MTU 12 V 2000 M40A Operating Instructions Manual Download

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Removing injector

Remove leak-off-fuel lines.

Remove fuel line (3).

Remove thrust screw (2).

Pull off pressure pipe union (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.

10.

Remove injector sealing ring using a self-

made hook.

11.

After removal, seal all openings with suita‐

ble covers.

MS150031/03E 2011-10 | Task Description | 125

TIM-ID: 0000004646 - 003

Summary of Contents for 12 V 2000 M40A

Page 1: ...Operating Instructions Diesel engine 8 V 2000 M40A 8 V 2000 M40B 12 V 2000 M40A 12 V 2000 M40B 12 V 2000 M41A 12 V 2000 M41B 16 V 2000 M40A 16 V 2000 M40B 16 V 2000 M41A 16 V 2000 M41B MS150031 03E ...

Page 2: ...tten permission of MTU Friedrichshafen GmbH This restriction also applies to copyright distribution translation micro filming and storage or processing on electronic systems including data bases and online services This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage during operation Subject to alterations and amendments ...

Page 3: ...mportant Please complete and return the Commissioning Note card below to MTU Friedrichshafen GmbH The Commissioning Note information serves as a basis for the contractually agreed logistic support war ranty spare parts etc ...

Page 4: ......

Page 5: ...gine data engine mounted heat exchanger reference conditions 25 C intake air temperature 55 2 6 10 16V 2000 M40A engine data engine mounted heat exchanger reference conditions 45 C intake air temperature 58 2 6 11 16V 2000 M40A engine data separate heat exchanger reference conditions 25 C intake air temperature 61 2 6 12 16V 2000 M40A engine data separate heat exchanger reference conditions 45 C i...

Page 6: ...t 146 6 13 1 Engine oil level Check 146 6 13 2 Engine oil Change 147 6 14 Oil Filtration Cooling 148 6 14 1 Oil dipstick Marking 148 6 14 2 Engine oil filter Replacement 149 6 14 3 Centrifugal oil filter Cleaning and filter sleeve replacement 151 6 15 Coolant Circuit General High Temperature Circuit 154 6 15 1 Drain and venting points 154 6 15 2 Engine coolant Level check 159 6 15 3 Engine coolant...

Page 7: ...8 Appendix B 8 1 Special Tools 188 8 2 Consumables 192 8 3 Index 194 MS150031 03E 2011 10 Table of Contents 7 DCL ID 0000005762 004 ...

Page 8: ... other use is considered improper use The engine manufacturer accepts no liability whatsoever for resultant damage or injury in such case The responsibility is borne by the user alone Correct use also includes observation of and compliance with the operating instructions and mainte nance and repair specifications Modifications or conversions Unauthorized modifications to the engine represent a saf...

Page 9: ...s accessible to operating maintenance repair and transport personnel at all times Use the manual as a basis for instructing personnel on engine operation and repair In particular person nel must have read and understood the safety relevant instructions This is especially important for personnel who work on the engine only on an occasional basis These persons shall receive repeated instruction Use ...

Page 10: ...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 10 Safety MS150031 03E 2011 10 TIM ID 0000002620 002 ...

Page 11: ...ift the engine 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 03E 2011 10 Safety 11 TIM ID 0000002620 002 ...

Page 12: ...crews for the engine mounts prior to engine trans portation Secure the engine against tilting during transport In particular when going down inclines or ramps the engine must be secured against moving and tilting Setting the engine down after transport 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 ...

Page 13: ...at all mounts and dampers are correctly installed Ensure that all fuel injection and pressurized oil lines are installed with enough space to prevent con tact with other components Do not place fuel or oil lines near hot components Do not touch elastomeric seals e g Viton sealing rings if they have carbonized or resinous appear ance Note cooling period for components which are heated for installat...

Page 14: ...nager or supervisor Before work is carried out on the assemblies the power supply to the relevant areas must be switched off Do not damage wiring during the removal work When reinstalling ensure that the wiring cannot be dam aged during engine operation through contact with sharp edges rubbing against a component or through contact with a hot surface Do not secure cables on lines carrying fluids D...

Page 15: ...rohibited by emission regulations Emission control units systems may only be main tained exchanged or repaired if the components used for this purpose are approved by MTU Noncom pliance with these guidelines might represent a violation of the Clean Air Act and could involve the termi nation of the operating license by the emission authorities MTU does not accept any liability for viola tions of th...

Page 16: ... danger class AI AII and B out of containers results in a risk of explosion Forcing compressed air into thin walled containers e g containers made of tin plastic and glass for drying purposes or to check for leaks results in a risk of bursting Carry out the leak check as specified Painting When carrying out painting work outside the spray stands provided with fume extraction systems en sure that t...

Page 17: ...es Minor injury or material damage Remedial action Note This manual contains highlighted safety warnings in accordance with the US ANSI Z535 standard which begin with one of the signal words listed above depending on the severity of the hazard Safety instructions 1 Read and familiarize yourself with all safety notices before starting up or repairing the product 2 Pass on all safety instructions to...

Page 18: ...gn permits Low surface temperature Reduced amount of heat to be dissipated by the coolant Absolute gas tightness Turbocharging Sequential turbocharging with intercooling turbochargers can be cut in out during operation Cooling system Engine cooled by split circuit cooling system with plate core heat exchanger Service block The service components are mounted at the auxiliary PTO end The arrangement...

Page 19: ...r coupling control Input output signals as well as data transfer to CAN field bus for remote control and ship side monitor ing Monitoring in engine room Engine control and monitoring unit LOP Functions Alphanumeric monochrome LCD display for monitoring of measured values as well as alarms when limits are violated Pushbuttons for menu control and dimming unit Combined control and display elements f...

Page 20: ...Fuel system covers 20 Product Summary MS150031 03E 2011 10 TIM ID 0000002178 003 ...

Page 21: ...MS150031 03E 2011 10 Product Summary 21 TIM ID 0000002178 003 ...

Page 22: ...Lube oil system covers 22 Product Summary MS150031 03E 2011 10 TIM ID 0000002178 003 ...

Page 23: ...MS150031 03E 2011 10 Product Summary 23 TIM ID 0000002178 003 ...

Page 24: ...e pressure is greatly reduced by a faulty O ring 3 The union is confirmed as being SOLAS compliant by DNV and GL Plugs and sensors Screw in plugs 2 are sealed toward the outside either with a copper sealing ring 1 according to DIN or an O ring ISO The fluid must first pass the thread in case of a loose threaded union or faulty sealing ring 2 The pressure is so greatly reduced by this and the fault...

Page 25: ...al sealing area 20 Leak fuel connection The HP fuel line is sealed by the thrust ring 8 If leakage in the area of the thrust ring 8 or the HP line 5 occurs the emerging fuel is routed to the leakage chamber Leak fuel is allowed to escape without pressure via the leakage overflow bore 7 The leakage chamber is sealed toward the outside by the O rings 3 This prevents leaking fuel from escaping The un...

Page 26: ...ateral 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 26 Product Summary MS150031 03E 2011 10 TIM ID 0000002178 003 ...

Page 27: ...ke air supply 140 Exhaust system 170 Starting equipment 180 Lube oil system lube oil circuit 200 Coolant circuit 230 Mounting support 250 PTO systems driving end and free end 500 Monitoring control and regulation system Engine model designation Key to the engine model designations 8 12 16V 2000 M40A B M41A B 8 12 16 Number of cylinders V Cylinder arrangement 2000 Series M4 Application segment 0 1 ...

Page 28: ...d those of the right side B as per DIN ISO 1204 The cylinders of each bank are numbered consecutively starting with No 1 at the driving end of the engine Other components are numbered in the same way i e starting with No 1 on driving end 1 KGS Free end 2 Right engine side 3 KS Driving end 4 Left engine side 28 Product Summary MS150031 03E 2011 10 TIM ID 0000000863 013 ...

Page 29: ...Height C 8V 2000 M40A M40B approx 2005 mm approx 1280 mm approx 1315 mm 12V 2000 M40A M40B M41A M41B approx 2106 mm approx 1398 mm approx 1291 mm 16V 2000 M40A M40B M41A M41B approx 2815 mm approx 1425 mm approx 1291 mm MS150031 03E 2011 10 Product Summary 29 TIM ID 0000002145 002 ...

Page 30: ...iring order Firing order 8V 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 30 Product Summary MS150031 03E 2011 10 TIM ID 0000002802 002 ...

Page 31: ...etric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power to ISO 3046 Number of cylinders 8 Engine rated speed A rpm 1500 Continuous power ISO 3046 10 overload capability design power DIN 6280 ISO 8528 A kW 385 GENERAL CONDITIONS for maximum power Number of cylinders 8 Intake air depression new filter A mbar 15 Intake air depression max L mba...

Page 32: ... SYSTEM Number of cylinders 8 Fuel pressure at engine supply connection min when engine is starting L bar 0 3 Fuel pressure at supply connection to engine min when engine is run ning L bar 0 3 Fuel pressure at engine supply connection max when engine is starting L bar 0 5 Fuel supply flow max R liter min 1 3 GENERAL OPERATING DATA Number of cylinders 8 Firing speed from R rpm 100 Firing speed to R...

Page 33: ...ns L liter 45 Oil pan capacity dipstick mark max standard oil system Option max op erating inclinations L liter 55 WEIGHTS MAIN DIMENSIONS Number of cylinders 8 Engine dry weight with attached standard accessories without coupling R kg 1790 ACOUSTICS Number of cylinders 8 Exhaust noise unsilenced DL free field sound pressure level Lp 1m dis tance ISO 6798 R db A 105 Engine surface noise with atten...

Page 34: ...e mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power to ISO 3046 Number of cylinders 8 Engine rated speed A rpm 1500 Continuous power ISO 3046 10 overload capability design power DIN 6280 ISO 8528 A kW 385 GENERAL CONDITIONS for maximum power Number of cylinders 8 Intake air depression new filter A mbar 15 Intake air depression max L mbar 50 MODEL RE...

Page 35: ...R rpm 100 Firing speed to R rpm 120 STARTING electric Number of cylinders 8 Starter rated voltage standard design R V 24 STARTING SYSTEM with air hydraulic starter motor Number of cylinders 8 Starting air pressure before starter motor min R bar 18 Starting air pressure before starter motor max R bar 30 CAPACITIES Number of cylinders 8 Engine oil at initial filling standard oil system Option max op...

Page 36: ...DL free field sound pressure level Lp 1m dis tance ISO 6798 R db A 105 Engine surface noise with attenuated intake noise filter DL free field sound pressure level Lp 1m distance ISO 6798 R db A 102 36 Product Summary MS150031 03E 2011 10 TIM ID 0000010986 001 ...

Page 37: ...sure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power to ISO 3046 Number of cylinders 8 Engine rated speed A rpm 1800 Continuous power ISO 3046 10 overload capability design power DIN 6280 ISO 8528 A kW 400 GENERAL CONDITIONS for maximum power Number of cylinders 8 Intake air depression new filter A mbar 15 Intake air depression max L mbar 50 MODEL...

Page 38: ... SYSTEM Number of cylinders 8 Fuel pressure at engine supply connection min when engine is starting L bar 0 3 Fuel pressure at supply connection to engine min when engine is run ning L bar 0 3 Fuel pressure at engine supply connection max when engine is starting L bar 0 5 Fuel supply flow max R liter min 1 6 GENERAL OPERATING DATA Number of cylinders 8 Firing speed from R rpm 100 Firing speed to R...

Page 39: ...ns L liter 45 Oil pan capacity dipstick mark max standard oil system Option max op erating inclinations L liter 55 WEIGHTS MAIN DIMENSIONS Number of cylinders 8 Engine dry weight with attached standard accessories without coupling R kg 1790 ACOUSTICS Number of cylinders 8 Exhaust noise unsilenced DL free field sound pressure level Lp 1m dis tance ISO 6798 R db A 105 Engine surface noise with atten...

Page 40: ...e mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power to ISO 3046 Number of cylinders 8 Engine rated speed A rpm 1800 Continuous power ISO 3046 10 overload capability design power DIN 6280 ISO 8528 A kW 400 GENERAL CONDITIONS for maximum power Number of cylinders 8 Intake air depression new filter A mbar 15 Intake air depression max L mbar 50 MODEL RE...

Page 41: ... R rpm 100 Firing speed to R rpm 120 STARTING electric Number of cylinders 8 Starter rated voltage standard design R V 24 STARTING SYSTEM with air hydraulic starter motor Number of cylinders 8 Starting air pressure before starter motor min R bar 18 Starting air pressure before starter motor max R bar 30 CAPACITIES Number of cylinders 8 Engine oil at initial filling standard oil system Option max o...

Page 42: ...DL free field sound pressure level Lp 1m dis tance ISO 6798 R db A 105 Engine surface noise with attenuated intake noise filter DL free field sound pressure level Lp 1m distance ISO 6798 R db A 103 42 Product Summary MS150031 03E 2011 10 TIM ID 0000011005 001 ...

Page 43: ...ressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power to ISO 3046 Number of cylinders 12 Engine rated speed A rpm 1500 Continuous power ISO 3046 10 overload capability design power DIN 6280 ISO 8528 A kW 575 GENERAL CONDITIONS for maximum power Number of cylinders 12 Intake air depression new filter A mbar 15 Intake air depression max L mbar 50 ...

Page 44: ...TEM Number of cylinders 12 Fuel pressure at supply connection on engine min when engine is start ing L bar 0 3 Fuel pressure at supply connection on engine min when engine is run ning L bar 0 3 Fuel pressure at supply connection on engine max when engine is start ing L bar 0 5 Fuel supply flow max R liter min 2 7 GENERAL OPERATING DATA Number of cylinders 12 Firing speed from R rpm 100 Firing spee...

Page 45: ...clinations L liter 73 Oil pan capacity dipstick mark max standard oil system Option max op erating inclinations L liter 88 WEIGHTS MAIN DIMENSIONS Number of cylinders 12 Engine dry weight with attached standard accessories without coupling R kg 2600 ACOUSTICS Number of cylinders 12 Exhaust noise unsilenced CP free field sound pressure level Lp 1m dis tance ISO 6798 R db A 111 Engine surface noise ...

Page 46: ...ressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power to ISO 3046 Number of cylinders 12 Engine rated speed A rpm 1500 Continuous power ISO 3046 10 overload capability design power DIN 6280 ISO 8528 A kW 575 GENERAL CONDITIONS for maximum power Number of cylinders 12 Intake air depression new filter A mbar 15 Intake air depression max L mbar 50 ...

Page 47: ...TEM Number of cylinders 12 Fuel pressure at supply connection on engine min when engine is start ing L bar 0 3 Fuel pressure at supply connection on engine min when engine is run ning L bar 0 3 Fuel pressure at supply connection on engine max when engine is start ing L bar 0 5 Fuel supply flow max R liter min 2 6 GENERAL OPERATING DATA Number of cylinders 12 Firing speed from R rpm 100 Firing spee...

Page 48: ...clinations L liter 73 Oil pan capacity dipstick mark max standard oil system Option max op erating inclinations L liter 88 WEIGHTS MAIN DIMENSIONS Number of cylinders 12 Engine dry weight with attached standard accessories without coupling R kg 2600 ACOUSTICS Number of cylinders 12 Exhaust noise unsilenced CP free field sound pressure level Lp 1m dis tance ISO 6798 R db A 111 Engine surface noise ...

Page 49: ...sure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power to ISO 3046 Number of cylinders 12 Engine rated speed A rpm 1500 Continuous power ISO 3046 10 overload capability design power DIN 6280 ISO 8528 A kW 575 GENERAL CONDITIONS for maximum power Number of cylinders 12 Intake air depression new filter A mbar 15 Intake air depression max L mbar 50 MOD...

Page 50: ...GENERAL OPERATING DATA Number of cylinders 12 Firing speed from R rpm 100 Firing speed to R rpm 120 STARTING electric Number of cylinders 12 Rated starter voltage standard design R V 24 STARTING pneumatic starter Number of cylinders 12 Starting air pressure before starter motor min R bar 21 Starting air pressure before starter motor max R bar 30 CAPACITIES Number of cylinders 12 Engine oil capacit...

Page 51: ... 2600 ACOUSTICS Number of cylinders 12 Exhaust noise unsilenced CP free field sound pressure level Lp 1m dis tance ISO 6798 R db A 111 Engine surface noise with attenuated intake noise filter CP free field sound pressure level Lp 1m distance ISO 6798 R db A 99 MS150031 03E 2011 10 Product Summary 51 TIM ID 0000003004 001 ...

Page 52: ...sure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power to ISO 3046 Number of cylinders 12 Engine rated speed A rpm 1500 Continuous power ISO 3046 10 overload capability design power DIN 6280 ISO 8528 A kW 575 GENERAL CONDITIONS for maximum power Number of cylinders 12 Intake air depression new filter A mbar 15 Intake air depression max L mbar 50 MOD...

Page 53: ...GENERAL OPERATING DATA Number of cylinders 12 Firing speed from R rpm 100 Firing speed to R rpm 120 STARTING electric Number of cylinders 12 Rated starter voltage standard design R V 24 STARTING pneumatic starter Number of cylinders 12 Starting air pressure before starter motor min R bar 21 Starting air pressure before starter motor max R bar 30 CAPACITIES Number of cylinders 12 Engine oil capacit...

Page 54: ... 2600 ACOUSTICS Number of cylinders 12 Exhaust noise unsilenced CP free field sound pressure level Lp 1m dis tance ISO 6798 R db A 111 Engine surface noise with attenuated intake noise filter CP free field sound pressure level Lp 1m distance ISO 6798 R db A 99 54 Product Summary MS150031 03E 2011 10 TIM ID 0000003019 001 ...

Page 55: ...sure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power to ISO 3046 Number of cylinders 16 Engine rated speed A rpm 1500 Continuous power ISO 3046 10 overload capability design power DIN 6280 ISO 8528 A kW 770 GENERAL CONDITIONS for maximum power Number of cylinders 16 Intake air depression new filter A mbar 15 Intake air depression max L mbar 50 MOD...

Page 56: ...ressure at engine supply connection min when engine is starting L bar 0 3 Fuel pressure at supply connection to engine min when engine is run ning L bar 0 3 Fuel pressure at engine supply connection max when engine is starting L bar 0 5 Fuel supply flow max R liter min 3 4 GENERAL OPERATING DATA Number of cylinders 16 Firing speed from R rpm 100 Firing speed to R rpm 120 STARTING electric Number o...

Page 57: ...ons L liter 97 Oil pan capacity dipstick mark max standard oil system Option max op erating inclinations L liter 117 WEIGHTS MAIN DIMENSIONS Number of cylinders 16 Engine dry weight with attached standard accessories without coupling R kg 3200 ACOUSTICS Number of cylinders 16 Exhaust noise unsilenced DL free field sound pressure level Lp 1m dis tance ISO 6798 R db A 109 Engine surface noise with a...

Page 58: ...sure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power to ISO 3046 Number of cylinders 16 Engine rated speed A rpm 1500 Continuous power ISO 3046 10 overload capability design power DIN 6280 ISO 8528 A kW 770 GENERAL CONDITIONS for maximum power Number of cylinders 16 Intake air depression new filter A mbar 15 Intake air depression max L mbar 50 MOD...

Page 59: ...ressure at engine supply connection min when engine is starting L bar 0 3 Fuel pressure at supply connection to engine min when engine is run ning L bar 0 3 Fuel pressure at engine supply connection max when engine is starting L bar 0 5 Fuel supply flow max R liter min 3 5 GENERAL OPERATING DATA Number of cylinders 16 Firing speed from R rpm 100 Firing speed to R rpm 120 STARTING electric Number o...

Page 60: ...ons L liter 97 Oil pan capacity dipstick mark max standard oil system Option max op erating inclinations L liter 117 WEIGHTS MAIN DIMENSIONS Number of cylinders 16 Engine dry weight with attached standard accessories without coupling R kg 3200 ACOUSTICS Number of cylinders 16 Exhaust noise unsilenced DL free field sound pressure level Lp 1m dis tance ISO 6798 R db A 109 Engine surface noise with a...

Page 61: ...e mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power to ISO 3046 Number of cylinders 16 Engine rated speed A rpm 1500 Continuous power ISO 3046 10 overload capability design power DIN 6280 ISO 8528 A kW 770 GENERAL CONDITIONS for maximum power Number of cylinders 16 Intake air depression new filter A mbar 15 Intake air depression max L mbar 50 MODEL ...

Page 62: ...ARTING electric Number of cylinders 16 Starter rated voltage standard design R V 24 STARTING SYSTEM with air hydraulic starter motor Number of cylinders 16 Starting air pressure before starter motor min R bar 24 Starting air pressure before starter motor max R bar 30 CAPACITIES Number of cylinders 16 Engine oil at initial filling standard oil system Option max operating incli nations R liter 134 O...

Page 63: ...DL free field sound pressure level Lp 1m dis tance ISO 6798 R db A 109 Engine surface noise with attenuated intake noise filter DL free field sound pressure level Lp 1m distance ISO 6798 R db A 107 MS150031 03E 2011 10 Product Summary 63 TIM ID 0000011000 001 ...

Page 64: ...e mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power to ISO 3046 Number of cylinders 16 Engine rated speed A rpm 1500 Continuous power ISO 3046 10 overload capability design power DIN 6280 ISO 8528 A kW 770 GENERAL CONDITIONS for maximum power Number of cylinders 16 Intake air depression new filter A mbar 15 Intake air depression max L mbar 50 MODEL ...

Page 65: ...ARTING electric Number of cylinders 16 Starter rated voltage standard design R V 24 STARTING SYSTEM with air hydraulic starter motor Number of cylinders 16 Starting air pressure before starter motor min R bar 24 Starting air pressure before starter motor max R bar 30 CAPACITIES Number of cylinders 16 Engine oil at initial filling standard oil system Option max operating incli nations R liter 134 O...

Page 66: ...DL free field sound pressure level Lp 1m dis tance ISO 6798 R db A 109 Engine surface noise with attenuated intake noise filter DL free field sound pressure level Lp 1m distance ISO 6798 R db A 107 66 Product Summary MS150031 03E 2011 10 TIM ID 0000010997 001 ...

Page 67: ...sure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power to ISO 3046 Number of cylinders 16 Engine rated speed A rpm 1800 Continuous power ISO 3046 10 overload capability design power DIN 6280 ISO 8528 A kW 930 GENERAL CONDITIONS for maximum power Number of cylinders 16 Intake air depression new filter A mbar 15 Intake air depression max L mbar 50 MOD...

Page 68: ...ressure at engine supply connection min when engine is starting L bar 0 3 Fuel pressure at supply connection to engine min when engine is run ning L bar 0 3 Fuel pressure at engine supply connection max when engine is starting L bar 0 5 Fuel supply flow max R liter min 4 2 GENERAL OPERATING DATA Number of cylinders 16 Firing speed from R rpm 100 Firing speed to R rpm 120 STARTING electric Number o...

Page 69: ...ons L liter 97 Oil pan capacity dipstick mark max standard oil system Option max op erating inclinations L liter 117 WEIGHTS MAIN DIMENSIONS Number of cylinders 16 Engine dry weight with attached standard accessories without coupling R kg 3200 ACOUSTICS Number of cylinders 16 Exhaust noise unsilenced DL free field sound pressure level Lp 1m dis tance ISO 6798 R db A 111 Engine surface noise with a...

Page 70: ...sure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power to ISO 3046 Number of cylinders 16 Engine rated speed A rpm 1800 Continuous power ISO 3046 10 overload capability design power DIN 6280 ISO 8528 A kW 930 GENERAL CONDITIONS for maximum power Number of cylinders 16 Intake air depression new filter A mbar 15 Intake air depression max L mbar 50 MOD...

Page 71: ...ressure at engine supply connection min when engine is starting L bar 0 3 Fuel pressure at supply connection to engine min when engine is run ning L bar 0 3 Fuel pressure at engine supply connection max when engine is starting L bar 0 5 Fuel supply flow max R liter min 4 2 GENERAL OPERATING DATA Number of cylinders 16 Firing speed from R rpm 100 Firing speed to R rpm 120 STARTING electric Number o...

Page 72: ...ons L liter 97 Oil pan capacity dipstick mark max standard oil system Option max op erating inclinations L liter 117 WEIGHTS MAIN DIMENSIONS Number of cylinders 16 Engine dry weight with attached standard accessories without coupling R kg 3200 ACOUSTICS Number of cylinders 16 Exhaust noise unsilenced DL free field sound pressure level Lp 1m dis tance ISO 6798 R db A 111 Engine surface noise with a...

Page 73: ...e mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power to ISO 3046 Number of cylinders 16 Engine rated speed A rpm 1800 Continuous power ISO 3046 10 overload capability design power DIN 6280 ISO 8528 A kW 930 GENERAL CONDITIONS for maximum power Number of cylinders 16 Intake air depression new filter A mbar 15 Intake air depression max L mbar 50 MODEL ...

Page 74: ...ARTING electric Number of cylinders 16 Starter rated voltage standard design R V 24 STARTING SYSTEM with air hydraulic starter motor Number of cylinders 16 Starting air pressure before starter motor min R bar 24 Starting air pressure before starter motor max R bar 30 CAPACITIES Number of cylinders 16 Engine oil at initial filling standard oil system Option max operating incli nations R liter 134 O...

Page 75: ...DL free field sound pressure level Lp 1m dis tance ISO 6798 R db A 111 Engine surface noise with attenuated intake noise filter DL free field sound pressure level Lp 1m distance ISO 6798 R db A 107 MS150031 03E 2011 10 Product Summary 75 TIM ID 0000011018 001 ...

Page 76: ...e mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power to ISO 3046 Number of cylinders 16 Engine rated speed A rpm 1800 Continuous power ISO 3046 10 overload capability design power DIN 6280 ISO 8528 A kW 930 GENERAL CONDITIONS for maximum power Number of cylinders 16 Intake air depression new filter A mbar 15 Intake air depression max L mbar 50 MODEL ...

Page 77: ...ARTING electric Number of cylinders 16 Starter rated voltage standard design R V 24 STARTING SYSTEM with air hydraulic starter motor Number of cylinders 16 Starting air pressure before starter motor min R bar 24 Starting air pressure before starter motor max R bar 30 CAPACITIES Number of cylinders 16 Engine oil at initial filling standard oil system Option max operating incli nations R liter 134 O...

Page 78: ...DL free field sound pressure level Lp 1m dis tance ISO 6798 R db A 111 Engine surface noise with attenuated intake noise filter DL free field sound pressure level Lp 1m distance ISO 6798 R db A 107 78 Product Summary MS150031 03E 2011 10 TIM ID 0000011022 001 ...

Page 79: ...tric pressure mbar 1000 1000 1000 1000 Site altitude above sea level m 100 100 100 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylinders 12 12 12 12 Rated engine speed A rpm 1500 1500 1800 1800 Continuous power ISO 3046 10 over load capability design power DIN 6280 ISO 8528 A kW 575 575 695 695 GENERAL CONDITIONS for maximum power Number of cylinders 12 12 12...

Page 80: ...ressure before en gine to R bar 8 5 8 5 8 5 8 5 Lube oil operating pressure low idle meas point before engine R bar 3 5 3 5 3 5 3 5 FUEL SYSTEM Number of cylinders 12 12 12 12 Fuel pressure at engine supply connec tion min when engine is starting L bar 0 3 0 3 0 3 0 3 Fuel pressure at engine supply connec tion min during engine operation L bar 0 3 0 3 0 3 0 3 Fuel pressure at engine supply connec ...

Page 81: ...98 98 98 Oil pan capacity at dipstick mark min standard oil system Option max op erating inclinations L liters 73 73 73 73 Oil pan capacity at dipstick mark max standard oil system Option max op erating inclinations L liters 88 88 88 88 WEIGHTS MAIN DIMENSIONS Number of cylinders 12 12 12 12 Dry engine weight with standard acces sories without coupling R kg 2600 2600 2600 2600 NOISE Number of cyli...

Page 82: ...tric pressure mbar 1000 1000 1000 1000 Site altitude above sea level m 100 100 100 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylinders 16 16 16 16 Rated engine speed A rpm 1500 1500 1800 1800 Continuous power ISO 3046 10 over load capability design power DIN 6280 ISO 8528 A kW 770 770 930 930 GENERAL CONDITIONS for maximum power Number of cylinders 16 16 16...

Page 83: ...ng pressure before en gine to R bar 7 0 7 0 7 0 7 0 Lube oil operating pressure low idle meas point before engine R bar N N N N FUEL SYSTEM Number of cylinders 16 16 16 16 Fuel pressure at engine supply connec tion min when engine is starting L bar 0 3 0 3 0 3 0 3 Fuel pressure at engine supply connec tion min during engine operation L bar 0 3 0 3 0 3 0 3 Fuel pressure at engine supply connec tion...

Page 84: ...127 127 Oil pan capacity at dipstick mark min standard oil system Option max op erating inclinations L liters 97 97 97 97 Oil pan capacity at dipstick mark max standard oil system Option max op erating inclinations L liters 117 117 117 117 WEIGHTS MAIN DIMENSIONS Number of cylinders 16 16 16 16 Dry engine weight with standard acces sories without coupling R kg 3200 3200 3200 3200 NOISE Number of c...

Page 85: ... the LCD screen 2 White F2 3 White F3 4 White F4 5 White F5 6 White ALARM AC KNOWLEDGE Pressing the key the first time stops alarm signalization Pressing the button a second time acknowledges an active alarm LED spot lights up when an alarm is active 7 White DIMMER Holding down the key increases LCD background illumina tion MS150031 03E 2011 10 Operation 85 TIM ID 0000008856 003 ...

Page 86: ...n Not ready for operation and Ready for operation status LED spot lights up at Ready for operation switch posi tion 17 Green LOCAL OPERA TION Pressing the switch activates changeover between local and remote control mode LED spot lights up when local mode is active 18 White START Pressing the pushbutton initiates the automatic engine start sequence LED spot lights up as long as the starting proced...

Page 87: ...age 139 Fuel prefilter pressure gauge Align adjustable pointer with position of pressure indicator Page 135 Fuel system Vent Page 131 Raw water pump if located above waterline Prime approx 3 to 4 liters Cooling system If engine is out of service for more than one year change coolant Page 160 Cooling system Check coolant level Page 159 Cooling system Preheat coolant with preheating unit ECU Check p...

Page 88: ...ck oil level Page 146 Cooling system Check coolant level Page 159 Cooling system Preheat coolant with preheating unit Fuel prefilter Drain Page 136 Battery charging generator drive Check condition of drive belt Page 166 Engine control system Switch ON Press READY FOR OPERATION button Page 85 LOP Press LAMP TEST button Page 85 88 Operation MS150031 03E 2011 10 TIM ID 0000002684 001 ...

Page 89: ...m LOP Item Task Engine Make sure that engine is in unloaded condition Engine control system Switch ON LOP LOCAL OPERATION button is illuminated brightly local operating mode is active Page 85 CLUTCH NEUTRAL button is illuminated brightly gearbox is disengag ed Page 85 LOP Press READY FOR OPERATION button briefly Page 85 READY FOR OPERATION button is illuminated brightly LOP Press START button brie...

Page 90: ...olor Page 96 Fuel prefilter Check if suction side pressure indicated at the fuel prefilter pressure gauge is within the limit Page 135 Drain off water and dirt Page 136 Intercooler Check drain line for water discharge and obstruction Page 141 Air filter Check signal ring position of service indicator Page 144 Replace air filter Page 142 if the signal ring is completely visible in the service indic...

Page 91: ...nts Before stopping the engine operate it at idle speed until operating temperatures decrease and stable values are indicated Stopping the engine at the LOP Item Action LOP Operate engine at idle speed Page 85 Temperature readings Wait until engine is at operating temperature LOP Press STOP pushbutton Page 85 STOP pushbutton is illuminated engine is stopped MS150031 03E 2011 10 Operation 91 TIM ID...

Page 92: ...supply to ECU Engine control is deactivated Engines with emergency air shut off flaps Flaps close EMERGENCY STOP button flashes signalization by horn flash lamp etc is released After emergency stop from LOP Item Task LOP Press ALARM ACKNOWLEDGE button Page 85 Audible and visual signalization stops LOP Press ALARM ACKNOWLEDGE button again Power supply to ECU is provided Alarm is acknowledged Engine...

Page 93: ...at a suitable temperature the antifreeze concentration is insufficient for the engine room tempera ture antifreeze concentration is 50 and engine room temperature is below 40 C Raw water Drain If freezing temperatures are to be expected and the engine is to remain out of service for an extended period Engine control system Switch off Air intake and exhaust sys tem Out of service period 1 week Seal...

Page 94: ...g sensors with compressed air Plant Cleaning 1 Carry out plant cleaning only in areas where an appropriate oil separator is provided environmental pro tection 2 Prior to putting the cleaning unit into operation read the Operating Instructions of the water steam jet unit carefully and observe the safety precautions 3 For external cleaning with high pressure jet use a flat mouth nozzle only 4 Carry ...

Page 95: ...reference to the maintenance tasks specified in the maintenance schedule Task W0500 Page 146 W0501 Page 90 W0502 Page 141 W0503 Page 90 W0505 Page 90 W0506 Page 96 W0507 Page 90 W0508 Page 90 W1001 Page 133 W1002 Page 115 W1005 Page 90 W1006 Page 123 W1007 Page 120 W1008 Page 149 W1009 Page 151 W1011 Page 106 W1140 Page 112 W1178 Page 128 Table 1 Maintenance task reference table QL1 MS150031 03E 2...

Page 96: ...181 ECU Plug in connections are loose Check plug in connections Page 176 Engine Running gear blocked engine cannot be barred manually Contact Service Start interlock limit switch Limit switch not installed Check limit switch Page 175 Limit switch defective Wiring defective Check wiring Page 172 Engine turns but does not fire Component Probable Cause Task Starter Poor rotation by starter Battery lo...

Page 97: ...ump defective Replace Page 119 Speed sensor Defective Contact Service Fuel system Not vented Vent fuel system Page 131 ECU Defective Contact Service Charge air temperature too high Component Probable Cause Task Engine coolant Incorrect coolant concentration Check MTU test kit Intercooler Contaminated Contact Service Engine room Air intake temperature too high Check fans Check air supply ventilatio...

Page 98: ...oo much oil in engine Drain engine oil Page 147 Oil separator or oil preseparator of crankcase breather clogged Replace Page 113 Exhaust turbocharger Cylinder head Piston rings Cylinder liner Defective Contact Service Exhaust gas white Component Probable Cause Task Engine Not at operating temperature Run engine to reach operating temper ature Fuel system Water in fuel Check fuel system on fuel pre...

Page 99: ... occurred Red alarm with engine shutdown will probably follow 1 Start the other genset as a preventive measure 2 Determine cause of yellow alarm and rectify AL Battery Charger Fail No battery charging 1 Check power circuit breakers and fuses 2 Check transistor controllers AL Press Monitoring Fail EMU EMU pressure monitoring failure Contact Service Have EMU replaced AL ECU Defect ECU 4 is defective...

Page 100: ...if required AL Water in Fuel Pre filter Water in fuel prefilter Drain fuel prefilter Page 136 DL 211 A001 A001 Display panel DIS not detected on de fault bus 1 Check LOP visually Page 181 2 Perform LOP test procedures Page 183 3 Check ECU plug in connections Page 176 4 Check engine wiring Page 172 5 Contact Service Have DIS checked and re placed if required DL 211 A001 A010 LCU of LOP 1 PIM No 21 ...

Page 101: ...f nec essary RL 211 A001 A001 DIS not detected on redundant bus 1 Check LOP visually Page 181 2 Perform LOP test procedures Page 183 3 Contact Service Have DIS checked and re placed if required RL 211 A001 A010 LCU of LOP 1 PIM No 21 X A001 A010 not detected on redundant bus 1 Check LOP visually Page 181 2 Perform LOP test procedures Page 183 3 Contact Service Have MPU 23 of PIM No 21 X A001 A010 ...

Page 102: ...d Page 159 SS P Lube Oil ECU Safety system detects that engine oil pressure is too low 1 Check lube oil level and top up if required Page 146 2 Contact Service SS P Lube Oil EMU Safety system detects that engine oil pressure is too low 1 Check lube oil level and top up if required Page 146 2 Contact Service SS Security Channel Def EMU Fault message of safety system Contact Service Have EMU checked...

Page 103: ...aced if required TD T Coolant Different measurement values trans mitted by the two sensors for coolant temperature measurement 1 Check LOP visually Page 181 2 Perform LOP test procedures Page 183 3 Check ECU plug in connections Page 176 4 Check engine wiring Page 172 5 Contact Service Have sensors checked and re placed if required Cylinder Cutout Measuring point Cylinder Cutout Status message of C...

Page 104: ...the danger zone After working on the engine check that all protective devices have been reinstalled and all tools removed from the engine Engine Barring manually 1 Remove cover plate 2 2 Attach ratchet with socket to barring tool 3 Rotate crankshaft in engine direction of ro tation Apart from the normal compression resistance there should be no abnormal re sistance Result If the resistance exceeds...

Page 105: ...e engine Engine Barring with starting system 1 Disengage the bayonet coupling 4 of con nector X4 with connector pliers 2 and withdraw connector 3 from engine gover nor 2 Bar engine in unloaded condition Press START button 3 Let the crankshaft rotate until oil pressure is indicated 4 Engine start is automatically interrupted when specified starting period is expired If necessary re start the engine...

Page 106: ...ns First signs of marks left by lower cooling bores Running pattern seems darker No action required Dark areas with even or varying degrees of discoloration Beginning and end of the discoloration are not sharply defined and do not cover the entire stroke area Dark areas in the upper section of the cooling bore remaining cir cumference without objections Piston rings without objections Further endo...

Page 107: ...Final steps 1 Install injector Page 124 2 Install cylinder head cover Page 118 MS150031 03E 2011 10 Task Description 107 TIM ID 0000000015 008 ...

Page 108: ... Smoothened areas appear brighter and more brilliant than the surrounding running surface Findings not critical Polished area Polished areas are on the running surface and show local removal of the hon ing pattern Grooves from honing process are not visible any more Discoloration This is caused by oxidation surface discoloration through oil or fuel and tem perature differences around the liner It ...

Page 109: ...n starting in the TDC ring 1 have to be replaced Seizures Seizure marks Irregular circumference lengths and depths Can be caused either by the pis ton skirt or the piston crown Material deposits on the liner smear heavy dis coloration Severe visible scoring Replace liner Evaluation of findings and further measures The findings in the start phase of oxidation discoloration and heat discoloration ar...

Page 110: ...ion residues which are harmful to health Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Replacing oil separator element 1 Remove cover 2 with O ring 3 2 Remove filter element 1 from housing 4 3 Insert new filter element in housing 4 4 Install cover 2 with new O ring 5 Use torque wrench to tighten the screws of co...

Page 111: ...aphragm 3 on housing 1 5 Install new seal 2 and spring 5 together with cover 4 6 Use torque wrench to tighten the screws of cover 4 to the specified torque Name Size Type Lubricant Value Standard Screw Tightening torque Engine oil 10 Nm 2 Nm 7 Check diaphragms in further oil separators in the same way MS150031 03E 2011 10 Task Description 111 TIM ID 0000000017 006 ...

Page 112: ...ressed air Risk of injury Do not direct compressed air jet at persons Wear protective goggles safety mask and ear protectors Crankcase breather Cleaning oil separator element 1 Remove cover 1 from housing 4 2 Remove oil separator 2 and gasket 3 3 Clean oil separator 2 in fuel and blow dry with compressed air 4 Moisten oil separator 2 with engine oil 5 Place oil separator 2 with new gasket 3 onto h...

Page 113: ...alth Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Replacing filter element of oil separator 1 Remove cover 2 with O ring 3 2 Remove filter element 1 from housing 4 3 Insert new filter element into housing 4 ensuring correct installation position and fit cover 2 with new O ring 4 Tighten screws of cover 2 to spe...

Page 114: ...ged 5 Mount diaphragm 3 on housing 1 6 Install new seal 2 and spring 5 together with cover 4 7 Tighten screws of cover 4 to specified tightening torque Name Size Type Lubricant Value Standard Screw Tightening torque 6 Nm 2 Nm 8 Check diaphragms in further oil separators in the same way 114 Task Description MS150031 03E 2011 10 TIM ID 0000003491 003 ...

Page 115: ...cial tools Material Spare parts Designation Use Part No Qty Torque wrench 20 100 Nm F30026582 1 Ratchet adapter F30062582 1 Feeler gage Y4342013 1 Preparatory steps 1 Remove cover plate 2 2 Remove cylinder head cover Page 118 3 Bar engine manually in engine direction of rotation until the markings 1 are aligned MS150031 03E 2011 10 Task Description 115 TIM ID 0000004360 003 ...

Page 116: ...e rocker arms are under load on cylinder A1 the piston is in overlap TDC 2 Check valve clearance with the engine cold Inlet 0 4 mm Exhaust 0 6 mm 3 Check all valve clearances in two crankshaft positions firing TDC and overlap TDC of cylinder A1 as per diagram 4 Use feeler gage to determine the distance between valve bridge and rocker arm 5 If the deviation from the set value exceeds 0 1 mm adjust ...

Page 117: ...fied tightening torque holding adjusting screw 2 firmly with screw driver Name Size Type Lubricant Value Standard Locknut Tightening torque 50 Nm 5 Insert feeler gage between valve bridge and rocker arm to verify that the gage just passes through the gap Result If not adjust valve clearance Final steps 1 Remove barring device 2 For barring device removal follow reverse sequence of working steps MS...

Page 118: ...ving and installing cylinder head cover 1 Remove screws 2 Remove cylinder head cover with gasket from cylinder head 3 Clean installation surface 4 Check condition of profile gasket in cylinder head cover 5 Replace damaged gaskets 6 Place cylinder head covers onto crankcase and tighten screws applying the specified tightening torque Name Size Type Lubricant Value Standard Screw Tightening torque 20...

Page 119: ...ection pump Replacement Special tools Material Spare parts Designation Use Part No Qty Injection pump Spare Parts Catalog Remove injection pump and install new one u Page 120 MS150031 03E 2011 10 Task Description 119 TIM ID 0000000020 001 ...

Page 120: ...aling ring Spare Parts Catalog Sealing ring Spare Parts Catalog DANGER Unguarded rotating and moving engine components Risk of serious injury Danger to life Before barring the engine ensure that nobody is in the danger zone WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke Preparatory steps 1 Shut off fuel supply line bef...

Page 121: ...ews 6 Remove injection pump 7 Remove sealing rings from injection pump 8 After removal seal all openings with suita ble covers Installing injection pump 1 Remove all blanking plugs and covers 2 Clean mating face of injection pump and roller Note Sealing ring 1 Ø47 mm 3 Coat sealing ring 1 with grease Kluthe Hakuform 30 10 Emulgier and fit on to in jection pump Note Sealing ring 2 Ø45 mm 4 Coat sea...

Page 122: ...rque using a torque wrench Maximum permissible tightening torque 35 Nm Name Size Type Lubricant Value Standard Union nut Tightening torque 20 Nm 5 Nm 13 Install injection pump cabling 1 14 Use torque wrench to tighten screws to the specified tightening torque Name Size Type Lubricant Value Standard Screw Tightening torque 1 0 Nm 0 2 Nm Final steps 1 Remove barring device Page 104 2 Clean mating fa...

Page 123: ...6 1 Injector Replacement Special tools Material Spare parts Designation Use Part No Qty Injector Spare Parts Catalog Remove injector and install new injector u Page 124 MS150031 03E 2011 10 Task Description 123 TIM ID 0000000022 010 ...

Page 124: ...ench F30011450 1 Ratchet adapter F30027340 1 Grease Kluthe Hakuform 30 10 Emulgier X00029933 1 Sealing ring Spare Parts Catalog Sealing ring Spare Parts Catalog WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke WARNING Compressed air Risk of injury Do not direct compressed air jet at persons Wear protective goggles safety...

Page 125: ...xtract fuel from the exposed bores using the suction device 6 Remove screw 2 7 Take off clamp 1 8 Screw puller into injector 9 Remove injector with puller 10 Remove injector sealing ring using a self made hook 11 After removal seal all openings with suita ble covers MS150031 03E 2011 10 Task Description 125 TIM ID 0000004646 003 ...

Page 126: ...un ion 1 with compressed air 9 Coat sealing ring with grease and fit onto pressure pipe union 1 10 Coat taper on pressure pipe union with en gine oil 11 Insert pressure pipe union into cylinder head until it is in contact with the sealing ring 12 Fully press in pressure pipe union 1 by hand 13 Tighten thrust screw 2 with torque wrench to the specified tightening torque Name Size Type Lubricant Val...

Page 127: ...ing torque using a torque wrench Name Size Type Lubricant Value Standard Union nut Tightening torque 20 Nm 5 Nm 18 Install leak off fuel lines Final steps 1 Install cylinder head cover Page 118 2 Vent fuel system Page 131 MS150031 03E 2011 10 Task Description 127 TIM ID 0000004646 003 ...

Page 128: ... F30011450 1 Ratchet adapter F30027340 1 Grease Kluthe Hakuform 30 10 Emulgier X00029933 Engine oil Pressure pipe union Spare Parts Catalog WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke WARNING Compressed air Risk of injury Do not direct compressed air jet at persons Wear protective goggles safety mask and ear protect...

Page 129: ... 2 with torque wrench to the specified tightening torque Name Size Type Lubricant Value Standard Thrust screw Tightening torque 40 Nm 5 Nm 10 Install fuel line 3 11 Tighten union nut on the injection pump to the specified tightening torque using a torque wrench Name Size Type Lubricant Value Standard Union nut Tightening torque 20 Nm 5 Nm 12 Tighten union nut on the pressure tube connection piece ...

Page 130: ...mes electrical sparks and ignition sources Do not smoke Fuel Draining 1 Release threaded vent plugs on filter head 2 Open nipple on fuel line and drain fuel into appropriate container 3 When fuel stops emerging from system close nipple on fuel line 4 Close vent plugs on filter head 130 Task Description MS150031 03E 2011 10 TIM ID 0000004703 001 ...

Page 131: ...es electrical sparks and ignition sources Do not smoke Fuel system venting 1 Unlock fuel priming pump unscrew handle 2 Open vent plugs on filter head 3 Operate the pump with the handle until fuel without bubbles comes out of the vent plugs and the nipples 4 Close vent plugs on filter head MS150031 03E 2011 10 Task Description 131 TIM ID 0000004712 001 ...

Page 132: ...s out of the nipple 7 Close nipple at fuel heat exchanger 8 Open nipple at fuel line 9 Operate the pump with the handle until fuel without bubbles comes out of the nipple 10 Close nipple at fuel line 11 Lock fuel priming pump screw in handle 132 Task Description MS150031 03E 2011 10 TIM ID 0000004712 001 ...

Page 133: ...ury danger to life Take special care when working on a running engine WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors CAUTION Damage to component Serious damage to plant For filter replacement with the engine running operate the engine at l...

Page 134: ...ters in the same way 9 Vent fuel system Page 131 Replacing fuel filter with the engine running 1 Shut down the filter to be replaced 2 Open the threaded vent plugs at the filter head of the cut out filter and make sure that the fuel filter is not pressurized 3 Close threaded vent plugs 4 Unscrew switched off easy change filter with oil filter wrench 5 Clean sealing surface on filter head 6 Check s...

Page 135: ...talling the new filter element align adjustable pointer 2 with pressure indicat ing pointer 3 of pressure gauge 1 2 Verify that differential pressure is within the limit Fuel prefilter Checking differential pressure 1 With the engine running at full load or rated power read off pressure at gauge 1 2 If differential pressure as indicated between position of adjustable pointer 2 and pressure indicat...

Page 136: ...eft filter cut in II Right filter cut in 2 Open threaded vent plug 5 of the filter to be drained 3 Unlock drain valve 6 by pressing toggle and open it 4 Drain water and contaminants from the filter until pure fuel emerges 5 Close drain valve 6 6 Remove screws securing the cover and take off cover 2 7 Fill filter housing with clean fuel 8 Place new seal in cover 2 9 Fit cover with gasket and secure...

Page 137: ...e Take special care when working on a running engine WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors Flushing fuel prefilter 1 Switch off contaminated filter I Left filter cut in II Right filter cut in MS150031 03E 2011 10 Task Description ...

Page 138: ... 6 Filling fuel prefilter with fuel 1 Stop engine Page 91 and disable engine start 2 Remove screws securing the cover and take off cover 2 3 Fill filter housing with clean fuel 4 Place new gasket in cover 2 5 Fit cover with gasket and secure it with screws 6 Check differential pressure Page 135 Result If flushing did not lead to an improvement of the differential pressure replace filter element of...

Page 139: ... Diesel fuel Filter element Spare Parts Catalog Seal Spare Parts Catalog WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke Replacing filter element 1 Cut out the contaminated filter I Left filter cut in II Right filter cut in MS150031 03E 2011 10 Task Description 139 TIM ID 0000004946 003 ...

Page 140: ...2 7 Remove spring housing 4 and filter ele ment 3 8 Insert new filter element 3 and spring housing 4 9 Fill filter housing with clean fuel 10 Place new seal in cover 2 11 Fit cover with gasket and secure it with screws 12 Cut in the cut out filter again 13 Close threaded vent plug 5 when fuel emerges 14 Set adjustable pointer of differential pres sure gauge Page 135 140 Task Description MS150031 0...

Page 141: ...te drain line for coolant discharge and obstruction 1 With the engine running check the conden sate drain line on engine driving end for air discharge 2 If no air emerges remove condensate drain line and blow out with compressed air 3 Replace obstructed drain line by new one 4 Install condensate drain line 5 If a large amount of coolant is continuously discharged the intercooler is leaking Con tac...

Page 142: ...ols Material Spare parts Designation Use Part No Qty Air filter Spare Parts Catalog Remove old air filter and install new air filter u Page 143 Reset signal ring of service indicator u Page 144 142 Task Description MS150031 03E 2011 10 TIM ID 0000005447 004 ...

Page 143: ...nstallation 1 Loosen clamp 2 2 Remove air filter 3 and clamp 2 from flange of intake housing 1 3 Verify that there are no objects in the flange of the intake housing 1 and clean it 4 Place new air filter 3 with clamp 2 onto intake housing 1 5 Tighten clamp 2 MS150031 03E 2011 10 Task Description 143 TIM ID 0000000904 005 ...

Page 144: ...bled Checking signal ring position 1 If the signal ring is completely visible in the control window 2 replace air filter Page 142 2 After installation of new filter press reset button 1 Result Engaged piston with signal ring moves back to initial position 144 Task Description MS150031 03E 2011 10 TIM ID 0000005484 004 ...

Page 145: ...heck Preconditions Engine is stopped and starting disabled Checking starter condition 1 Check securing screws of starter for secure seating and tighten if required 2 Check wiring Page 172 MS150031 03E 2011 10 Task Description 145 TIM ID 0000000905 009 ...

Page 146: ...ck Page 148 4 If necessary top up to max mark Page 147 5 Insert oil dipstick into guide tube up to the stop Checking oil level after the engine is stopped 1 5 minutes after stopping the engine remove oil dipstick from the guide tube and wipe it 2 Insert oil dipstick into guide tube up to the stop withdraw after approx 10 seconds and check oil level 3 Oil level must be between min and max marks Res...

Page 147: ...and pump Draining oil at drain plug on oil pan 1 Provide a suitable container to collect the oil 2 Remove drain plug and drain oil 3 Install drain plug with new sealing ring 4 Replace engine oil filter Page 149 Oil change with semirotary hand pump Oil extraction 1 Provide a suitable container to collect the oil 2 Extract all oil from oil pan using the semirotary hand pump 3 Replace engine oil filt...

Page 148: ... case of new engines and spare parts oil dipsticks are delivered without marks Oil dipstick Marking 1 Draw off or bleed out engine oil completely of oil pan 2 Withdraw oil dipstick 3 Fill in minimum oil quantity 4 Insert oil dipstick and withdraw it again 5 Mark a Min notch on the oil dipstick Max notch depth 1mm 6 Shorten oil dipstick 7 Fill in maximum oil quantity 8 Insert oil dipstick and withd...

Page 149: ...rs WARNING Hot oil Oil can contain combustion residues which are harmful to health Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor CAUTION Damage to component Serious damage to plant For filter replacement with the engine running operate the engine at low engine load The filter which is to be exchanged must be cut...

Page 150: ...0 After each oil change and filter replace ment crank engine with starting system Page 105 11 Check oil level Page 146 Replacing oil filters on a running engine 1 Reduce engine speed to 1100 rpm 2 Remove cut out oil filter using the oil filter wrench 3 Clean sealing surface on connecting piece 4 Check condition of new oil filter sealing ring and coat it with oil 5 Fit SOLAS shield Page 18 6 Screw ...

Page 151: ...Hakutex 50 50622 1 Filter sleeve Spare Parts Catalog O ring Spare Parts Catalog O ring Spare Parts Catalog WARNING Compressed air Risk of injury Do not direct compressed air jet at persons Wear protective goggles safety mask and ear protectors Centrifugal oil filter Rotor removal 1 Release nuts 3 2 Remove housing cover 1 3 Remove complete rotor 2 from housing MS150031 03E 2011 10 Task Description ...

Page 152: ...Measure the layer thickness of the oil resi due 5 If maximum layer thickness 25 mm is ex ceeded shorten maintenance interval 6 Clean rotor components and remove strain ers 2 7 Wash standpipes 3 and nozzles 4 with cleaner blow out with compressed air 8 Insert the new filter sleeve with the smooth surface facing the rotor cap 152 Task Description MS150031 03E 2011 10 TIM ID 0000006418 001 ...

Page 153: ... 10 Nm 13 Hold rotor old design with strap wrench and tighten nut 1 with torque wrench to the specified torque Name Size Type Lubricant Value Standard Nut M16 x 1 5 Tightening torque 40 Nm to 50 Nm 14 Insert complete rotor 2 into the housing and check for ease of movement 15 Set housing cover 1 with new sealing ring onto lower section observe marks 16 Tighten nuts 3 crosswise and evenly MS150031 0...

Page 154: ...perature Circuit 6 15 1 Drain and venting points Top view 1 Engine coolant vent 2 Intercooler 3 Overflow line 4 Engine coolant expansion tank 5 Fuel filter 6 Engine oil filter 154 Task Description MS150031 03E 2011 10 TIM ID 0000006697 001 ...

Page 155: ...Left side 1 Engine coolant drain plug 2 Engine coolant drain plug 3 Raw water pump drain plug MS150031 03E 2011 10 Task Description 155 TIM ID 0000006697 001 ...

Page 156: ...illing plug 5 Raw water pump drain plug 6 Connection for oil extrac tion 7 Oil dipstick connection left or right engine side optional 8 Oil filler neck connection left or right engine side optional 9 Fuel priming pump 156 Task Description MS150031 03E 2011 10 TIM ID 0000006697 001 ...

Page 157: ...ine oil filter 4 Fuel priming pump 5 Raw water pump filling plug 6 Oil filler neck connection left or right engine side optional 7 Oil dipstick connection left or right engine side optional 4 Leak off fuel tank MS150031 03E 2011 10 Task Description 157 TIM ID 0000006697 001 ...

Page 158: ... optional 3 Oil dipstick connection left or right engine side optional 4 Oil dipstick connection left or right engine side optional 5 Oil filler neck connection left or right engine side optional 6 Engine coolant drain plug 7 Fuel vent 158 Task Description MS150031 03E 2011 10 TIM ID 0000006697 001 ...

Page 159: ...ve counter clockwise and remove 3 Check coolant level coolant must be visible at the lower edge of the cast in eye Checking coolant level at external cooler 1 Check coolant level coolant must be visible at marker plate 2 If required top up with treated engine cool ant Page 162 3 Check proper condition of breather valve and clean sealing faces 4 Fit breather valve on filler neck and close it Checki...

Page 160: ...ant Change Special tools Material Spare parts Designation Use Part No Qty Engine coolant Drain engine coolant u Page 161 Fill with engine coolant u Page 162 160 Task Description MS150031 03E 2011 10 TIM ID 0000000036 022 ...

Page 161: ...alve of coolant expansion tank counterclockwise until the first stop and allow pressure to escape 2 Continue to turn breather valve counter clockwise and remove 3 Draw off separated corrosion inhibitor oil in expansion tank through the filler neck 4 Open drain valves and or drain plugs and drain coolant at the following points Drain plug 4 Crankcase 1 Intercooler 6 Exhaust pipe elbow 5 Heating con...

Page 162: ...ll top up coolant only into cold engine Engine coolant filling 1 Turn breather valve on coolant expansion tank counterclockwise to first stop and allow pressure to escape 2 Continue to turn breather valve counter clockwise and remove 3 Remove plug required only for first fill 4 Pour coolant into engine until coolant level reaches lower edge of cast in eye of filler neck 5 Install plug 6 Check prop...

Page 163: ...earing Wear ear protectors HT coolant pump Relief bore check 1 Check relief bore for oil and coolant dis charge 2 Stop the engine Page 91 and disable engine start 3 Clean the relief bore with a wire if it is dirty Permissible coolant discharge up to 10 drops per hour Permissible oil discharge up to 5 drops per hour 4 If discharge exceeds the specified limits contact Service MS150031 03E 2011 10 Ta...

Page 164: ...oolant expansion tank counterclockwise to first stop and allow pressure to escape 2 Continue to turn breather valve counter clockwise and remove 3 Draw off precipitated corrosion inhibitor oil from expansion tank and dispose of it 4 Draw off approx 1 liter coolant and drain in to a clean container 5 Using the equipment and chemicals from the MTU test kit examine coolant for antifreeze concentratio...

Page 165: ...on a running engine WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors Raw water pump Relief bore check 1 Check relief bore for oil and coolant dis charge 2 Clean relief bore using a wire if required Permissible coolant discharge up to 10 drops per hour Permissible oil discharge up to 5 drops per hour 3 If discharge exceeds the specified limits contact Service MS15003...

Page 166: ...led 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 heating Replace Page 169 Drive belt B Cracks on entire circumference Drive belt C Chunking 166 Task Description MS150031 03E 2011 10 TIM ID 0000000920 008 ...

Page 167: ...mbly device F6559691 1 Preparatory steps 1 Remove limit switch 4 2 Remove indicator 1 3 Remove screws 3 of protective cover 2 4 Remove protective cover 5 Check drive belt condition Page 166 Belt drive Checking distance 1 Measure distance A with assembly de vice 2 If measured value of distance A is not within the tolerance of 98 mm 1 5 mm re adjust belt tension MS150031 03E 2011 10 Task Description...

Page 168: ...4 Use assembly device to adjust distance A by turning adjustment lever 2 5 Tighten screws 1 and 3 6 Measure distance A with assembly device Final steps 1 Install protective cover 2 2 Install securing screws 3 of protective cov er 2 3 Install indicator 1 4 Install limit switch 4 168 Task Description MS150031 03E 2011 10 TIM ID 0000007388 003 ...

Page 169: ...ctive cover 2 4 Take off protective cover Replacing drive belt 1 Counterhold adjustment lever 2 at square 5 using a square socket wrench 2 Use the square wrench to turn the adjust ment lever until the drive belt 4 is re leased 3 Take off drive belt 4 Make sure that the belt pulleys are clean 5 Fit new drive belt 6 Adjust belt tension Page 167 MS150031 03E 2011 10 Task Description 169 TIM ID 000000...

Page 170: ...Final steps 1 Install guard 2 Install securing screws 3 of protective cov er 2 3 Install indicator 1 4 Install limit switch 4 Page 175 170 Task Description MS150031 03E 2011 10 TIM ID 0000007423 001 ...

Page 171: ...silient mounts 1 Measure height setting b with feeler gage 2 Measure dimension a with calipers 3 Calculate permissible value of dimension a considering the measured value of height adjustment b Reference values The permissible value of dimension a is 144 mm when b 5 mm When measured height setting b 6 mm the permissible value of a is 145 mm When measured height setting b 4 mm the permissible value...

Page 172: ...annot swing freely 3 Check that cable ties are firm tighten loose cable ties 4 Replace faulty cable ties 5 Visually inspect the following electrical line components for damage connector housings contacts sockets cables and terminals plug in contacts 6 Contact Service if cable conductors are damaged Note Close male connectors that are not plugged in with the protective cap supplied 7 Clean dirty co...

Page 173: ... surface of connectors 1 connector sockets and shrink formed com ponents 2 using a cloth moistened with isopropyl alcohol 3 Check legibility of cable labels Clean or re place illegible labels Cleaning heavily soiled connectors on engine control unit 1 Use connector pliers 2 to disengage bayo net union nut 4 and withdraw connector 3 2 Clean connector housings connector sock et housings 1 and all co...

Page 174: ...onnectors 1 connector sockets and shrink sleeves 2 using a cloth moistened with isopropyl alco hol 3 Check legibility of cable labels Clean or re place illegible labels Cleaning severely contaminated EMU connectors 1 Use connector pliers 2 to disengage bayo net union nut 4 and withdraw connector 3 2 Clean connector housings connector sock et housings 1 and all contacts with iso propyl alcohol 3 Wh...

Page 175: ...ing 1 and or cover plate 3 is are not mounted Secure cover plate 3 with screws Then install switch housing 1 with screws ensuring that the switch 2 is actuated by the cover plate 3 3 If switch housing 1 and cover plate 3 are mounted but switch 2 is in OFF position Make certain that the cover plate 3 at the side of the switch 2 is not distorted Loosen switch housing 1 and fit it with screws in a po...

Page 176: ...ions on ECU 1 Use connector pliers 3 to make certain that all plug connections of ECU are se curely seated 2 Tighten loose bayonet union nuts 2 with connector pliers 3 by turning them clock wise until they lock into place 3 Make sure that unassigned sockets are closed off with cover caps 4 Contact Service if bayonet union nuts are defective 176 Task Description MS150031 03E 2011 10 TIM ID 00000084...

Page 177: ...nit plug connections 1 Use connector pliers 3 to make certain that all engine monitoring unit plug connec tions are securely seated 2 Tighten loose bayonet union nuts 2 with connector pliers 3 by turning them clock wise until they lock into place 3 Make sure that unassigned sockets are closed off with cover caps 4 If bayonet couplings are defective contact Service MS150031 03E 2011 10 Task Descrip...

Page 178: ...5483 1 Covering caps for Cannon sockets Removing control unit from engine 1 Note or mark assignment of cables to con nector sockets 2 Use connector pliers 2 to disengage the bayonet union nuts 4 of the connectors 3 by turning them counterclockwise 3 Remove all connectors 4 Close connector sockets with appropriate covering caps 1 178 Task Description MS150031 03E 2011 10 TIM ID 0000008487 002 ...

Page 179: ...he screws 4 are not easily accessible 1 Unscrew screws 1 2 Remove engine control unit housing 3 together with mounting plates 2 3 Unscrew cable shock absorbers 5 and further securing parts 6 as one unit from engine Installing engine control unit on engine 1 Install in reverse order Ensure correct assignment of plugs and sockets 2 Use connector pliers to turn the bayonet union nuts of the connector...

Page 180: ... Cleaning LOP 1 Wipe LCD display with dry cloth without applying excessive pressure 2 Remove dirt from keys using isopropyl alcohol 3 Remove heavy soiling from housing surface with isopropyl alcohol Cleaning connectors on LOP 1 Remove dirt from connector and socket surfaces using isopropyl alcohol 2 Check legibility of cable labels Clean or replace illegible labels 180 Task Description MS150031 03...

Page 181: ...Check securing screws 1 3 4 7 for firm seating Tighten loose threaded connec tions 3 Check internal assemblies for firm seating this applies in particular to printend circuit board 2 and PIMs 5 6 Tighten loose threaded connections 4 Close LOP front door Checking plug connections 1 Check all connected cables to verify that the two securing elements 1 are engaged on the lugs 2 so that the respective...

Page 182: ... similar damage Pushbuttons move easily Pushbutton housings are seated secure ly Seals 2 between PAN control panels and LOP housing are not damaged 2 Display Ensure that Front glass is not damaged or pressed in Seal 1 between display housing and LOP housing is not damaged 3 Have damaged components replaced im mediately by Service Performing lamp test 1 Connect battery in accordance with battery ma...

Page 183: ...l control mode is active Switching between Local and Remote mode automatic on board network 1 Press LOCAL OPERATION pushbutton 1 Result LOCAL OPERATION pushbutton 1 flashes Setting does not correspond with feedback signal from Engine Control Unit LOCAL OPERATION pushbutton 1 is illuminated at basic brightness Remote mode active 2 Press LOCAL OPERATION pushbutton 1 again Result LOCAL OPERATION push...

Page 184: ...ress ALARM ACKNOWLEDGE pushbut ton 1 again Result Power supply to Engine Control Unit is pro vided 4 On engines with emergency air shutoff flaps Open flaps Emergency stop simulation with the engine at standstill 1 Open cap of EMERGENCY STOP pushbut ton 2 2 Press EMERGENCY STOP pushbutton 2 Result Engine Control Unit is deenergized by the safety system Engine governing is completely deacti vated On...

Page 185: ...rm Measured value exceeds 1st maximum limit HIHI High High Alarm Measured value exceeds 2nd maximum lim it HT High Temperature ICFN ISO Continuous rating Fuel stop power Net Power specification in accordance with DIN ISO 3046 7 IDM Interface Data Module IMO International Maritime Organisation ISO International Organization for Stand ardization KGS Kraftgegenseite Engine free end in accordance with...

Page 186: ...ntrol System RL Redundancy Lost Alarm Redundant CAN bus failure SAE Society of Automotive Engineers U S standardization organization SD Sensor Defect Alarm Sensor failure SDAF Shut Down Air Flaps SS Safety System Alarm initiated by safety system SSK Schnellschlussklappe n Emergency air shut off flaps SPC Spare Parts Catalog T xyz Temperature xyz Temperature measuring point xyz TC Tools Catalog TD ...

Page 187: ...r during operation for preventive maintenance corrective work in case of malfunction or changed operating conditions or for spare parts supply Your contact at Headquarters Service support mtu online com Spare parts service Fast simple and correct identification of spare parts for your drive system or vehicle fleet The right spare part at the right time at the right place With this aim in mind we c...

Page 188: ... 6 21 5 Engine monitoring unit plug connections Check Page 177 Qty Used in 1 6 21 6 Engine control unit Removal and installation Page 178 Crow foot box wrench Part No F30027424 Qty Used in 1 6 5 2 Injection pump Removal and installation Page 120 Qty Used in 1 6 6 2 Injector Removal and installation Page 124 Qty Used in 1 6 7 1 HP fuel line Pressure pipe union replacement Page 128 Crow foot box wre...

Page 189: ...TU test kit Part No 5605892099 00 Qty Used in 1 6 15 7 Engine coolant Sample extraction and analysis Page 164 Oil filter wrench Part No F30379104 Qty Used in 1 6 8 1 Fuel filter Replacement Page 133 Qty Used in 1 6 14 2 Engine oil filter Replacement Page 149 Open end socket wrench Part No F30025897 Qty Used in 1 6 6 2 Injector Removal and installation Page 124 Qty Used in 1 6 7 1 HP fuel line Pres...

Page 190: ...el line Pressure pipe union replacement Page 128 Ratchet adapter Part No F30062582 Qty Used in 1 6 4 1 Valve clearance Checking and adjusting Page 115 Rigid endoscope Part No Y20097353 Qty Used in 1 6 2 1 Cylinder liner Endoscopic examination Page 106 Socket Part No F30005655 Qty Used in 1 6 1 1 Engine Barring manually Page 104 Steam jet cleaner Part No Qty Used in 1 3 9 Plant Cleaning Page 94 Str...

Page 191: ...nd installation Page 120 Torque wrench 6 50 Nm Part No F30027336 Qty Used in 1 6 3 1 Crankcase breather Oil separator element replacement diaphragm check and replacement Page 110 Qty Used in 1 6 3 3 Crankcase breather Oil separator replacement diaphragm check and replace ment Page 113 Qty Used in 1 6 4 2 Cylinder head cover Removal and installation Page 118 Vernier caliper Part No 2000275 Qty Used...

Page 192: ...2 Covering caps for Cannon sockets Part No Qty Used in 6 21 6 Engine control unit Removal and installation Page 178 Diesel fuel Part No Qty Used in 6 8 1 Fuel filter Replacement Page 133 Qty Used in 6 8 3 Fuel prefilter Draining Page 136 Qty Used in 6 8 4 Fuel prefilter Flushing Page 137 Qty Used in 6 8 5 Fuel prefilter Filter element replacement Page 139 Engine coolant Part No Qty Used in 6 15 3 ...

Page 193: ... 30 10 Emulgier Part No X00029933 Qty Used in 6 5 2 Injection pump Removal and installation Page 120 Qty Used in 1 6 6 2 Injector Removal and installation Page 124 Qty Used in 6 7 1 HP fuel line Pressure pipe union replacement Page 128 Isopropyl alcohol Part No X00058037 Qty Used in 1 6 20 1 Engine wiring Check Page 172 Isopropyl alcohol Part No 46181 Qty Used in 1 6 21 1 Engine control unit and c...

Page 194: ...ine mounted heat ex changer reference condition 25 C intake air temper ature 37 8V 2000 M40B engine data separate heat exchanger reference condition 25 C intake air temperature 40 A Abbreviations 185 After stopping the engine 93 Air filter Removal and installation 143 Replacement 142 B Battery charging generator drive Adjustment 167 Check 167 Battery charging generator drive Drive belt replace men...

Page 195: ...st procedures 183 LOP alarms 99 LOP and connectors Cleaning 180 LOP Controls 85 LOP Visual inspection 181 M Maintenance and repair work Safety requirements 13 Maintenance task reference table QL1 95 MTU contact persons 187 O Oil dipstick Marking 148 Operational checks 90 P Personnel and organizational requirements 9 Plant Cleaning 94 Product description 18 Putting the engine into operation out of ...

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MTU 12 V 2000 M40A, Operating Instructions Manual

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Summary of Contents for 12 V 2000 M40A

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