MTU 8 V 4000 M40A Operating Instructions Manual
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MTU 8 V 4000 M40A Operating Instructions Manual

MTU 8 V 4000 M40A Operating Instructions Manual

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Operating Instructions

Diesel engine
8 V 4000 M40A
8 V 4000 M40B
Application group 3B
MS15021/01E

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Summary of Contents for MTU 8 V 4000 M40A

  • Page 1: Operating Instructions

    Operating Instructions Diesel engine 8 V 4000 M40A 8 V 4000 M40B Application group 3B MS15021/01E...
  • Page 2 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.

  • Page 3: Table Of Contents

    7 Task Description 3 Technical Data 7.1 Engine 7.1.1 Engine – Barring manually 3.1 8 V 4000 M40A engine data 7.1.2 Engine cranking on starter 3.2 8 V 4000 M40A engine data 3.3 8 V 4000 M40A engine data 7.2 Cylinder Liner 3.4 8 V 4000 M40B engine data...
  • Page 4 7.16.1 Venting points 8.1 Abbreviations 7.16.2 Engine coolant – Level check 7.16.3 Engine coolant – Change 8.2 MTU contacts/service partners 7.16.4 Engine coolant – Draining 7.16.5 Engine coolant – Filling 7.16.6 Engine coolant pump – Relief bore check 7.16.7 Engine coolant – Sample extraction and...

  • Page 5: Safety

    Correct use also includes observation of and compliance with the maintenance specifications. Modifications or conversions Unauthorized modifications to the engine represent a safety risk. MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or conversions. Spare parts Only genuine MTU spare parts must be used to replace components or assemblies.

  • Page 6: Personnel And Organizational Requirements

    1.2 Personnel and organizational requirements Personnel requirements Work on the engine must only be carried out by appropriately qualified and instructed personnel. Observe the minimum legal age. Responsibilities of the operating, maintenance and repair personnel must be specified by the operating company.

  • Page 7: Transportation

    Set the engine down on a firm, level surface only. Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate. Never set an engine down on the oil pan unless expressly authorized to do so by MTU on a case-to-case basis .

  • Page 8: Crankshaft Transport Locking Device

    1.4 Crankshaft transport locking device Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10-60 Nm F30510423 Torque wrench, 60-320 Nm F30047446 Engine oil Transport locking device Note: The locking device protects the crankshaft bearings from shocks and vibration damage during engine transport.
  • Page 9 Fitting the transport locking device on driving end (KS) Note: Attach plates (2) only to the upper part of the openings. Secure the two plates (2) with screws (6) and washers (5) at the bores on both sides of the flywheel housing and tighten to the specified tightening torque.
  • Page 10 Installing guard plates and engine mounting brackets (if applicable) on driving end (KS) Note: Always use the screws supplied with the or removed from the guard plates and engine mounting brackets to secure them on the engine. Install engine mounting brackets (2) on both sides with guard plates (1) washers (3), and screws (4).

  • Page 11: Safety Regulations For Startup And Operation

    Safety requirements for initial operation Prior to initial operation of the unit, install the assembly or unit according to the specifications and check the installation according to the MTU specifications. Before putting the device or plant into operation, always ensure: •...

  • Page 12: Explosion Hazard When Removing Inspection Port Cover On Engine

    1.6 Explosion hazard when removing inspection port cover on engine DANGER Explosion hazard due to oil vapors. Risk of serious injury – danger to life! • Allow the engine to cool down before opening the crankcase! • Avoid open flames, electrical sparks and ignition sources. Safety instructions Before starting maintenance work, allow the engine to cool down for at least 10 min.

  • Page 13: Safety Regulations For Maintenance And Repair Work

    1.7 Safety regulations for maintenance and repair work Safety regulations for maintenance and repair work Have maintenance and repair work carried out by qualified and authorized personnel only. Allow the engine to cool down before starting maintenance work (risk of explosion of oil vapors). Before starting work, relieve pressure in systems and compressed-air lines which are to be opened.
  • Page 14 Do not use the assembly or system as ground terminal. Do not route the welding lead over or near the wiring harnesses of MTU systems. The welding current may otherwise induce an interference voltage in the wiring harnesses which could conceivably damage the electrical system.
  • Page 15 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.

  • Page 16: Auxiliary Materials, Fire Prevention And Environmental Protection

    MTU will provide assistance and advice if emission-relevant components are intended to be modified. The MTU Maintenance Schedules ensure the reliability and performance of MTU engines and must be complied with over the entire life cycle of the engine.
  • Page 17 Lead • When working with lead or lead-containing pastes, avoid direct contact with the skin and do not inhale lead vapors. • Adopt suitable measures to avoid the formation of lead dust! • Switch on fume extraction system. • After coming into contact with lead or lead-containing materials, wash hands! Acids and alkaline solutions •...
  • Page 18 Used oil Used oil may contain health-threatening combustion residues. Rub barrier cream into hands! Wash hands after contact with used oil. 18 | Safety | MS15021/01E 2012-02...

  • Page 19: Conventions For Safety Instructions In The Text

    1.9 Conventions for safety instructions in the text DANGER In the event of immediate danger. Consequences: Death or serious injury • Remedial action WARNING In the event of potentially dangerous situations. Consequences: Death or serious injury • Remedial action CAUTION In the event of dangerous situations.

  • Page 20: General Information

    2 General Information 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).

  • Page 21: Product Description

    2.2 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 (MDEC). Monitoring in the engine room is facilitated with the local engine control and monitoring unit (LOP).
  • Page 22 • Data processing logistics for analog and binary signals; • Interface for data transfer to CAN field bus for remote control and ship-side monitoring; • RS 232 interface for connection of MTU dialog unit. Electronic Engine Monitoring Unit (EMU), optional Functions: •...
  • Page 23 5 Fuel line on HP fuel 2 Fuel line on fuel delivery 4 Sealing cone pump pump 6 Fuel line on vent line All lines with SOLAS-compliant covers for pipe connections, according to MTU standard MTN5233, are shown. MS15021/01E 2012-02 | General Information | 23...
  • Page 24 13 Connection, oil line to ac‐ 5 Oil line, lube oil pump 10 Oil line, valve housing tuating cylinder All lines with SOLAS-compliant covers for pipe connections, according to MTU standard MTN5233, are shown. 24 | General Information | MS15021/01E 2012-02...
  • Page 25 Special connections In case of leakage, the following connection types are spray-protected even without a cover and have been confirmed compliant with SOLAS by GL and DNV. Plug-in pipe connection The sleeve (3) covers the joint to prevent lateral spray. Only leak-off along the line is possible, the pressure is decreased significantly if an O-ring (3) defect oc‐...
  • Page 26 HP connections 1 Jacket pipe 8 Leakage overflow bore 15 Snap ring 2 HP line 9 Thrust ring 16 Thrust ring 3 O-ring 10 Union nut 17 Compensating washers 4 Union nut 11 Internal pipe of HP line 18 Leak fuel connection 5 Recess for O-ring 12 External pipe of HP line 19 Union nut...
  • Page 27 Shielding of fuel filter and lube oil filter Shielding with synthetic ring – Shielding by overhang design The synthetic ring (1) or the overhang (2) prevents lateral spray. The fluid is diverted to the catch basin whereby the pressure is significantly reduced. MS15021/01E 2012-02 | General Information | 27...

  • Page 28: Engine - Overview

    2.3 Engine – Overview 1 Exhaust pipework 15 Fuel system (high pres‐ 24 Engine coolant pump 2 Air recirculation valve sure) 25 Charge-air line 3 Exhaust turbocharger 16 Fuel system (low pres‐ 26 Mounting/support 4 Air intake/air supply sure) 27 Starting equipment 5 Oil separator 17 Inspection port cover 28 Flywheel housing...

  • Page 29: Sensors, Actuators And Injectors - Overview

    2.4 Sensors, actuators and injectors – Overview 1 Injector Y39.1 (cylinder 6 B6.2 (coolant tempera‐ 11 Injector Y39.11 (cylinder ture) 2 Injector Y39.2 (cylinder 7 B06 (coolant tempera‐ 12 B44.2 (turbocharger ture) speed, B-side) 3 Injector Y39.3 (cylinder 8 Injector Y39.14 (cylinder 13 B44.1 (turbocharger speed, A-side) 4 Injector Y39.4 (cylinder...
  • Page 30 1 B10 (charge-air pressure) 5 B05 (lube oil pressure) 9 B4.2 (exhaust tempera‐ 2 B09 (charge-air tempera‐ 6 B50 (crankcase pressure) ture, cylinder A2) ture) 7 B4.4 (exhaust tempera‐ 10 B4.1 (exhaust tempera‐ 3 F46 (leak-off fuel level) ture, cylinder A4) ture, cylinder A1) 4 B07 (lube oil tempera‐...
  • Page 31 1 B5.2 (lube-oil pressure) 4 B33 (fuel temperature in 2 B01 (camshaft speed) common rail) 3 Sensor B34 (fuel pres‐ 5 B48 (fuel pressure in sure after filter) common rail) MS15021/01E 2012-02 | General Information | 31...
  • Page 32 1 B4.11 (exhaust tempera‐ 3 B4.13 (exhaust tempera‐ 5 B16 (coolant pressure) ture, cylinder B1) ture, cylinder B3) 6 F33 (coolant level) 2 B4.12 (exhaust tempera‐ 4 B4.14 (exhaust tempera‐ ture, cylinder B2) ture, cylinder B4) 32 | General Information | MS15021/01E 2012-02...
  • Page 33 1 B4.21 (exhaust bulk tem‐ 3 B4.22 (exhaust bulk tem‐ perature, A side) perature, B side) 2 B49 (T-charge air, air re‐ 4 B13 (crankshaft speed) circulation valve) 5 B13.2 (crankshaft speed) MS15021/01E 2012-02 | General Information | 33...

  • Page 34: Technical Data

    3 Technical Data 3.1 8 V 4000 M40A engine data Explanation: Abbrevia‐ Meaning tion Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated, without change (e.g. of power set‐...
  • Page 35 Number of cylinders Stroke Cylinder displacement Liters 4.06 Total displacement Liters 32.5 Number of inlet valves per cylinder Number of exhaust valves per cylinder RAW WATER CIRCUIT (open circuit) Number of cylinders Raw water pump: Inlet pressure, min. -0.2 Raw water pump: Inlet pressure, max. +0.5 Pressure loss in off-engine raw water system, max.
  • Page 36 CAPACITIES Number of cylinders Engine coolant, engine side (with cooling system) Liters Engine oil on initial filling (standard oil system) (option: max. operating incli‐ Liters nations) Oil change quantity, max. (standard oil system) (option: max. operating in‐ Liters clinations) Oil pan capacity, dipstick mark "min." (standard oil system) (option: max. Liters operating inclinations) Oil pan capacity at dipstick mark "max."...

  • Page 37: 4000 M40A Engine Data

    3.2 8 V 4000 M40A engine data Explanation: Abbrevia‐ Meaning tion Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated, without change (e.g. of power set‐...
  • Page 38 Number of cylinders Total displacement Liters 32.5 Number of inlet valves per cylinder Number of exhaust valves per cylinder LUBE OIL SYSTEM Number of cylinders Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C Lube oil operating pressure before engine, from Lube oil operating pressure before engine, to...
  • Page 39 Number of cylinders Oil pan capacity, dipstick mark "min." (standard oil system) (option: max. Liters operating inclinations) Oil pan capacity at dipstick mark "max." (standard oil system) (option: max. Liters operating inclinations) WEIGHTS / MAIN DIMENSIONS Number of cylinders Engine dry weight (with attached standard accessories, without coupling) 4430 ACOUSTICS Number of cylinders...

  • Page 40: 4000 M40A Engine Data

    3.3 8 V 4000 M40A engine data Explanation: Abbrevia‐ Meaning tion Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated, without change (e.g. of power set‐...
  • Page 41 Number of cylinders Total displacement Liters 32.5 Number of inlet valves per cylinder Number of exhaust valves per cylinder LUBE OIL SYSTEM Number of cylinders Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C Lube oil operating pressure before engine, from Lube oil operating pressure before engine, to...
  • Page 42 Number of cylinders Oil pan capacity, dipstick mark "min." (standard oil system) (option: max. Liters operating inclinations) Oil pan capacity at dipstick mark "max." (standard oil system) (option: max. Liters operating inclinations) WEIGHTS / MAIN DIMENSIONS Number of cylinders Engine dry weight (with attached standard accessories, without coupling) 4430 ACOUSTICS Number of cylinders...

  • Page 43: 4000 M40B Engine Data

    3.4 8 V 4000 M40B engine data Explanation: Abbrevia‐ Meaning tion Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated, without change (e.g. of power set‐ ting) Not yet defined value Not applicable...
  • Page 44 Number of cylinders Total displacement Liters 32.5 Number of inlet valves per cylinder Number of exhaust valves per cylinder RAW WATER CIRCUIT (open circuit) Number of cylinders Raw water pump: Inlet pressure, min. -0.2 Raw water pump: Inlet pressure, max. +0.5 Pressure loss in off-engine raw water system, max.
  • Page 45 CAPACITIES Number of cylinders Engine coolant, engine side (with cooling system) Liters Engine oil on initial filling (standard oil system) (option: max. operating incli‐ Liters nations) Oil change quantity, max. (standard oil system) (option: max. operating in‐ Liters clinations) Oil pan capacity, dipstick mark "min." (standard oil system) (option: max. Liters operating inclinations) Oil pan capacity at dipstick mark "max."...

  • Page 46: 4000 M40B Engine Data

    3.5 8 V 4000 M40B engine data Explanation: Abbrevia‐ Meaning tion Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated, without change (e.g. of power set‐ ting) Not yet defined value Not applicable...
  • Page 47 Number of cylinders Total displacement Liters 32.5 Number of inlet valves per cylinder Number of exhaust valves per cylinder LUBE OIL SYSTEM Number of cylinders Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C Lube oil operating pressure before engine, from Lube oil operating pressure before engine, to...
  • Page 48 Number of cylinders Oil pan capacity, dipstick mark "min." (standard oil system) (option: max. Liters operating inclinations) Oil pan capacity at dipstick mark "max." (standard oil system) (option: max. Liters operating inclinations) WEIGHTS / MAIN DIMENSIONS Number of cylinders Engine dry weight (with attached standard accessories, without coupling) 4430 ACOUSTICS Number of cylinders...

  • Page 49: 4000 M40B Engine Data

    3.6 8 V 4000 M40B engine data Explanation: Abbrevia‐ Meaning tion Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated, without change (e.g. of power set‐ ting) Not yet defined value Not applicable...
  • Page 50 Number of cylinders Total displacement Liters 32.5 Number of inlet valves per cylinder Number of exhaust valves per cylinder LUBE OIL SYSTEM Number of cylinders Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C Lube oil operating pressure before engine, from Lube oil operating pressure before engine, to...
  • Page 51 Number of cylinders Oil pan capacity, dipstick mark "min". (standard oil system) (option: max. Liters operating inclinations) Oil pan capacity at dipstick mark "max." (standard oil system) (option: max. Liters operating inclinations) WEIGHTS / MAIN DIMENSIONS Number of cylinders Engine dry weight (with attached standard accessories, without coupling) 4430 ACOUSTICS Number of cylinders...

  • Page 52: Firing Order

    3.7 Firing order Firing order Number of cylin‐ Firing order ders A1-B4-A4-A2-B3-A3-B2-B1 A1-B2-A5-B4-A3-B1-A6-B5-A2-B3-A4-B6 16 V A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B7 20 V A1-B5-A8-B7-A5-B2-A7-B10-A2-B3-A10-B6-A3-B4-A6-B9-A4-B1-A9-B8 52 | Technical Data | MS15021/01E 2012-02...

  • Page 53: Engine - Main Dimensions

    3.8 Engine – Main dimensions Engine – Main dimensions Engine model Length (A) Width (B) Height (C) 8 V 4000 M40/50 A/B approx. 2340 mm approx. 1380 mm approx. 1990 mm 12 V 4000 M40/50 A/B approx. 3220 mm approx. 1520 mm approx.

  • Page 54: Operation

    4 Operation 4.1 LOP – Controls LOP – Controls Item Color Inscription Meaning / Function White Function keys for operating the screen. White Functions vary and are displayed on the LCD screen. White White White White ALARM AC‐ Pressing the key the first time stops alarm signalization. KNOWLEDGE Pressing the key a second time acknowledges an active alarm.
  • Page 55 Item Color Inscription Meaning / Function White DIMMER ↓ Holding down the key decreases LCD background illumina‐ tion. White LAMP TEST Pressing the key initiates lamp test. TEST OVER‐ Pressing the key initiates overspeed test. SPEED LED (spot) lights up as long as the overspeed test is run‐ ning.

  • Page 56: Engine - Preparations For Putting Into Operation After Extended Out-Of-Service Periods (>3 Months)

    4.2 Engine – Preparations for putting into operation after extended out-of-service periods (>3 months) Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Putting into operation after extended out-of-service periods (>3 months) Item Measure Engine Depreserve (→...

  • Page 57: Putting The Engine Into Operation After Scheduled Out-Of-Service-Period

    4.3 Putting the engine into operation after scheduled out-of- service-period Preconditions ☑ Engine is stopped and starting disabled. Putting into operation Item Action Lube oil system Check engine oil level (→ Page 120); , preheat engine oil, if required. Coolant circuit Check coolant level (→...

  • Page 58: Tasks After Extended Out-Of-Service Periods (>3 Weeks)

    4.4 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. Start up fuel treatment system (→ Page 60). Shut down fuel treatment system (→ Page 68). 58 | Operation | MS15021/01E 2012-02...

  • Page 59: Checks Prior To Start-Up

    Checks prior to start-up 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/..). Close drain valves on housing. Open all supply and discharge valves.

  • Page 60: Fuel Treatment System - Putting Into Operation

    4.6 Fuel treatment system – Putting into operation Fuel treatment system – Overview Switch on fuel treatment system (→ Page 63). Check the differential pressure at differential pressure gauge (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.
  • Page 61 Simulation of filter replacement with the engine running: HAT Switch on fuel treatment system (→ Page 63). Start engine (→ Page 62). Run engine at idling speed. Close ball cock (5) at the inlet to the 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).

  • Page 62: Engine - Starting

    4.7 Engine – Starting Preconditions ☑ External start interlock is not activated. ☑ Emergency-air shutoff flaps (if fitted) must be opened. DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Before barring or starting the engine, make sure that nobody is in the danger zone. WARNING Engine noise above 85 dB (A).

  • Page 63: Fuel Treatment System - Switching On

    4.8 Fuel treatment system – Switching on Preconditions ☑ The on-board power supply is switched on. CAUTION Damage to engine/plant. Major material damage! • Before switching on, ensure that the engine/plant is ready for operation. • Before switching on, ensure that all housings are closed. •...

  • Page 64: Operational Checks

    4.9 Operational checks DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...

  • Page 65: Stopping The Engine At The Lop

    4.10 Stopping the engine at the LOP Preconditions ☑ Engine is running in local mode. CAUTION Stopping the engine when it is running at full load causes extreme stress to the engine. Risk of overheating, damage to components! • Before stopping the engine, operate it at idle speed until operating temperatures decrease and stable values are indicated.

  • Page 66: Emergency Stop From Lop

    4.11 Emergency stop from LOP CAUTION An emergency stop causes extreme stress to the engine. Risk of overheating, damage to components! • Initiate emergency stop only in emergency situations. Emergency stop from LOP Item Task Open cap of EMERGENCY STOP button (→ Page 54). Press EMERGENCY STOP button.

  • Page 67: After Stopping The Engine

    4.12 After stopping the engine Preconditions ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. After stopping the engine Item Action Coolant circuit Drain coolant (→ Page 131) 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;...

  • Page 68: Fuel Treatment System - Shutdown

    4.13 Fuel treatment system – Shutdown Shutting down fuel treatment system Press the illuminated pushbutton "Water drain" on the switch cabinet until water discharge from the outlet stops. Switch off fuel treatment system. Close ball valve at the inlet to the fuel treatment system. Close ball valve at the outlet of the fuel treatment system.

  • Page 69: Plant - Cleaning

    4.14 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 Cleaner (Hakupur 312) 30390 WARNING Compressed air Risk of injury! •...

  • Page 70: Maintenance

    5 Maintenance 5.1 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.

  • Page 71: Fuel Treatment System - Troubleshooting

    6 Troubleshooting 6.1 Fuel treatment system – Troubleshooting Illuminated pushbutton “Water alarm” is lit. Cause Corrective action When the maximum water level 1. Press illuminated pushbutton “Water alarm” to acknowledge. is reached, the water level elec‐ 2. In addition to the automatic water drain function, water can also trode opens the water drain be drained manually.

  • Page 72: Troubleshooting

    6.2 Troubleshooting Engine does not turn when starter is actuated Component Cause Measure Battery Discharged or faulty Charge or replace (see manufacturer's documentation). Cable connections faulty Check if cable connections are proper‐ ly secured (see manufacturer's docu‐ mentation). Starter Engine cabling or starter faulty Check if cable connections are proper‐...
  • Page 73 Faulty Contact Service. Charge-air temperature too high Component Cause Measure Engine coolant Engine coolant treatment incorrect Check (MTU test kit). Intercooler Contaminated Contact Service. Engine room Air-intake temperature too high Check fans and air supply / ventilation ducts. Charge-air pressure too low...
  • Page 74 White exhaust gas Component Cause Measure Engine Not at operating temperature Run engine to reach operating temper‐ ature. Fuel system Water in fuel Check fuel system at fuel prefilter Drain fuel prefilter (→ Page 108). Intercooler Leaking Contact Service. 74 | Troubleshooting | MS15021/01E 2012-02...

  • Page 75: Lop Fault Messages

    6.3 LOP fault messages Fault messages and measuring points (status reports) are displayed as text messages on the LOP dis‐ play (DIS). Explanation of the displayed texts can be gathered by pressing the help button on the touchscreen. Fault messages can also be caused by faulty sensors/actuators. Contact Service to have sensors/actuators checked and replaced as necessary if the troubleshooting measures listed in the table below prove unsuccessful.
  • Page 76 Display text Meaning Measure AL Power Amplifier 2 Power amplifier cylinder bank B fault 1. Check LOP visually (→ Page 157); Failure 2. Perform LOP test procedures (→ Page 160); 3. Check ECU plug-in connections (→ Page 153); 4. Check engine wiring (→ Page 149); 5.
  • Page 77 Display text Meaning Measure DL 211+A003-ECU ECU 4 not recognized on default bus 1. Check LOP visually (→ Page 157); 2. Perform LOP test procedures (→ Page 160); 3. Check ECU plug-in connections (→ Page 153); 4. Check engine wiring (→ Page 149); 5.
  • Page 78 Display text Meaning Measure RL 211+A004-EMU EMU 1 not recognized on redundant 1. Check LOP visually (→ Page 157); 2. Perform LOP test procedures (→ Page 160); 3. Contact Service. • Have EMU checked and re‐ placed, if required. SS Safety System Safety system has determined fault on contact Service.
  • Page 79 Display text Meaning Measure TD P-Lube Oil Different measurement values trans‐ 1. Check LOP visually (→ Page 157); mitted by the two sensors for lube oil 2. Perform LOP test procedures pressure (→ Page 160); 3. Check ECU plug-in connections (→...

  • Page 80: Task Description

    7 Task Description 7.1 Engine 7.1.1 Engine – Barring manually Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Barring device F6555766 Ratchet with extension F30006212 DANGER Unguarded rotating and moving engine components. Risk of serious injury –...

  • Page 81: Engine Cranking On Starter

    7.1.2 Engine cranking on starter Special tools, Material, Spare parts Designation / Use Part No. Qty. Connector pliers 0135315483 DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • before barring or starting the engine, ensure that nobody is in the danger zone. •...

  • Page 82: Cylinder Liner

    7.2 Cylinder Liner 7.2.1 Cylinder liner – Endoscopic examination Preconditions ☑ Engine is stopped and starting disabled Special tools, Material, Spare parts Designation / Use Part No. Qty. Rigid endoscope Y20097353 Preparatory steps Remove cylinder head cover (→ Page 95). Remove injector (→...
  • Page 83 Final steps Install injector (→ Page 98). Install cylinder head cover (→ Page 95). MS15021/01E 2012-02 | Task Description | 83...

  • Page 84: Cylinder Liner - Instructions And Comments On Endoscopic And Visual Examination

    7.2.2 Cylinder liner – Instructions and comments on endoscopic and visual examination Terms used for endoscopic examination Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic exami‐ nation report. Findings Measure Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing prod‐...
  • Page 85 Findings Measure 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 becoming more visible from the second TDC-ring 2 onwards and less pro‐ nounced from TDC-ring 1.

  • Page 86: Crankcase Breather

    7.3 Crankcase Breather 7.3.1 Crankcase breather – Oil separator replacement, diaphragm check and replacement Preconditions ☑ Engine shut down and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 6-50 Nm F30027336 Ratchet adapter F30027340 Engine oil Filter element...
  • Page 87 Crankcase breather – replacing filter element (variant B) Remove cover (2) with O-ring (3). Remove filter element (1) from housing (4). Insert new filter element in housing (4). Install cover (2) with new O-ring. Use torque wrench to tighten the screws of cover (2) to the specified torque. Name Size Type...

  • Page 88: Crankcase Breather - Oil Separator Replacement

    7.3.2 Crankcase breather – oil separator replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Ethanol, denatured Oil separator (→ Spare Parts Catalog) Crankcase breather – oil separator replacement Loosen clamps (1), push rubber sleeves (2) over tubes (3).

  • Page 89: Valve Drive

    7.4 Valve Drive 7.4.1 Valve gear - Lubrication Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil Lubricating valve gear (valve bridge with guide) Remove cylinder head covers (→ Page 95). Fill oil chambers of valve bridges with oil.

  • Page 90: Valve Clearance - Check And Adjustment

    7.4.2 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 gauge Y20010128 Torque wrench 10-60 Nm F30510423...
  • Page 91 Checking valve bridge balance Fig. Component Valve bridge with guide Flying valve bridge Note: Not applicable for engines with flying valve bridge. Prior to adjusting valve clearance, check valve bridge balance on all valve bridges. Use feeler gauge to determine distance be‐ tween valve bridge and rocker arm.
  • Page 92 Insert feeler gauge with determined value between valve bridge and valve-stem end (A). At the opposite valve-stem end (B), a feeler gauge thicker by 0.05 mm should not fit, otherwise adjust valve bridge balance. Adjusting valve bridge balance Note: Not applicable for engines with flying valve bridge.
  • Page 93 Tighten locknut (2) to 35 Nm +5 Nm, hold‐ ing valve bridge (1) in position with open- end wrench. Recheck valve bridge balance. Checking valve clearance at two crankshaft positions Item Explanation Cylinder A1 is in firing TDC Cylinder A1 is in overlap TDC Inlet valve Exhaust valve MS15021/01E 2012-02 | Task Description | 93...

  • Page 94: Adjusting Valve Clearance

    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 under load on cylinder A1, the piston is in overlap TDC. Check valve clearance with cold engine: •...

  • Page 95: Cylinder Head Cover - Removal And Installation

    7.4.3 Cylinder head cover – Removal and installation Preconditions ☑ Engine shut down and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Gasket (→ Spare Parts Catalog) Removing cylinder head cover Clean cylinder head covers prior to removal if they are heavily soiled.

  • Page 96: Injection Pump / Hp Pump

    7.5 Injection Pump / HP Pump 7.5.1 HP pump – Relief bore check DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...

  • Page 97: Injection Valve / Injector

    7.6 Injection Valve / Injector 7.6.1 Injector – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Injector (→ Spare Parts Catalog) Replacing injector Remove injector and install new injector (→ Page 98). MS15021/01E 2012-02 | Task Description | 97...
  • Page 98 7.6.2 Injector – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Installation and removal device for injector F6790161 Milling cutter F30452739 Slotted nut screwdriver F30452578 Torque wrench, 0.5-5 Nm 0015384230 Torque wrench, 10-60 Nm F30510423...
  • Page 99 Removing injector Note: Always replace the first and last injectors of one engine side first. Replace the inner in‐ jectors only after the installation of the outer injectors on this engine side is completed. Undo cable terminal screws (arrow) on in‐ jector and remove cable terminals.
  • Page 100 Remove sealing ring (1) from injector or use a self-made wire hook to remove it from the cylinder head. Remove O-rings (2) from injector. Cover all connections and bores, or seal with suitable plugs. Installing injector Remove all plugs before installing. Coat nozzle retaining nut area of injector with assembly paste.
  • Page 101 Use slotted screwdriver to check thrust ring at both line ends for secure seating. Tighten loose thrust ring to the specified tightening torque. Name Size Type Lubricant Value/Standard Thrust ring Tightening torque 5 Nm to 10 Nm Coat screw head mating face (2) and thread with engine oil.
  • Page 102 Tighten union nut of connecting piece (limiting valve) to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Union nut Tightening torque 140 Nm + 10 Nm Tighten union nut of connecting piece (injector) to specified torque using a torque wrench. Name Size Type...

  • Page 103: Fuel System

    7.7 Fuel System 7.7.1 Fuel system – Venting and filling Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filling device B80144852 Diesel fuel WARNING Fuels are combustible. Risk of fire and explosion! •...
  • Page 104 Venting and filling HP fuel system Connect filling device to connection (3). Remove flushing line (4) from HP pump (1). Connect return hose of filling device to HP pump (1). Unscrew vent line (8) from connection (7). Seal connection (7) with sealing cone. Note: During filling, the opening of the valves in the HP pump must be audible (whistling noise).

  • Page 105: Fuel Filter

    7.8 Fuel Filter 7.8.1 Fuel filter – Replacement Preconditions ☑ Engine shut down and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Oil filter wrench F30379104 Diesel fuel Easy-change filter (→ Spare Parts Catalog) Plastic ring (→...
  • Page 106 Replacing fuel filter with the engine stopped Cut out the filter to be replaced. A Both filters cut in (operating position) B Left filter cut out C Right filter cut out Unscrew cut-out easy-change filter with oil filter wrench. Clean sealing face on filter head. Check sealing ring on new easy-change fil‐...
  • Page 107 7.8.2 Fuel prefilter – Differential pressure gauge check and adjustment DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...
  • Page 108 7.8.3 Fuel prefilter – Draining Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel Gasket (→ Spare Parts Catalog) WARNING Fuels are combustible. Risk of fire and explosion! •...

  • Page 109: Fuel Prefilter ‒ Flushing

    7.8.4 Fuel prefilter ‒ Flushing Special tools, Material, Spare parts Designation / Use Part No. Qty. Fuel Gasket (→ Spare Parts Catalog) DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Fuels are combustible.
  • Page 110 Open threaded vent plug (5) of filter to be flushed. Unlock drain valve (6) by pressing valve toggle, open it and drain fuel. Result: Fuel flows from filtered side back to the un‐ filtered side, flushing the filter deposits downwards out of the filter. Close threaded vent plug (5) and drain valve (6).
  • Page 111 7.8.5 Fuel prefilter – Filter element replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel Filter element (→ Spare Parts Catalog) Gasket (→ Spare Parts Catalog) WARNING Fuels are combustible.
  • Page 112 Open threaded vent plug (5) of contaminat‐ ed filter. Unlock drain valve (6) by pressing toggle and open it. Drain water and dirt from filter. Close drain valve (6). Remove screws securing the cover and take off cover (2). Remove spring housing (4) and filter ele‐ ment (3).
  • Page 113 7.9 Charge-Air Cooling 7.9.1 Intercooler – checking condensate drain line for coolant discharge and obstruction DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A).

  • Page 114: Air Filter

    7.10 Air Filter 7.10.1 Air filter – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Air filter (→ Spare Parts Catalog) Replacing the air filter Remove old air filter and install new air filter (→ Page 115). Reset signal ring of contamination indicator (→...
  • Page 115 7.10.2 Air filter – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Air filter – Removal and installation Release clamp (2). Remove air filter (3) and clamp (2) from flange of intake housing (1). Verify that there are no objects in the flange of the intake housing (1) and clean it.

  • Page 116: Check

    7.11 Air Intake 7.11.1 Contamination indicator – Signal ring position check Preconditions ☑ Engine is stopped and starting disabled. Checking signal ring position If the signal ring is completely visible in the control window (2), replace air filter (→ Page 114). After installation of new filter, press reset button (1).
  • Page 117 7.11.2 Air flap – Check for ease of movement Preconditions ☑ Engine is stopped and starting disabled. Checking air flap for easy movement Actuate lever several times to check ease of movement. Result: The spring must push back the air flap. If spring does not return air flap to initial po‐...

  • Page 118: Exhaust Flap With Actuator

    7.12 Exhaust Flap with Actuator 7.12.1 Exhaust flap – Check for easy movement Preconditions ☑ Engine is stopped and starting disabled. Checking exhaust flap for easy movement Actuate control linkage several times by hand to check for ease of movement. Contact Service if the control linkage is sluggish.

  • Page 119: Starting Equipment

    7.13 Starting Equipment 7.13.1 Starter – Condition check Preconditions ☑ Engine is stopped and starting disabled. Starter – Condition check Check securing screws of starter for secure seating and tighten if required. Check wiring (→ Page 149). MS15021/01E 2012-02 | Task Description | 119...
  • Page 120 7.14 Lube Oil System, Lube Oil Circuit 7.14.1 Engine oil level – Check Preconditions ☑ Engine shut down and starting disabled. Checking oil level prior to engine start Withdraw oil dipstick from guide tube and wipe it. Insert oil dipstick into guide tube up to stop, withdraw after approx.
  • Page 121 7.14.2 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...
  • Page 122 Tighten drain plugs (2) and (3) with torque wrench to specified tightening torque. Name Size Type Lubricant Value/Standard Screw M26 x 1.5 Tightening torque (Engine oil) 100 Nm +10 Nm Filling with new engine oil Open cover on filler neck. Pour engine oil through the filler neck up to the "max."...
  • Page 123 7.14.3 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 DANGER Unguarded rotating and moving engine components.
  • Page 124 7.15 Oil Filtration / Cooling 7.15.1 Engine oil filter - Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Oil filter wrench F30379104 Engine oil Oil filter (→ Spare Parts Catalog) DANGER Unguarded rotating and moving engine components. Risk of serious injury –...

  • Page 125: Engine Running

    Oil filter replacement with the engine running 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 po‐ sition) •...
  • Page 126 7.15.2 Centrifugal oil filter – Cleaning and filter sleeve replacement Preconditions ☑ Engine shut down and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Torque wrench, 6-50 Nm F30027336 Ratchet adapter F30027339 Cold cleaner (Hakutex 60) 50602 Grease (Kluthe Hakuform 30-10/emulsifier)
  • Page 127 Cleaning centrifugal oil filter and replacing filter sleeve Undo screw (1) and remove. Remove clamp (3) and take off hood (2). Carefully remove rotor (5) from housing. Hold rotor assembly (5) firmly in position with filter wrench and undo knurled nut (7). Take off rotor cap (8).

  • Page 128: Venting Points

    7.16 Coolant Circuit, General, High-Temperature Circuit 7.16.1 Venting points Coolant lines on ETC 1 Venting point Vent line – Cross-distributionn expansion tank 1 Venting point 128 | Task Description | MS15021/01E 2012-02...
  • Page 129 7.16.2 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.
  • Page 130 7.16.3 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine coolant Changing engine coolant Drain engine coolant (→ Page 131). Fill with engine coolant (→ Page 132). 130 | Task Description | MS15021/01E 2012-02...

  • Page 131: Engine Coolant – Draining

    7.16.4 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 Provide a suitable receptacle to catch the coolant.

  • Page 132: Engine Coolant – Filling

    7.16.5 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.
  • Page 133 Filling with coolant using a pump Connect appropriate pump with hose to fill‐ ing connection (arrow) on A side or B side. Alternatively: Connect a suitable pump with a hose to drain valve (arrowed). Pump coolant into engine at 0.5 bar mini‐ mum until coolant emerges from the loos‐...
  • Page 134 Filling with coolant through filler neck Alternatively: Fill coolant through filler neck on expansion tank until coolant emerges from the loosened unions at the coolant distribution. Tighten the union for coolant line at the coolant distributor (→ Page 128). Continue to fill until coolant level remains constant at top edge of filler neck. Tighten the coolant line union on both turbochargers (→...

  • Page 135: Engine Coolant Pump – Relief Bore Check

    7.16.6 Engine coolant pump – Relief bore check DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...
  • Page 136 7.16.7 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 DANGER Unguarded rotating and moving engine components.

  • Page 137: Raw Water Pump – Relief Bore Check

    7.17 Raw Water Pump with Connections 7.17.1 Raw water pump – Relief bore check DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A).
  • Page 138 7.18 Battery-Charging Generator 7.18.1 Battery-charging generator drive – Coupling condition check Preconditions ☑ Engine shut down and starting disabled. Checking condition of battery- charging generator drive coupling Remove protective cover. Check resilient coupling for cracks and de‐ formation (arrow). Contact Service in case of severe deforma‐ tion or cracking.
  • Page 139 7.19 Engine Mounting / Support 7.19.1 Engine mounts – Checking securing screws for firm seating Preconditions ☑ Engine is stopped and starting disabled. Engine mounts – Checking securing screws for firm seating Check securing screws for firm seating. Tighten loose threaded connections. MS15021/01E 2012-02 | Task Description | 139...
  • Page 140 7.19.2 Engine mounts – Resilient element check Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine is filled with coolant and engine oil. Special tools, Material, Spare parts Designation / Use Part No. Qty. Feeler gauge Y20010128 Calipers Y20001743 Box wrench F30379609 Engine oil...
  • Page 141 Engine mounts – Checking buffer clearance Take off protective cap (2). Check marking (1): • With marking 30: a = 3 mm +0,3 mm. • With marking 40: a = 4 mm +0,3 mm. Check dimension (a) with feeler gauge on measuring groove (4).

  • Page 142: Auxiliary Pto

    7.20 Auxiliary PTO 7.20.1 Bilge pump – Relief bore check DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...

  • Page 143: Fuel Supply System

    7.21 Fuel Supply System 7.21.1 Water drain valve – Check Checking water drain valve Open water drain valve. Check water outlet for obstructions. Close water drain valve. MS15021/01E 2012-02 | Task Description | 143...
  • Page 144 7.21.2 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 Switch on fuel treatment system (→ Page 63). Set the alarm points at the differential pressure gauge to zero.
  • Page 145 7.21.3 Water level probe (3-in-1 rod electrode) – Check Preconditions ☑ System is put out of service and emptied. WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Water level probe (3-in-1 rod electrode) –...
  • Page 146 7.21.4 Pump capacity – Check WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Checking pump capacity Install suitable pressure gauge at the neck of the intake side of the pump. Check pump pressure.
  • Page 147 7.21.5 Coalescer filter element – Replacement Preconditions ☑ System is switched off and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 6-50 Nm F30027336 Ratchet adapter F30027339 Diesel fuel Engine oil Coalescer filter element (→...
  • Page 148 Tighten nut (3) to specified tightening torque using a torque wrench. Name Size Type Lubricant Value/Standard Tightening torque (Engine oil) 30 Nm +3 Nm Fit gasket (10). Install cover. Install screw (1), washer (2) and nut (9). Tighten nut (9). Open ball valve at the inlet and outlet of the fuel treatment system.
  • Page 149 7.22 Wiring (General) for Engine/Gearbox/Unit 7.22.1 Engine wiring – Check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Isopropyl alcohol X00058037 Engine wiring – Check Check securing screws of cable clamps on engine and tighten loose threaded connections. Ensure that cables are fixed in their clamps and cannot swing freely.
  • Page 150 7.23 Accessories for (Electronic) Engine Governor / Control System 7.23.1 Engine governor and connectors – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Connector pliers 0135315483 Isopropyl alcohol X00058037 Cleaning engine governor and connectors...
  • Page 151 7.23.2 Engine monitoring unit and connectors – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Connector pliers 0135315483 Isopropyl alcohol X00058037 Engine monitoring unit and connectors – Cleaning Remove coarse dirt from housing surface with isopropyl alcohol.
  • Page 152 7.23.3 Start interlock limit switch – Check Preconditions ☑ Engine is stopped and starting disabled. Note: Being in OFF-position, the limit switch initiates start interlock, i.e. the engine cannot be started. Start interlock limit switch – Check Check if switch housing (1) and cover plate (3) are mounted and the switch (2) is in ON- position.

  • Page 153: Checking Engine Control Unit Plug Connections

    7.23.4 Checking engine control unit plug connections Preconditions ☑ Engine shut down and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Connector pliers 0135315483 Checking engine control unit plug connections Use connector pliers (3) to make certain that all plug-in connections on engine con‐...
  • Page 154 7.23.5 Engine monitoring unit – Plug connection check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Connector pliers 0135315483 Checking engine monitoring unit plug connections Use connector pliers (3) to make certain that all engine monitoring unit plug connec‐...
  • Page 155 7.23.6 Engine control unit – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Connector pliers 0135315483 Covering caps for Cannon sockets Removing control unit from engine Note or mark assignment of cables to con‐...
  • Page 156 Disconnect ground strap from engine con‐ trol unit grounding stud (7). If the screws (4) are easily accessible: 1. Remove screws (4). 2. Remove engine control unit housing (3) from mounting plates (2). 3. Unscrew mounting plates (2), cable shock absorbers (5) and further fasten‐ ing parts (6) as one unit from engine.
  • Page 157 7.24 Emergency Instrumentation (Local Operating Panel) 7.24.1 LOP – Visual inspection Preconditions ☑ Engine is stopped and starting disabled. Preparatory steps If READY FOR OPERATION button is illuminated brightly, press switch briefly. Result: READY FOR OPERATION button returns to basic brightness. Switch master power switch to OFF.
  • Page 158 Checking plug connections Check all connected cables to verify that the two securing elements (1) are engaged on the lugs (2) so that the respective male connector (3) is held firmly in place in the socket. If this is not the case, press the securing el‐ ements (1) concerned in the direction of the arrow until they engage noticeably.
  • Page 159 Performing lamp test Connect battery in accordance with battery manufacturer's instructions. Switch master power switch to ON. Switch on Engine Control System. Keep LAMP TEST button pressed: Result: Indicators and controls light up. Have damaged lamps immediately replaced by Service. MS15021/01E 2012-02 | Task Description | 159...
  • Page 160 7.24.2 LOP – Test procedures Preconditions ☑ Engine is stopped and starting disabled. Preparatory steps Connect battery in accordance with battery manufacturer's instructions. Switch master power switch to ON. Switch on engine management system ECS-5. Result: • LOCAL OPERATION pushbutton (1) is il‐ luminated brightly (local control mode is active);.
  • Page 161 Overspeed test with the engine at standstill Note: Overspeed test with the engine at standstill can only be carried out if the engine is equipped with Engine Monitoring Unit. Press OVERSPEED TEST illuminated pushbutton (3). Observe speed limit and speed simulated by Engine Monitoring Unit on display.
  • Page 162 Abgasturbolader Exhaust turbocharger (ETC) Baureihe Series Betriebsstoffvorschrift MTU Fluids and Lubricants Specifications, Publica‐ tion No. A01061/.. Controller Area Network Data bus system, bus standard Deutsches Institut für Normung e. V. At the same time identifier of German standards (DIN = “Deutsche Industrie-Norm”)
  • Page 163 Abbrevia‐ Meaning Explanation tion LOLO Low Low Alarm: Measured value lower than 2nd minimum limit value Local Operating Panel Control console, control panel Local Operating Station Monitoring and Control System Management Computer Unit Computer for control stand, 19"/9.5" unit size Message Microprocessor Unit, Microprocessing Unit...
  • Page 164 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.

  • Page 165: Special Tools

    9 Appendix B 9.1 Special Tools Barring device Part No.: F6555766 Qty.: Used in: 7.1.1 Engine – Barring manually (→ Page 80) Box wrench Part No.: F30379609 Qty.: Used in: 7.19.2 Engine mounts – Resilient element check (→ Page 140) Calipers Part No.: Y20001743...
  • Page 166 7.6.2 Injector – Removal and installation (→ Page 98) Milling cutter Part No.: F30452739 Qty.: Used in: 7.6.2 Injector – Removal and installation (→ Page 98) MTU test kit Part No.: 5605892099/00 Qty.: Used in: 7.14.3 Engine oil – Sample extraction and analysis (→ Page 123) Qty.: Used in: 7.16.7 Engine coolant –...
  • Page 167 Ratchet with extension Part No.: F30006212 Qty.: Used in: 7.1.1 Engine – Barring manually (→ Page 80) Rigid endoscope Part No.: Y20097353 Qty.: Used in: 7.2.1 Cylinder liner – Endoscopic examination (→ Page 82) Ring socket wrench Part No.: F30039518 Qty.: Used in: 7.4.2 Valve clearance –...
  • Page 168 Torque wrench, 40-200 Nm Part No.: F30027337 Qty.: Used in: 7.14.2 Engine oil – Change (→ Page 121) Torque wrench, 6-50 Nm Part No.: F30027336 Qty.: Used in: 7.21.5 Coalescer filter element – Replacement (→ Page 147) Torque wrench, 6-50 Nm Part No.: F30027336 Qty.:...
  • Page 169 9.2 Index 8 V 4000 M40A engine data 34, 37, 40 8 V 4000 M40B engine data 43, 46, 49 Emergency stop from LOP 66 Engine – Barring manually  80 Abbreviations 162 – Cranking on starter  81 Actuators – Main dimensions  53 – Overview  29...
  • Page 170 Main dimensions – Engine  53 Maintenance work Water drain valve – Safety regulations  13 – Check  143 MTU contact persons 164 Water level probe (3-in-1 rod electrode) – Check  145 Wiring - engine Operation – Check  149 – Safety regulations  11...

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