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16 V 2000 M40A
MTU 16 V 2000 M40A Manuals
Manuals and User Guides for MTU 16 V 2000 M40A. We have
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MTU 16 V 2000 M40A manuals available for free PDF download: Operating Instructions Manual
MTU 16 V 2000 M40A Operating Instructions Manual (246 pages)
Brand:
MTU
| Category:
Engine
| Size: 28.71 MB
Table of Contents
Operating Instructions
1
Table of Contents
3
MS150031/05E 2013-01 | Table of Contents
5
1 Safety
6
Important Provisions for All Products
6
Personnel and Organizational Requirements
7
Transportation
8
Safety Regulations for Maintenance and Repair Work
11
Fire Prevention and Environmental Protection, Fluids and Lubricants, Auxiliary Materials
14
Compressed Air
15
Standards for Warning Notices in the Text
16
2 General Information
17
Engine Side and Cylinder Designations
17
Product Description
18
Series 2000 M40A/B - M41A/B
27
Sensors, Actuators and Injectors - Overview
28
Sensors, Actuators and Injectors - Overview
32
3 Technical Data
42
2000 M40A Engine Data: Engine-Mounted Heat Exchanger, Reference Conditions: 25 °C Intake Air Temperature
42
2000 M40A Engine Data: Separate Heat Exchanger, Reference Conditions: 25 °C Intake Air Temperature
45
2000 M40A Engine Data: Separate Heat Exchanger, Reference Conditions
45
2000 M40B Engine Data, Engine-Mounted Heat Exchanger, Reference Condition: 25 °C Intake Air Temperature
48
2000 M40B Engine Data, Separate Heat Exchanger, Reference Condition: 25 °C Intake Air Temperature
51
2000M41A Engine Data: Engine-Mounted Heat Exchanger
54
2000M41A Engine Data: Remote Heat Exchanger
57
2000M41B Engine Data: Engine-Mounted Heat Exchanger
60
2000M41B Engine Data: Remote Heat Exchanger
63
Number of Cylinders
64
Exhaust Noise, Unsilenced - DL (Free-Field Sound Pressure Level Lp, 1M Dis-R Db(A)
65
Tance, ISO 6798, +3Db(A) Tolerance)
65
Engine Surface Noise with Attenuated Intake Noise (Filter) - DL (Free-Field R Db(A)
65
Sound Power Level Lp, 1 M Distance, ISO 6798, +2Db(A) Tolerance)
65
2000 M40A Engine Data: Engine-Mounted Heat Exchanger, Reference Conditions: 45 °C Intake Air Temperature
66
2000 M40A Engine Data: Engine-Mounted Heat Exchanger, Reference Conditions: 25 °C Intake Air Temperature
69
C Intake Air Temperature
72
C Intake Air Temperature
75
2000 M40A Engine Data: Engine-Mounted Heat Exchanger, Reference Conditions: 25 °C Intake Air Temperature
78
2000 M40A Engine Data: Engine-Mounted Heat Exchanger, Reference Conditions: 45 °C Intake Air Temperature
81
C Intake Air Temperature
84
C Intake Air Temperature
87
2000 M40B Engine Data, Engine-Mounted Heat Exchanger, Reference Condition: 45 °C Intake Air Temperature
90
2000 M40B Engine Data, Engine-Mounted Heat Exchanger, Reference Condition: 25 °C Intake Air Temperature
93
2000 M40B Engine Data, Separate Heat Exchanger, Reference Condition: 45 °C Intake Air Temperature
96
2000 M40B Engine Data, Separate Heat Exchanger, Reference Condition: 25 °C Intake Air Temperature
99
Engine Data 12V 2000M41A/B
102
Engine Data 16V 2000M41A/B
105
Firing Order
108
Engine - Main Dimensions
109
4 Operation
110
LOP - Controls
110
Putting the Engine into Operation (Out-Of- Service Period > 3 Months)
112
Putting the Engine into Operation after Scheduled Out-Of-Service Period
113
Starting the Engine from LOP
114
Operational Checks
115
Stopping the Engine at the LOP
116
Emergency Stop from LOP
117
After Stopping the Engine
118
Plant Cleaning
119
5 Maintenance
120
Maintenance Task Reference Table [QL1]
120
6 Troubleshooting
121
ECU Alarms
121
Troubleshooting
132
LOP Fault Messages
135
Solas
140
SOLAS Shielding as Per MTN 5233 - Installation
140
SOLAS Shielding - Installation
141
Installation Locations for SOLAS Shielding
142
Installation Locations for SOLAS Shielding
147
7 Task Description
140
Engine
153
Engine - Barring Manually
153
Engine - Barring with Starting System
154
Cylinder Liner
155
Cylinder Liner Endoscopic Examination
155
Instructions and Comments on Endoscopic and Visual Examination of Cylinder Liners
157
Crankcase Breather
159
Crankcase Breather - Oil Separator Element Replacement, Diaphragm Check and Replacement
159
Crankcase Breather - Cleaning Oil Separator Element
161
Crankcase Breather - Oil Separator Replacement, Diaphragm Check and Replacement
162
Valve Drive
164
Valve Clearance - Check and Adjustment
164
Adjusting Valve Clearance
165
Cylinder Head Cover - Removal and Installation
167
Injection Pump / HP Pump
168
Injection Pump - Replacement
168
Injection Pump - Removal and Installation
169
Injection Valve / Injector
172
Injector - Replacement
172
Injector - Removal and Installation
173
Installing Injector
175
Fuel System
177
HP Fuel Line - Pressure Pipe Neck Replacement
177
Fuel - Draining
179
Fuel System - Venting
180
Fuel Filter
182
Fuel Filter - Replacement
182
Fuel Prefilter - Differential Pressure Check and Adjustment of Gauge
184
Fuel Prefilter - Draining
185
Fuel Prefilter - Flushing
186
Fuel Prefilter - Filter Element Replacement
188
Charge-Air Cooling
190
Intercooler - Checking Condensate Drain Line for Coolant Discharge and Obstruction
190
Air Filter
191
Air Filter - Replacement
191
Air Filter - Removal and Installation
192
Air Intake
193
Service Indicator - Signal Ring Position Check
193
(Optional)
193
Starting Equipment
194
Starter - Condition Check
194
Lube Oil System, Lube Oil Circuit
195
Engine Oil - Level Check
195
Engine Oil - Change
196
Oil Filtration / Cooling
197
Oil Dipstick - Marking
197
Engine Oil Filter - Replacement
198
Centrifugal Oil Filter - Cleaning and Filter-Sleeve Replacement
200
Coolant Circuit, General, High-Temperature Circuit
203
Drain and Venting Points
203
Engine Coolant - Level Check
208
Engine Coolant - Change
209
Engine Coolant - Draining
210
Engine Coolant - Filling
211
HT Coolant Pump - Relief Bore Check
212
Engine Coolant - Sample Extraction and Analysis
213
Raw Water Pump with Connections
214
Raw Water Pump - Relief Bore Check
214
Belt Drive
215
Drive Belt - Condition Check
215
Battery-Charging Generator
216
Battery-Charging Generator Drive - Drive Belt Check and Adjustment
216
Battery-Charging Generator Drive - Drive Belt Replacement
218
Engine Mounting / Support
220
Engine Mounting - Checking Condition of Resilient Mounts
220
Wiring (General) for Engine/Gearbox/Unit
221
Engine Wiring - Check
221
Accessories for (Electronic) Engine Governor / Control System
222
Engine Governor and Connectors - Cleaning
222
Engine Monitoring Unit and Connectors - Cleaning
223
Start Interlock Limit Switch - Check
224
ECU - Plug Connections Check
225
Engine Monitoring Unit - Plug Connection Check
226
Engine Control Unit - Removal and Installation
227
Emergency Instrumentation (Local Operating Panel)
229
LOP and Connectors - Cleaning
229
Checking Threaded Connections
230
LOP - Visual Inspection
230
LOP - Test Procedures
232
8 Appendix A
234
Abbreviations
234
Appendix A 8.1 Abbreviations
234
MTU Contact Persons/Service Partners
236
9 Appendix B
237
Special Tools
237
Index
244
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MTU 16 V 2000 M40A Operating Instructions Manual (195 pages)
Brand:
MTU
| Category:
Engine
| Size: 8.39 MB
Table of Contents
Table of Contents
5
Operating Instructions
1
1 Safety
8
General Conditions
8
Personnel and Organizational Requirements
9
Transportation
10
Safety Precautions When Working on the Engine
13
Fluids and Lubricants, Fire Prevention and Environmental Protection
15
Conventions for Safety Instructions in the Text
17
2 Product Summary
18
Product Description
18
Series 2000 M40A/B - M41A/B
27
Engine Side and Cylinder Designations
28
Engine - Main Dimensions
29
Firing Order
30
Technical Data
31
2000 M40A Engine Data: Engine-Mounted Heat Exchanger, Reference Conditions: 25 °C Intake Air Temperature
31
2000 M40A Engine Data: Separate Heat Exchanger, Reference Conditions: 25 °C Intake Air Temperature
34
2000 M40B Engine Data, Engine-Mounted Heat Exchanger, Reference Condition: 25 °C Intake Air Temperature
37
2000 M40B Engine Data, Separate Heat
40
2000 M40A Engine Data: Engine-Mounted Heat Exchanger, Reference Conditions: 45 °C Intake Air Temperature
43
2000 M40A Engine Data: Engine-Mounted Heat Exchanger, Reference Conditions: 25 °C Intake Air Temperature
46
2000 M40A Engine Data: Separate Heat Exchanger, Reference Conditions: 25 °C Intake Air Temperature
49
2000 M40A Engine Data: Separate Heat Exchanger, Reference Conditions: 45 °C Intake Air Temperature
52
2000 M40A Engine Data: Engine-Mounted Heat Exchanger, Reference Conditions: 25 °C Intake Air Temperature
55
2000 M40A Engine Data: Engine-Mounted Heat Exchanger, Reference Conditions: 45 °C Intake Air Temperature
58
2000 M40A Engine Data: Separate Heat Exchanger, Reference Conditions: 25 °C Intake Air Temperature
61
2000 M40A Engine Data: Separate Heat Exchanger, Reference Conditions: 45 °C Intake Air Temperature
64
2000 M40B Engine Data, Engine-Mounted Heat Exchanger, Reference Condition: 45 °C Intake Air Temperature
67
2000 M40B Engine Data, Engine-Mounted Heat Exchanger, Reference Condition: 25 °C Intake Air Temperature
70
2000 M40B Engine Data, Separate Heat Exchanger, Reference Condition: 45 °C Intake Air Temperature
73
2000 M40B Engine Data, Separate Heat Exchanger, Reference Condition: 25 °C Intake Air Temperature
76
Engine Data 12V 2000M41A/B
79
Engine Data 16V 2000M41A/B
82
3 Operation
85
LOP - Controls
85
Putting the Engine into Operation
87
Putting the Engine into Operation (Out-Of- Service Period > 3 Months)
87
Putting the Engine into Operation after Scheduled Out-Of-Service Period
88
Starting the Engine from LOP
89
Operational Checks
90
Stopping the Engine at the LOP
91
Emergency Stop from LOP
92
After Stopping the Engine
93
Plant - Cleaning
94
4 Maintenance
95
Maintenance Task Reference Table [QL1]
95
5 Troubleshooting
96
LOP Alarms
99
6 Task Description
104
Engine
104
Engine - Barring Manually
104
Engine - Barring with Starting System
105
Cylinder Liner
106
Cylinder Liner - Endoscopic Examination
106
Instructions and Comments on Endoscopic and Visual Examination of Cylinder Liners
108
Crankcase Breather
110
Crankcase Breather - Oil Separator Element Replacement, Diaphragm Check and Replacement
110
Crankcase Breather - Cleaning Oil Separator Element
112
Crankcase Breather - Oil Separator Replacement, Diaphragm Check and Replacement
113
Valve Clearance - Checking and Adjusting
115
Valve Drive
115
Cylinder Head Cover - Removal and Installation
118
Injection Pump - Replacement
119
Injection Pump / HP Pump
119
Injection Pump - Removal and Installation
120
Injection Valve / Injector
123
Injector - Replacement
123
Injector - Removal and Installation
124
Installing Injector
126
6.7 Fuel System
128
Fuel System
128
HP Fuel Line - Pressure Pipe Union Replacement
128
Fuel - Draining
130
Fuel System Venting
131
Fuel Filter
133
Fuel Filter - Replacement
133
Engine Is Stopped and Starting Disabled
133
Special Tools, Material, Spare Parts
133
Designation / Use Part no
133
WARNING Fuels Are Combustible
133
Risk of Fire and Explosion
133
Avoid Open Flames, Electrical Sparks and Ignition Sources
133
Do Not Smoke
133
Fuel Prefilter - Differential Pressure Check and Adjustment of Gauge
135
Fuel Prefilter - Draining
136
Fuel Prefilter - Flushing
137
Fuel Prefilter - Filter Element Replacement
139
Charge-Air Cooling
141
Intercooler - Checking Condensate Drain Line for Coolant Discharge and Obstruction
141
WARNING Compressed Air Risk of Injury
141
Do Not Direct Compressed-Air Jet at Persons
141
Wear Protective Goggles / Safety Mask and Ear Protectors
141
Air Filter
142
Air Filter - Replacement
142
Air Filter - Removal and Installation
143
Air Intake
144
Service Indicator - Signal Ring Position Check
144
Starting Equipment
145
Starter - Condition Check
145
Lube Oil System, Lube Oil Circuit
146
Engine Oil Level - Check
146
Engine Oil - Change
147
Oil Filtration / Cooling
148
Oil Dipstick - Marking
148
Engine Oil Filter - Replacement
149
Centrifugal Oil Filter - Cleaning and Filter-Sleeve Replacement
151
Coolant Circuit, General, High-Temperature Circuit
154
Drain and Venting Points
154
Engine Coolant - Level Check
159
Engine Coolant - Change
160
Engine Coolant - Draining
161
Preparatory Steps
161
Engine Coolant Filling
162
HT Coolant Pump - Relief Bore Check
163
Engine Coolant - Sample Extraction and Analysis
164
Raw Water Pump with Connections
165
Raw Water Pump - Relief Bore Check
165
Belt Drive
166
Drive Belt - Condition Check
166
Battery-Charging Generator
167
Battery-Charging Generator Drive - Drive Belt Check and Adjustment
167
Battery-Charging Generator Drive - Drive Belt Replacement
169
Engine Mounting / Support
171
Engine Mounting - Checking Condition of Resilient Mounts
171
Wiring (General) for Engine/Gearbox/Unit
172
Engine Wiring - Check
172
Accessories for (Electronic) Engine Governor / Control System
173
Engine Control Unit and Connectors - Cleaning
173
Engine Monitoring Unit and Connectors
174
Cleaning
174
Start Interlock Limit Switch - Check
175
ECU - Checking Plug Connections
176
Engine Monitoring Unit, Plug Connections - Check
177
Engine Control Unit - Removal and Installation
178
Emergency Instrumentation (Local Operating Panel)
180
LOP and Connectors - Cleaning
180
LOP - Visual Inspection
181
LOP - Test Procedures
183
7 Appendix A
185
Abbreviations
185
MTU Contacts/Service Partners
187
Special Tools
188
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