving shaft and the
instructions in chapter 2.2.5. driven shaft coaxial when operating at the nominal
conditions (machine rotating; at its operating temperature)
The shrinking of the half coupling onto the electrical
machine shaft end must be chosen, by the gen-set The machine must be aligned according to the Leroy
manufacturer, in such way as it should be removable for Somer standard and adhere to the manufacturer's
maintenance (e.g.: bearing change) alignment standard for the drive machine and coupling
tolerance
When heating the machine has its shaft line which grow
3.2.2 Fitting the stator
up. Between stop and rotation the shaft axis location inside
Four plates on the frame enable the unit to be fitted to a its bearing is different. The total axis height elevation is
skid. composed of the thermal elevation and of the bearing
The fixing bolts must support the forces created by the elevation.
static and dynamic loads.
CAUTION:
The machine may be positioned by means of 4 dowel pins.
THE ALIGNMENT MUST BE DONE TAKING IN
The dowel pins make later realignment easier. (The use of
CONSIDERATION OF THE SHAFT THERMAL GROWTH
pins is optional).
CORRECTION
The machine may be aligned through the use of 4 jacking-
screws. These jacking-screws allow the machine to be The correct locating of the parts must be obtained by
positioned according to the various axes. inserting shims under the machine feet.
The double-bearing machines are mounted with bearings
(ball or roller) or Sleeve bearings. The axial clearance of
the bearings (if the machine has Sleeve bearings) must be
distributed as well as possible, taking into account the axial
thermal expansion. The Anti friction-bearing machines with
a positioning bearing (standard machine) do not have axial
play.
The machines are delivered with the rotor mechanically
centered (axially and radially) in relation to the stator.

CAUTION :
THE ALIGNMENT STANDARDS OF MANUFACTURERS
OF DRIVE MACHINES ARE FREQUENTLY MORE
ACCURATE THAN THOSE OF LEROY SOMER

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3.3.1.2 Shaft elevation caused by Thermal elevation simultaneously, the measurement is not affected by the
error resulting from run out of the two shaft ends.
∆ H (mm) =λ (°K-1) . H(m) . ∆T(°K)
H(m) = Height of the machine axis
∆T= frame temperature elevation = 30°C C1
λ = Coefficient of steel elongation = 0.012 °K-1

3.3.1.3 Not applicable 12h B

3.3.1.4 Shaft elevation of Anti-friction bearing machine

9h
Caused by thermal growth of the anti friction bearing.itself
A
"2" 3h

Y ° 0,01 mm
6h C2

L
"1"
1 - cold, in rotation, or stopped
2 - hot, in rotation, or stopped The "C1" and "C2" micrometers are located at an angular
difference of 180°.
3.3.1.5 Generator check before alignment More the distance "L" is long better should be the
Check the generator shaft end run out. sensitivity to detect the angular error
Total Indicator Reading must be within 0.04 mm
The reading should be performed 4 times for the "C1" and
NOTE: "C2" micrometers : at 12h, 3h, 6h, 9h
RUN OUT CHECK CAN BE NOT FEASABLE ON It is recommended to record the results and draw the axes
SLEEVE BEARING MACHINE BECAUSE OF THE TOO for better evaluation, as explained below. Interpretation of
HIGH NECESSARY BREAK AWAY TORQUE NEEDED measurements by means of an example.
TO TURN THE ROTOR Values given in millimeters. The reading is considered
positive (+) when the micrometer stylus is pushed inwards.

3.3.1.6 Alignment procedure"Double concentricity"

alignment method
NOTE:
LASER DEVICES CAN MAKE THE JOB EASIER THAN
WITH THE SHOWN PROCEDURE

This method is not sensitive to axial movements.(the

alignment methods using axial measure may often be
perturbed by small axial movement of the rotor)
It is possible to check the alignment with the coupling
installed.
Equipment required :
Two rigid brackets. The rigidity of the two brackets is very
important.
Two micrometers
Implementation :
During the measures, both shafts must turn simultaneously
in the same direction. (For example : the coupling installed
with its screws untightened). By turning both shafts

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MEASUREMENTS In the both planes the parallelism error is:
+ 1.34 52 + 9 2 = 0.103mm or 16 2 + 47 2 = 0.496 mm (not
C1 C2 acceptable)
+ 0.90
+ 0.70 3.3.2 Two bearings machine alignment (flanged)
12h B
3.3.2.1 Machines without axial end play (standard)
+ 0.164
The alignment must take the tolerances of the coupling
9h into account.
+ 0.86 A 3h
+ 1.04 CAUTION:
+ 0.102
A MISALIGNMENT EVEN IF ACCEPTABLE BY THE
6h L=400 COUPLING MUST NOT CREATE STRESSES LEVEL
+ 1.00 NOT ACCEPTABLE BY THE BEARING
Measurements referring to the vertical plane: Shafts alignment limits to follow:
Considering the vertical plane "C1" : The vertical action
towards the top of shaft "A" on the micrometer is dominant.
In the plane "C1" the axis "A" is higher than axis "B” Angular error
( 0.9 – 0.1 ) / 2 = - 0.05 mm
0.01 mm
In the vertical plane "C2", the vertical action towards the
0.08 mm 100 mm
top of shaft "B" on the micrometer is greater.
parallelism error
In the plane "C2" the axis "B" is higher than axis "A"
( 0.134 – 0.102 ) / 2 = 0.16 mm To check the alignment, there are different methods: the
"double concentricity" method is described in the
The respective position of the axes is as follows: "alignment procedure" chapter 3.3.1.6.

3.3.2.2 Machines with axial end play

C1 The alignment must be performed using the same method
B as for a machine having no axial end play.
A The assembler should ensure that the generator shaft will
be properly located (centered) and the shaft line should be
0.16 hold in place while in operation
C2 CAUTION:
0.05
THE ROTOR AXIAL LOCATION MUST BE CHECKED TO
Regarding the vertical plane the angular alignment error is: AVOID ANY MAGNETIC OFFSET
( 0.16 + 0.05 ) *100 / 400 = 0.0525 mm/100mm (not
acceptable) CAUTION:
Measurements referring to the horizontal axis: THE FAN THRUST OF THE GENERATOR MUST BE
In the plane "C1" the axis "B" is further to the right than "A” HELD THROUGH THE COUPLING.
( 0.104 – 0.86 ) / 2 = 0.09 mm
A needle fitted on the drive end side bearing must face a
In the plane "C2" the axis "B" is further to the left than "A” groove machined on the shaft. If the needle is missing the
( 0.70 - 1.64 ) / 2 = - 0.47 mm distance "A" (distance from the groove up to the first
The representation of the shafts is as follows: bearing part) is stamped on the shaft enabling checking.
Example for a sleeve bearing machine :
C1
B
A
0.47
1
C2
0.09

Regarding the horizontal plane the angular error is:

( 0.47 + 0.09 ) *100/ 400 = 0.14 mm/100mm (not
acceptable) "A"

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3.4.1 Phase-sequence
3.4 ELECTRICAL CONNECTIONS
3.4.1.1 Standard units ; IEC 34-8
3.4.0. General points Except by special request of the customer, the phase-
The installation must comply with the electrical schematics sequence is carried out using the IEC 34-8 standard.
attached in Section 5 An arrow located on the front bearing indicates the
Check that all the protection devices are correctly direction of rotation.
connected and in good working order. In the terminal box a specific marking plate indicates the
The assembler has the responsibility to mechanically and specific generator phase sequence.
electrically protect the generator within the best practice
rules and to secure any operation over the defined tender
(respect of capability curve ; overspeed …) Clockwise rotation viewed Counter clockwise rotation
from the shaft drive end viewed from the shaft
For low-voltage machines, power supply cables must be drive end
connected directly to the machine terminals (without
adding washers etc) The phases are marked: The phases are marked:
U1, V1, W1. U1, V1, W1.
For high-voltage machines, power supply cables should be
connected to separate terminals or to current transformer Viewed from the front of Viewed from the front of
terminals. the terminal box the the terminal box the
terminals are : terminals are :
NOTE: U1, V1, W1 U1, V1, W1
THE GLAND PLATE IS MADE OF NON MAGNETIC
The installer connects : The installer connects :
MATERIAL.
L1 --> U1 L3 --> U1
L2 --> V1 L2 --> V1
CAUTION
L3 --> W1 L1 --> W1
DO NOT ADD WASHERS TO THE POWER SUPPLY
CABLE TERMINALS OTHER THAN THOSE USED BY
THE MANUFACTURER OF THE ELECTRIC MACHINE

Check that the lugs are tightened.(refer to chapter 5.8)

U2 V2 W2 U2 V2 W2
CAUTION
ALL CURRENT TRANSFORMERS MUST BE
CONNECTED OR SHUNTED

CAUTION
THE VOLTAGE TRANSFORMER MUST NEVER BE
SHUNTED
U1 V1 W1 U1 V1 W1
CAUTION
THE INSTALLED POWER CABLES MUST BE FIXED
AND SUPPORTED IN SUCH A WAY AS TO BE ABLE TO
WITHSTAND THE VIBRATION LEVEL REACHED BY
THE GENERATOR IN OPERATION (refer to chapter L1 L2 L3 L3 L2 L1
2.1.3.4)

The power cables must not stress (push, pull, bend ...) the
generator terminals

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3.4.1.2 On request ; NEMA

3.4.2 Insulating distances
An arrow located on the front bearing indicates the
direction of rotation. Products not delivered by Leroy Somer and then installed
in the terminal box must meet the electrical insulating
In the terminal box a specific marking plate indicates the distances.
specific generator phase sequence.
This applies to power cables and lugs, and to added
transformers, etc.
Counter clockwise rotation Clockwise rotation viewed Nominal Voltage 500 V 1 KV 2 KV 3 KV
viewed from the stator from the stator connection
connection (NEMA) (NEMA) Phase-Phase in 25 30 40 60
the air (mm)
(Clockwise rotation viewed (Counter clockwise
from the shaft drive end rotation viewed from the Phase-Earth in the 25 30 40 60
following IEC) shaft drive end following air (mm)
IEC)
Phase-Phase 25 30 40 70
The cables are marked: The cables are marked: Creeping (mm)
U1, V1, W1. U1, V1, W1. Phase-Earth 25 30 40 70
The terminals are marked The terminals are marked Creeping (mm)
: :
T3, T2, T1 T3, T2, T1
Viewed from the front of Viewed from the front of Nominal Voltage 5 KV 7,5KV 12,5KV 15 KV
the terminal box the the terminal box the Phase-Phase in 120 180 190 190
cables are : cables are : the air (mm)
U1, V1, W1 U1, V1, W1
Phase-Earth in the 90 120 125 125
The installer connects : The installer connects : air (mm)
L1 --> (U1) T3 L3 --> (U1) T3 Phase-Phase 120 180 190 190
L2 --> (V1) T2 L2 --> (V1) T2 Creeping (mm)
L3 --> (W1) T1 L1 --> (W1) T1
Phase-Earth 120 180 190 190
Creeping (mm)

T6 T5 T4 T6 T5 T4 3.4.3 Added products in the terminal box

This may apply to site added customer CTs ; VTs etc.
Leroy Somer must be informed if some appliances have to
be installed in the generator terminal box.
The products not delivered by Leroy Somer and then
U1 V1 W1
installed in the terminal box must meet the electrical
U1 V1 W1 insulating distances. Refer to chapter 3.4.2
1
T3 T2 T1 The installed appliances must be able to withstand
T3 T2 T1 vibration.

L1 L2 L3 L3 L2 L1

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3.5 WATER COOLER INSTALLATION 4. START-UP

Assembly example:
1 Outlet flange 4.1 ELECTRICAL START-UP INSPECTION
2 Inlet flange
3 Water cooler
4.1.0 General points
4 Connecting flange
5 Tap Electrical connections (auxiliaries, safeties and power
6 Flexible junction connections) must comply with the schematics provided.
7 Pipe Refer to Section 5 to get the concerned schematics
8 Draining and de aeration
9 Water leakage detector DANGER:
CHECK THAT ALL SAFETY EQUIPMENT OPERATES
CORRECTLY.

4.1.1 Winding Insulation

The insulation and the polarization index must be
measured on start up and then as per chapter 5.1.0
recommendation.
To measure the insulation (refer to chapter 5.10)

4.1.2 Electrical connections

The phases must be connected directly to the machine
links (with no spacers or washers, etc).
Make sure that the lugs are sufficiently tightened.

CAUTION:
Water pipes must be connected stress free ALL CURRENT TRANSFORMERS MUST BE
Water pipes must be able to expand without restraint CONNECTED BEFORE START UP. IF CURRENT
TRANSFORMER NOT USED ITS OUTPUT MUST BE
CAUTION: SHORTED
FOR MACHINE SUPPORTING A VIBRATION LEVEL
HIGHER THAN 5 MM/S RMS WE RECOMMEND THE
USE OF HYDRAULIC FLEXIBLE JUNCTION 4.1.3 Parallel operation

A pressure limitor must be installed on the system to 4.1.3.1 Definition of parallel operation
protect the complete assembly against abnormal over • Between machines
pressure Operation mode named by Leroy Somer "1F"
At least two alternators are connected in parallel to supply
a load
The Automatic Voltage Regulator is in voltage regulation
mode
A droop Current Transformer is necessary to share the
reactive load
• With the mains
Operation mode named by Leroy Somer "2F"
At least one alternator is connected in parallel with the
mains (Public electricity network)
The Automatic Voltage Regulator is in Power Factor
regulation mode

4.1.3.2 Possibility of parallel operation

CAUTION:
PARALLEL OPERATION CAN ONLY BE USED FOR
ALTERNATOR ENGINEERED FOR SUCH OPERATION

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4.2.2 Not applicable
4.1.3.3 Parallel coupling
CAUTION: 4.2.3 water cooler Start-up
A WRONG SYNCHRONIZATION CAN LEAD TO MAIN If the cooler has been stocked for more than 6 months,
DAMAGES (HIGH MECHANICAL OVERTORQUE AND recheck the correct tightening of the water boxes .The
st
OVER CURRENT) tightening must be done in 4 steps (1 step , tightening at
nd
¼ of the nominal torque ; 2 step , tightening at 1/2 of the
During synchronization the following values must not be rd
nominal torque ; 3 step , tightening at 3/4 of the nominal
overpass: torque ; final step ; tightening at 4/4 of the nominal torque).
Max frequency shift : 0,1 Hz The tightening must be done "diagonally" using a torque
Max phase offset : 10° (electrical angle) wrench (torque following chapter 5.8.1)
Max voltage (phase - neutral) between machines : "diagonally" tightening principle :
(at phase offset =0) 5 % of the nominal voltage
In case of wrong synchronization, or mains micro
interruption inducing a fault over the indicated limits Leroy
Somer will not be considered as responsible of the
damages.

4.2 MECHANICAL START-UP INSPECTION Make sure that the safety devices are operating.
Connect the supply and return lines.
4.2.0 General points Fill with water, whilst carefully draining the circuit.
4.2.0.1 Alignment ; fixing ; prime mover
CAUTION: (machine with motorized fan only)
The installation must comply with the manufacturer’s
WE RECOMMEND THAT THE FREE OPERATION OF
installation rules for drive machine (alignment, mounting).
THE FAN BE CHECKED (NO FRICTION, NO
An arrow at the drive end, end shield, indicates the BLOCKING).
direction of rotation.

4.2.0.2 Cooling CAUTION:

BEFORE START-UP, CHECK THE CLEANLINESS OF
The air inlet and exhaust must be unobstructed.
THE COOLER FINS.
The cooling auxiliaries (water circulation in the cooler, etc)
must be operating. Start up the installation (if the other sub-assemblies allow
this).
4.2.0.3 Lubrication
Load the machine (KVA); adjust the water flow-rate to
Lubrication must be carried out as per chapter 5. Lubricant obtain the rated flow-rate (refer to Section 1).
quantity and periodicity as per Section 1
Check the water tightness of the lines and of the
exchanger.
4.2.1 Anti friction bearing machines start up
Check that the temperatures comply with the
The bearings are pre-lubricated in the factory, but before recommended temperatures.
they are put into service, it is necessary to re grease in
order to fill the free spaces in the greasing circuit and to
evacuate the storage grease. 4.2.4 Vibrations
The vibration measurement must be taken on each
CAUTION bearing in the three directions. The measured levels must
UPON START-UP, GREASE THE MACHINE WHILE IT IS be lower than the specified values indicated in the chapter
RUNNING. 2.1.3.4
Adjust the sensor as per chapter 2.1.3.4
Record the temperature of the bearings during the initial
operating hours. Poor lubrication can cause abnormal
heating.
If the bearing hisses, lubricate it immediately. Some
bearings may make a clattering noise if they do not
operate at normal temperature. This may occur if the
weather is very cold or when the machine is operating
under abnormal temperature conditions (start-up phase,
for example). The bearings will become quieter after
having reached their normal operating temperature.

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Load the generator step by step. :
Check the excitation current at 25%of the rated load
4.3 START-UP SEQUENCE Check the excitation current at 100%of the rated load
The generator start up (commissioning) must follow the At the nominal speed (full load) measure the vibrations.
following sequences: Check that the vibration level is in accordance with the
generator duty (as per chapter 2.1.3.4).
4.3.1 Static checks
Machine fixing as per chapter 4.2
Alignment as per chapter 3.3
Cooling as per chapter 4.2.0.2 & 4.2.3
Bearing lubrication as per chapter 4.2.2
Electrical connections as per chapter 4.1.2
Winding insulation as per chapter 5.10

4.3.2 Rotating checks

4.3.2.0 Rotor speed rate of rise (Standard unit)
There is no restriction regarding the rate of rise of the rotor
spin up from stop to nominal speed
There is no restriction regarding the load rate of rise

4.3.2.1 Rotating checks not excited

Run the generator without excitation by steps to verify the
bearings temperature as per chapter 2.5.1 or 2.6.2
At the nominal speed (not excited) measure the vibrations.
Check that the vibration level is in accordance with the
generator duty (as per chapter 2.1.3.4).

4.3.2.2 Rotating checks at no load excited

In AVR manual mode; Voltage adjustment; check the
excitation current value (refer to Section 4 for the AVR
manual and to Section 2 for the generator test report)
In AVR automatic mode; Voltage adjustments; Voltage
range; check the excitation current value value (refer to
Section 4 for the AVR manual and to Section 2 for the
generator test report)
At the nominal speed (excited) measure the vibrations.
Check that the vibration level is in accordance with the
generator duty (as per chapter 2.1.3.4).

4.3.2.3 Generator and site safety parameters

Proceed to the site safeties adjustment (over voltage relay,
over current relay, differential protection; negative
sequence relay...). The setting points are not in Leroy
Somer scope of supply.
The settings must comply with the generator data sheet
(eg: capability curve; thermal damage curve …)
Check the synchronizer setting following chapter 4.1.3.3
For any operation at a speed exceeding the nominal range
(generally the main frequency +3%) the generator
excitation must be shut off (refer to the electrical
schematics)

4.3.2.4 Rotating checks at full load

Operating In parallel with the mains
Adjust the Power Factor

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4.3.3 Generator start up check list

TYPE SERIAL N°

Voltage V Frequency Hz Speed rpm

Output Power kVA Power Factor

STATIC CHECKS

Mechanical checks
• Direction of Rotation (refer to Section1) Clock Wise or Anti-clock Wise
• Mechanical Fixing of the generator (refer to chapter 4.2) ________________________________________
• Coupling - Alignment to the engine (refer to chapter 3.3) ________________________________________
• Cooling : Coolant flow (refer to Section1 ; chapter 4.2.0.2 & 4.2.3) _________________________________
• Air inlet and exhaust free ___________________________________________________
• Bearing lubrication : Sleeve Bearings Lubrication (flow ; level ; oil type) (refer to Section1 & chapter 4.2.2) __
Or Anti-friction Bearings Greasing (refer to Section1 & chapter 4.2.1)
Temperature sensors (correct readings) (refer to Section1 & chapter 2.5.1 & 2.6.2) __
• Space Heaters (refer to Section1) ___________________________________________________

Type of AVR : 1F 2F 3F

Electrical connections between alternator, AVR and main panel : (refer to Section 4 & drawing Section 5)
• Output power cables connections following phase order (refer to chapter 3.4.1) ______________________
• Terminal box connections ________________________________________
• AVR detection voltage ________________________________________
• Supply power and excitation terminals ________________________________________
• Network detection (3F only) ________________________________________
• Command signals (equalisation and synchronisation for 2F and 3F) ________________________________
• Excitation polarity and booster ________________________________________
• Protective devices : (Bearing oil level fault detectors; Temperature sensors, etc) ______________________
• External accessories (e.g.. remote potentiometer) ________________________________________

ALL CURRENT TRANSFORMERS MUST BE CONNECTED

Windings insulation
Winding temp:…….°C Voltage 1 minute 10 minutes Polarisation
(MΩ) (MΩ) index
3 Phases / Ground
"U" /Ground
Static parts

"V" /Ground
"W" /Ground
"U" / "V"
"U" / "W"
Exciter field / Ground
Rotor / Ground ≤ 500 V
Rotatin
g parts

Exciter armature / Ground ≤ 500 V

Rotating resistances ≤ 500 V
Rotating diodes ≤ 500 V

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All works must be carried out by a qualified and authorized person.

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ROTATING CHECKS

WITH EXCITATION - AT NO LOAD CONDITIONS

• Verification of the bearings temperature (refer to chapter 2.5.1 or 2.6.2) °C ______________

• In manual mode : Voltage adjustment ___________________________________

Excitation current check ___________________________________

• In automatic mode : Voltage Setting (referring to nominal voltage) ________________________

Excitation current check ________________________

• Parallel coupling : Adjustment to parallel operation (3F) ________________________

A FAULTY SYNCHRONISING CAN BE THE ORIGIN OF DAMAGES (HIGH MECHANICAL OVER-TORQUE)

• Maximum acceptable values for synchronisation to the mains :
Maximum frequency shift 0,1 Hz _________________________
Maximum Phase offset 10 ° _________________________
Maximum voltage (P.N.) difference 5% of Un _________________________

Control / Adjustment of the site safety Parameters

• Over-voltage, _____________________________________________________________
• Over-current (by short-circuit on stator in separate excitation mode), _________________________
• Negative sequence relay, _____________________________________________________________
• Over-speed, _____________________________________________________________
• Differential protection (in static conditions), _____________________________________
• Other protective device. _____________________________________________________________

CHECK THAT ALL SAFETY EQUIPMENT OPERATES CORRECTLY

WITH EXCITATION - LOADED

Take the load gradually from 0 to 100% in steps of 25%
Record for each step (refer to Section 1):
• Electrical output (KW)
• POWER FACTOR
• Voltage (V)
• Current (A)
• Excitation Current / voltage
• Winding temperature
Time KW pf Volts I (A) I (ex) U1 (°C) V1 (°C) W1 (°C)

• Bearings temperature (if thrust sensor available, please record its value)
Time DE Thrust (°C) DE Radial (°C) NDE Radial (°C)

• Oil inlet temperature (if applicable ; refer to Section 1)

• Oil flows (if applicable ; refer to Section 1)
• Bearings vibrations (mm/s) (refer to chapter 2.1.3.4)
DE-V DE-H DE-A DE-V DE-H DE-A

All works must be carried out by a qualified and authorized person.

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5. MAINTENANCE AND SERVICING

5.0 GENERAL
DANGER :
BEFORE ANY WORK ON THE GENERATOR, MAKE
SURE THAT THE START-UP CANNOT BE ACTIVATED
BY ANY MANUAL OR AUTOMATIC SIGNAL.
CHECK THAT ALL LOCKS ARE ENGAGED AND
FOLLOW THE SITE SAFETY PROCEDURES

DANGER:
BEFORE WORKING ON THE MACHINE, MAKE SURE
THAT YOU HAVE UNDERSTOOD THE OPERATING
PRINCIPLES OF THE SYSTEM. IF NECESSARY, REFER
TO THE APPROPRIATE CHAPTERS IN THIS MANUAL.

To obtain additional information on the maintenance of

sub-assemblies, refer to the chapters dealing with the sub-
assemblies concerned.
When a defective part is replaced with a spare part, make
sure that it is in good condition.
For any electrical work use electrical schematics for
assistance
The whole machine must be kept clean.

CAUTION :
ALL THE CLEANING PERIODS INDICATED IN THIS
MANUAL MAY BE CHANGED (INCREASED OR
DECREASED) ACCORDING TO SITE CONDITIONS

The air inlet and air outlet surfaces must be maintained

clean (Louvers can be cleaned as per the filters) refer to
chapter 5.7.1.

CAUTION :
DIRT ENTERING THE MACHINE MAY POLLUTE AND
THUS REDUCE THE ELECTRICAL INSULATION

CAUTION :
ANY PRODUCT (SEALING COMPOUND, CLEANING
PRODUCT…) USED DURING MAINTENANCE OR
SERVICING MUST BE IN ACCORDANCE WITH LOCAL
REGULATION AND ENVIRONMENTAL STANDARD

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5.1 MAINTENANCE SCHEDULE

5.1.0 Not applicable

5.1.1 Stator
Hours Comments Task duration
Winding temperature 24 Daily operation, (without gen stop)Refer to 2.1.3.2
Insulation 8000 (*1) Refer to 5.10
4hrs
Polarisation index 8000 (*1) Refer to 5.10.4
Bolts tightening 8000 (*1) Refer to 5.8 2 hrs
Winding visual inspection 8000 (*1) Refer to 5.10 1 hr
Stator RTD function 8000 (*1) Refer to 2.1.3.2
Cleaning air inlet and outlet 1000 (*1) Refer to 5.7

5.1.2 Rotor
Insulation 8000 (*1) Refer to 5.10
0.5 hr
Polarisation index 8000 (*1) Refer to 5.10.4
Winding visual inspection 8000 (*1)
Cleaning diodes 8000 (*1)
Diodes and varistor check 8000 (*1) 0.5 hr
Diodes tightening 8000 (*1)

5.1.3 Terminal box

Cleaning 8000 (*1) 0.5 hr
Regulator assembly & supports 8000 (*1) Applicable if mounted in the terminal box
Bolts tightening 8000 (*1) 1.5 hrs

5.1.4 Not applicable

5.1.5 Anti friction bearing

Following technical specification in "Section 1"
Re greasing See lub plate; Or every 6 months whichever come first
Bearing temperature 24 Daily operation, (without gen stop)Refer to 2.5.1

5.1.6 Machine cooler

Following technical specification in "Section 1"
Leakage level 24 Daily operation, (without gen stop)Refer to 5.6.1.3 &
2.9.2.1
Water temperature 24 Daily operation, (without gen stop)Refer to 2.9.2.2
Cleaning of the fins 8000 Cleaning following site conditions; Refer to 5.6.1.2 2 hrs

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5.1.7 Rubber dampers
Rubber dampers 8000 Refer 2.3.1

5.1.8 Not applicable

5.1.9 Not applicable

5.1.10 Protection devices

Protection devices 8000 (*1)

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5.2 AIR GAP CHECK 5.3 ANTI FRICTION-BEARINGS

5.2.1 General points 5.3.1 General points

The air gap measurement is not always possible because
NOTE:
of a lack of access. When the air gap can be reached the
Few international studies report that more than 80% of the
measure can be distorted because of paint and resin
coating on the checked surfaces. anti friction bearing installed worldwide for any duty are
prematurely damaged because of lubrication trouble.
To preserve your machine we recommend to closely fulfill
5.2.2 Double bearing machine the recommendations of this manual.
Verification of the air gap is not necessary. The rotor is
mechanically centered by its construction. Even after They must be lubricated regularly with the same type of
dismantling and reassembling the machine, the rotor will grease as used in the factory. For information concerning
return to its position without verification of the air gap. the lubrication quantity and interval, refer to Section 1:
The exciter air gap of generators type A60 and A62 can be "Characteristics and Performance".
adjusted on site.
CAUTION:
5.2.3 Single bearing machine LUBRICATION MUST BE CARRIED OUT AS PER
When the machine is delivered, the rotor is mechanically SECTION 1 OR AT LEAST EVERY 6 MONTHS
centered in the stator (see chapter on alignment). After WHICHEVER COME FIRST
dismantling the machine, it will be necessary to center the
rotor in the stator, by using the two half-shells (delivered NOTE:
with the machine) as explained in the chapter 3.3.3. After a regreasing the bearing temperature may increase
If you do not have 1/2 shells, use a dial indicator to check of 10 to 20°C
the concentricity between the shaft (machined surface) This temporary temperature increase may stay few tens of
and the front end shield (machined surface). hours

NOTE:
For re greasing period lower than 2000 hours we
recommend to install a continuous greasing system to limit
the maintenance operators visit
These type of system must be disable during machine stop
The grease contained in these systems must not be stored
over a period of 1 year

5.3.2 Cleaning bearings from old grease

This note is applicable when the type of grease is
changed.
Dismantle the machine in order to get to the bearing
Remove the old grease with a palette knife.
Clean the lubricator and the grease removal tube.
For greater cleaning efficiency, use a brush with solvent.

NOTE:
Used solvent must be in accordance with local regulation
and environmental standard.

DANGER:
THE PROHIBITED SOLVENTS ARE:
CHLORINATED SOLVENT
(TRICHLORETHYLENE,TRICHLOROETHANE) WHICH
BECOMES ACID
FUEL-OIL (EVAPORATES TOO SLOWLY)
GASOLINE CONTAINING LEAD
BENZINE (TOXIC)

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After cleaning ensure that the bearing becomes perfectly
dry. 5.3.5 Bearing re-assembly
Fill the bearing with the new grease. A bearing can be refitted if it is known to be in perfect
condition. As far as possible we recommend to use a
Re-assemble the cage and the parts, which have been
brand new bearing
dismantled, filling them with grease (2/3 of the empty
spaces must be filled with new grease) Before refitting a bearing, carefully clean the surface of the
bearing and the other parts of the bearing.
Use a grease pump to complete the bearing lubrication
(while machine running) Measure the shaft diameter to check it is within the
recommended tolerances.
5.3.3 Cleaning bearings assembly area To install the bearing on the shaft, it is necessary to heat
Bearing life is directly impacted by the cleanliness of the the bearing. The heat source may be an oven or a space
lubricant. The dirt must not enter or pollute the bearings. heater (the use of oil baths is not recommended). The use
of an induction bearing heater is recommended.
Excess of grease must be removed before operation in
order to avoid pollution of the environment as well as the CAUTION:
alternator NEVER HEAT A BEARING TO MORE THAN 125°C
Periodically: (257°F)
clean the labyrinth seals outside face. Remove the excess
Push the bearing up to the shaft shoulder, and check after
of grease which may appears onto the shaft.
cooling that the inner ring is still in contact with the
Remove the excess of dry old grease from the bearing
shoulder. Lubricate using the recommended grease. Fill
exhaust channel (use a clean blade)
the bearing covers with new grease
After removing the old grease check that a small fresh
volume of grease will plug the exhaust channel (to avoid
pollution coming back to the bearing) 5.4 Not applicable
5.3.4 Bearing removal
The inner bearing race is mounted, shrunk onto the shaft.
The outer bearing race is free, or slightly tightened, on the
hub (depending on the type of bearing). To remove the
bearing from the shaft, it is necessary to use a dedicated
hub-puller to avoid damaging the surface of the shaft.
Typical bearing drawing assembly is joined in chapter 10

CAUTION:
CLEANLINESS IS IMPERATIVE

NOTE:
Heat the bearing during the pulling operation is
recommended to prevent the shaft from being scored.

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5.5.2 Oils
5.5 LUBRICANTS
5.5.2.1 General
5.5.1 Greases We do not have any special recommendation regarding
Recommended lubricant: any mineral oil manufacturer.
SHELL GADUS S3 V220C2 (lithium complex base). The used oil must comply with the requested viscosity
SHELL RETINAX LX2 (lithium complex base). (refer to Section 1).
For frequent cold starting (lower than -15°C) without oil
Recommendation for a substitution grease choice :: sump heater, please contact us. A new oil viscosity may be
Mineral oil or PAO (SHC) advised.
Base (soap ) grade NLGI 2
Use a non-foaming mineral oil, without additives. If an oil
Lithium complex base
containing additives has to be used, make sure that the
Base oil viscosity at 40°C: 100 to 200 mm2/s
supplier confirms the chemical compatibility of the oil and
Dye penetration test (DIN 51817) : 2% minimum
the lead anti-friction properties.
Use of grease which do not fit to the recomended figure
Viscosity data (for information) :
(substitution grease) :
Mineral oil or PAO (SHC) x y
Base (soap ) grade NLGI 2
Lithium base 850 42
Base oil viscosity at 40°C: 100 to 200 mm2/s (high 775 40
viscosity preferred) 700 38
680
Dye penetration test (DIN 51817) : 2% minimum 625 36
550 34
Greases recognized as possible substitution grease: 500 140 32
SKF LGWA2 450 460 30
CASTROL LMX NLGI2 400 28
TOTAL Multis complex EP2 365 26
315 320 24
CAUTION : 280 22
THE USE OF A SUBSTITUTION GREASE CONDUCE TO 240 20
REDUCE THE RE GREASING PERIOD OF 30% 205 220 90 50
18
175 16
NOTE: 140 150 40 14
Lithium and complex lithium soap can be mixed 115 85 12
100 30
Lithium complex and calcium lithium soap can be mixed 85 10
60 68 80
In case of change of grease brand it is recommended to 20 8
40 46 6
proceed to a massive greasing to waste the previous 32 75 10W
20 22 4
grease. 10 0W & 5W 2

NOTE:
A B C
Mixing different types of grease never give as result an x - CST at 40°C
addition of the good greases properties ! Mixing of different y - CST at 100°C
types of grease must be done only after getting the grease A - ISO (VG)
supplier agreement or after cleaning the bearing from the B - SAE J306c Transmissions
old grease C - SAE J300d motors

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5.5.2.2 Synthetic oils 5.5.2.3 Mineral oils

Since the synthetic lubricants are not standardized, no Mineral oils containing special additives (diesel engine oils)
guarantee can be given regarding their chemical and must have a Total Base Number (marked TBN or BN)
mechanical behavior. Some synthetic lubricant may strictly below 40 mgKOH/g
become acid and destroys bearing parts (white metal, oil
ring, sight indicator..) in a short time 5.5.2.4 Oil filtering and pollution
If synthetic oil has to be used; during the first 2000 hours Following indications are related to the maximum
of use the lubricant should be checked at short intervals. acceptable oil pollution level and to the oil filtering level
(filter efficiency) which has to be installed to obtain a clean
Synthetic oils group concerns : oil
Synthetic hydrocarbons (SHC)
Poly-Alpha-Olefins (PAO) Refer to Section 1 to get data about the used bearing
Esther (Diester/Polyolester) The viscosity change must remains within +/- 10% of a
Phosporic ester / Phosphoric triarylester fresh oil lubricant
Polyglycols / Polyalkylglycols Acid Number (TAN) : must not exceed 2
Biodegradable lubricants Acidity change must remains (TAN) +/- 0.5 mg KOH/g of a
White oils fresh oil lubricant
Humidity ratio must remains below 0.05 %
CAUTION:
This paragraph applies to bearings designed for high axial
SYNTHETIC OILS MAY BE USED WITHOUT "LS"
thrust (tilting pads technology as used in bearings type
APPROVALONLY IF USED LUBRICANT ARE ISSUED
.....A).or oil lubricated anti friction bearing :
FROM THE FOLLOWING LIST Maximum acceptable pollution:
Authorized synthetic oils without "LS" special agreement: following ISO 4406 : 17/15/12
following NAS 1638 classe 7
viscosité Type
(cSt ; 40°C)
Filtering level to ensure :
following ISO 16889 : β 10 ( c ) = 100 (filtering 10µ)
KLUBER 32 Summit SH 32
44 Summit SH 46 This paragraph applies to standard bearings with low axial
62 Summit SH 68 thrust , self lub or oil circulation (as types E..Z.K ; E..Z.Q) :
81 Summit SH 100 Maximum acceptable pollution:
following ISO 4406 : 18/16/13
MOBIL 31 SHC 624 following NAS 1638 class 9
65 SHC 626
Filtering level to ensure (oil circulation bearing):
SHELL 32 Madrella Oil AS 32
48 Madrella Oil AS 46 following ISO 16889 : β 25 ( c ) = 100 (filtering 25µ)
68 Madrella Oil AS 68

5.6 WATER COOLER

5.6.1 Maintenance of the water-cooler

5.6.1.1 General points
A regular cooler clogging will have the result to a regular
winding temperature increasing.
The loss of performance of the cooler can come from a
clogging effect of the water tubes or by dust on the cooler
fins
Dust on the cooler fins has to cleaned using a soft brush.
The cooler tubes cleaning period is mainly function of the
water purity
In case of used of non recirculated water with risk (eg: river
water with algae passing trough the cooler) we recommend
the tubes are inspected after one year of operation. The
Inspection should be scheduled following any observed dirt
level.

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5.6.1.2 Cleaning 5.6.2 Servicing the water-cooler
Stop the machine.
5.6.2.1 Cooler removal
Cut off the power supply by isolating the inlet and outlet The cooler unit is slid into its housing. It is possible to
lines, and drain the water. remove the cooler from the housing without removing the
Disconnect the leak sensor (option with double-tube water boxes. The cooler is fastened to the housing via a
cooler), and make sure that there are no leaks. series of screws on the housing.
Remove the water headers on each side of the machine. Remove the supply and return pipes.
Rinse and brush each water box. Provide two supports to hold the cooler when it comes out
of its housing.
Remove the cooler using slings that can be attached to the
connecting flanges.

5.6.2.2 Cooler re-assembly

Carry out the operations of the "Cooler Removal" chapter
in the reverse order. Be careful to push the cooler
completely into its housing before tightening the fastening
screws of the cooler to the casing.

5.7 Not applicable

5.8 BOLT TIGHTENING

5.8.0 General
It is recommended to use a Liquid thread lock compound
on any fixing screws, or plugs (except for electrical contact)
1 - Water header, water connecting side which have been untighten or dismantled during any
2 - Gasket operation.
3 - Internal end plate A medium strength thread locker as or similar as "Loctite
4 - Cooler structure 242" ; or "Omnifit 100M" (from Henkel)
5 - Fins
6 - Gasket 5.8.1 Steel screw in steel tapping
7 - Water header, blind side If no torque value is specified into the concerned chapter
the following values can be used for fixation of parts metal
NOTE:
onto metal
Do not use a hard wire brush as this will remove the
protective oxidation layer which has formed on the Bolt : Steel / Steel
surfaces of the water boxes. Clean each tube with a metal (with medium strength thread locker)
scraper. Rinse in soft water.
Ø nominal Torque Ø nominal Torque
Keep the leakage chamber dry (double-tube water-cooler (mm) (N.m) (mm) (N.m)
only) 3 1,0 18 222
Proceed to a gasket change 4 2,3 20 313
5 4.6 22 430
5.6.1.3 Leak detection for a double-tube exchanger 6 7.9 24 540
If a leak is detected, it is necessary to ascertain its origin 8 19.2 27 798
immediately and repair it. 10 37.7 30 1083
Remove the two water boxes, apply a slight positive 12 64.9 33 1467
pressure in the leakage chamber and thus between the 14 103 36 1890
two tubes (only concerns double-tube coolers). 16 160
If a tube is damaged plug it at BOTH ends. Use a tapered
plug. The plug should preferably be made of salt-water
resistant aluminum bronze or of a synthetic material.

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5.8.2 Plugs 5.9 ELECTRICAL MEASURING
If no torque value is specified into the concerned chapter INSTRUMENTS
the following values can be used for plugs tightening
5.9.1 Instruments used
Steel and copper alloy Plugs
(medium strength thread locker) - AC voltmeter 0-600 Volts
- DC voltmeter 0-150 Volts
Ø nominal Torque Ø nominal Torque - Ohmmeter 10E-3 to 10 ohms
(inches) (N.m) (inches) (N.m) - Megohmmeter 1 to 100 MOhms / 500 Volts
G3/8 30 G1 ¼ 160 - AC Ammeter 0- 4500 A
G1/2 40 G1 ½ 230 - DC Ammeter 0-150 A
G3/4 60 G2 320 - Frequency meter 0-80 Hz
G1 110 G2 ½ 500 Low resistance can be measured by means of an
appropriate ohmmeter or by using a Kelvin or Wheatstone
bridge.
5.8.3 Electrical contact NOTE :
If no torque value is specified into the concerned chapter The identification of the equipment polarity may differ from
the following values can be used for brass (or copper alloy) one ammeter to another.
clean and dry threads.

CAUTION :
5.10 WINDINGS INSULATION CHECK
THE USE OF ANY COMPOUND ONTO ELECTRICAL
CONTACT THREAD IS FORBIDDEN
5.10.0 General
Thread M5 M6 M8 M10 M12 M14 M16 The insulation resistance enables the status of the
machine insulating to be verified.
Torque 2.5 4 8 20 35 57 87
The following measurements can be taken at any time
[N.m]
without any damage to machine insulating material.
The insulation check must be done :
- Before the start up
5.8.4 Rotating diodes
- After a long standstill
CAUTION : - As soon as an abnormal operation occurs.
THE ROTATING DIODE FASTENING SCREWS MUST - At maintenance intervals (refer to chapter 5.1)
BE TIGHTENED USING A TORQUE WRENCH
If the measurement indicates a poor result we advise
CALIBRATED TO THE RECOMMENDED
contacting our Service department.
TORQUE.WITHOUT USING ANY THREAD COMPOUND
To perform the measurement the generator must be
Diode Tightening torque stopped.

SKx 100/..xx 10 N.m If the insulation resistance is less than that required, it is
necessary, to clean and to dry the machine (refer to
SKx 130/..xx 10 N.m chapter 5.13).
SKx 240/..xx 30 N.m DANGER :
BEFORE ANY WORK THE RULES CONCERNING THE
SAFETY OF MATERIALS AND PERSONS MUST BE
5.8.5 Synthetic parts APPLIED (TOTAL LOCKING OF THE GENERATOR
This applies to parts made of light synthetic raw material FUNCTIONS, GROUNDING OF THE PHASES …)
(plastic covers; fiber glass covers; fiber glass fan air
shroud …)
5.10.1 Insulation measure
CAUTION : Disconnect the three phases at the generator terminals.
THE USE OF A THREAD LOCK COMPOUND IS
IMPERATIVE CAUTION
ALL ACCESSORIES MUST BE DISCONNECTED (AVR ,
Thread M8 M10 M12 M14 M16 EMC FILTER ;;;)
REFER TO THE ELECTRICAL SCHEMATICS TO
Torque 15 15 15 15 15 IDENTIFY THE ACCESSORIES TO DISCONNECT
[N.m]

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The measurement has to be taken between one phase
and the earth. Reading is done after 1 minute of test 5.10.2 Polarization index
Test voltage Criteria The polarization index enables the status of the machine
(VDC) (MΩ ; 40°C) insulating to be verified and gives an indication of the
pollution of the winding.
Stator: U ≤ 3 kV 500 200 A poor polarization index may be corrected by a cleaning
Stator: 3 kV< U ≤ 6.6 kV 2500 1000 and drying of the winding
The following measurements can be taken at any time
Stator: U > 6.6 kV 5000 1000 without any damage to the machine insulating material.
Rotor 500 100 CAUTION
Exciter (Stator & Rotor) 500 100 ALL ACCESSORIES MUST BE DISCONNECTED (AVR ,
EMC FILTER…)
Excitation auxiliary 250 100 REFER TO THE ELECTRICAL SCHEMATICS TO
windings (AREP) IDENTIFY THE ACCESSORIES TO DISCONNECT
PMG (stator) 100 100
NOTE:
Heating element 500 100 It must be done using a stable DC source.
Use a specific polarization index appliance (refer to
Resistance Temperature 500 100 chapter 5.10.1 for the correct applied voltage)
Detectors
Proceed for each phase
Open the winding star point
If the insulation resistance is not measured with a tested
element à 40°C a corrective factor has to be used
Rm 40°C= Rt x Kt40
Rt Measured insulation resistance
Kt40 Corrective factor
Curve LV for generator voltage ≤ 3 kV
Curve HV for generator voltage > 3 kV
100

LV
Kt40°C

10 Apply the requested voltage

HV After 1 minute record the Insulating resistance "R 1 min"
After 10 minutes record the Insulating resistance "R 10 min"
1
R (t =10minutes)
ip =
R (t =1minute)
0,1

(°C) polarization index Diagnostic

0,01 ip < 1 Poor

-10 0 1 2 3 4 5 6 7 8 9 10 110
2 < ip < 1 Monitored
If the minimum insulation level is not reached, dry the
windings (refer to chapter 5.13) 2 < ip < 4 Good
ip > 4 Very good

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CAUTION:
DO NOT USE TRICHLORETHYLENE,
5.11 ROTATING DIODE BRIDGE TEST PERCHLORETHYLENE, OR TRICHLORETHANE
Carry out the test using a D.C. source as indicated below.
A diode in good condition should allow the current to flow Avoid mixtures sold under various trademarks which often
only in the anode-to-cathode direction. contain white spirit (which evaporates too slowly) or
chlorinated products (which are likely to become acidified).
Disconnect the diodes before the test.
3 ... 48 volts CAUTION:
DO NOT USE TOO STRONG ALKALINE PRODUCTS.
- + THEY ARE DIFFICULT TO RINSE AND CAUSE
REDUCTION OF INSULATION RESISTANCE BY FIXING
1 2
THE HUMIDITY

5.12.2 Cleaning operation

Use a soft alkaline product or a dedicated cleaning agent
1 - Anode We recommend the use of the cleaning agent "ASOREL
2 - Cathode CN" from "Rhône Chimie Industrie" ; 07300 Tournon ;
France. This cleaning agent do not make the rinsing
operation imperative.
Diode type Positive Negative
It is essential to avoid entry of cleaning agents and dirt into
SKR diode housing diode wire the slots. Apply the product with a brush, sponging
frequently in order to avoid accumulation in the housing.
SKN diode wire diode housing
After cleaning, a rinsing operation is imperative. Hot soft
water (less than 80°C) used under pressure (less than 20
When reassembling ensure that the diodes are tightened bars) can be used.
to the correct torque
CAUTION:
AFTER CLEANING THE GENERATOR, DRYING IS
5.12 CLEANING THE WINDINGS IMPERATIVE TO RECOVER THE CORRECT WINDING
INSULATION
5.12.0 General points
The cleaning of the winding is a heavy service operation
which has to be engaged only if necessary.
The cleaning of the windings become necessary as soon
as the insulation resistance and/or the polarization index
are not satisfactory (refer to chapter 5.10.2)

5.12.1 Coil-cleaning products

A long term efficient cleaning can only be done in a work
Shop if equipped with specialized devices. A site cleaning,
because less efficient, can be considered only for a
transient period.

CAUTION :
USED CLEANING AGENT MUST BE IN ACCORDANCE
WITH LOCAL REGULATION AND ENVIRONMENTAL
STANDARD

CAUTION:
SOLVENTS, WHICH ARE HIGHLY CHLORINATED AND
SUBJECT TO HYDROLYSIS IN DAMP ATMOSPHERES
ARE PROHIBITED. THEY QUICKLY BECOME
ACIDIFIED, PRODUCING CORROSIVE AND
CONDUCTIVE HYDROCHLORIC ACID.

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5.13.1.3 Drying generator in rotation

5.13 DRYING THE WINDING CAUTION
THIS OPERATION MUST BE DONE BY A QUALIFIED
5.13.0 General points OPERATOR
All electric machines must be stored under dry conditions.
If a machine is placed in damp surroundings, it must be Disconnect the machine from the mains
dried before it is put into service. Units operating Short circuit the machine stator at the machine terminals
intermittently or placed in areas with high temperature
variations, are exposed to dampness and must be dried Disconnect the Voltage regulator. If booster current
very thoroughly if necessary. transformer used, short-circuit the booster.
Run the machine at its nominal speed (to air cool the
5.13.1 Drying method machine) with cooling system in operation.
Energized the machine (exciter field) using an separate ex
5.13.1.1 General points
citation source. Use a DC source (batteries ...).
During the drying operation measure the winding insulation
and the polarization index each 12 hours. Install an amp meter on excitation supply line.
To survey the insulation progress, record the measured Adjust the excitation current to get 2/3 of the nominal
values and plot the obtained progress function of the time. excitation current (refer to name plate data or alternator
test report)
When the insulation value becomes constant, the machine
can be considered as dry. Warm up during 4 hours, stop and leave it to cool down
(winding temperature < 50°C)
When the resistance is constant, it may be assumed that
the machine is dry. This operation may take up to 72 Check the winding insulation and the polarization index
hours, depending on the size of the machine and on the If necessary conduce other drying period...
degree of dampness.
U1 E
CAUTION: U2
TAKE FIRE-PREVENTION MEASURES DURING THE V1 S R
DRYING OF THE MACHINE. V2
W1
ALL THE CONNECTIONS MUST BE TIGHTENED. W2

5.13.1.2 Drying generator in a stopped position + -

The procedure " Drying generator in rotation" should be A
preferred to the following one if it is possible to run the DC
generator at its nominal speed
Several thermometers must be positioned onto the winding
S - Stator
and the temperature must not exceed 75°C (167°F). If one
R - Rotor
of the thermometers exceeds this value, immediately
E - Exciter
reduce the heating effect.
Dry by using an external source of heat, for example,
heaters; lamps; or hot air blowers.
Leave openings to exhaust the damp air.

605809 S3_4994_d_en.doc SECTION 3 Page 38

 LEROY SOMER SERVICING & OPERATING

ALTERNATOR MANUAL

5.14 RE-VARNISHING
CAUTION:
RE VARNISHING MUST ONLY BE CONSIDERED IF
ABSOLUTLY NECESSARY. A RE VARNISHING
OPERATION DONE ON A WINDING STILL DIRTY OR
NOT PERFECTLY DRY MAY CONDUCE TO A
DEFINITIVE LOSS OF INSULATION

605809 S3_4994_d_en.doc SECTION 3 Page 39

 LEROY SOMER SERVICING & OPERATING

ALTERNATOR MANUAL

10. TYPICAL ASSEMBLIES AND DRAWINGS

10.1 MACHINE CUT VIEWS

10.1.1 Machine type A52

1 Rotor 10 Polar wheel
2 Bearing (drive end) 11 Balancing disc
3 Fan hub 12 Exciter field
4 Drive end shield 13 Exciter armature
5 Fan 14 Non drive end shield
6 Fan screen 15 Bearing (non drive end)
7 Stator winding 16 Rotating resistances
8 Stator ribs 17 Rotating diodes
9 Stator lamination 18 Diode bridge cover

4 5 6 7 8 9 10 11 12 13 14

15

16

17
1

605809 S3_4994_d_en.doc SECTION 3 Page 40

 LEROY SOMER SERVICING & OPERATING

ALTERNATOR MANUAL

10.1.1 Machine type A60 ; A62

1 Rotor 10 Polar wheel
2 Bearing (drive end) 11 Balancing disc
3 Fan hub 12 Exciter field
4 Drive end shield 13 Exciter armature
5 Fan 14 Non drive end shield
6 Fan screen 15 Bearing (non drive end)
7 Stator winding 16 Rotating resistances
8 Stator ribs 17 Rotating diodes
9 Stator lamination

4 5 6 7 8 9 10 11 12 13 14

18 17
2

15

16

605809 S3_4994_d_en.doc SECTION 3 Page 41

 LEROY SOMER SERVICING & OPERATING

ALTERNATOR MANUAL
10.2 ANTI FRICTION BEARING ASSEMBLY

10.2.1 Machine type A52.2

2 1

4
1

Ø 210 K6

Ø 140 n5
3

6 3.5
3
1
Ø 290 H6

Ø 160 n5

2
3

5
Ø 230 H6

Ø 130 n5

Bearing assembly "Power plant"

Drive end Non drive end
1 End cover 1 End shield
2 End cover fixing screw 2 End cover
3 Ball bearing 6232 MC3 3 End cover fixing screw
4 End shield 4 Roller bearing NU 1028 MC3

Bearing assembly " Marine "

Drive end Non drive end
1 End cover 1 End shield
2 End cover fixing screw 2 End cover
3 Ball bearing 6232 MC3 3 End cover fixing screw
4 End shield 4 Bearing pre load spring
5 Ball bearing 6226 C3
6 O-Ring

605809 S3_4994_d_en.doc SECTION 3 Page 42

LEROY SOMER AUTOMATIC VOLTAGE REGULATOR SECTION 4

ALTERNATOR MANUAL

SECTION 4

AUTOMATIC VOLTAGE REGULATOR

SECTION 4 Page 0
LEROY SOMER DRAWINGS ATTACHED SECTION 5

ALTERNATOR MANUAL

SECTION 5

DRAWINGS ATTACHED

SECTION 5 Page 0
 LEROY SOMER DRAWINGS ATTACHED SECTION 5

ALTERNATOR MANUAL

1. DRAWINGS

1.1 Find there the listing of the attached drawings :

Main dimensions EN 605 809

Rotating part P1 605 809
Terminal box TB 605 809
Terminal box wiring S4 605 809
Connexion of the regulator S4 605 809
Protection and measuring S4 605 809
Electrical nomenclature S4 605 809

SECTION 5 Page 1
 P

A
301 776,5 800

Minimum length for cooler 1370

removal: 1600 8

4
8

CHARACTERISTICS: 124
Type : LUVATA
WATER:
Flow : 11.5 m³/h
Inlet temperature : 40 °C
Outlet temperature : 45 °C
Pressure drop : 8 kPa Cables

350

733
Maxi operating pressure : 6 bar

520
1058 Test pressure : 9 bar 7
7

Velocity : 1.3 m/s

Lifting 1510

196,5
40

1747
O 850,9

510
6
6

16 x M12
NFE 22-177
G M30

36
O 150 m6

101

4950 kg

1010

22,5°
138 20

0
500 -1
5
5

34,5
7
250 318,5 220 775 220 324 140 610 140

10 660 1000 Generator 1 & 3 890

Flanges DN50 Pn16 4 holes O28

(Fixation) 4
4

781 EN1092-1
Leakage detector MCT S6x1
Supplied by LS

7 260 750
185

Characteristics
Nb of poles: 4
3
Power: 1850 kVA
3

1000
Voltage: 690 V
420

Power factor: 0.8

Speed: 1800 rpm
Protection: IP55
O 787,4 f8
O 880

160

2
2

420

1:7
1:12 Articles usinés : Tolérances ISO 2768-mH & rugosité générale : Ra 3.2 Articles bruts: Tolérances ISO 2768-cH Ce plan est la propriété de la société MOTEURS LEROY SOMER et ne peut être communiqué sans son autorisation

G . . . Zhejiang

Doc 006 C
Projet :
F . . . N°: 605 809
E . . . Divers: Water and cables left hand side
D . . . Machine:
LSA52.2 M60 / 4p
185

C . . .
B Water cooler dimensions uptated T.A 27.02.2014 Désignation:

No dowell pins A First issue / 1ère création D.H 03.02.2014 1

1

Rev Description Nom Date Main dimensions

Encombrement
No jacking screws Dessiné: D.Hussonnois
Verifié: D.Hussonnois
le: 03.02.2014
le: 03.02.2014
R

Page 1 / 1 Rév
2217,5
Visa:
Méth.: .
. le: .
le: . ORLEANS-FRANCE Voir échelle
sous la vue A1 EN 605 809_T1 B
P O N M L K J I H G F E D C B A
 P

A
301 776,5 800
1370 Minimum length for cooler
removal: 1600 8
8

4
CHARACTERISTICS: 124
Type : LUVATA
WATER:
Flow : 11.5 m³/h
Inlet temperature : 40 °C
Outlet temperature : 45 °C
Pressure drop : 8 kPa

350
733
1057
Maxi operating pressure : 6 bar Cables

520
Test pressure : 9 bar lifting 1510 7
7

Velocity : 1.3 m/s

196,5
40

1747
O 850,9
6

510
6

NFE 22-177 16 x M12

G
M30

36
O 150 m6

99

4950 kg

1010
22,5°
138 20

0
500 -1
5
5

34,5
7
250 318,5 220 775 220 324 140 610 140
890
10 660

2217,5
1000
Generator 2 & 4
4 holes O28
(Fixation) 4
4

7 260
185

750

Characteristics
Nb of poles: 4
3
420

Power: 1850 kVA

3

1000
Voltage: 690 V
Power factor: 0.8
Speed: 1800 rpm
Protection: IP55
O 787,4 f8
O 880

160

2
2

420

1:7
Articles usinés : Tolérances ISO 2768-mH & rugosité générale : Ra 3.2 Articles bruts: Tolérances ISO 2768-cH Ce plan est la propriété de la société MOTEURS LEROY SOMER et ne peut être communiqué sans son autorisation

1:12 G . . . Zhejiang

Doc 006 C
Projet :
F . . . N°: 605 809
185

E . . . Divers: Water and cables right hand side

D . . . Machine:
C . . . LSA52.2 M60 / 4p
B Water cooler dimensions uptated T.A 27.02.2014 Désignation:

No dowell pins A First issue / 1ère création D.H 03.02.2014 1

1

Rev Description Nom Date Main dimensions

Leakage detector Encombrement
781 Flanges DN50 Pn16
MCT S6x1
Supplied by LS No jacking screws Dessiné: D.Hussonnois
Verifié: D.Hussonnois
le: 03.02.2014
le: 03.02.2014
R

Page 1 / 1 Rév
EN1092-1
Visa:
Méth.: .
. le: .
le: . ORLEANS-FRANCE Voir échelle
sous la vue A1 EN 605 809_T2 B
P O N M L K J I H G F E D C B A
 G
H

C
E

B
F

A
A-A 8
8

1905 Rectifiers
6 kg
1626 Exciter 0.5 kg.m²
39 kg
1016 Magnet wheel 0.9 kg.m²
809 kg
950 36 kg.m²

420 Shaft
456 kg
Fan 2.5 kg.m²
85 kg 7
7

331
10.5 kg.m²
1470 A

R1: 765 daN

R2: 603 daN

Insulated
6226C3
48 60 6
6

6232 MC3
40

NFE 22-177

M30
O 150 m6

O 534,2

O 97,5
O 224
O 160

O 175

O 182

O 240

O 225

O 180

O 170

O 151
O 378

O 142

O 130

O 55

36
5
5

138 20
14

25
1:5
4
4

616
O 860

A
250 105 76 85 192 630 173 85 60 69 56 80
1900

3
3

G is situated to 979 mm from drive end shaft

Total mass applied at G : 1395 kg 2

2

Articles usinés : Tolérances ISO 2768-mH & rugosité générale : Ra 3.2 Articles bruts: Tolérances ISO 2768-cH Ce plan est la propriété de la société MOTEURS LEROY SOMER et ne peut être communiqué sans son autorisation

G . . . Zhejiang

Doc 007 C
Projet :

Approximate inertia : 50.4 kg.m² F . . . N°: 605 809

1:10 E .
D .
.
.
.
.
Divers: .
Machine:
LSA52.2 M60 / 4p
Magnetic attraction : 24939 N/mm C .
B .
.
.
.
. Désignation:
A First issue / 1ère création D.H 03.02.2014
Rev Description Nom Date Rotating part
. 1
1

Dessiné: D.Hussonnois le: 03.02.2014 R

Verifié: D.Hussonnois le: 03.02.2014 Rév

Page 1 / 1
Visa:
Méth.: .
. le: .
le: .
ORLEANS-FRANCE Voir échelle
sous la vue A2 P1 605 809 A
H G F E D C B A
 P

A
A A-A
1796,5 1:6 8
8

776,5 800 185 420 160 420 185

4
41,5 86,5 2 holes O16,5
267,5 80 80 360 80 80
U2
60 7
7

15
U1

350

733
N

145
V2

520
U1 V1 W1

157
V1

145
W2
W1
196,5

196
95
40
6
6

10
A 1:6 1420

Flanges DN50 Pn16

Cables outlet
5
5

EN1092-1
Leakage detector
MCT S6x1
Supplied by LS

65 65 65 671

3 x 4 holes Ø16,5

4
4

W1
809

V1

U1
Drive end shaft

3
3

1370

U2
TI06
N V2
TI07
W2
TI08
TI04
1:7
2
2

Articles usinés : Tolérances ISO 2768-mH & rugosité générale : Ra 3.2 Articles bruts: Tolérances ISO 2768-cH Ce plan est la propriété de la société MOTEURS LEROY SOMER et ne peut être communiqué sans son autorisation

G . . . Zhejiang

Doc 006 C
Projet :
F . . . N°: 605 809
E . . . Divers: Cables left hand side
Generator 1 & 3 D .
C .
.
.
.
.
Machine:
A52.2
B . . . Désignation:
480 A First issue / 1ère création D.H 05.03.2014 1
1

Rev Description Nom Date Terminal box

Aux. Dessiné: D.Hussonnois le: 05.03.2014 R Boîte à bornes
Verifié: D.Hussonnois le: 05.03.2014 Rév
Page 1 / 1
Visa:
Méth.: .
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le: . ORLEANS-FRANCE Voir échelle
sous la vue A1 TB 605 809_T1 A
P O N M L K J I H G F E D C B A
 P

A
A-A
A 1:6
8
8

1796,5

776,5 800 185 420 160 420 185

4
2 holes O16,5
86,5 41,5
80 80 360 80 80 267,5
U2 60
7
7

15
U1

350

733
V2

145
U1 V1 W1

520

157
V1

145
W2
W1
196,5

196

95
40
6
6

10
A 1:6 1420

5
5

Aux.

4
4

TI04
TI08
W2
TI07
N V2
Drive end shaft

TI06
U2
3
3

1370

U1

V1 1:7
809

2
2

W1

3 x 4 holes Ø16,5
65 65 65 671
Articles usinés : Tolérances ISO 2768-mH & rugosité générale : Ra 3.2 Articles bruts: Tolérances ISO 2768-cH Ce plan est la propriété de la société MOTEURS LEROY SOMER et ne peut être communiqué sans son autorisation

G . . . Zhejiang

Doc 006 C
Projet :
F . . . N°: 605 809
E . . . Divers: Cables right hand side
Generator 2 & 4 D .
C .
.
.
.
.
Machine:
A52.2
MCT S6x1 B . . . Désignation:
Leakage detector Supplied by LS A First issue / 1ère créattion D.H 05.03.2014 1
1

480 Rev Description Nom Date Termina box

Flanges DN32 Pn16 Dessiné: D.Hussonnois le: 05.03.2014 R Boîte à bornes
EN1092-1
Cables outlet Verifié: D.Hussonnois le: 05.03.2014
Page 1 / 1 Rév
Visa:
Méth.: .
. le: .
le: . ORLEANS-FRANCE Voir échelle
sous la vue A1 TB 605 809_T2 A
P O N M L K J I H G F E D C B A
 A B C D E F G H I J K L M N O P Q

2 605 809 - MTU BENELUX BV

3
Type alternateur: LSA 52.2 M60 - 4 P Date Commentaire Service Initiales
Generator type:
4
Puissance: 1850 KVA
Power:
5

Tension: 690 V
Voltage:
6

Fréquence: 60 Hz
7
Frequency:

Type excitation: AREP

8 Type of excitation :

Type de régulateur: Rolls Royce DES - 1F

9
AVR type: Service: P (Plateforme) - M (Montage - F (Finition)

Statut
10
Mise en service Plateforme

Finition Montage
11

Moteurs LEROY SOMER Page de garde D

1, rue de la Burelle Dessiné par: I.C.TAMAS C Voir folio 03 / See page 03 07/05/14
01
45 800 St Jean de Braye-FRANCE Flyleaf
+33.2.38.60.42.00 Vérifié par: J.JANVOIE B Voir folio 03 / See page 03 28/03/14
[email protected] S4 605809 C A Version originale / First issue 13/03/14
21
 A B C D E F G H I J K L M N O P Q
Folio Titre Title Date Indice/Revision
1 01 Page de garde Flyleaf 07/05/14 C
02 Sommaire Summary 07/05/14 C
03 Révision Revision 07/05/14 C
2 04 Câblage Wiring 07/05/14 C
05 Fileries Wiring 07/05/14 C
06 Annotations - Généralités et straps Annotations - Generalities and straps 07/05/14 C
07 Annotations - Régulation Annotations - Regulation 07/05/14 C
3
08 Branchement extérieur alternateur Generator external wiring 07/05/14 C
09 Branchement boîte à bornes Terminal box wiring 07/05/14 C
10 TI protection et/ou mesure Protection and/or measurement CT 07/05/14 C
4
11 Equipements de protection Protection devices wiring 07/05/14 C
12 Equipements de protection Protection devices wiring 07/05/14 C
13 Bornier interne LS LS internal terminal block 07/05/14 C
5 14 Bornier excitation Excitation terminal block 07/05/14 C
15 Bornier contacts auxiliaires Auxiliary contacts terminal block 07/05/14 C
16 Bornier résistance de réchauffage Heater resistors terminal block 07/05/14 C
6 17 Bornier sondes de température Temperature sensors terminal block 07/05/14 C
18 Bornier détection de fuite Leakage detectors terminal block 07/05/14 C
19 Bornier transformateurs de courant Current transformers terminal block 07/05/14 C
7 20 Nomenclature Component list 07/05/14 C
21 Nomenclature Component list 07/05/14 C

10

11

Moteurs LEROY SOMER Sommaire D

1, rue de la Burelle Dessiné par: I.C.TAMAS C Voir folio 03 / See page 03 07/05/14
02
45 800 St Jean de Braye-FRANCE Summary
+33.2.38.60.42.00 Vérifié par: J.JANVOIE B Voir folio 03 / See page 03 28/03/14
[email protected] S4 605809 C A Version originale / First issue 13/03/14
21
 A B C D E F G H I J K L M N O P Q
Révision Date Auteur Objet
1 A 13/03/14 I.C.TAMAS Version originale / First issue
Remplacer 1 résistance 230V-500W par 2 résistances 230V-250W
B 28/03/14 P.PERRON
2 heater resistor 230V-250W instead of 1 heater resistor 230V-500W
2 C 07/05/14 I.C.TAMAS Correction type et valeur disjoncteur Q3 - page 20,21 / Correction type and value circuit breaker Q3 - page 20,21

10

11

Moteurs LEROY SOMER Révision D

1, rue de la Burelle Dessiné par: I.C.TAMAS C Voir folio 03 / See page 03 07/05/14
03
45 800 St Jean de Braye-FRANCE Revision
+33.2.38.60.42.00 Vérifié par: J.JANVOIE B Voir folio 03 / See page 03 28/03/14
[email protected] S4 605809 C A Version originale / First issue 13/03/14
21
 A B C D E F G H I J K L M N O P Q

Câblage Des connecteurs intermédiaires peuvent être présents dans le Intermediate connectors may be present in the wiring for Systeme de repérage:
1 câblage des matériels suivants : the following materials: Marking identification system:
Wiring * Sondes S10 à S830 et S'10 à S'13 * Sensors from S10 to S830 and from S'10 to S'13
* Inducteur d'excitateur * Exciter Inductor Exemple de repère:
* Résistances de réchauffage * Heater resistor
Marking example:
2

! Dans le cas où les connecteurs sont présents, les rallonges

de fils seront effectuées comme suit :
In cases the connectors are present, extension of wires
will be made as follows:
06. R00. 101

3 Sondes 3 fils / 3 wires resistor thermometer Num. du folio aboutissant Num. du fil
blanc/white blanc/white Page Nbr. Component Wire Nbr.
bleu/blue rouge/red Inducteur d'excitateur / Exciter inductor
rouge/red rouge/red
-
Bornier / Terminal block
bleu/blue noir/black
4
Sondes 4 fils / 4 wires resistor thermometer
Exemple de repère:
blanc/white blanc/white marron/brown rouge/red
blanc/white blanc/white + Marking example:
blanc/white rouge/red
Résistances de réchauffage / Heater resistors C . 25
5 blanc/white rouge/red
bleu/blue bleu/blue
Bornier Borne
Sondes 6 fils / 6 wires resistor thermometer marron/brown marron/brown R Terminal block Terminal
blanc/white blanc/white
6 blanc/white rouge/red
blanc/white rouge/red
Borne / Terminal
Désignation / Description Référence / Reference
blanc/white blanc/white Connecteur 2 points
blanc/white rouge/red 11 235 360 402
2 pole connector
7
blanc/white rouge/red Légende filerie
Wiring caption
Câble blindé / Shielded wire
Résistances de réchauffage / Heater resistors Filerie équipements internes
ou Internal equipments wires
8
or bleu/blue R
Neutre
bleu/blue bleu/blue R Neutral
marron/brown marron/brown
Désignation / Description Référence / Reference marron/brown Puissance phase
9
Connecteur 3 points mâle Power phase
11 235 731 603
3 pole male connector
Filerie équipements extérieurs
Connecteur 3 points femelle Désignation / Description Référence / Reference (filerie non fournie)
11 235 231 203
3 pole female connector Connecteur 4 points External equipments wires
10 11 235 360 403 (wires not supplied)
Connecteur 4 points mâle 4 pole connector
11 235 731 604
4 pole male connector
Connecteur 4 points femelle
11 235 231 204
4 pole female connector
11

Moteurs LEROY SOMER Câblage D

1, rue de la Burelle Dessiné par: I.C.TAMAS C Voir folio 03 / See page 03 07/05/14
04
45 800 St Jean de Braye-FRANCE Wiring
+33.2.38.60.42.00 Vérifié par: J.JANVOIE B Voir folio 03 / See page 03 28/03/14
[email protected] S4 605809 C A Version originale / First issue 13/03/14
21
 A B C D E F G H I J K L M N O P Q
Matériel - Device Section - Section Couleur - Color Reférence - Reference Style - Style
1
TP
B 1b
Transformateurs de tension - Voltage transformer
* détection - sensing 1.5mm² Blanc - White 02 234 001 509 UL 3289
* mesure - measure
A 1a
2

P1 S1 Transformateur de courant - Current transformer

* détection - sensing S1 : Noir - Black 02 234 001 500 UL 3289
TI 1.5mm²
* mesure - measure S2 : Rouge - Red 02 234 001 502
3
P2 S2 * statisme - droop

Excit.+ Noir - Black 02 206 002 500

4 Inducteur excitateur - Exciter inductor 2.5mm² UL 3513
Rouge - Red 02 206 002 502

Excit.-

Rallonge Inducteur excitateur - Exciter inductor extension 2.5mm² Marron/bleu - Brownn/blue 02 210 002 250 UL 4389
5

6
X2 Z2
Noir - Black 02 209 002 500
AREP AREP 2.5mm² Rouge - Red 02 209 002 502 UL 3512
Jaune - Yellow 02 209 002 504
Vert - Green 02 209 002 505
7 X1 Z1

8
2.5mm² Marron / Bleu UL 4389
02 210 002 250
Brown / Blue
R Résistance de réchauffage - Heater resistor
Marron / Bleu UL 4389
4mm² 02 210 002 400
Brown / Blue
9

Sondes PT100 - PT100 sensors 0.5mm² Bleu/blanc/rouge - Blue/white/red 02 239 003 050
0.5mm² 6 Couleurs - 6 colors 02 239 006 050
10
1.5mm² Noir - Black 02 234 001 500 UL 3289
2.5mm² Noir - Black 02 234 001 500 UL 3289
Autres matériels - Other devices 14G0.5mm² Noir numéroté - Black numbered 02 240 014 050 UL 3289
19G0.5mm² Noir numéroté - Black numbered 02 240 019 050 UL 3289
11 2.5mm² Vert/jaune - Green/yellow 02 234 002 512 UL 3289
4mm² Vert/jaune - Green/yellow 02 234 004 012 UL 3289
Moteurs LEROY SOMER Fileries D
1, rue de la Burelle Dessiné par: I.C.TAMAS C Voir folio 03 / See page 03 07/05/14
05
45 800 St Jean de Braye-FRANCE Wiring
+33.2.38.60.42.00 Vérifié par: J.JANVOIE B Voir folio 03 / See page 03 28/03/14
[email protected] S4 605809 C A Version originale / First issue 13/03/14
21
 A B C D E F G H I J K L M N O P Q

Contacts
1
et
Straps

Contacts
2
and
Straps

3
Courant maximum dans tous les fils de câblage : 20 A Maximum current in all wires : 20 A
Généralités
TI04 Le transformateur de courant de marche parallèle est monté : The current transformer for parallel operation is installed :
Sens de rotation de la machine
4
Comments * soit sur une barre, * either on a bar Direction of rotation of the machine
* soit sur une partie du bobinage (V1-V2) * either on a part of the winding (V1-V2)
IEC 34-8 NEMA
Sens de rotation de la machine Sens de rotation de la machine,
AP01 Débrancher le condensateur avant d'effectuer une mesure d'isolement Disconnect the capacitor before doing an insulation measurement Horaire, anti-horaire
de l'alternateur ou un test di-électrique or a high voltage test of the generator vu côté bout d'arbre. vu coté connexions stator
Direction of rotation of the Direction of rotation of the
5 machine clockwise, machine counterclockwise
seen from drive end shaft seen from stator connection side

L4 L5 L6 Neutre L6 L5 L4
Neutral

7 U2 V2 W2 T4 T5 T6

Machine synchrone
Synchronous machine

U1 V1 W1 T1 T2 T3

Réseau
8 Mains
L1 L2 L3 L3 L2 L1

10

11

Moteurs LEROY SOMER Annotations - Généralités et straps D

1, rue de la Burelle Dessiné par: I.C.TAMAS C Voir folio 03 / See page 03 07/05/14
06
45 800 St Jean de Braye-FRANCE Annotations - Generalities and straps
+33.2.38.60.42.00 Vérifié par: J.JANVOIE B Voir folio 03 / See page 03 28/03/14
[email protected] S4 605809 C A Version originale / First issue 13/03/14
21
 A B C D E F G H I J K L M N O P Q

Régulation
1

Regulation

10

11

Moteurs LEROY SOMER Annotations - Régulation D

1, rue de la Burelle Dessiné par: I.C.TAMAS C Voir folio 03 / See page 03 07/05/14
07
45 800 St Jean de Braye-FRANCE Annotations - Regulation
+33.2.38.60.42.00 Vérifié par: J.JANVOIE B Voir folio 03 / See page 03 28/03/14
[email protected] S4 605809 C A Version originale / First issue 13/03/14
21
 A B C D E F G H I J K L M N O P Q

1
U1/T3 09 - B1

V1/T2 09 - B2

W1/T1
2 09 - B2

10

11

Moteurs LEROY SOMER Branchement extérieur alternateur D

1, rue de la Burelle Dessiné par: I.C.TAMAS C Voir folio 03 / See page 03 07/05/14
08
45 800 St Jean de Braye-FRANCE Generator external wiring
+33.2.38.60.42.00 Vérifié par: J.JANVOIE B Voir folio 03 / See page 03 28/03/14
[email protected] S4 605809 C A Version originale / First issue 13/03/14
21
 A B C D E F G H I J K L M N O P Q

1
08 - Q1
U1/T3 U1 A01 U2 U2/T6 10 - B1

V1 V2 P2 TI04 P1
08 - Q2
V1/T2 V2/T5 10 - B2
S2 S1
W1/T1 W1 W2 W2/T4
2 08 - Q2 10 - B2

4 10 - B2

01

02

03
Blue AREP
X1 X2
3 Black
Green/yellow

Black Z1 Z2
Black

RV01
AP01
4

7
011
4

012

010
09
CR00
SP.4

SP.1

SP.2

SP.3

Excit.+
Excit.-
5
Q1 1 3 5
01

02

03

5
Q3 2 4 6
6 1 3 5 14 12 11

602
601
600

10

12
9
A.10

A.12

A.11
A.9

A.6

A.5
2 4 6
4

A.8

A.7
14 12 11

XAC.3
XAC.2
XAC.1
608
607
606

7 3
A.1

A.2

A.3
XAC.9
XAC.8
XAC.7
A.4
A.PE

10
Détection Puissance Excitateur
Sensing Power Exciter TI Para
Droop CT

11

Moteurs LEROY SOMER Branchement boîte à bornes D

1, rue de la Burelle Dessiné par: I.C.TAMAS C Voir folio 03 / See page 03 07/05/14
09
45 800 St Jean de Braye-FRANCE Terminal box wiring
+33.2.38.60.42.00 Vérifié par: J.JANVOIE B Voir folio 03 / See page 03 28/03/14
[email protected] S4 605809 C A Version originale / First issue 13/03/14
21
 A B C D E F G H I J K L M N O P Q

1 TI06
U2/T6 P2 P1
09 - Q1
S2 S1 TI07
V2/T5 P2 P1 N
09 - Q2
S2 S1 TI08
W2/T4 P2 P1
2 09 - Q2
S2 S1
09 - Q2
4

202

201

204

203

206

205
4

XCT.2

XCT.1

XCT.4

XCT.3

XCT.6

XCT.5
7 10VA-Cl:5P10

10VA-Cl:5P10

10VA-Cl:5P10
8

10

11

Moteurs LEROY SOMER TI protection et/ou mesure D

1, rue de la Burelle Dessiné par: I.C.TAMAS C Voir folio 03 / See page 03 07/05/14
10
45 800 St Jean de Braye-FRANCE Protection and/or measurement CT
+33.2.38.60.42.00 Vérifié par: J.JANVOIE B Voir folio 03 / See page 03 28/03/14
[email protected] S4 605809 C A Version originale / First issue 13/03/14
21
 A B C D E F G H I J K L M N O P Q

Stator
2 Résistance de réchauffage Stator
Heater resistor
106 Ohms Température bobinage (Alarme) Température bobinage (Réserve)
Winding temperature (Alarm) Winding temperature (Spare)

U V W U V W

R001

S01 S02 S03 S04 S05 S06

5

R002
6
Blanc / White

Blanc / White

Blanc / White

Blanc / White

Blanc / White

Blanc / White
Rouge / Red
Rouge / Red

Rouge / Red
Rouge / Red

Rouge / Red
Rouge / Red

Rouge / Red
Rouge / Red

Rouge / Red
Rouge / Red

Rouge / Red
Rouge / Red
101

102

8
XHR.1

XHR.2

XSE.1
XSE.2
XSE.3

XSE.4
XSE.5
XSE.6

XSE.7
XSE.8
XSE.9

XSE.10
XSE.11
XSE.12

XSE.13
XSE.14
XSE.15

XSE.16
XSE.17
XSE.18
9

10

11

Moteurs LEROY SOMER Equipements de protection D

1, rue de la Burelle Dessiné par: I.C.TAMAS C Voir folio 03 / See page 03 07/05/14
11
45 800 St Jean de Braye-FRANCE Protection devices wiring
+33.2.38.60.42.00 Vérifié par: J.JANVOIE B Voir folio 03 / See page 03 28/03/14
[email protected] S4 605809 C A Version originale / First issue 13/03/14
21
 A B C D E F G H I J K L M N O P Q

Palier - Côté accouplement Palier - Côté opposé accouplement Entrée d'air Sortie d'air Echangeur
2 Bearing - Drive end side Bearing - Non drive end side Air inlet Air outlet Exchangeur

Température (Alarme) Température (Alarme) Température (Alarme) Température (Alarme) Détecteur de fuite
Temperature (Alarm) Temperature (Alarm) Temperature (Alarm) Temperature (Alarm) Leakage detector

4
LD01

S10 S11 S14 S15

5

Marron / Brown
Noir / Black
Bleu / Blue
6
Blanc / White

Blanc / White

Blanc / White

Blanc / White
Rouge / Red
Rouge / Red

Rouge / Red
Rouge / Red

Rouge / Red
Rouge / Red

Rouge / Red
Rouge / Red

410
411
412
7

8
XSE.41
XSE.42
XSE.43

XSE.44
XSE.45
XSE.46

XSE.61
XSE.62
XSE.63

XSE.71
XSE.72
XSE.73

XLD.1
XLD.2
XLD.3
9

10

11

Moteurs LEROY SOMER Equipements de protection D

1, rue de la Burelle Dessiné par: I.C.TAMAS C Voir folio 03 / See page 03 07/05/14
12
45 800 St Jean de Braye-FRANCE Protection devices wiring
+33.2.38.60.42.00 Vérifié par: J.JANVOIE B Voir folio 03 / See page 03 28/03/14
[email protected] S4 605809 C A Version originale / First issue 13/03/14
21
 A B C D E F G H I J K L M N O P Q

3 09.AP01.Blue.Neutre.4
09.AP01.Black.W1.03
09.AP01.Black.U1.01
09.AP01.Black.V1.02

6
SP
1
2
3
4

7
09.Q3.1.01
09.Q3.3.02
09.Q3.5.03
09.A.4.4

10

11

Moteurs LEROY SOMER Bornier interne LS D

1, rue de la Burelle Dessiné par: I.C.TAMAS C Voir folio 03 / See page 03 07/05/14
13
45 800 St Jean de Braye-FRANCE LS internal terminal block
+33.2.38.60.42.00 Vérifié par: J.JANVOIE B Voir folio 03 / See page 03 28/03/14
[email protected] S4 605809 C A Version originale / First issue 13/03/14
21
 A B C D E F G H I J K L M N O P Q

3
09.AP01.Green/yellow

4
09.TI04.S1.7
09.TI04.S2.8
09..Excit.+.5
09..Excit.-.6

09.Q1.4.10

09.Q1.6.12
09.Q3.2.1
09.Q3.4.2
09.Q3.6.3
09.SP.4.4

09.Q1.2.9

6
PE

10
11
12
A

1
2
3
4
5
6
7
8
9

10

11

Moteurs LEROY SOMER Bornier excitation D

1, rue de la Burelle Dessiné par: I.C.TAMAS C Voir folio 03 / See page 03 07/05/14
14
45 800 St Jean de Braye-FRANCE Excitation terminal block
+33.2.38.60.42.00 Vérifié par: J.JANVOIE B Voir folio 03 / See page 03 28/03/14
[email protected] S4 605809 C A Version originale / First issue 13/03/14
21
 A B C D E F G H I J K L M N O P Q

4
09.Q1.11.600
09.Q1.12.601
09.Q1.14.602
09.Q3.11.606
09.Q3.12.607
09.Q3.14.608

6
XAC
1
2
3
7
8
9

10

11

Moteurs LEROY SOMER Bornier contacts auxiliaires D

1, rue de la Burelle Dessiné par: I.C.TAMAS C Voir folio 03 / See page 03 07/05/14
15
45 800 St Jean de Braye-FRANCE Auxiliary contacts terminal block
+33.2.38.60.42.00 Vérifié par: J.JANVOIE B Voir folio 03 / See page 03 28/03/14
[email protected] S4 605809 C A Version originale / First issue 13/03/14
21
 A B C D E F G H I J K L M N O P Q

4
11.R001.R002.101
11.R001.R002.102

6
XHR

1
2

10

11

Moteurs LEROY SOMER Bornier résistance de réchauffage D

1, rue de la Burelle Dessiné par: I.C.TAMAS C Voir folio 03 / See page 03 07/05/14
16
45 800 St Jean de Braye-FRANCE Heater resistors terminal block
+33.2.38.60.42.00 Vérifié par: J.JANVOIE B Voir folio 03 / See page 03 28/03/14
[email protected] S4 605809 C A Version originale / First issue 13/03/14
21
 9
8
7
6
5
4
3
2
1

11
10
A

XSE
B

11.S01.Blanc / White
1
11.S01.Rouge / Red
2
11.S01.Rouge / Red
3
11.S02.Blanc / White
4
11.S02.Rouge / Red
C

5
11.S02.Rouge / Red
6
11.S03.Blanc / White
7
11.S03.Rouge / Red
8
11.S03.Rouge / Red
D

9
11.S04.Blanc / White
10

+33.2.38.60.42.00
1, rue de la Burelle
11.S04.Rouge / Red
11
11.S04.Rouge / Red
12

Moteurs LEROY SOMER

E

11.S05.Blanc / White
13

[email protected]
11.S05.Rouge / Red
14

45 800 St Jean de Braye-FRANCE

11.S05.Rouge / Red
15
11.S06.Blanc / White
16
F

11.S06.Rouge / Red
17
11.S06.Rouge / Red
18
12.S10.Blanc / White
41
12.S10.Rouge / Red
42
12.S10.Rouge / Red
G

43
12.S11.Blanc / White
44
12.S11.Rouge / Red
45
12.S11.Rouge / Red
46
12.S14.Blanc / White
H

Bornier sondes de température

61
12.S14.Rouge / Red
62

Temperature sensors terminal block

12.S14.Rouge / Red

S4 605809
63
12.S15.Blanc / White
71
I

12.S15.Rouge / Red
72
12.S15.Rouge / Red
73
J

C
K

Vérifié par:
Dessiné par:
L

I.C.TAMAS
J.JANVOIE
D
M
N

B Voir folio 03 / See page 03

C Voir folio 03 / See page 03
O

A Version originale / First issue

P

13/03/14
28/03/14
07/05/14
Q

17

21
 A B C D E F G H I J K L M N O P Q

3
12.LD01.Com..411

4
12.LD01.NO.412
12.LD01.NC.410

6
XLD
1
2
3

10

11

Moteurs LEROY SOMER Bornier détection de fuite D

1, rue de la Burelle Dessiné par: I.C.TAMAS C Voir folio 03 / See page 03 07/05/14
18
45 800 St Jean de Braye-FRANCE Leakage detectors terminal block
+33.2.38.60.42.00 Vérifié par: J.JANVOIE B Voir folio 03 / See page 03 28/03/14
[email protected] S4 605809 C A Version originale / First issue 13/03/14
21
 A B C D E F G H I J K L M N O P Q

4
10.TI06.S1.201
10.TI06.S2.202
10.TI07.S1.203
10.TI07.S2.204
10.TI08.S1.205
10.TI08.S2.206

6
XCT
1
2
3
4
5
6

10

11

Moteurs LEROY SOMER Bornier transformateurs de courant D

1, rue de la Burelle Dessiné par: I.C.TAMAS C Voir folio 03 / See page 03 07/05/14
19
45 800 St Jean de Braye-FRANCE Current transformers terminal block
+33.2.38.60.42.00 Vérifié par: J.JANVOIE B Voir folio 03 / See page 03 28/03/14
[email protected] S4 605809 C A Version originale / First issue 13/03/14
21
 A B C D E F G H I J K L M N O P Q
Repère Désignation Référence Valeur Code produit Fourn. Ind.
A01 Alternateur LSA 52.2 M60 - 4 Pôles 1850 KVA - 690 V - 60 Hz L.S.
1
AP01 Condensateur antiparasitage 411158 4x0.47µF - 750VAC Réf: N° 18 234 075 447 L.S.
CR00 Pont de diodes tournantes SKN-SKR 130/12 130A/1200V Réf : N° DT 081 3938 L.S.
LD01 Détecteur de fuite KUBLER Réf : N° 13 300 100 100 L.S.
Q1 Disjoncteur tripolaire 16A - 400VAC Réf: N° PEL 016 DI 036+18 561 010 000 L.S.
2
Q3 Disjoncteur tripolaire 6A - 690VAC Réf: N° PEL 006 DI 031+PEL 000 AC 136 L.S. C
R001 Résistance de réchauffage 230V / 250W Réf : N° 13 180 500 089 L.S. B
R002 Résistance de réchauffage 230V / 250W Réf : N° 13 180 500 089 L.S. B
RV01 Varistance LP2 Z320 260J/470V Réf : N° 18 140 275 087 L.S.
3
S01 Sonde à résistance - Stator - Phase U (Alarme) Pt100 100 Ohms (0°C) Réf : N° 13 190 800 013 L.S.
S02 Sonde à résistance - Stator - Phase V (Alarme) Pt100 100 Ohms (0°C) Réf : N° 13 190 800 013 L.S.
S03 Sonde à résistance - Stator - Phase W (Alarme) Pt100 100 Ohms (0°C) Réf : N° 13 190 800 013 L.S.
S04 Sonde à résistance - Stator - Phase U (Réserve) Pt100 100 Ohms (0°C) Réf : N° 13 190 800 013 L.S.
4
S05 Sonde à résistance - Stator - Phase V (Réserve) Pt100 100 Ohms (0°C) Réf : N° 13 190 800 013 L.S.
S06 Sonde à résistance - Stator - Phase W (Réserve) Pt100 100 Ohms (0°C) Réf : N° 13 190 800 013 L.S.
S10 Sonde à résistance - Palier - Côté accouplement (Alarme) Pt100 100 Ohms (0°C) Réf : N° 13 190 804 001 L.S.
S11 Sonde à résistance - Palier - Côté opposé accouplement (Alarme) Pt100 100 Ohms (0°C) Réf : N° 13 190 804 001 L.S.
5
S14 Sonde à résistance - Entrée d'air (Alarme) Pt100 100 Ohms (0°C) Réf : N° 13 190 800 005 L.S.
S15 Sonde à résistance - Sortie d'air (Alarme) Pt100 100 Ohms (0°C) Réf : N° 13 190 800 005 L.S.
TI04 Transformateur de courant - Marche parallèle 1700/1,2A-10VA-Cl:1 Réf : N° TI 034 0833 L.S.
TI06 Trasnformateur de courant - Protection FR56 2000/5-10VA-Cl:5P10 Réf : N° TRF 020 PB 030 L.S.
6
TI07 Trasnformateur de courant - Protection FR56 2000/5-10VA-Cl:5P10 Réf : N° TRF 020 PB 030 L.S.
TI08 Trasnformateur de courant - Protection FR56 2000/5-10VA-Cl:5P10 Réf : N° TRF 020 PB 030 L.S.

10

11

Moteurs LEROY SOMER Nomenclature D

1, rue de la Burelle Dessiné par: I.C.TAMAS C Voir folio 03 / See page 03 07/05/14
20
45 800 St Jean de Braye-FRANCE Component list
+33.2.38.60.42.00 Vérifié par: J.JANVOIE B Voir folio 03 / See page 03 28/03/14
[email protected] S4 605809 C A Version originale / First issue 13/03/14
21
 A B C D E F G H I J K L M N O P Q
Item Description Reference Value Part number Sup. Rev.
A01 Generator LSA 52.2 M60 - 4 Pôles 1850 KVA - 690 V - 60 Hz L.S.
1
AP01 Spark capacitor 411158 4x0.47µF - 750VAC Réf: N° 18 234 075 447 L.S.
CR00 Rotating diode bridge SKN-SKR 130/12 130A/1200V Réf : N° DT 081 3938 L.S.
LD01 Leakage detector KUBLER Réf : N° 13 300 100 100 L.S.
Q1 Three pole circuit breaker 16A - 400VAC Réf: N° PEL 016 DI 036+18 561 010 000 L.S.
2
Q3 Three pole circuit breaker 6A - 690VAC Réf: N° PEL 006 DI 031+PEL 000 AC 136 L.S. C
R001 Heater resistor 230V / 250W Réf : N° 13 180 500 089 L.S. B
R002 Heater resistor 230V / 250W Réf : N° 13 180 500 089 L.S. B
RV01 Varistor LP2 Z320 260J/470V Réf : N° 18 140 275 087 L.S.
3
S01 Resistance temperature detector - Stator - Phase U (Alarm) Pt100 100 Ohms (0°C) Réf : N° 13 190 800 013 L.S.
S02 Resistance temperature detector - Stator - Phase V (Alarm) Pt100 100 Ohms (0°C) Réf : N° 13 190 800 013 L.S.
S03 Resistance temperature detector - Stator - Phase W (Alarm) Pt100 100 Ohms (0°C) Réf : N° 13 190 800 013 L.S.
S04 Resistance temperature detector - Stator - Phase U (Spare) Pt100 100 Ohms (0°C) Réf : N° 13 190 800 013 L.S.
4
S05 Resistance temperature detector - Stator - Phase V (Spare) Pt100 100 Ohms (0°C) Réf : N° 13 190 800 013 L.S.
S06 Resistance temperature detector - Stator - Phase W (Spare) Pt100 100 Ohms (0°C) Réf : N° 13 190 800 013 L.S.
S10 Resistance temperature detector - Bearing - Drive end side (Alarm) Pt100 100 Ohms (0°C) Réf : N° 13 190 804 001 L.S.
S11 Resistance temperature detector - Bearing - Non drive end side (Alarm) Pt100 100 Ohms (0°C) Réf : N° 13 190 804 001 L.S.
5
S14 Resistance temperature detector - Air inlet (Alarm) Pt100 100 Ohms (0°C) Réf : N° 13 190 800 005 L.S.
S15 Resistance temperature detector - Air outlet (Alarm) Pt100 100 Ohms (0°C) Réf : N° 13 190 800 005 L.S.
TI04 Current transformer - Droop 1700/1,2A-10VA-Cl:1 Réf : N° TI 034 0833 L.S.
TI06 Current transformer - Protection FR56 2000/5-10VA-Cl:5P10 Réf : N° TRF 020 PB 030 L.S.
6
TI07 Current transformer - Protection FR56 2000/5-10VA-Cl:5P10 Réf : N° TRF 020 PB 030 L.S.
TI08 Current transformer - Protection FR56 2000/5-10VA-Cl:5P10 Réf : N° TRF 020 PB 030 L.S.

10

11

Moteurs LEROY SOMER Nomenclature D

1, rue de la Burelle Dessiné par: I.C.TAMAS C Voir folio 03 / See page 03 07/05/14
21
45 800 St Jean de Braye-FRANCE Component list
+33.2.38.60.42.00 Vérifié par: J.JANVOIE B Voir folio 03 / See page 03 28/03/14
[email protected] S4 605809 C A Version originale / First issue 13/03/14
21