Page 1: Operating Instructions
Operating Instructions Diesel engine 8 V 2000 M40A, 8 V 2000 M40B 8 V 2000 M41A, 8 V 2000 M41B 12 V 2000 M40A, 12 V 2000 M40B 12 V 2000 M41A, 12 V 2000 M41B 16 V 2000 M40A, 16 V 2000 M40B...
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
Table of Contents 1 Safety 3.10 12V 2000 M40A engine data: Engine- mounted heat exchanger, reference 1.1 Important provisions for all products conditions: 25 °C intake air temperature 1.2 Personnel and organizational requirements 3.11 12V 2000 M40A engine data: Separate 1.3 Transportation heat exchanger, reference conditions: 25 1.4 Safety regulations for maintenance and...
Page 4 4.8 After stopping the engine 7.8 Fuel System 4.9 Plant cleaning 7.8.1 HP fuel line – Pressure pipe neck replacement 7.8.2 Fuel – Draining 7.8.3 Fuel system – Venting 5 Maintenance 7.9 Fuel Filter 5.1 Maintenance task reference table [QL1] 7.9.1 Fuel filter –...
Page 5: Ms150031/05E 2013-01 | Table Of Contents
8 Appendix A Governor / Control System 8.1 Abbreviations 7.22.1 Engine governor and connectors – Cleaning 8.2 MTU contact persons/service partners 7.22.2 Engine monitoring unit and connectors – Cleaning 7.22.3 Start interlock limit switch – Check 7.22.4 ECU – Plug connections check 9 Appendix B 7.22.5 Engine monitoring unit –...
Page 6: Safety
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 in‐ formation 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: •...
Page 7: Personnel And Organizational Requirements
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 transportation. Keep this manual handy in the vicinity of the product such that it is accessible to operating, maintenance, repair and transport personnel at all times.
Page 8: Transportation
1.3 Transportation Transport without flange-mounted gearbox Illustration is essentially valid for 8V 2000 M engines Illustration is essentially valid for 12/16V 2000 M engines Transport with flange-mounted gearbox Illustration is essentially valid for 8V 2000 M engines 8 | Safety | MS150031/05E 2013-01...
Page 9 The eyebolts mounted at the driving end and on the gearbox must not be used for transporting plants with flange-mounted gearboxes. Only use transport and lifting devices approved by MTU. Take the engine's center of gravity into account. MS150031/05E 2013-01 | Safety | 9...
Page 10 Only set down engine on a firm, level surface. 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 expressively authorized to do so by MTU on a case-to- case basis.
Page 11: Safety Regulations For Maintenance And Repair Work
1.4 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 less than 50°C before starting maintenance work (risk of explosion of oil vapors, fluids and lubricants, risk of burning).
Page 12 Ensure particular cleanness during maintenance and repair work on the product. After completion of maintenance and repair work, make sure that no loose objects are in/on the product (e.g. cloths and ca‐ ble 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.
Page 13 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.
Page 14: Fire Prevention And Environmental Protection, Fluids And Lubricants, 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 applicable version may be downloaded at: http:// www.mtu-online.com/mtu/mtu-valuecare/mtu-valueservice-Technische-Dokumentation. Auxiliary materials, fluids and lubricants might be hazardous goods or toxic substances.When using flu‐...
Page 15: Compressed Air
Lead • Adopt suitable measures to avoid the formation of lead dust. • Switch on extraction system. • When working with lead or lead-containing compounds, avoid direct contact to the skin and 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: •...
Page 16: Standards For Warning Notices In The Text
1.6 Standards for warning notices in the text DANGER In the event of immediate danger. Consequences: Death, serious or irreversible injury • Remedial action WARNING In the event of a situation involving potential danger. Consequences: Death, serious or permanent injury •...
Page 17: 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 18: 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, exhaust turbocharging and intercooling. The engine is monitored by an engine control and monitoring system. Monitoring in the engine room is carried out by the engine control and monitoring unit.
Page 19 • Interface to CAN field bus for connected, communicating monitoring system components. SOLAS – Fire protection specifications All fuel lines with fuel pressure >1.8 bar are fitted with SOLAS-compliant covers acc. to MTU standard MTN5233. All oil lines with oil pressure >1.8 bar are fitted with SOLAS-compliant covers acc. to MTU standard MTN5233.
Page 20 Fuel system covers 20 | General Information | MS150031/05E 2013-01...
Page 21 MS150031/05E 2013-01 | General Information | 21...
Page 22 Lube oil system covers 22 | General Information | MS150031/05E 2013-01...
Page 23 MS150031/05E 2013-01 | General Information | 23...
Page 24 Special unions 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. Plug-in pipe union Design precludes lateral spray as the parting line is shielded by the sleeve (4). Only seepage along the pipeline is possible whereby the pressure is greatly reduced by a faulty O-ring (3).
Page 25 High-pressure unions 1 Jacketed pipe 8 Thrust ring 15 Union nut 2 HP line 9 Union nut 16 Thrust ring 3 O-ring 10 Union nut 17 External pipe of HP line 4 Union nut 11 Connecting piece 18 Internal pipe of HP line 5 Recess for O-ring 12 Snap ring 19 Spherical sealing area...
Page 26 Shielding of fuel filters and lube-oil filters Shielding with plastic ring The plastic ring (1) precludes lateral spray. The fluid is diverted to the catch basin whereby the pressure is greatly reduced. Shielding by structural overhang The overhang (1) prevents lateral spray. The fluid is diverted to the catch basin whereby the pressure is greatly reduced.
Page 27: Series 2000 M40A/B - M41A/B
2.3 Series 2000 M40A/B - M41A/B Engine – Overview of functional groups 010 Crankcase and exter‐ 080 Fuel system (low pres‐ 180 Lube oil system/lube oil nally mounted compo‐ sure) circuit nents 100 Exhaust turbocharger 200 Coolant circuit 020 Gear train 110 Intercooler 230 Mounting/support 030 Crank drive...
Page 28: Sensors, Actuators And Injectors - Overview
2.4 Sensors, actuators and injectors – Overview Engine overhead view 1 Intake air temperature 4 Lube oil differential pres‐ 7 Lube oil temperature 2 Fuel pressure after filter sure 8 Lube oil pressure 3 Fuel temperature 5 Lube oil pressure 6 Coolant level 28 | General Information | MS150031/05E 2013-01...
Page 29 Engine free end 1 Raw water pressure 3 Coolant temperature 2 Coolant pressure 4 Coolant temperature MS150031/05E 2013-01 | General Information | 29...
Page 30 Right engine side 1 Charge-air temperature 3 Leak-fuel level 2 Charge-air pressure 4 Adapter 30 | General Information | MS150031/05E 2013-01...
Page 31 Engine driving end 1 Exhaust temperature, A 3 Camshaft speed 5 Crankshaft speed side 4 Crankshaft speed 2 Exhaust temperature, B-side MS150031/05E 2013-01 | General Information | 31...
Page 32: Sensors, Actuators And Injectors - Overview
2.5 Sensors, actuators and injectors – Overview Top view 12V 2000 M 1 B03 (T-Intake air) 4 B5.2 (P-Lube oil) 7 B07 (T-Lube oil) 2 B10 (P-Charge-air pres‐ 5 F25 (P-Lube-oil differ‐ 8 B05 (P-Lube oil) sure) ence over filter) 3 B09 (T-Charge air) 6 B34 (P-Fuel after filter) 32 | General Information | MS150031/05E 2013-01...
Page 33 Left engine side 12V 2000 M 1 F33 (H-Engine coolant) 2 Y27 (Turbocharger con‐ 3 B21 (Raw water pres‐ trol valve) sure) MS150031/05E 2013-01 | General Information | 33...
Page 34 Engine free end 12V 2000 M 1 B06 (T-Coolant) 2 B6.2 (T-Coolant) 34 | General Information | MS150031/05E 2013-01...
Page 35 Right engine side 12V 2000 M 1 B44 (N-turbocharger) 3 F46 (H-Leak-off fuel) 2 B16 (P-Coolant) 4 B33 (T-Fuel) MS150031/05E 2013-01 | General Information | 35...
Page 36 Driving end 12V 2000 M 1 B01 (N-Camshaft) 3 B13 (N-Crankshaft) 5 B4.21 (T-Exhaust bulk, 2 B4.22 (T-Exhaust bulk, 4 B13.2 (N-Crankshaft) A side) B side) 36 | General Information | MS150031/05E 2013-01...
Page 37 Top view 16V 2000 M 1 B03 (T-Intake air) 4 B5.2 (P-Lube oil) 7 B07 (T-Lube oil) 2 B10 (P-Charge air) 5 F25 (P-Lube-oil differ‐ 8 B05 (P-Lube oil) 3 B09 (T-Charge air) ence over filter) 6 B34 (P-Fuel after filter) MS150031/05E 2013-01 | General Information | 37...
Page 38 Left engine side 16V 2000 M 1 F33 (H-Coolant) 2 Y27 (Turbocharger con‐ 3 B21 (Raw water pres‐ trol valve) sure) 38 | General Information | MS150031/05E 2013-01...
Page 39 Free end 16V 2000 M 1 B06 (T-Coolant) 2 B6.2 (T-Coolant) MS150031/05E 2013-01 | General Information | 39...
Page 40 Right engine side 16V 2000 M 1 B44 (N-Turbocharger) 3 F46 (H-Leak-off fuel) 2 B16 (P-Coolant) 4 B33 (T-Fuel) 40 | General Information | MS150031/05E 2013-01...
Page 41 Driving end 16V 2000 M 1 B01 (N-Camshaft) 3 B13 (N-Crankshaft) 5 B4.21 (T-Exhaust bulk, 2 B4.22 (T-Exhaust bulk, 4 B13.2 (N-Crankshaft) A side) B side) MS150031/05E 2013-01 | General Information | 41...
Page 42: Technical Data
3 Technical Data 3.1 8V 2000 M40A engine data: engine-mounted heat exchanger, reference conditions: 25 °C intake air temperature 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 changes (e.g.
Page 43 Number of cylinders Total displacement liter 15.92 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 external raw water system, max.
Page 44 CAPACITIES Number of cylinders Engine coolant, engine-side (with cooler) liter Engine oil at initial filling (standard oil system) (Option: max. operating incli‐ liter nations) Oil change quantity, max. (standard oil system) (Option: max. operating in‐ liter clinations) Oil pan capacity, dipstick mark min. (standard oil system) (Option: max. op‐ liter erating inclinations) Oil pan capacity, dipstick mark max.
Page 45: 2000 M40A Engine Data: Separate Heat Exchanger, Reference Conditions: 25 °C Intake Air Temperature
3.2 8V 2000 M40A engine data: separate heat exchanger, reference conditions: 25 °C intake air temperature 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 changes (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
Page 46 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 Lube oil operating pressure (low idle) (meas. point: before engine) FUEL SYSTEM Number of cylinders Fuel pressure at engine supply connection, min.
Page 47 ACOUSTICS Number of cylinders Exhaust noise, unsilenced, DL, (free-field sound pressure level Lp, 1m dis‐ db(A) tance, ISO 6798) Engine surface noise with attenuated intake noise (filter), DL, (free-field db(A) sound pressure level Lp, 1m distance, ISO 6798) MS150031/05E 2013-01 | Technical Data | 47...
Page 48: 2000 M40B Engine Data, Engine-Mounted Heat Exchanger, Reference Condition: 25 °C Intake Air Temperature
3.3 8V 2000 M40B engine data, engine-mounted heat exchanger, reference condition: 25 °C intake air temperature 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 changes (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
Page 49 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 external raw water system, max. LUBE OIL SYSTEM Number of cylinders Lube-oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C...
Page 50 Number of cylinders Oil pan capacity, dipstick mark min. (standard oil system) (Option: max. op‐ liter erating inclinations) Oil pan capacity, dipstick mark max. (standard oil system) (Option: max. op‐ liter erating inclinations) WEIGHTS / MAIN DIMENSIONS Number of cylinders Engine dry weight (with attached standard accessories, without coupling) 1790 ACOUSTICS...
Page 51: 2000 M40B Engine Data, Separate Heat Exchanger, Reference Condition: 25 °C Intake Air Temperature
3.4 8V 2000 M40B engine data, separate heat exchanger, reference condition: 25 °C intake air temperature 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 changes (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
Page 52 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 Lube oil operating pressure (low idle) (meas. point: before engine) FUEL SYSTEM Number of cylinders Fuel pressure at engine supply connection, min.
Page 53 ACOUSTICS Number of cylinders Exhaust noise, unsilenced, DL , (free-field sound pressure level Lp, 1m dis‐ db(A) tance, ISO 6798) Engine surface noise with attenuated intake noise (filter), DL, (free-field db(A) sound pressure level Lp, 1m distance, ISO 6798) MS150031/05E 2013-01 | Technical Data | 53...
Page 54: 2000M41A Engine Data: Engine-Mounted Heat Exchanger
3.5 8V 2000M41A engine data: Engine-mounted heat exchanger 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 settings). N Not yet defined value - Not applicable X Applicable...
Page 55 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 Lube oil operating pressure (low idle) (meas. point: before engine) Fuel system Number of cylinders Fuel pressure at engine inlet connection, min.
Page 56 Acoustics Number of cylinders Exhaust noise, unsilenced - DL (free-field sound pressure level Lp, 1m dis‐ dB(A) tance, ISO 6798, +3dB(A) tolerance) Engine surface noise with attenuated intake noise (filter) - DL (free-field dB(A) sound power level Lp, 1 m distance, ISO 6798, +2dB(A) tolerance) 56 | Technical Data | MS150031/05E 2013-01...
Page 57: 2000M41A Engine Data: Remote Heat Exchanger
3.6 8V 2000M41A engine data: Remote heat exchanger 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 settings). N Not yet defined value - Not applicable X Applicable...
Page 58 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 Lube oil operating pressure (low idle) (meas. point: before engine) Fuel system Number of cylinders Fuel pressure at engine inlet connection, min.
Page 59 Acoustics Number of cylinders Exhaust noise, unsilenced - DL (free-field sound pressure level Lp, 1m dis‐ dB(A) tance, ISO 6798, +3dB(A) tolerance) Engine surface noise with attenuated intake noise (filter) - DL (free-field dB(A) sound power level Lp, 1 m distance, ISO 6798, +2dB(A) tolerance) MS150031/05E 2013-01 | Technical Data | 59...
Page 60: 2000M41B Engine Data: Engine-Mounted Heat Exchanger
3.7 8V 2000M41B engine data: Engine-mounted heat exchanger 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 settings). N Not yet defined value - Not applicable X Applicable...
Page 61 Raw-water circuit (open circuit) Number of cylinders Raw water pump: Inlet pressure, min. -0.2 Raw water pump: inlet pressure, max. Pressure loss in off-engine raw-water system, max. 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...
Page 62 Number of cylinders Oil pan capacity at 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 standard accessories installed, w/o coupling) 1790 Acoustics...
Page 63: 2000M41B Engine Data: Remote Heat Exchanger
3.8 8V 2000M41B engine data: Remote heat exchanger 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 settings). N Not yet defined value - Not applicable X Applicable...
Page 64: Number Of Cylinders
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 Lube oil operating pressure (low idle) (meas. point: before engine) Fuel system Number of cylinders Fuel pressure at engine inlet connection, min.
Page 65: Exhaust Noise, Unsilenced - Dl (Free-Field Sound Pressure Level Lp, 1M Dis-R Db(A)
Acoustics Number of cylinders Exhaust noise, unsilenced - DL (free-field sound pressure level Lp, 1m dis‐ dB(A) tance, ISO 6798, +3dB(A) tolerance) Engine surface noise with attenuated intake noise (filter) - DL (free-field dB(A) sound power level Lp, 1 m distance, ISO 6798, +2dB(A) tolerance) MS150031/05E 2013-01 | Technical Data | 65...
Page 66: 2000 M40A Engine Data: Engine-Mounted Heat Exchanger, Reference Conditions: 45 °C Intake Air Temperature
3.9 12V 2000 M40A engine data: Engine-mounted heat exchanger, reference conditions: 45 °C intake air temperature Explanation: CP Ref. value: Continuous power (CP) FSP Ref. 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...
Page 67 Number of cylinders 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 external raw water system, max. LUBE OIL SYSTEM Number of cylinders Lube oil temperature before engine, from...
Page 68 CAPACITIES Number of cylinders Engine coolant capacity (with cooling equipment) liter Engine oil capacity, initial filling (standard oil system) (Option: max. operat‐ liter ing inclinations) Oil change quantity, max. (standard oil system) (Option: max. operating in‐ liter clinations) Oil pan capacity, dipstick mark min. (standard oil system) (Option: max. op‐ liter erating inclinations) Oil pan capacity, dipstick mark max.
Page 69: 2000 M40A Engine Data: Engine-Mounted Heat Exchanger, Reference Conditions: 25 °C Intake Air Temperature
3.10 12V 2000 M40A engine data: Engine-mounted heat exchanger, reference conditions: 25 °C intake air temperature Explanation: CP Ref. value: Continuous power (CP) FSP Ref. 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...
Page 70 Number of cylinders 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 external raw water system, max. LUBE OIL SYSTEM Number of cylinders Lube oil temperature before engine, from...
Page 71 CAPACITIES Number of cylinders Engine coolant capacity (with cooling equipment) liter Engine oil capacity, initial filling (standard oil system) (Option: max. operat‐ liter ing inclinations) Oil change quantity, max. (standard oil system) (Option: max. operating in‐ liter clinations) Oil pan capacity, dipstick mark min. (standard oil system) (Option: max. op‐ liter erating inclinations) Oil pan capacity, dipstick mark max.
Page 72: C Intake Air Temperature
3.11 12V 2000 M40A engine data: Separate heat exchanger, reference conditions: 25 °C intake air temperature Explanation: CP Ref. value: Continuous power (CP) FSP Ref. 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...
Page 73 LUBE OIL SYSTEM Number of cylinders Lube oil temperature before engine, from °C Lube oil temperature before engine, to °C Lube oil operating pressure before engine, from Lube oil operating pressure before engine, to Lube oil operating pressure, low idle (meas. point: before engine) FUEL SYSTEM Number of cylinders Fuel pressure at supply connection on engine, min.
Page 74 WEIGHTS / MAIN DIMENSIONS Number of cylinders Engine dry weight (with attached standard accessories, without coupling) 2600 ACOUSTICS Number of cylinders Exhaust noise, unsilenced, CP, (free-field sound pressure level Lp, 1m dis‐ db(A) tance, ISO 6798) Engine surface noise with attenuated intake noise (filter), CP (free-field db(A) sound pressure level Lp, 1m distance, ISO 6798) 74 | Technical Data | MS150031/05E 2013-01...
Page 75: C Intake Air Temperature
3.12 12V 2000 M40A engine data: Separate heat exchanger, reference conditions: 45 °C intake air temperature Explanation: CP Ref. value: Continuous power (CP) FSP Ref. 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...
Page 76 LUBE OIL SYSTEM Number of cylinders Lube oil temperature before engine, from °C Lube oil temperature before engine, to °C Lube oil operating pressure before engine, from Lube oil operating pressure before engine, to Lube oil operating pressure, low idle (meas. point: before engine) FUEL SYSTEM Number of cylinders Fuel pressure at supply connection on engine, min.
Page 77 WEIGHTS / MAIN DIMENSIONS Number of cylinders Engine dry weight (with attached standard accessories, without coupling) 2600 ACOUSTICS Number of cylinders Exhaust noise, unsilenced, CP, (free-field sound pressure level Lp, 1m dis‐ db(A) tance, ISO 6798) Engine surface noise with attenuated intake noise (filter), CP (free-field db(A) sound pressure level Lp, 1m distance, ISO 6798) MS150031/05E 2013-01 | Technical Data | 77...
Page 78: 2000 M40A Engine Data: Engine-Mounted Heat Exchanger, Reference Conditions: 25 °C Intake Air Temperature
3.13 16V 2000 M40A engine data: engine-mounted heat exchanger, reference conditions: 25 °C intake air temperature 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 changes (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
Page 79 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 external raw water system, max. LUBE OIL SYSTEM Number of cylinders Lube-oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C...
Page 80 Number of cylinders Oil pan capacity, dipstick mark min. (standard oil system) (Option: max. op‐ liter erating inclinations) Oil pan capacity, dipstick mark max. (standard oil system) (Option: max. op‐ liter erating inclinations) WEIGHTS / MAIN DIMENSIONS Number of cylinders Engine dry weight (with attached standard accessories, without coupling) 3200 ACOUSTICS...
Page 81: 2000 M40A Engine Data: Engine-Mounted Heat Exchanger, Reference Conditions: 45 °C Intake Air Temperature
3.14 16V 2000 M40A engine data: engine-mounted heat exchanger, reference conditions: 45 °C intake air temperature 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 changes (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
Page 82 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 external raw water system, max. LUBE OIL SYSTEM Number of cylinders Lube-oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C...
Page 83 Number of cylinders Oil pan capacity, dipstick mark min. (standard oil system) (Option: max. op‐ liter erating inclinations) Oil pan capacity, dipstick mark max. (standard oil system) (Option: max. op‐ liter erating inclinations) WEIGHTS / MAIN DIMENSIONS Number of cylinders Engine dry weight (with attached standard accessories, without coupling) 3200 ACOUSTICS...
Page 84: C Intake Air Temperature
3.15 16V 2000 M40A engine data: separate heat exchanger, reference conditions: 25 °C intake air temperature 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 changes (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
Page 85 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 FUEL SYSTEM Number of cylinders Fuel pressure at engine supply connection, min.
Page 86 ACOUSTICS Number of cylinders Exhaust noise, unsilenced, DL , (free-field sound pressure level Lp, 1m dis‐ db(A) tance, ISO 6798) Engine surface noise with attenuated intake noise (filter), DL, (free-field db(A) sound pressure level Lp, 1m distance, ISO 6798) 86 | Technical Data | MS150031/05E 2013-01...
Page 87: C Intake Air Temperature
3.16 16V 2000 M40A engine data: separate heat exchanger, reference conditions: 45 °C intake air temperature 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 changes (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
Page 88 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 FUEL SYSTEM Number of cylinders Fuel pressure at engine supply connection, min.
Page 89 ACOUSTICS Number of cylinders Exhaust noise, unsilenced, DL , (free-field sound pressure level Lp, 1m dis‐ db(A) tance, ISO 6798) Engine surface noise with attenuated intake noise (filter), DL, (free-field db(A) sound pressure level Lp, 1m distance, ISO 6798) MS150031/05E 2013-01 | Technical Data | 89...
Page 90: 2000 M40B Engine Data, Engine-Mounted Heat Exchanger, Reference Condition: 45 °C Intake Air Temperature
3.17 16V 2000 M40B engine data, engine-mounted heat exchanger, reference condition: 45 °C intake air temperature 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 changes (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
Page 91 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 external raw water system, max. LUBE OIL SYSTEM Number of cylinders Lube-oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C...
Page 92 Number of cylinders Oil pan capacity, dipstick mark min. (standard oil system) (Option: max. op‐ liter erating inclinations) Oil pan capacity, dipstick mark max. (standard oil system) (Option: max. op‐ liter erating inclinations) WEIGHTS / MAIN DIMENSIONS Number of cylinders Engine dry weight (with attached standard accessories, without coupling) 3200 ACOUSTICS...
Page 93: 2000 M40B Engine Data, Engine-Mounted Heat Exchanger, Reference Condition: 25 °C Intake Air Temperature
3.18 16V 2000 M40B engine data, engine-mounted heat exchanger, reference condition: 25 °C intake air temperature 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 changes (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
Page 94 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 external raw water system, max. LUBE OIL SYSTEM Number of cylinders Lube-oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C...
Page 95 Number of cylinders Oil pan capacity, dipstick mark min. (standard oil system) (Option: max. op‐ liter erating inclinations) Oil pan capacity, dipstick mark max. (standard oil system) (Option: max. op‐ liter erating inclinations) WEIGHTS / MAIN DIMENSIONS Number of cylinders Engine dry weight (with attached standard accessories, without coupling) 3200 ACOUSTICS...
Page 96: 2000 M40B Engine Data, Separate Heat Exchanger, Reference Condition: 45 °C Intake Air Temperature
3.19 16V 2000 M40B engine data, separate heat exchanger, reference condition: 45 °C intake air temperature 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 changes (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
Page 97 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 FUEL SYSTEM Number of cylinders Fuel pressure at engine supply connection, min.
Page 98 ACOUSTICS Number of cylinders Exhaust noise, unsilenced, DL , (free-field sound pressure level Lp, 1m dis‐ db(A) tance, ISO 6798) Engine surface noise with attenuated intake noise (filter), DL, (free-field db(A) sound pressure level Lp, 1m distance, ISO 6798) 98 | Technical Data | MS150031/05E 2013-01...
Page 99: 2000 M40B Engine Data, Separate Heat Exchanger, Reference Condition: 25 °C Intake Air Temperature
3.20 16V 2000 M40B engine data, separate heat exchanger, reference condition: 25 °C intake air temperature 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 changes (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
Page 100 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 FUEL SYSTEM Number of cylinders Fuel pressure at engine supply connection, min.
Page 101 ACOUSTICS Number of cylinders Exhaust noise, unsilenced, DL , (free-field sound pressure level Lp, 1m dis‐ db(A) tance, ISO 6798) Engine surface noise with attenuated intake noise (filter), DL, (free-field db(A) sound pressure level Lp, 1m distance, ISO 6798) MS150031/05E 2013-01 | Technical Data | 101...
Page 102: Engine Data 12V 2000M41A/B
3.21 ENGINE DATA 12V 2000M41A/B 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 settings). N Not yet defined value - Not applicable X Applicable...
Page 103 Number of cylinders 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 -0.2 Raw water pump: Inlet pressure, max. +0.5 +0.5 Pressure loss in off-engine raw water system, max.
Page 104 STARTING SYSTEM (with compressed air/hydraulic starter motor) Number of cylinders Starting-air pressure before starter mo‐ tor, min. Starting-air pressure before starter, max. R FILLING CAPACITIES Number of cylinders Engine coolant, engine side (with cool‐ liters ing system) Engine oil, total, for initial filling (stand‐ liters ard oil system) (option: max.
Page 105: Engine Data 16V 2000M41A/B
3.22 ENGINE DATA 16V 2000M41A/B 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 settings). N Not yet defined value - Not applicable X Applicable...
Page 106 Number of cylinders 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 -0.2 Raw water pump: Inlet pressure, max. +0.5 +0.5 Pressure loss in off-engine raw water system, max.
Page 107 STARTING SYSTEM (with compressed air/hydraulic starter motor) Number of cylinders Starting-air pressure before starter mo‐ tor, min. Starting-air pressure before starter, max. R FILLING CAPACITIES Number of cylinders Engine coolant, engine side (with cool‐ liters ing system) Engine oil, total, for initial filling (stand‐ liters ard oil system) (option: max.
Page 108: Firing Order
3.23 Firing order Number of cylin‐ Firing order ders A1-B4-A4-A2-B3-A3-B2-B1 12 V A1-B2-A5-B4-A3-B1-A6-B5-A2-B3-A4-B6 16 V A1-B5-A3-A5-B2-B8-A2-A8-B3-A7-B4-B6-A4-A6-B1-B7 108 | Technical Data | MS150031/05E 2013-01...
Page 109: Engine - Main Dimensions
3.24 Engine – Main dimensions Engine – Main dimensions Engine model Length (A) Width (B) Height (C) 8V 2000 M40A / M40B approx. 2005 mm approx. 1280 mm approx. 1315 mm 12V 2000 M40A / M40B / approx. 2106 mm approx.
Page 110: 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 111 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 112: Putting The Engine Into Operation (Out-Of- Service Period > 3 Months)
4.2 Putting the engine into operation (out-of-service period > 3 months) Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specification (A001061/..) is available. Putting the engine into operation (out-of-service period > 3 months) Item Task Engine Depreserve (→...
Page 113: 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 Task Lube oil system Check oil level (→ Page 195). Cooling system Check coolant level (→ Page 208). Cooling system Preheat coolant with preheating unit.
Page 114: Starting The Engine From Lop
4.4 Starting the engine from LOP Preconditions ☑ Gearbox is disengaged. ☑ External start interlock is not activated. ☑ Emergency air-shut-off flaps (if provided) are open. DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! •...
Page 115: Operational Checks
4.5 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 116: Stopping The Engine At The Lop
4.6 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 117: Emergency Stop From Lop
4.7 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 110). Press EMERGENCY STOP button.
Page 118: After Stopping The Engine
4.8 After stopping the engine Preconditions ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. After stopping the engine Item Action Coolant circuit Drain coolant (→ Page 210) 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 119: Plant Cleaning
4.9 Plant cleaning Preconditions ☑ Engine is stopped and starting disabled. ☑ Operating voltage is not present. Special tools, Material, Spare parts Designation / Use Part No. Qty. Steam jet cleaner Cleaner (Hakupur 312) 30390 WARNING Compressed air Risk of injury! •...
Page 120: 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 121: Ecu Alarms
6 Troubleshooting 6.1 ECU alarms The ECU generates alarms which are indicated in different ways depending on the equipment configura‐ tion: • as four-digit code on a PIM • as alarm text on a display • as four-digit code on a dialog PC The four-digit code consists of one letter and three figures: •...
Page 122 Fault Alarm text Meaning Task code L2 P-LUBE OIL Lube-oil pressure too low (2nd 1. Check engine-oil level and top up, if limit) required (→ Page 195); 2. Try to re-start the engine automatic engine shutdown (→ Page 114). 3. Contact Service. L1 COOLANT Engine coolant level too low Check coolant level and top up, if re‐...
Page 123 Fault Alarm text Meaning Task code LIM INTER‐ Alarm from external charge-air (Depending on the corresponding meas‐ COOLER LEV. coolant level monitoring uring point, which is read via CAN bus) L Bin-EXTERN 3 Alarm from external binary (Depending on the corresponding meas‐ channel 3 uring point, which is read via CAN bus) L Bin-EXTERN 4...
Page 124 Fault Alarm text Meaning Task code ERR REC1 NOT Check sum error of fault mem‐ If fault occurs repeatedly: Contact Serv‐ VALID ory in EDM (redundant data ice. record 1) ERR REC2 NOT Check sum error of fault mem‐ If fault occurs repeatedly: Contact Serv‐ VALID ory in EDM (redundant data ice.
Page 125 Fault Alarm text Meaning Task code L1 AD-TEST1 A/D-converter supply voltage Contact Service. SUPPLY too low AD-TEST1 ECU Electronic equipment defec‐ Contact Service. DEFECT tive; automatic engine shutdown L1 AD-TEST2 A/D-converter supply voltage Contact Service. SUPPLY too low AD-TEST2 ECU Electronic equipment defec‐...
Page 126 Fault Alarm text Meaning Task code SD T-COOLANT Sensor defect (coolant tem‐ 1. Check wiring. perature) 2. Contact Service. SD T-FUEL Sensor defect (Fuel tempera‐ 1. Check wiring. ture) 2. Contact Service. SD T-CHARGE Sensor defect (charge-air 1. Check wiring. temperature) 2.
Page 127 Fault Alarm text Meaning Task code SD P-EXTERN 2 External device defective Contact Service. (CAN P-EXTERN 2) SD EXT.COOL‐ External coolant-level monitor‐ Contact Service. ANT LEVEL ing defective (CAN) SD INTERCOOL‐ External charge-air coolant- Contact Service. ER LEVEL level monitoring defective (CAN) SD BIN-EXTERN External device defective...
Page 128 Fault Alarm text Meaning Task code TIMING CYLIN‐ Injection timing fault cylinder If fault occurs repeatedly: Contact Serv‐ DER B9 ice. TIMING CYLIN‐ Injection timing fault cylinder If fault occurs repeatedly: Contact Serv‐ DER B10 ice. WIRING CYLIN‐ Faulty wiring to solenoid valve 1.
Page 129 Fault Alarm text Meaning Task code WIRING CYLIN‐ Faulty wiring to solenoid valve 1. Check wiring. DER B4 cylinder B4; 2. Contact Service. Misfiring WIRING CYLIN‐ Faulty wiring to solenoid valve 1. Check wiring. DER B5 cylinder B5; 2. Contact Service. Misfiring WIRING CYLIN‐...
Page 130 Fault Alarm text Meaning Task code OPEN_LOAD Disconnection in wiring to sol‐ 1. Check wiring. CYL. A8 enoid valve cylinder A8; 2. Contact Service. Misfiring OPEN_LOAD Disconnection in wiring to sol‐ 1. Check wiring. CYL. A9 enoid valve cylinder A9; 2.
Page 131 Fault Alarm text Meaning Task code STOP POWER Solenoid valve or wiring or 1. Check wiring. STAGE 1 ECU defective 2. Try to re-start the engine (→ Page 114). automatic engine shutdown 3. Contact Service. STOP POWER Solenoid valve or wiring or 1.
Page 132: 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 (electric) Engine wiring or starter faulty Check if cable connections are proper‐...
Page 133 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 Check air inlet/outlet ducts. Charge-air pressure too low...
Page 134 Black exhaust gas Component Cause Measure Air supply Air filter clogged Check signal ring position of contami‐ nation indicator (→ Page 193). Fuel injection equip‐ Injector faulty Replace (→ Page 172). ment Injection pump defective Replace (→ Page 168). Engine Overloaded Contact Service.
Page 135: 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 key 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 136 Display text Meaning Measure AL Output Stage Fault message re. power amplifier, cyl‐ 1. Check LOP visually (→ Page 230). Bank 2 Fault inder bank B 2. Perform LOP test procedures (→ Page 232). 3. Check ECU plug connection (→ Page 225). 4.
Page 137 Display text Meaning Measure DL 211+A003-ECU ECU 4 not recognized on default bus 1. Check LOP visually (→ Page 230). 2. Perform LOP test procedures (→ Page 232). 3. Check ECU plug connection (→ Page 225). 4. Check engine wiring (→ Page 221). 5.
Page 138 Display text Meaning Measure RL 211+A004-EMU EMU 1 not recognized on redundant 1. Check LOP visually (→ Page 230). 2. Perform LOP test procedures (→ Page 232). 3. Contact Service. • Have EMU checked and re‐ placed if required. SS Safety System Safety system has determined fault on Contact Service.
Page 139 Display text Meaning Measure TD P-Lube Oil Different measurement values trans‐ 1. Check LOP visually (→ Page 230). mitted by the two sensors for lube-oil 2. Perform LOP test procedures pressure (→ Page 232). 3. Check ECU plug connection (→ Page 225). 4.
Page 140: Task Description
7 Task Description 7.1 SOLAS 7.1.1 SOLAS shielding as per MTN 5233 – Installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Shield A4 735233000100 Shield A5 735233000101 Shield A7 735233000103 Shield A8 735233000104...
Page 141: Solas Shielding - Installation
7.1.2 SOLAS shielding – Installation Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine is cooled down to ambient temperature. Special tools, Material, Spare parts Designation / Use Part No. Qty. Oil filter shield X00009628 Fuel filter shield X00009654 Installing SOLAS shield on oil filter and fuel filter Pinpoint installation location (→...
Page 142: Installation Locations For Solas Shielding
7.1.3 Installation locations for SOLAS shielding General information Primarily fit SOLAS shielding as per MTN 5233 (→ Page 140). Free end B-side Item Type of shielding Comments 1 (free end, B-side) Shield (A7) On fuel delivery pump 2 (free end, B-side) Shield (A7) On HP fuel pump Free end...
Page 143 Item Type of shielding Comments 1 (free end) Shield (A8) On fuel filter 2 (free end) Shield (A7) Above fuel priming pump 3 (free end) Shield (A7) Below fuel priming pump Driving end A-side Item Type of shielding Comments 1 (Driving end, A-side) Shield (A5) On air flap 2 (Driving end, A-side)
Page 144 Item Type of shielding Comments 1 (driving end, A-side) Shield (A5) To turbocharger lubrication 2 (driving end, A-side) Shield (A5) On valve plate Driving end Item Type of shielding Comments 1 (driving end) Shield (A4) Turbocharger lubrication, left side 2 (driving end) Shield (A4) Turbocharger lubrication, center Driving end...
Page 145 Driving end B-side Item Type of shielding Comments 1 (driving end, B-side) Shield (A5) Turbocharger flap 2 (driving end, B-side) Shield (A5) Turbocharger flap 3 (driving end, B-side) Shield (A4) On brazed-on union 4 (driving end, B-side) Shield (A5) On air flap 5 (driving end, B-side) Shield (A4) To turbocharger lubrication...
Page 146 Driving end A-side Item Type of shielding Comments 1 (driving end, A-side) Shield (A5) To flap control Driving end B-side Item Type of shielding Comments 1 (driving end, B-side) Shield (A5) To flap control 146 | Task Description | MS150031/05E 2013-01...
Page 147: Installation Locations For Solas Shielding
7.1.4 Installation locations for SOLAS shielding General information Primarily fit SOLAS shielding as per MTN 5233 (→ Page 140). On crankcase Item Type of shielding Remarks Shield (A4) On brazed-on union Shield (A5) On crankcase Free end B-side MS150031/05E 2013-01 | Task Description | 147...
Page 148 Item Type of shielding Remarks Shield (A7) On fuel delivery pump Free end B-side Free end B-side Item Type of shielding Remarks Shield (A7) On HP fuel pump Free end B-side Free end 148 | Task Description | MS150031/05E 2013-01...
Page 149 Item Type of shielding Remarks Shield (A7) Above fuel priming pump Free end Free end Item Type of shielding Remarks Shield (A7) Below fuel priming pump Free end Free end Item Type of shielding Remarks Shield (A8) On fuel filter housing Free end MS150031/05E 2013-01 | Task Description | 149...
Page 150 Driving end A-side Item Type of shielding Remarks Shield (A5) On valve plate Driving end Driving end A-side Item Type of shielding Remarks Shield (A5) On air flap control Driving Shield (A4) On brazed-on union Driving 150 | Task Description | MS150031/05E 2013-01...
Page 151 Item Type of shielding Remarks Shield (A5) On exhaust turbocharger flap control Driving Shield (A5) On exhaust turbocharger flap control Driving Driving end Item Type of shielding Remarks Shield (A4) Exhaust turbocharger lubrication Driving Shield (A4) On brazed-on union Driving MS150031/05E 2013-01 | Task Description | 151...
Page 152 Driving end Item Type of shielding Remarks Shield (A4) Exhaust turbocharger lubrication Driving 152 | Task Description | MS150031/05E 2013-01...
Page 153: Engine
7.2 Engine 7.2.1 Engine – Barring manually Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Ratchet F30006212 Socket F30005655 DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! •...
Page 154: Engine - Barring With Starting System
7.2.2 Engine – Barring with starting system 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 155: Cylinder Liner
7.3 Cylinder Liner 7.3.1 Cylinder liner – Endoscopic examination Preconditions ☑ Engine is stopped and starting disabled Special tools, Material, Spare parts Designation / Use Part No. Qty. Barring device F6555766 Ratchet with extension F30006212 Endoscope Y20097353 Preparatory steps Remove cylinder head cover (→ Page 167). Remove injector (→...
Page 156 Compile endoscopy report using the table. Use technical terms for description of the liner surface (→ Page 157). Depending on findings: • Do not take any action or • carry out a further endoscopic examination as part of maintenance work or •...
Page 157: Instructions And Comments On Endoscopic And Visual Examination Of Cylinder Liners
7.3.2 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 exami‐ nation report. Findings Action Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing prod‐...
Page 158 Findings Action 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.
Page 159: Crankcase Breather
7.4 Crankcase Breather 7.4.1 Crankcase breather – Oil separator element replacement, diaphragm check and replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 6-50 Nm F30027336 Ratchet F30027340 Engine oil Filter element...
Page 160 Checking diaphragm Remove cover (4). Remove spring (5), gasket (2) and dia‐ phragm (3). Check diaphragm (3) for damage, fit new diaphragm if used one is damaged. Install diaphragm (3) on housing (1). Install new seal (2) and spring (5) together with cover (4).
Page 161: Crankcase Breather - Cleaning Oil Separator Element
7.4.2 Crankcase breather – Cleaning oil separator element Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Fuel Gasket (→ Spare Parts Catalog) WARNING Fuels are combustible. Risk of fire and explosion! •...
Page 162: Crankcase Breather - Oil Separator Replacement, Diaphragm Check And Replacement
7.4.3 Crankcase breather – Oil separator replacement, diaphragm check and replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 6-50 Nm F30027336 Ratchet adapter F30027340 Filter element (→...
Page 163 Checking diaphragm Remove cover (4). Take off spring (5), seal (2) and diaphragm (3). Check diaphragm (3) for damage. Fit new diaphragm if used one is damaged. Mount diaphragm (3) on housing (1). Install new seal (2) and spring (5) together with cover (4).
Page 164: Valve Drive
7.5 Valve Drive 7.5.1 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.
Page 165: Adjusting Valve Clearance
Checking valve clearance at two crankshaft positions Check TDC position of piston in cylinder • If the rocker arms are not under load on cylinder A1, the piston is in firing TDC. • If the rocker arms are under load on cyl‐ inder A1, the piston is in overlap TDC.
Page 166 Insert feeler gauge between valve bridge and rocker arm to verify that the gauge just passes through the gap. Result: If not, adjust valve clearance. Final steps Remove barring device. For installation of removed parts, follow reverse sequence of working steps. 166 | Task Description | MS150031/05E 2013-01...
Page 167: Cylinder Head Cover - Removal And Installation
7.5.2 Cylinder head cover – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 6-50 Nm F30027336 Ratchet adapter F30027340 Gasket (→ Spare Parts Catalog) Preparatory steps Remove air filter (→...
Page 168: Injection Pump / Hp Pump
7.6 Injection Pump / HP Pump 7.6.1 Injection pump – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Injection pump (→ Spare Parts Catalog) Injection pump – Replacement Remove injection pump and install new one (→ Page 169). 168 | Task Description | MS150031/05E 2013-01...
Page 169: Injection Pump - Removal And Installation
7.6.2 Injection pump – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 20-100 Nm F30026582 Ratchet adapter F30027340 Crow-foot box wrench F30027424 Crow-foot box wrench F30027425 Torque wrench, 0.5-5 Nm 0015384230...
Page 170 Removing injection pump Mark installation position of injection pump. Disconnect cabling (1) from injection pump. Remove fuel line (2). Unscrew securing screws of injection pump by approx. 6 mm. Result: The pretensioned compression spring presses the injection pump out of the crank‐ case;...
Page 171 Install injection pump in the installation po‐ sition marked prior to removal. Install securing screws of injection pump and tighten with torque wrench to the specified torque. Name Size Type Lubricant Value/Standard Securing screw Tightening torque 60 Nm + 12 Nm Install fuel line (2).
Page 172: Injection Valve / Injector
7.7 Injection Valve / Injector 7.7.1 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 173). 172 | Task Description | MS150031/05E 2013-01...
Page 173: Injector - Removal And Installation
7.7.2 Injector – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Puller 3555890163/00 Fuel suction device F30378207 Torque wrench, 20-100 Nm F30026582 Open end socket wrench F30025897 Crowfoot box wrench F30027425...
Page 174 Removing injector Remove leak-off-fuel lines. Remove fuel line (3). Remove thrust screw (2). Withdraw pressure pipe neck (1). Extract fuel from the exposed bores using the suction device. Remove screw (2). Take off clamp (1). Screw puller into injector. Remove injector with puller. Remove injector sealing ring using a self- made hook.
Page 175: Installing Injector
Installing injector Remove all covers before installation. Clean sealing surface on cylinder head and protective sleeve. Coat sealing ring (1) with grease and fit on‐ to injector. Coat sealing ring (2) with grease and fit on‐ to injector. Press injector into cylinder head by hand. Result: •...
Page 176 Tighten union nut on the pressure pipe neck to the specified tightening torque using a torque wrench. Name Size Type Lubricant Value/Standard Union nut Tightening torque 20 Nm +5 Nm Install leak-off-fuel lines. Final steps Install cylinder head cover (→ Page 167). Vent fuel system (→...
Page 177: Fuel System
7.8 Fuel System 7.8.1 HP fuel line – Pressure pipe neck replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 20-100 Nm F30026582 Open end socket wrench F30025897 Crowfoot box wrench F30027425...
Page 178 Replacing pressure pipe neck Remove fuel line (3). Remove thrust screw (2). Withdraw pressure pipe neck (1). Coat sealing ring with grease (Kluthe Haku‐ form 30-10/emulsifier) and fit on to new pressure pipe neck (1). Blow out fuel line (3) with compressed air. Coat sealing cone of pressure pipe neck with engine oil.
Page 179: Fuel - Draining
7.8.2 Fuel – 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. Fuel – Draining Release threaded vent plugs on filter head. Open nipple on fuel line and drain fuel into appropriate container.
Page 180: Fuel System - Venting
7.8.3 Fuel system – Venting 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. Venting fuel system Unlock fuel priming pump, unscrew handle. Open vent plugs on filter head.
Page 181 Open nipple at fuel heat exchanger. Operate the pump with the handle until bub‐ ble-free fuel emerges at the nipple. Close nipple at fuel heat exchanger. Open nipple at fuel line. Operate the pump with the handle until bub‐ ble-free fuel emerges at the nipple. Close nipple at fuel line.
Page 182: Fuel Filter
7.9 Fuel Filter 7.9.1 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 183 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 184: Fuel Prefilter - Differential Pressure Check And Adjustment Of Gauge
7.9.2 Fuel prefilter – Differential pressure check and adjustment of gauge 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 185: Fuel Prefilter - Draining
7.9.3 Fuel prefilter – Draining Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel Seal (→ Spare Parts Catalog) WARNING Fuels are combustible. Risk of fire and explosion! •...
Page 186: Fuel Prefilter - Flushing
7.9.4 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 187 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 188: Fuel Prefilter - Filter Element Replacement
7.9.5 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) Seal (→ Spare Parts Catalog) WARNING Fuels are combustible.
Page 189 Open threaded vent plug (5) of contaminat‐ ed filter. Unlock drain valve (6) by pressing toggle and open it. Drain water and contaminants from the fil‐ ter. Close drain valve (6). Remove screws securing the cover and take off cover (2). Remove spring housing (4) and filter ele‐...
Page 190: Charge-Air Cooling
7.10 Charge-Air Cooling 7.10.1 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 191: Air Filter
7.11 Air Filter 7.11.1 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 192). Reset signal ring of contamination indicator (→...
Page 192: Air Filter - Removal And Installation
7.11.2 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 193: Air Intake
7.12 Air Intake 7.12.1 Service indicator – Signal ring position check (optional) 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 191). After installation of new filter, press reset button (1).
Page 194: Starting Equipment
7.13 Starting Equipment 7.13.1 Starter – Condition check Preconditions ☑ Engine is stopped and starting disabled. Checking starter condition Check securing screws of starter for secure seating and tighten if required. Check wiring (→ Page 221). 194 | Task Description | MS150031/05E 2013-01...
Page 195: Lube Oil System, Lube Oil Circuit
7.14 Lube Oil System, Lube Oil Circuit 7.14.1 Engine oil – Level check Preconditions ☑ Engine is stopped 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 the stop, withdraw after approx.
Page 196: Engine Oil - Change
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. Engine oil Sealing ring (→...
Page 197: Oil Filtration / Cooling
7.15 Oil Filtration / Cooling 7.15.1 Oil dipstick – Marking Preconditions ☑ Engine is stopped and starting disabled. 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. •...
Page 198: Engine Oil Filter - Replacement
7.15.2 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) SOLAS shield (→ Spare Parts Catalog) DANGER Unguarded rotating and moving engine components. Risk of serious injury –...
Page 199 Remove cut-out oil filter using the oil filter wrench. Clean sealing surface on connecting piece. Check condition of new oil filter sealing ring and coat it with oil. Fit SOLAS shield (→ Page 140). Screw on and tighten new oil filter by hand. Replace other oil filters in the same way.
Page 200: Centrifugal Oil Filter - Cleaning And Filter-Sleeve Replacement
7.15.3 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. Strap wrench F30379104 Cold cleaner (Hakutex 50) 50622 Filter sleeve (→ Spare Parts Catalog) O-ring (→...
Page 201 Cleaning centrifugal oil filter and replacing filter sleeve Remove nut, holding the rotor with a strap wrench. Remove nut (1), washer (2), rotor cap (3) and sealing ring (4). Remove sleeve (1). Measure the layer thickness of the oil resi‐ due.
Page 202 Fit new sealing ring (4). Set on rotor cap (3), observe marks. Fit washer (2). Hold rotor (new design) with strap wrench and tighten nut (1) with torque wrench to the specified torque. Name Size Type Lubricant Value/Standard M18 x 1.5 Tightening torque 10 Nm Hold rotor (old design) with strap wrench and tighten nut (1) with torque wrench to the specified torque.
Page 203: Coolant Circuit, General, High-Temperature Circuit
7.16 Coolant Circuit, General, High-Temperature Circuit 7.16.1 Drain and venting points Top side 1 Engine coolant vent 3 Overflow line 5 Fuel filter 2 Intercooler 4 Engine coolant expan‐ 6 Engine oil filter sion tank MS150031/05E 2013-01 | Task Description | 203...
Page 204 Left side 1 Engine coolant drain 2 Engine coolant drain 3 Raw water pump drain plug plug plug 204 | Task Description | MS150031/05E 2013-01...
Page 205 Free end (KGS) 1 Three-way cock 4 Raw water pump filling 7 Oil dipstick (connection 2 Fuel filter plug left or right engine side 3 Fuel vent valve 5 Raw water pump drain optional) plug 8 Oil filler neck (connec‐ 6 Connection for oil ex‐...
Page 206 Right side 1 Engine coolant drain 4 Fuel priming pump 7 Oil dipstick (connection plug 5 Raw water pump filling left or right engine side 2 Engine coolant drain plug optional) plug 6 Oil filler neck (connec‐ 4 Leak-off fuel tank 3 Engine oil filter tion left or right engine side optional)
Page 207 Driving end (KS) 1 Engine coolant drain 4 Oil dipstick (connection 7 Fuel vent plug left or right engine side 2 Oil filler neck (connec‐ optional) tion left or right engine 5 Oil filler neck (connec‐ side optional) tion left or right engine 3 Oil dipstick (connection side optional) left or right engine side...
Page 208: Engine Coolant - Level Check
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 209: Engine Coolant - Change
7.16.3 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant – Change Drain engine coolant (→ Page 210). Fill with engine coolant (→ Page 211). MS150031/05E 2013-01 | Task Description | 209...
Page 210: 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 211: 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 212: Ht Coolant Pump - Relief Bore Check
7.16.6 HT 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 213: Engine Coolant - Sample Extraction And Analysis
7.16.7 Engine coolant – Sample extraction and analysis 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. MTU test kit 5605892099/00 WARNING Coolant is hot and under pressure.
Page 214: Raw Water Pump With Connections
7.17 Raw Water Pump with Connections 7.17.1 Raw water pump – Relief bore check Preconditions ☑ Engine is stopped and starting disabled. 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 215: Belt Drive
7.18 Belt Drive 7.18.1 Drive belt – Condition check Preconditions ☑ Engine is stopped and starting disabled. ☑ Guard is removed. Drive belt – Condition check Item Findings Action Drive belt A Singular cracks None Drive belt Belt is oily, shows signs of over‐ Replace (→...
Page 216: Battery-Charging Generator
7.19 Battery-Charging Generator 7.19.1 Battery-charging generator drive – Drive belt check and adjustment Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Assembly device F6559691 Preparatory steps Remove limit switch (4). Remove indicator (1).
Page 217 Adjusting belt tension Hold adjustment lever (2) at square (5). Rotate adjusting lever until drive belt (4) is released. Loosen screws (1) and (3). Use assembly device to adjust distance (A) by turning adjustment lever (2). Tighten screws (1) and (3). Measure distance (A) with assembly device.
Page 218: Battery-Charging Generator Drive - Drive Belt Replacement
7.19.2 Battery-charging generator drive – Drive belt replacement Preconditions ☑ Engine is stopped and starting disabled. Preparatory steps Remove limit switch (4). Remove indicator (1). Remove screws (3) of protective cover (2). Take off protective cover. Replacing belt drive Counterhold adjustment lever (2) at square (5) using a square socket wrench.
Page 219 Final steps Install protective device. Install securing screws (3) of protective cov‐ er (2). Install indicator (1). Install limit switch (4) (→ Page 224). MS150031/05E 2013-01 | Task Description | 219...
Page 220: Engine Mounting / Support
7.20 Engine Mounting / Support 7.20.1 Engine mounting – Checking condition of resilient mounts Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine is filled with engine coolant and engine oil. ☑ Engine is under static load. Special tools, Material, Spare parts Designation / Use Part No.
Page 221: Wiring (General) For Engine/Gearbox/Unit
7.21 Wiring (General) for Engine/Gearbox/Unit 7.21.1 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 222: Accessories For (Electronic) Engine Governor / Control System
7.22 Accessories for (Electronic) Engine Governor / Control System 7.22.1 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 Engine governor and connectors - Cleaning...
Page 223: Engine Monitoring Unit And Connectors - Cleaning
7.22.2 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 224: Start Interlock Limit Switch - Check
7.22.3 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 225: Ecu - Plug Connections Check
7.22.4 ECU – Plug connections check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Connector pliers 0135315483 Checking plug connection to ECU Use connector pliers (3) to make certain that all plug-in connections of ECU are se‐...
Page 226: Engine Monitoring Unit - Plug Connection Check
7.22.5 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 227: Engine Control Unit - Removal And Installation
7.22.6 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 228 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 229: Emergency Instrumentation (Local Operating Panel)
7.23 Emergency Instrumentation (Local Operating Panel) 7.23.1 LOP and connectors – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Isopropyl alcohol X00058037 Cleaning LOP Wipe LCD display with dry cloth, without applying excessive pressure. Remove dirt from keys using isopropyl alcohol.
Page 230: Checking Threaded Connections
7.23.2 LOP – Visual inspection Preconditions ☑ Engine is stopped and starting disabled. Preparatory steps If READY FOR OPERATION pushbutton is illuminated brightly, press switch briefly. Result: READY FOR OPERATION pushbutton returns to basic brightness. Switch master power switch to OFF. Disconnect battery in accordance with battery manufacturer's instructions.
Page 231 Checking unassigned connector sockets Ensure that non-assigned connector sock‐ ets are protected with covering caps. Make certain that the two securing ele‐ ments (1) are engaged in the lugs (2) so that the covering cap (3) is held firmly in place in the socket.
Page 232: Lop - Test Procedures
7.23.3 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 233 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 234: Abbreviations
Alarm: Default CAN bus failure Engine Control System Engine Control Unit Engine Data Module Engine Monitoring Unit Fluids and Lubricants Specification MTU Publication No. A01061/.. High Alarm: Measured value exceeds 1st maximum limit HIHI High High Alarm: Measured value exceeds 2nd maximum lim‐...
Page 235 Abbrevia‐ Meaning Explanation tion Local Operating Panel Local Operating Station Monitoring and Control System Message Microprocessor Unit, Microprocessing Unit Oberer Totpunkt Top dead center (TDC) P-xyz Pressure-xyz Pressure measuring point xyz Panel Peripheral Interface Module Remote Control System Redundancy Lost Alarm: Redundant CAN bus failure Society of Automotive Engineers U.S.
Page 236: Mtu Contact Persons/Service Partners
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 –...
Page 237: Special Tools
9 Appendix B 9.1 Special Tools Assembly device Part No.: F6559691 Qty.: Used in: 7.19.1 Battery-charging generator drive – Drive belt check and adjustment (→ Page 216) Barring device Part No.: F6555766 Qty.: Used in: 7.3.1 Cylinder liner – Endoscopic examination (→ Page 155) Connector pliers Part No.:...
Page 238 Crow-foot box wrench Part No.: F30027424 Qty.: Used in: 7.6.2 Injection pump – Removal and installation (→ Page 169) Crow-foot box wrench Part No.: F30027425 Qty.: Used in: 7.6.2 Injection pump – Removal and installation (→ Page 169) Crowfoot box wrench Part No.: F30027425 Qty.:...
Page 239 (→ Page 220) Fuel suction device Part No.: F30378207 Qty.: Used in: 7.7.2 Injector – Removal and installation (→ Page 173) MTU test kit Part No.: 5605892099/00 Qty.: Used in: 7.16.7 Engine coolant – Sample extraction and analysis (→ Page 213)
Page 240 Oil filter wrench Part No.: F30379104 Qty.: Used in: 7.9.1 Fuel filter – Replacement (→ Page 182) Qty.: Used in: 7.15.2 Engine oil filter – Replacement (→ Page 198) Open end socket wrench Part No.: F30025897 Qty.: Used in: 7.7.2 Injector – Removal and installation (→ Page 173) Qty.: Used in: 7.8.1 HP fuel line –...
Page 241 Ratchet Part No.: F30006212 Qty.: Used in: 7.2.1 Engine – Barring manually (→ Page 153) Ratchet adapter Part No.: F30027340 Qty.: Used in: 7.4.3 Crankcase breather – Oil separator replacement, diaphragm check and replacement (→ Page 162) Qty.: Used in: 7.5.2 Cylinder head cover –...
Page 242 Socket Part No.: F30005655 Qty.: Used in: 7.2.1 Engine – Barring manually (→ Page 153) Steam jet cleaner Part No.: Qty.: Used in: 4.9 Plant cleaning (→ Page 119) Strap wrench Part No.: F30379104 Qty.: Used in: 7.15.3 Centrifugal oil filter – Cleaning and filter-sleeve replacement (→...
Page 243 Torque wrench, 6-50 Nm Part No.: F30027336 Qty.: Used in: 7.4.3 Crankcase breather – Oil separator replacement, diaphragm check and replacement (→ Page 162) Qty.: Used in: 7.5.2 Cylinder head cover – Removal and installation (→ Page 167) Torque wrench, 6-50 Nm Part No.: F30027336 Qty.:...
Page 244: Index
9.2 Index 12V 2000 M40A engine data: Engine-mounted heat ex‐ changer, reference conditions: 25 °C intake air tem‐ Battery-charging generator drive perature 69 – Adjustment 216 12V 2000 M40A engine data: Engine-mounted heat ex‐ – Check 216 changer, reference conditions: 45 °C intake air tem‐ –...
Page 245 Engine side – Designation 17 Engine wiring Maintenance schedule – Check 221 – Maintenance task reference table [QL1] 120 Engine – Barring manually 153 MTU contact persons 236 Engine – Main dimensions 109 Oil dipstick Fault messages at LOP 135 – Marking 197 Firing order 108...
Page 246 SOLAS shielding – Installation 141 – Installation locations 147 SOLAS shielding as per MTN 5233 – Installation 140 Spare parts service 236 Start interlock limit switch – Check 224 Starter – Condition check 194 Starting the engine from LOP 114 Transport 8 Troubleshooting 132 Valve clearance –...

This manual is also suitable for:

8 v 2000 m40b 12 v 2000 m40b 12 v 2000 m41a 12 v 2000 m41b 16 v 2000 m40a 16 v 2000 m40b ... Show all

MTU 12 V 2000 M40A Operating Instructions Manual

1 Safety

2 General Information

3 Technical Data

4 Operation

5 Maintenance

6 Troubleshooting

7 Task Description

8 Appendix A

Appendix A 8.1 Abbreviations

9 Appendix B

Quick Links

Operating Instructions

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Summary of Contents for MTU 12 V 2000 M40A

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Table of Contents